BRC Food 6

P=Pr

oced

ure

Clause Issue Requirement Evidence Trai

ning

requ

ired

Exam

ple

evid

ence

1.11.1.1 Policy, signed and communicated x Policy

1.1.2 Objectives x

1.1.3 Senior management review x

1.1.4 Managmeent meeting program x1.1.5 Provision of resources

1.1.6 Industry updates

1.1.7 Copy of the standard1.1.8 Maintain certification

1.1.9

1.1.10 x

A=As

sess

E=

Evid

ence

I=

Inte

rvie

w

Risk

Ass

essm

ent

requ

ired

Doc

umen

tatio

n re

quire

d

Seni

or

Man

agem

ent

Revi

ew

Asse

ss d

urin

g fa

cilit

y to

ur

Senior Management

Objectives and attainment plan

Review meeting minutes

Monthly meeting minutes

Conferences, memberships, technical journals, e-mail updates

Copy of the standard or receipt

Attendance at opening and closing audit meetings

Root cause analysis of past non-conformances

Review of non-conformances, root cause analysis, verification

1.2

1.2.1 x

1.2.2 Job descriptions and work instructions x

2 HACCP

2.1 HACCP team

2.1.1 HACCP team, training x

2.22.2.1 Prerequisite programs

2.3

2.3.1 x

2.3.2 Source of product / process description x

2.4 Intended use

2.4.1 x

2.5 Flow diagram

2.5.1 x

Organizational structure and authority

Organizational chart and absence coverage

Organizational chart, deputies, list of responsibilities

Job descriptions and work instructions

Team list and training records

Prerequisite programs

Product description

Scope of HACCP plan, products and process descriptions

Description of intended use, specific risk target groups, potenital misuse of product

Diagrams illustrating process flow and layout schematic

2.6

2.6.1 x

2.7 Listing of hazards x2.7.1 Listing of potential hazards x2.7.2 Definition of hazards x2.7.3 hazard control measures x

2.8

2.8.1 x decision tree

2.9 CCP limits2.9.1 Limits for each CCP defined x

2.9.2 Validation of CCP's x

2.10 CCP monitoring

2.10.1 P

2.10.2 Recording of monitoring P

Verification of flow diagram

Flow diagrams verified and challenged annually

CCP determination

Using decision tree, identify which control points are CCP's

validation studies showing that control measures and limits will effectiveyly control hazards in all forseeable circumstances

Procedures for monitoring CCP limits, and corrective actions in case of limits being exceeded

Recording and verification procedures (verification to include verifying records as well as actions)

2.11 Corrective action

2.11.1 P

2.12 Verification

2.12.1

2.13

2.13.1 x

2.14 HACCP review

2.14.1 x

3

3.1

3.1.1

3.1.2

Procedures to follow in the event of limits being exceded as well as failure of control measures

Activities to ensure the HACCP plan is effective

HACCP documentation and record keeping

Records created and maintained to verify HACCP is actively in place

Review of both implementation and effetiveness of the HACCP plan verified annually or in the event of significant changes

Food safety and quality management systems

Food safety and quality manuals

All policies and procedures are documented.

Fully implemented and available where needed

3.1.3

3.2 Document control

3.2.1 P

3.3 Records

3.3.1 P3.3.2 Record retention procedure P

3.4 Internal audit

3.4.1 x

3.4.2 Internal auditors appropriately trained x

3.4.3 x

3.4.4 x inspection reports

3.5

3.5.1

Policies, procedures and work instructions are formatted as to be understandable to staff

Mechanism for controlling document versions, change log and update procedure

list of controlled documents, change log, change procedure

Records are understandble, record alteration procedure

reasons for alteration of records is documented on record

Internal audits cover all requirements of the Standard

Internal audit report

audit technique training for internal auditors

Internal audit reports show evidence of conformance, and closure of non-conformance

