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BRCBRC -- FOODFOOD
Food Safety ManagementFood Safety ManagementSystemSystem
(Issue(Issue 05,2008)05,2008)
You canYou can t buy trust.t buy trust. Show your commitment to Food Safety & Food Quality THROUGHTHROUGH
Vimal Patel
Build it.Build it.
Food Safety Management System BRC
BRC
-- IOP
IOP
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Benefits for yourBenefits for your Customers / suppliersCustomers / suppliers
Focus on Quality Management Systems,providing a platform for;
Food safetySupply chain traceabilityHACCP development
Legal complianceTechnical competence
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
1.0 Senior Management Commitment & 1.0 Senior Management Commitment & Continual ImprovementContinual Improvement
Curr ent Applicable B RC standa r d is 5: 2008
Identification & compliance to all applicable legal & c u stome r r eq u ir ements incl u ding co u nt r y specific r eq u ir ements as pe r theG lobal Standa r d fo r Food SafetyImpo r tance of meeting c u stome r r eq u ir ementsEstablishing and R eview of Food Safety P olicy & O bjectivesC ond u cting Management R eviewsEns ur ing the Availability of R eso ur ces
S u pplie r confo r mance with H ACCP by S u pplie r a u dits(p r og r amme)Ve r ification of s u pplie r claims / app r ovalsMethod and f r eq u ency of assessment in conside r ation of r isk
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4
7 Principles
Step 1
Step 2
Step 3
Step 4
Step 5
Assemble HACCP Team
Describe product
Identify intended use
Construct flow diagram
Onsite confirmation of flow diagram
Pr inciple 1
Pr inciple 2
Pr inciple 3Pr inciple 4
Pr inciple 5
Pr inciple 6
Pr inciple 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 anddocumentation procedures
5 Preliminary Steps
BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
2.0 Food Safety Plan2.0 Food Safety Plan HACCPHACCP Based on codex alimentariusBased on codex alimentarius
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
3.1 Food Safety & Quality Policy3.1 Food Safety & Quality Policy
In line with the p r od u ction of safe p r od u ct
to the specified q u ality.R eviewed pe r iodically
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
3.3 Organization structure, Responsibilities and Management3.3 Organization structure, Responsibilities and ManagementAuthority.Authority.
Defined Job R esponsibility
R epo r ting R elationships
Job F u nctions
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
3.4 Contract Review & Customer focus3.4 Contract Review & Customer focus
Doc u mentation & pe r iodic r eview of
c u stome r r eq u ir ements, specifications, a r two r k , packing details etc.
Cu stome r feedback
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
3.5 Internal Audit3.5 Internal Audit
Programme of audits in consideration of risk
Trained and independent auditorsDocumented results of audit
Review of audit results
Corrective and preventive actions
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 20083.6 Supplier approval & performance3.6 Supplier approval & performancemonitoringmonitoringE valuation and selection of suppliers
Selection criteria against procedures
Assess ability to supply conforming product
Maintain an approved supplier list
Measurement of supplier performanceVerification of supplier claims / approvals
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3.7.1 Documentation Control3.7.1 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
BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
3.7.2 Specifications3.7.2 SpecificationsSpecifications for all Raw materials, Packing
materials & ingredientsDetails of Recipes for all products mainly
process foods
Availability of specification with relevant staff
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 20083.7.3 Record completion & Maintenance3.7.3 Record completion & Maintenance
Different records are established and maintained toprovide evidence of conformity to requirements andeffective operations of the FSMSA documented procedure has been established andmaintained to define the controls needed for theidentification, storage, protection, retrieval, retention anddisposition of the records.It is ensured that records remain legible, readilyidentifiable and retrievable.Responsibility to maintain the records is defined.
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 20083.8 Corrective and Preventive Actions3.8 Corrective and Preventive Actions
Reviewing nonconformities (including customer complaints)Reviewing trends in monitoring results that may indicatedevelopment towards Loss of ControlDetermining the causes of nonconformitiesE valuating the need for action to ensure thatnonconformities do not occurDetermining and implementing the actions neededRecords of the results of corrective actions taken, and
Reviewing corrective actions taken to ensure that they areeffective Corrective Actions are recorded.
