BRC - FOOD

Food Safety Management System (Issue 05,2008)

Vimal Patel

You cant buy trust. can Build it.

Show your commitment to Food Safety & Food Quality

THROUGH

Food Safety Management System BRC - IOP

Benefits for your Customers / suppliers



Focus on Quality Management Systems, providing a platform for; Food safety Supply chain traceability HACCP development Legal compliance Technical competence

    

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BRC FOOD , Issue 05, 2008 1.0 Senior Management Commitment & Continual Improvement
 

Current Applicable BRC standard is 5: 2008 Identification & compliance to all applicable legal & customer requirements including country specific requirements as per the Global Standard for Food Safety Importance of meeting customer requirements Establishing and Review of Food Safety Policy & Objectives Conducting Management Reviews Ensuring the Availability of Resources Supplier conformance with HACCP by Supplier audits (programme) Verification of supplier claims / approvals Method and frequency of assessment in consideration of risk

    

 

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BRC FOOD , Issue 05, 2008

2.0 Food Safety Plan HACCP
5 Preliminary Steps Step 1 Step 2 Step 3 Step 4 Step 5 7 Principles Principle 1 Principle 2 Principle 3 Principle 4 Principle 5 Principle 6 Principle 7
Conduct a Hazard Analysis Determine CCPs Establish Critical Limits for each CCP Establish monitoring procedures for each CCP Establish corrective actions Establish verification procedures Establish record keeping and documentation procedures
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Based on codex alimentarius

Assemble HACCP Team Describe product Identify intended use Construct flow diagram Onsite confirmation of flow diagram

BRC FOOD , Issue 05, 2008 3.1 Food Safety & Quality Policy


In line with the production of safe product to the specified quality.

Reviewed periodically

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BRC FOOD , Issue 05, 2008 3.2 Food Safety & Quality Manual

A Quality Manual shall be established and maintained that includes the following: Scope of BRC - Documented procedures or reference to them

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BRC FOOD , Issue 05, 2008

3.3 Organization structure, Responsibilities and Management Authority.

Defined Job Responsibility Reporting Relationships Job Functions

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BRC FOOD , Issue 05, 2008 3.4 Contract Review & Customer focus


Documentation & periodic review of customer requirements, specifications, art work , packing details etc.

Customer feedback

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BRC FOOD , Issue 05, 2008 3.5 Internal Audit

    

Programme of audits in consideration of risk Trained and independent auditors Documented results of audit Review of audit results Corrective and preventive actions

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BRC FOOD , Issue 05, 2008 3.6 Supplier approval & performance monitoring
     

Evaluation and selection of suppliers Selection criteria against procedures Assess ability to supply conforming product Maintain an approved supplier list Measurement of supplier performance Verification of supplier claims / approvals

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BRC FOOD , Issue 05, 2008 3.7.1 Documentation Control

 

Demonstrate compliance with the standard Documented management system (procedures / methods) shall be authorised (at all levels)

  

Formally issued and controlled Obsolete documentation removed from use Complete records controlled at all appropriate levels

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BRC FOOD , Issue 05, 2008 3.7.2 Specifications



Specifications for all Raw materials, Packing materials & ingredients

Details of Recipes for all products mainly process foods

Availability of specification with relevant staff

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BRC FOOD , Issue 05, 2008

3.7.3


Record completion & Maintenance

Different records are established and maintained to provide evidence of conformity to requirements and effective operations of the FSMS A documented procedure has been established and maintained to define the controls needed for the identification, storage, protection, retrieval, retention and disposition of the records. It is ensured that records remain legible, readily identifiable and retrievable. Responsibility to maintain the records is defined.

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BRC FOOD , Issue 05, 2008

3.8 Corrective and Preventive Actions
 

 

  

Reviewing nonconformities (including customer complaints) Reviewing trends in monitoring results that may indicate development towards Loss of Control Determining the causes of nonconformities Evaluating the need for action to ensure that nonconformities do not occur Determining and implementing the actions needed Records of the results of corrective actions taken, and Reviewing corrective actions taken to ensure that they are effective Corrective Actions are recorded.