internal audit report

Internal inspections covering site conditions and hygiene

Supplier approval and monitoring

Raw materials and packaging

3.5.1.1 x

3.5.1.2 P

3.5.1.3 P

3.5.2

3.5.2.1 P

3.5.2.2 Records of acceptance x Proof of acceptance

3.5.3

3.5.3.1 P

3.5.3.2 x

3.5.4

3.5.4.1 x

3.5.4.2 Monitoring of contracted processing x

3.5.4.3 Managing of contracted processing x

Listing of all ingredients and packaging, and associated risks

grouped or individual listing of all materials

Supplier approval procedure, and ongoing monitoring procedure

Exception procedure in case of non-approved supplies being used

Acceptance monitoring

Procedure on how incoming materials are assessed for acceptance

reveiving inspections, pre-use testing, additional document requirements

Service supplier management

Procedure for approval and monitoring of service suppliers

Service contracts adressing specifications or expectations

contracts and specifications for service suppliers

outsourced processing management

Brand owner is aware of outsourced processing

docmented in contract with brand owner

verification of certification or audit reports

contracts of specification and expectation in place

3.5.4.4 Monitoring of contract processing results P

3.6 Specifications

3.6.1 x specifications

3.6.2

3.6.3 x specifications

3.6.4

3.6.5

3.7 Corrective action

3.7.1 x

3.8

3.8.1 x

3.9 Traceability

3.9.13.9.2 Mass balace and traceability test x test results

3.9.3

results and analysis of process outcome

Specifications in place for all raw materials and packaging

Activities and instructions on the process floor equate to product and customer specifications

Specifications in place for all finished products

Specifications are agreed with or available to customers

Specifications are reviewed when required, minimum every 3 years

Documented procedure for corrective actions

Control of non-conforming product

Hold program, including dispensation program

Identification of all materials within site to allow traceability

Rework is included in traceability program

3.10

3.10.1 x

3.10.2 x

3.11

3.11.1 P

3.11.2 Recall and product withdrawal procedure P3.11.3 Procedures tested annually

3.11.4 Notification of CB in the event of recall

4 Site Standards

4.1

4.1.1 A

4.1.2 Site exterior maintained in good order A

4.1.3 A

4.2 Security

4.2.1 x

4.2.2 x

Complaint handling

Complaint program, resolved through trained staff

Complaint data analyzed for trends and used for improivements

ongoing trend analysis for complaint data

Incident management

Incident management procedures based on potential large scale interruptions

CB on recall contact list

External standards

Protecting site from external contaminants and impacts

Building exterior maintained in good condition

Security risk assessment and mitigation completed, reviewed annually

Controlled access and employee security training

4.2.3

4.3

4.3.1 Site map designating product risk zones x4.3.2 Site map identifying activites x site map

4.3.3 Visitors and contractors managed on site

4.3.4 Contamination control in low risk areas A

4.3.5 A

4.3.6

4.3.74.3.8 Temporary structures do not add risk

4.4 Building

4.4.1

4.4.2

4.4.3

4.4.4

Registered with appropriate government agencies, where required

Proof of registration

Layout, flow and segregation

site map, appropriate zone designations

sign in and awareness activities

High care areas provide appropriate practices

High risk areas segregated, and use appropriate practices

Sufficient space to work effecitvely hygenically

Walls constructed and maintained to appropriate standard

Floors constructed and maintained to appropriate standard

Drains constructed and maintained to appropriate standard. Drainage does not impact product integrity

If HC /HR, then msut have a drain plan showing drains, flow direction, back flow prevention or other risks.

Drain plan / drawing

4.4.5

4.4.6 R4.4.7 Ventilation to outside is pest proof.

4.4.8

4.4.94.4.10 Lighting is suitable and sufficient4.4.11 Light bulbs protected from breakage4.4.12 Adequate ventilation and extraction4.4.13 HR areas using filtered air.

4.5 Utilities

4.5.1 R

4.5.2 Water distribution plan x

4.5.3 Restrictions if non-potable water is used.

4.5.4

4.6 Equipment

4.6.1

4.6.2

Ceilings and overheads construted and maintained to appropriate standard

Suspended ceilings (building voids) on inspection program

Void inspection record

Windows protected from breakage where they pose a risk

Doors constructed and maintained to appropriate standard. Doors do not allow pest ingress.

Water is potable, plant tested for relevant contaminants.

Plant sample test results.

plan showing all taps, outlets and storage.

If used, reference to legislation.

Steam, compressed air, gasses, do not pose contamination risks. Compressed air with direct product contact is filtered.

HACCP process flow diagram showing use of utilities, verify protection.

Equipment designed, constructed and installed to be effectively cleaned and maintained.

Equipment with direct food contact made of suitable materials.