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
3.9 Traceability3.9 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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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
3.10 Complaint Handling3.10 Complaint Handling
Documented system for complaints
E ffective management review for investigations
Implementation of corrective and preventive
actions
Complete records of action taken
Approval of actions
Avoid Reoccurances
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
3.11 Management of Incidents, Product3.11 Management of Incidents, Productwithdrawal & Product Recallwithdrawal & Product Recall
Documented incident reporting procedureCustomer notificationDocumented recall procedureProduct re-call at all stages of production
Control of non conforming productsCorrective and preventive actionsVerification of recall systems
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
4.1 E xternal standards4.1 E xternal standards
U nobstructed Access and Debris Free
Defined E xternal E ating Area
Access Points Proofed
Protected Appropriate Drainage Systems
Traffic Routes Surfaced
Protected E xternal Storage
Designated Refuse Collection Areas
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
4.2 Security4.2 Security
Designated area for entry
Log of visitor entry
Physical security for unauthorized access
Secure storage of RM, WIP & FGS
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
4.3 Layout, Product Flow & Segregation4.3 Layout, Product Flow & Segregation
Prevention of cross contamination
Control of work in progress
Product handling areas
Designated personnel routes
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 20084.3.2 Building Fabric4.3.2 Building Fabric Walls, Floors, Ceilings,Walls, Floors, Ceilings,
Windows, Doors, Lighting, ACWindows, Doors, Lighting, AC
Sound constructionSuspended ceilings accessible
Adequate lightingCleaning schedules for internal surfacesWalls capable of being cleaned
Drainage protectionSufficient ventilationProofing of ventilation openingsProofed against pest ingress
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
4.4 U tilities4.4 U tilities
Availability of water & potability through testing
as per IS 10500
Microbial, Physical & chemical testing of Ice,
steam & water also
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
4.5 E quipments :4.5 E quipments :
Suitable design of equipments.Appropriate constructed materials.
Permit effective cleaning.On time Inspection and servicing.Certificate of confirmity for the direct contactwith the food : vessels / Belt conveyers.
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
4.6 Maintenance of Plant & E quipment4.6 Maintenance of Plant & E quipment
Planned maintenance programmes
Control of compressed air
U se of tape engineering
Operate to hygiene, health and safety
requirementsControl of contractors
Post maintenance checks & Documents
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
4.6 Maintenance of Plant & E quipment4.6 Maintenance of Plant & E quipment
W ell maintained
C leaning sched u les
W ooden eq u ipment
Minimised u se
G ood condition
Pr ope r ly sealed
Notice-boa r ds
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
4.7 Staff Facilities4.7 Staff Facilities ContiConti
Change rooms with lockers
Separate storage of protective clothing &
personal clothing & footwearHand wash facilities with liquid soap, hand drier& Advisory signs
Hands free wash basinHand disinfectant such as IPA
Smoking, eating & drinking not allowed inside
plant area
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
4.7 Staff Facilities4.7 Staff Facilities
No food o r T iffin sto r age inside plant a r ea
C anteen facility o r eating facility with
waste sto r age facility
Visito r s and cont r acto r facilities
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 20084.8 Chemical and physical product contamination control4.8 Chemical and physical product contamination control
MSDS fo r all chemicals , sanitize r s, l u b r icants
u sed
Sepa r ate sto r age & away f r om p r od u ctsPr ope r labelling & identification
Sec ur e sto r age & u se by a u tho r ized & t r ained
pe r sonnel only
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
4.8.3 Metal control4.8.3 Metal control
Snap off type blades not allowed
C ont r ol on iss u e, sto r age & u sage of all
metal a r ticles s u ch as knives, needles etc
Avoid u sage of staple r s, boa r d pins, pins,
u -pins etc. in plant a r ea
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
Glass , brittle plastic , WoodGlass , brittle plastic , Wood
Details of all glass, b r ittle plastic a r ticles with ID
no., location & nos.
All sho u ld be cove r ed app r op r iately with s u itable
enclos ur e
Monito r ing fo r b r eakage & action
Non u sage of woods as fa r as possible
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
4.9 Housekeeping & Cleaning4.9 Housekeeping & Cleaning
Clean as you go policyCleaning schedules
Item to be cleanedFrequencyMethodCleaning materials
ResponsibilityCleaning record checks
U se of approved cleaning detergentsMonitoring of effectiveness
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
4.9 Housekeeping & Cleaning4.9 Housekeeping & Cleaning
Sto r age of cleaning eq u ipment
T oilet cleaning p r od u cts seg r egated
C ont r ol of tools and maintenance eq u ipment
Cont
rol of wo
rkstations to p
revent p
rod
uct
contamination
S u itable sto r age facilities fo r wo r kstations
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
4.10 Waste & Waste Disposal4.10 Waste & Waste Disposal
Minimise accumulation of waste in production
U se of appropriate containers
Disposal of Trademarked waste
U se of licensed waste contractors
Collection of recycling waste
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
4.11 Pest Control4.11 Pest Control
Formalised preventative programme
U se of approved contractors for pest control
Records and location of pest control baits
Correctly sited E FKs
Follow up actions
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
4.12 Transport, Storage & Distribution4.12 Transport, Storage & Distribution
N on conforming products
Vehicle drivers
Clean and suitable transport
Cleaning programme for vehicles
Pre loading checks of vehiclesControl of off site storage
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
5.1 Product Design & Development5.1 Product Design & Development
Review of Customer design
Formal approval of product concept includingart work by specifier
Retention of product samples as agreed withcustomer
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 20085.2 Handling requirements for specific materials5.2 Handling requirements for specific materials Like allergensLike allergens
Review of specific preserved materials.Proper labellingContamination controlsSeparate storageTraining to personalsCross packing errors.Changes in allergen legislation or scientificinformation's.