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BRC FOOD , Issue 05, 2008 3.9 Traceability



Raw materials Packing materials / Work in progress & Finished goods

Product identifiable at all stages of production Testing of traceability system once / year

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BRC FOOD , Issue 05, 2008 3.10 Complaint Handling

  

Documented system for complaints Effective management review for investigations Implementation of corrective and preventive actions

  

Complete records of action taken Approval of actions Avoid Reoccurances

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BRC FOOD , Issue 05, 2008 3.11 Management of Incidents, Product withdrawal & Product Recall
      

Documented incident reporting procedure Customer notification Documented recall procedure Product re-call at all stages of production Control of non conforming products Corrective and preventive actions Verification of recall systems
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BRC FOOD , Issue 05, 2008 4.1 External standards

      

Unobstructed Access and Debris Free Defined External Eating Area Access Points Proofed Protected Appropriate Drainage Systems Traffic Routes Surfaced Protected External Storage Designated Refuse Collection Areas
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BRC FOOD , Issue 05, 2008 4.2 Security



Designated area for entry Log of visitor entry Physical security for unauthorized access Secure storage of RM, WIP & FGS

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BRC FOOD , Issue 05, 2008 4.3 Layout, Product Flow & Segregation


Prevention of cross contamination Control of work in progress Product handling areas Designated personnel routes

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BRC FOOD , Issue 05, 2008

4.3.2 Building Fabric Walls, Floors, Ceilings, Windows, Doors, Lighting, AC
        

Sound construction Suspended ceilings accessible Adequate lighting Cleaning schedules for internal surfaces Walls capable of being cleaned Drainage protection Sufficient ventilation Proofing of ventilation openings Proofed against pest ingress
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BRC FOOD , Issue 05, 2008

4.4 Utilities

Availability of water & potability through testing as per IS 10500

Microbial, Physical & chemical testing of Ice, steam & water also

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BRC FOOD , Issue 05, 2008

4.5 Equipments :
    

Suitable design of equipments. Appropriate constructed materials. Permit effective cleaning. On time Inspection and servicing. Certificate of confirmity for the direct contact with the food : vessels / Belt conveyers.

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BRC FOOD , Issue 05, 2008 4.6

   

Maintenance of Plant & Equipment

Planned maintenance programmes Control of compressed air Use of tape engineering Operate to hygiene, health and safety requirements

 

Control of contractors Post maintenance checks & Documents

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BRC FOOD , Issue 05, 2008 4.6

  

Maintenance of Plant & Equipment

Well maintained Cleaning schedules Wooden equipment

  

Minimised use Good condition Properly sealed

Notice-boards
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BRC FOOD , Issue 05, 2008 4.7 Staff Facilities Conti

Change rooms with lockers Separate storage of protective clothing & personal clothing & footwear Hand wash facilities with liquid soap, hand drier & Advisory signs Hands free wash basin Hand disinfectant such as IPA Smoking, eating & drinking not allowed inside plant area
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BRC FOOD , Issue 05, 2008 4.7



Staff Facilities

No food or Tiffin storage inside plant area Canteen facility or eating facility with waste storage facility

Visitors and contractor facilities

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BRC FOOD , Issue 05, 2008

4.8 Chemical and physical product contamination control

MSDS for all chemicals , sanitizers, lubricants used

  

Separate storage & away from products Proper labelling & identification Secure storage & use by authorized & trained personnel only

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BRC FOOD , Issue 05, 2008 4.8.3



Metal control

Snap off type blades not allowed Control on issue, storage & usage of all metal articles such as knives, needles etc

Avoid usage of staplers, board pins, pins, u-pins etc. in plant area
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BRC FOOD , Issue 05, 2008 Glass , brittle plastic , Wood



Details of all glass, brittle plastic articles with ID no., location & nos.

All should be covered appropriately with suitable enclosure

Monitoring for breakage & action Non usage of woods as far as possible
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BRC FOOD , Issue 05, 2008 4.9

 

Housekeeping & Cleaning

Clean as you go policy Cleaning schedules

     

Item to be cleaned Frequency Method Cleaning materials Responsibility Cleaning record checks

 

Use of approved cleaning detergents Monitoring of effectiveness

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BRC FOOD , Issue 05, 2008 4.9

 

Housekeeping & Cleaning

Clean as you go policy Cleaning schedules

     

Item to be cleaned Frequency Method Cleaning materials Responsibility Cleaning record checks

 

Use of approved cleaning detergents Monitoring of effectiveness

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BRC FOOD , Issue 05, 2008 4.9



Housekeeping & Cleaning

Storage of cleaning equipment Toilet cleaning products segregated Control of tools and maintenance equipment Control of workstations to prevent product contamination

Suitable storage facilities for workstations

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BRC FOOD , Issue 05, 2008 4.10 Waste & Waste Disposal
    

Minimise accumulation of waste in production Use of appropriate containers Disposal of Trademarked waste Use of licensed waste contractors Collection of recycling waste

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BRC FOOD , Issue 05, 2008 4.11 Pest Control

    

Formalised preventative programme Use of approved contractors for pest control Records and location of pest control baits Correctly sited EFKs Follow up actions

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BRC FOOD , Issue 05, 2008 4.12 Transport, Storage & Distribution
     

Non conforming products Vehicle drivers Clean and suitable transport Cleaning programme for vehicles Pre loading checks of vehicles Control of off site storage

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BRC FOOD , Issue 05, 2008 5.1 Product Design & Development
 

Review of Customer design Formal approval of product concept including art work by specifier Retention of product samples as agreed with customer

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BRC FOOD , Issue 05, 2008

5.2 Handling requirements for specific materials Like allergens

      

Review of specific preserved materials. Proper labelling Contamination controls Separate storage Training to personals Cross packing errors. Changes in allergen legislation or scientific information's.