Approvals of suitability or conformance

4.7 Maintenance

4.7.1 x PM program

4.7.2 Inspection program

4.7.3 Temporary repairs controlled I

4.7.4 P I

4.7.5

4.7.6 Shop and engineering rooms maintained

4.8 Staff facilities

4.8.14.8.2 Personal storage for employees.

4.8.3

4.8.4 P

4.8.5 P

Preventative maintenance program is effective

Equipment inspection program where not covered by PM program

Work orders tied to temporary repairs

Product protected during maintenance activities. Post maintenance line clearance procedure used.

Approved chemicals / materials used in maintenance.

Approvals for materials based on use

Adequate changing facilities for employees and visitors

Separate storage for clean uniforms provided.

In HC areas: - segragated changerooms, changing instructions, footwear dedicated to high care area only, distinctive clothing, handwashing during changing, handwash and sanitize on entry

In HR areas: - changing instructions, dedicated footwear, footwear barrier system, disctinctive clothing, handwashing during changing, hand wash and sanitize on entry

4.8.6

4.8.7

4.8.8

4.8.9

4.8.10 x

4.9

4.9.1 Chemical controls

4.9.1.1 x4.9.1.2 protect product from chemical taint4.9.2 Metal control4.9.2.1 Sharps and knife control procedures p sharps policy

4.9.2.2

4.9.34.9.3.1 Excluded or protected

Handwashing to include: - suitable temperature, liquid soap, single use drying, hands free taps, signage

Washrooms: - segragated, handwashing with signange

Smoking and waste managed to protect product

Employee food stored in clean hygienic state. No food in production or storage areas.

Cafetria operations suitably controlled to prevent contamination and employee illness

cafeteria training, inspections

Chemical and physical contamination control

Approved purchase, specifications, suitability proof, avoidance of scented products, appropriate labeling, segregated and secure storage, use by trained personnel

Protection from staples, paper clips, and other closures

Glass and brittle material control

4.9.3.2 p

4.9.3.3 x p

4.9.3.4

4.9.3.4.1 Segragated storage of empty containers

4.9.3.4.24.9.3.4.3 records of breakage4.9.4 Wood

4.9.4.1 Restricted use, monitoring of condition

4.10

4.10.14.10.1.1 Risk assessment to assess need x

4.10.1.24.10.1.3 System testing frequency risk based

List of items, location and condition. Periodic check program, procedures for cleaning and replacing as needed.

Glass breakage procedure: - quarantine, cleaning, inspection and authorization, clothing change, training and recording

Products packed in glass

Breakage control: - removal of product, cleaning, designated cleaning materials, lidded waste containers, post breakage inspection, restart authorization

Foreign body detection and removal equipment

Foreign body detection and removal equipment

choice and installation based on industry best practice

4.10.1.4 x

4.10.2 Filters and sieves

4.10.2.14.10.2.2 inspected and checks recorded

4.10.3

4.10.3.1 x

4.10.3.24.10.3.3 Reject or stop and alarm system4.10.3.4 Operating and testing procedures. p

4.10.3.5 p4.10.3.6 Test failure procedure p4.10.4 Magnets

4.10.4.1 p4.10.5 Optical sorting 4.10.5.1 Operating and testing procedures. p

4.10.6

4.10.6.1 p4.10.6.2 Cleaning effectiveness tests.

4.114.11.1 SSOP's x p

Investigation and trend analysis of findings

findings report / investigations /trend analysis

Investigation and trend analysis of findings

Metal detectors and x-ray

Risk assessment to assess need. Justification for absence

choice and installation based on industry best practice

checks to include: - labelled test pieces, ferrous stainless and non-ferrous, detect and reject tested, memory / reset tests, use of sample test packs