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
5.3 Foreign body control5.3 Foreign body control
Metal detector sensitivity specified, validated& calibrated
Metal detector with alarm system or autostop conveyor
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5.4 Foreign body control5.4 Foreign body control
Training for avoidance & detection of foreignbodies
Documented policy non production glass ,brittle plastics, all materials part of construction, fixture which may get confusedwith products
Protection of glass & brittle plastics againstbreakage including bulbs, TL, Insect catcher
BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
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Responsibility post breakage incident
Incident reporting mechanism if breakage
A documented Sharp policy / Metal policy
Storage provision for stationary / loose items
5.7 Foreign body control5.7 Foreign body control
BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
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Snap-off blades
Drawing pins / staples onN otice boards
5.3 Foreign body control5.3 Foreign body control
BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
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Certificate of Conformity for suitableuse.
Separate storage for packaging
Food Grade
Special handling proceduresAvoid accidental contamination also.
5.4 Product Packaging5.4 Product Packaging
BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
5.5 Production Inspection & Analysis5.5 Production Inspection & Analysis
Quality Plan establishment incl. tolerances
Inspection as per Quality Plan
Competency of Quality inspector
All external testing lab accredited withrecognized or agreed competent body
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5.7 Product Release5.7 Product Release
Based on risk assessment.
Defined specification for the dispatched
Only by authorized persons approval only.
BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
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6.1 Process Control6.1 Process Control
Control of Operations
ICP Quality Plan
Declaration of conformity from suppliers
Segregation of RM, WIP, FGS Products
A Specific control for N C Products or customerreturn product
BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 20086.2 Quantity6.2 Quantity Weight, Volume and N umber ControlWeight, Volume and N umber Control
Identification of meas ur ements, meas ur ing andmonito r ing devices fo r p r od u ct confo r mityC ont r ol of Meas ur ing and monito r ing devices to
ens ur e consistency of meas ur ement capabilitywith the meas ur ed r eq u ir ementsW he r eve r necessa r y to ens ur e valid r es u lts, themeas ur ing eq u ipment:
Shall be calib r atedSafeg u a r ded, p r otected f r om damage and dete r io r ationR eassessment of r es u lts if o u t of calib r ationC alib r ation r eco r ds to be availableSoftwa r e u sed shall be validated p r io r to u seApp r opi r ate legislation weight and meas ur ement
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
6.3 Calibration6.3 Calibration
Identification of meas ur ements, meas ur ing andmonito r ing devices fo r p r od u ct confo r mityC ont r ol of Meas ur ing and monito r ing devices to
ens ur e consistency of meas ur ement capabilitywith the meas ur ed r eq u ir ementsW he r eve r necessa r y to ens ur e valid r es u lts, themeas ur ing eq u ipment:
Shall be calib r atedSafeg u a r ded, p r otected f r om damage and dete r io r ationR eassessment of r es u lts if o u t of calib r ationC alib r ation r eco r ds to be availableSoftwa r e u sed shall be validated p r io r to u se
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7.1 Training & Competence7.1 Training & Competence
All personnel covered including contractual
Induction training hygiene rules
Competency assessment & training based on
Gaps
Retention of training recordsA programme for Refresher training
BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
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7.2 Access & Movement of Personnel7.2 Access & Movement of Personnel
Designated entrances
Site security
Designated walkways
Logical movements
BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
7.3 Personal hygiene7.3 Personal hygiene
J ewellery Policy plain wedding ring / weddingwristband / sleeper earrings
Drinking water @ confined area
Personal medicine policy
Hand wash ( employee, visitors, contractors )after toilet, eating, smoking or drinking
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
7.4 Medical Screening7.4 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 withcolored plaster ( blue ) / metal detectable
strip if Metal detector used ( issued by
company
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
Rings / stones in exposed parts of bodysuch as noses, tongues & eyebrows
Writs watchesMobile phones in production area
False fingernails / nail polish
E ating , drinking, smoking in productionarea
7.5 Personal hygiene7.5 Personal hygiene
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
7.5 Protective Clothing7.5 Protective Clothing
Appropriate protective clothing
Sufficient set of clothingClothing without external pockets on upperbody garments or sewn buttons
Policy of Protective clothing wear on locationSnoods for breads & moustaches
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BRCBRC FOOD , IssueFOOD , Issue 05, 200805, 2008
7.5 Protective Clothing7.5 Protective Clothing
Containing of Scalp hair
Cleaning & laundering of clothingSelf care laundry Specific precautions
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