brc food -training kalpesh corporation

8/6/2019 BRC Food -Training Kalpesh Corporation

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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


2.0 Food Safety Plan2.0 Food Safety Plan HACCPHACCP Based on codex alimentariusBased on codex alimentarius


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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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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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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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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



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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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



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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




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Snap-off blades

Drawing pins / staples onN otice boards




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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



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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.



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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



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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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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



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7.2 Access & Movement of Personnel7.2 Access & Movement of Personnel

Designated entrances

Site security

Designated walkways

Logical movements



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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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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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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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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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7.5 Protective Clothing7.5 Protective Clothing

Containing of Scalp hair

Cleaning & laundering of clothingSelf care laundry Specific precautions