Magnet specification, inspection, cleaning and testing

Container cleaning

cleaning and protection of containers based on best practice

Housekeeping and hygiene

4.11.2 Defined expectations for cleaning

4.11.3 Time and resources for effective cleaning4.11.4 Cleaning verification

4.11.54.11.6 CIP4.11.6.1 Systems monitored and maintained

4.11.6.2 x schematic

4.11.6.3 P

4.12 Waste

4.12.1 x contracts / licences

4.12.2

4.12.3

4.12.4 P

4.13 Pest control

4.13.1 x

4.13.2 x

4.13.3

Dedicated, distinctive cleaning equipment properly managed

Appropriate desgin and installation, system change log maintained

Monitored system conditions, effectiveness testing

Licences of waste contractors, including those for recycling

Food waste and animal feed streams segragated

External waste collection identified and maintained

Unsafe or trademarked materials appropriately denatured and destroyed

licence, record of destruction

Competent persons perform risk assessment and manage pest control

contract, training or licencing

If company managed pest control, effective competency and systems in place

licencing, training records, chemical controls

Adequate pest control documentation and records

site map, product specifications, pest control reports

4.13.4

4.13.5

4.13.6

4.13.7

4.13.8

4.13.9 trend analysis

4.14 Storage facilities

4.14.1 P

4.14.2

4.14.3

4.14.5

4.15

4.15.1 P

4.15.2 Traceability is maintained during shipping

4.15.3 P inspection records

Outdoor baits secured in place, no rodenticides indoors

Bug lights appropriately locted and functional

Approprate actions in the event of infestation

Inspection records and follow up of recommendations

pest inspection records

Additional effectiveness survey, typically quarterly

effectiveness report

Trend analysis of inspections and catch records minimum annually

Procedures adequate to ensure product integrity during storage are in place, understood and followed

Where temperature control is required, it is sufficient and monitored

temperature monitoring

Where controlled atmosphere is required, it is maintained and records maintained

Stock rotation systems are effectively in place during storage

Shipping and transportation

Product integrity is maintained during loading

shipping records indicate lots

Pre-load inspections performed and recorded

4.15.4

4.15.5

4.15.6 P

4.15.7

5 Product control

5.1

5.1.1 R&D review policy

5.1.2

5.1.35.1.4 Shelf life trails or data completed

5.1.5

5.1.6 Lable claims have validated evidence

5.2

5.2.1 x

5.2.2 List showing all allergens on site x

Where temperature control is required, it is documented

temperature monitoring records

Unloading equipment maintained and clean

Transport procedures to ensure product integrity, including security and breakdown

Sub-contracted transportation meets all requirements of section 4.15

contract, load sign off documents

Design and development

Guidelines and restrictions on R&D introducing new hazards

HACCP review completed prior to product introduction to operations

Product trials where needed to validate process

Label design satisfies requirements and regulations of country of sale

target market label regulations and approval process

Allergen management

Risk assessment as to potential for raw materials to be contaminated with allergens

supplier certification or questionaires

what and where allergens are found

5.2.3 x

5.2.4 P

5.2.5

5.2.6

5.2.7 Validation of allergen free label claims validation studies

5.2.8

5.2.9 x

5.2.10 Effective packaging changeover system

5.3

5.3.1

5.3.2 x

5.3.3

5.4

Risk assessment to identify vectors of allergen contamination

Documented allergen segregation procedures in place and effective

If rework of allergen containing materials is carried out, appropriate controls in place

If contamination connot be effectively controlled, appropriate consumer lable warnings in place

Allergen cleaning procedures validated and verified. Allergen cleaning equipment segragated and identified

cleaning validation studiues

All persons entering the site shall have allergen awareness training

visitor and contractor training

Provenance and assured status

Where provenance is required, raw material verification in place

certificates for raw materials

Records of material provenance maintained. Mass balance every 6 months

mass balance results

Process flow specific to assured status products documented and appropriate controls to maintain in place

flow diagram specific to assured status product

Product packaging

5.4.1 x

5.4.2

5.4.3

5.5

5.5.1

5.5.1.1 Product testing program based on risk

5.5.1.2 x trend analysis

5.5.1.3 Ongoing shelf life studies in place

5.5.2 Lab testing5.5.2.1 Pathogen testing fully segragated

5.5.2.2

5.5.2.3 x lab accreditation

5.5.2.4 Good lab practices in place x

5.6 Product release

Documented evidence of suitability based on intended use for all packaging

proof of material compatability

Storage conditions suitable to maintain packaging integrity. Obsolete packaging suitably controlled

Product contact liners for work in process and ingredients purchased by the company appropriately colored

Inspection and testing

Product inspection and testing

Results reviewed, analyzed, and where needed, acted upon

Laboratory controls in place to prevent contamination

Critical lab testing performed by accredted laborotory, or in accordance to accredtation guidelines