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BRC FOOD , Issue 05, 2008 5.3 Foreign body control



Metal detector sensitivity specified, validated & calibrated Metal detector with alarm system or auto stop conveyor

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BRC FOOD , Issue 05, 2008 5.4 Foreign body control



Training for avoidance & detection of foreign bodies Documented policy non production glass , brittle plastics, all materials part of construction, fixture which may get confused with products Protection of glass & brittle plastics against breakage including bulbs, TL, Insect catcher
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BRC FOOD , Issue 05, 2008 5.7 Foreign body control

   

Responsibility post breakage incident Incident reporting mechanism if breakage A documented Sharp policy / Metal policy Storage provision for stationary / loose items

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BRC FOOD , Issue 05, 2008 5.3 Foreign body control

 

Snap-off blades Drawing pins / staples on Notice boards

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BRC FOOD , Issue 05, 2008 5.4 Product Packaging



Certificate of Conformity for suitable use. Separate storage for packaging Food Grade Special handling procedures Avoid accidental contamination also.

   

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BRC FOOD , Issue 05, 2008 5.5 Production Inspection & Analysis
   

Quality Plan establishment incl. tolerances Inspection as per Quality Plan Competency of Quality inspector All external testing lab accredited with recognized or agreed competent body

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BRC FOOD , Issue 05, 2008 5.6 Control of Non-conforming Product Non 

Procedure for NC products Documentation of all NC cases & actions taken

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BRC FOOD , Issue 05, 2008 5.7 Product Release

  

Based on risk assessment. Defined specification for the dispatched Only by authorized persons approval only.

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BRC FOOD , Issue 05, 2008 6.1 Process Control

    

Control of Operations ICP Quality Plan Declaration of conformity from suppliers Segregation of RM, WIP, FGS Products A Specific control for NC Products or customer return product

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BRC FOOD , Issue 05, 2008

6.2 Quantity Weight, Volume and Number Control

Identification of measurements, measuring and monitoring devices for product conformity Control of Measuring and monitoring devices to ensure consistency of measurement capability with the measured requirements Wherever necessary to ensure valid results, the measuring equipment:
     

Shall be calibrated Safeguarded, protected from damage and deterioration Reassessment of results if out of calibration Calibration records to be available Software used shall be validated prior to use Appropirate legislation weight and measurement
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BRC FOOD , Issue 05, 2008 6.3 Calibration



Identification of measurements, measuring and monitoring devices for product conformity Control of Measuring and monitoring devices to ensure consistency of measurement capability with the measured requirements Wherever necessary to ensure valid results, the measuring equipment:
    

Shall be calibrated Safeguarded, protected from damage and deterioration Reassessment of results if out of calibration Calibration records to be available Software used shall be validated prior to use
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BRC FOOD , Issue 05, 2008 7.1 Training & Competence

  

All personnel covered including contractual Induction training hygiene rules Competency assessment & training based on Gaps

 

Retention of training records A programme for Refresher training

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BRC FOOD , Issue 05, 2008 7.2 Access & Movement of Personnel


Designated entrances Site security Designated walkways Logical movements

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BRC FOOD , Issue 05, 2008 7.3 Personal hygiene



Jewellery Policy plain wedding ring / wedding wristband / sleeper earrings Drinking water @ confined area Personal medicine policy Hand wash ( employee, visitors, contractors ) after toilet, eating, smoking or drinking

  

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BRC FOOD , Issue 05, 2008 7.4 Medical Screening



Mechanism for reporting in case suffering from communicable diseases, wound, skin or gastrointestinal illness

Health questionnaire for visitors / contractors Covering of cuts & gazes exposed on skin with colored plaster ( blue ) / metal detectable strip if Metal detector used ( issued by company

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BRC FOOD , Issue 05, 2008 7.5 Personal hygiene



Rings / stones in exposed parts of body such as noses, tongues & eyebrows Writs watches Mobile phones in production area False fingernails / nail polish Eating , drinking, smoking in production area

   

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BRC FOOD , Issue 05, 2008 7.5 Protective Clothing

  

Appropriate protective clothing Sufficient set of clothing Clothing without external pockets on upper body garments or sewn buttons Policy of Protective clothing wear on location Snoods for breads & moustaches

 

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BRC FOOD , Issue 05, 2008 7.5 Protective Clothing

  

Containing of Scalp hair Cleaning & laundering of clothing Self care laundry Specific precautions

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