BRC Global Standard for Food Safety

Dr Ron Kill has worked in the technical side of the food industry for 40 years including laboratory, manufacturing, retail, auditing and training aspects.  He has been involved with the Global Standard for Food Safety since its beginnings and is MD of a Certification Body, Micron2 Ltd. He is also an Approved Training Provider for the BRC.

• About the Online Training Resources xiCast of Characters xiiiAbbreviations xvAcknowledgements xviiIntroduction to Second Edition xixIntroduction to First Edition xxiPart One Before the Audit 1Chapter 1 The Changes: Issue 5 to Issue 6 3Reasons for Change 3Two-Part Auditing: Increased Focus on GMP 4Vertical Audits 4Unannounced Audits 4Enrolment Programme 4High Care and High Risk 5New Report Format 5Other Protocol Changes 5Changes to Requirements 6Chapter 2 Keys to Success 7Success 7Failure 8Embrace the Standard 8Preparation 9Documented Procedures and Records 9Evidence 10Track Record 10Team Building 10Internal Audit 11See Yourselves as Others See You 11Summary 12Chapter 3 Some Background 13What is a Certification Body? 13Accreditation and Competency 13A CB’s Contract with the BRC 15Consistency 15Summary 18Chapter 4 Familiarity with the Standard: Part 1 – Structure and Concepts 19Why Choose the Global Standard for Food Safety? 19Global Food Safety Initiative 20Issue 6 20The Structure of the Standard 20Section I 20Section II: The Requirements 21Recurring Themes 25Section III: The Audit Protocol 29Section IV: The Appendices and the Glossary 29The BRC Guideline Series and Other Support Information 30Summary 30Chapter 5 Familiarity with the Standard: Part 2 – The Protocol 31Paragraph 1: Introduction 31Paragraph 2: Self-Assessment of Compliance with the Standard 32Paragraph 3: Selection of an Audit Option 32Paragraph 4: Selection of a CB 37Paragraph 5: Company/CB Contractual Arrangements 37Paragraph 6: Scope of Audit 38What About ‘Factored Goods’? 38Paragraph 7.1: Audit Planning 38Paragraph 7.2: Information to be Provided to the CB for Audit Preparation 38Paragraph 7.3: Duration of the Audit 39Paragraph 8: The On-Site Audit 39Paragraph 9: Nonconformities and Corrective Action 39Summary 43Chapter 6 Familiarity with the Standard: Part 3 – Section IV and the Appendices 45Section IV: Management and Governance of the Scheme 45The Appendices 45Summary 50Chapter 7 Final Steps to the Audit 51Choosing a Certification Body 51The Application Form and Contract 53Agreeing the Scope 54Registering with the BRC 57Fixing a Date 57Key Staff 58Availability of Records and Other Evidence 58Pre-Audits 59Facilities for the Auditor 60Summary 60Chapter 8 The Global Standards Website and Directory 63The BRC Global Standards Website 63The Directory 66Summary 68Chapter 9 Training for the Standard 69Official BRC Courses 69Approved Training Providers 71Other Training Requirements 71Finding the Right Course for You 71Summary 73Part Two The Audit 75Chapter 10 How to Survive the Audit 77The Format of the Audit 77Keeping the Auditor Safe 81Preventing Interruptions 82Letting the Auditor Lead the Audit 82Listening to the Question 82Knowing When to be Quiet 83Being Positive and Co-operative 84Consultants 84Remembering the Obvious 84Correcting Nonconformities During the Audit 85May We Offer the Auditor a Gift? 85Summary 85Chapter 11 Clause 1: Senior Management Commitment 87Clause 1.1: Senior Management Commitment and Continual Improvement (Fundamental) 87Clause 1.2: Organisational Structure, Responsibilities and Management Authority 96Summary 99Chapter 12 Clause 2: Food Safety Plan – HACCP 101Clause 2.0: Food Safety Plan – HACCP (Fundamental) 101Codex Alimentarius 103Other Aspects 103Clause 2.1 103Clause 2.2 106Clause 2.3 107Clause 2.4 109Clause 2.5 110Clause 2.6 