5.6.1 P

6 Process controls

6.1

6.1.1 x

6.1.2

6.1.3

6.1.4 Process validation frequency basd on risk x

6.1.5 P

6.1.6 Product changeover procedure P

6.1.7 Product packaging verification P

6.2 Quantity control

6.2.1

6.2.2

6.3 Calibration

6.3.1

Where required, positive release procedures fully implemented

Control of operations

Process specifications and work instructions available and suitable

Process monitoring in place to esnure production meets specifications

If process controls are automated, suitable tested failure alert system is in place

process validation matrrix

Procedures to evaluate product in the event of process deviation

changeover pre-op inspections

packaging verification checks

Weight control programs meet regulatory requirements

regulation for country of destination

Weight control programs meet customer specifications

Equipment to be calibrated is: documented, identified, scheduled, protected

6.3.2 P

6.3.3

6.3.4 P

7 Personnel7.1 Training

7.1.1 x7.1.2 Training relevant to CCP`s x

7.1.37.1.4 Records of training R

7.1.5

7.2 Personal hygiene P jewelry policy

7.2.1

7.2.2

7.2.3

7.2.4 x test results

7.2.5 Personal medicine policy and procedure x P

Calibration frequency based on risk and procedures based on standard

calbration methods and matrix

Reference calibration equipment traceable to Standard

calbration certificate of standards

Procedures to follow in the event of equipment found out of calibration and product potentially at risk

Pre-employment training for staff, temps and contractors

Assessment and delivery plan for staff training

job / training matrix

Staff competency and training effectiveness assessments

Policies for jewelry, nail care and personal hygiene

Hand cleaning on entry to production areas

Cuts protected, bandages appropriately colored, meteal detectable.

If metal detectors are present, bandages are tested for detection

7.3 Medical screening

7.3.1 P

7.3.2 P

7.3.3 P

7.4

7.4.1 P

7.4.2

7.4.3

7.4.4 P

7.4.5

7.4.6

Procedure for employees to notify site of sickness or sympton if relevant

Notification to visitors of health and sickness risk and procedures

Procedure for site to follow if employees or visitors indicate they may be suffering from a relevant disease

Protective clothing

Protctive clothing policy, including wearing outside of the work environment

Protective clothing is suitable to protect the product

Work wear laundered by service contractor or in house. Self laundry only for enclosed or low risk zones

Laundry for HC / HR areas includes: laundry procedures, commercial sterilization, segragation, protection of clean work wear

Gloves suitable for purpose, preferably colored.

Non-launderable articles maintained clean and sanitary.

High care / high risk

Clause Event Expectation Evidence Outcome

1.1.3 Meeting minutes

1.1.4 Meeting minutes

2.6.1

2.14.1 HACCP review Review notes

3.4.1 Internal audit Internal audit report

3.4.4 Inspection report

Senior management review

Meeting to ensure food safety and quality measures are in place and appropriate action plans managed

Issues identified, action plans in place, resources allocated, targets defined, verification of results

Management meetings

Program of meetings to track objectives, issues and ongoing operational results

Periodic review of objectives and operational performance, a means of steering the operation to ensure overall goals are met and maintained. Data analysis for senior management review.

Verification of HACCP flow diagrams

Ensure flow diagrams used within the HACCP plan and other areas are up to date and accurate

Singed and dated flow diagrams, or other evidance of their verification

Flow diagrams support control activities, reported in internal audit

Comprehensive review of the HACCP plan, to ensure it is effectively in place and adequately manages risk within the operation

HACCP plan accurately reflects the process. Reported to senior management review

All clauses and requirements of the stadnard are audited to ensure effective compliance

Documented evidence showing conformance to the standard. Reproted to senior management review

Internal inspections

Environmental and hygiene programs and results audited and inspected

Site conditions and activities meet expectations. Reported to monthly management meetings

3.6.5 Specifications

3.9.2 Traceability test Test results

3.11.3 Recall test Test report

4.2.1

Specifications are periodically reviewed to ensure accuracy to current operations

Specification review program or dated specifications

Site ensures specifications are up to date.

Mass balance of finished goods, raw materials and packaging tested

Full traceability achieved within 4 hours

Recall procedure is validated and tested to ensure operational readiness and effectiveness

Opportunity for process improvements

Security risk assessment

Operation security risks assessed

Security risk assessment report

Opportunity for improvements

Annual

Monthly

Monthly

Minimum frequency

Annual, or in the event of changes

Annual, or in the event of changes

Annual, or more frequent based on risk

Annual

Annual

Annual

Every 3 years or more as required