111Clause 2.7 112Clause 2.8 116Clause 2.9 118Clause 2.10 121Clause 2.11 123Clause 2.12 124Clause 2.13 125Clause 2.14 126Summary 127Chapter 13 Clause 3: Food Safety and Quality Management System 129Clause 3.1: Food Safety and Quality Manual 129Clause 3.2: Documentation Control 132Clause 3.3: Record Completion and Maintenance 135Clause 3.4: Internal Audit (Fundamental) 137Summary of Internal Audit 144Clause 3.5: Supplier and Raw Material Approval and Performance Monitoring 145Clause 3.6: Specifications 152Clause 3.7: Corrective Action (Fundamental) 155Clause 3.8: Control of Nonconforming Product 157Clause 3.9: Traceability (Fundamental) 159Clause 3.10: Complaint Handling 165Clause 3.11: Management of Incidents, Product Withdrawal and Product Recall 167Summary 172Chapter 14 Clause 4: Site Standards 173Production Risk Zones 173Clause 4.1: External Standards 174Clause 4.2: Security 177Clause 4.3: Layout, Product Flow and Segregation (Fundamental) 179Clause 4.4: Building Fabric – Raw Material Handling, Preparation, Processing, Packing and Storage Areas 185Clause 4.5: Utilities – Water, Ice, Air and Other Gases 196Clause 4.6: Equipment 198Clause 4.7: Maintenance 200Clause 4.8: Staff Facilities 206Clause 4.9: Physical and Chemical Product Contamination Control – Raw Material Handling, Preparation, Processing, Packing and Storage Areas 215Clause 4.10: Foreign Body Detection and Removal Equipment 225Clause 4.11: Housekeeping and Hygiene (Fundamental) 235Clause 4.12: Waste/Waste Disposal 241Clause 4.13: Pest Control 244Clause 4.14: Storage Facilities 253Clause 4.15: Dispatch and Transport 257Summary 262Chapter 15 Clause 5: Product Control 263Clause 5.2: Management of Allergens (Fundamental) 263Clause 5.1: Product Design/Development 271Clause 5.3: Provenance, Assured Status and Claims of Identity Preserved Materials 275Clause 5.4: Product Packaging 276Clause 5.5: Product Inspection and Laboratory Testing 278Clause 5.6: Product Release 284Summary 285Chapter 16 Clause 6: Process Control 287Clause 6.1: Control of Operations (Fundamental) 287Clause 6.2: Quantity – Weight, Volume and Number Control 292Clause 6.3: Calibration and Control of Measuring and Monitoring Devices 295Summary 300Chapter 17 Clause 7: Personnel 301Clause 7.1: Training – Raw Material Handling, Preparation, Processing, Packing and Storage Areas (Fundamental) 301Clause 7.2: Personal Hygiene – Raw Material Handling, Preparation, Processing, Packing and Storage Areas 306Clause 7.3: Medical Screening 311Clause 7.4: Protective Clothing – Employees or Visitors to Production Areas 313Summary 319Part Three After the Audit 321Chapter 18 From Audit to Certification 323Paragraph 9.2: Procedures for Handling Nonconformities and Corrective Action 323Paragraph 10: Grading of the Audit 326Paragraph 11: Audit Reporting 327Paragraph 12: Certification 327Summary 328Chapter 19 Correcting Nonconformities 329Documentary Evidence 329Stating the Corrective Action 330Conclusion 346The Nature of the Evidence 346Corrective Actions: Follow Up 347Ways of Sending Evidence 348Other Ways of Helping the CB 349Returning to Your Site 349Root Cause 350Enrolment Programme 352Summary 352Chapter 20 Certification and What Happens Next 353Success! 353Paragraph 13: BRC Logos and Plaques 355Paragraph 14: The BRC Global Standards Directory 355Paragraph 15: Surveillance of Certificated Companies 355Paragraph 16: Ongoing Audit Frequency and Certification 355Paragraph 17: Communication with CBs 356Paragraph 18: Appeals 357Other Matters 357Summary 358References 359Useful Websites 360Appendices 361Appendix 1 Answers to Quizzes and Exercise 363Appendix 2 Where Did Issue 5 Go? 367Appendix 3 New Clauses for Issue 6 375Appendix 4 Changes to Product Categories from Issue 5 to Issue 6 377Index 379