The BRC Global Standard for Food Safety: A Guide to a Successful Audit

"This book offers companies in the food industry the first comprehensive guide to preparing for the Global Standard Audit." Beverage and Food World, May 2009 BASED ON ISSUE 5 OF THE BRC STANDARD The British Retail Consortium Global Standard for Food Safety was originally conceived to meet an increasing demand for a unified standard to be used by the major retailers in the UK for their suppliers of "own label" food products. The system has proved so successful that it is now used throughout the food industry, and over 7000 food manufacturers worldwide already have the Standard. Companies are often unsure about how to approach attaining certification—often a demanding process, especially at the first attempt. Not only are there over 300 clauses to satisfy, there are also general concerns such as how to correct non-conformities within very specific deadlines. Even when their operations are actually quite satisfactory, many suppliers find themselves poorly prepared for the audit and do not perform as well as they might. This book offers companies in the food industry the first comprehensive guide to preparing for the Global Standard audit. Using over 600 real life examples, it enables manufacturers to ensure that the correct systems are in place to achieve the Standard and present themselves in the best way during the audit process. It also recommends the steps to take following the audit and how to correct non-conformities. The book is an essential resource for suppliers wishing to attain certification for the first time and those already in the scheme seeking to improve their grades. It is also of interest to certification bodies and consultants to the food industry.

Table of Contents:
Acronyms xi Acknowledgements xiii Introduction 1 Part One Preparation for the Audit 5 Chapter 1 Keys to Success 7 Success 7 Failure 7 Preparation 8 Documented Procedures and Records 8 Evidence 9 Track Record 10 Team Building 10 See Yourselves as Others See You 11 Chapter 2 Familiarity with the Standard 12 Why Choose the Global Standard for Food Safety? 12 The Structure of the Standard 13 Section I: 1. The Introduction 13 Section I: 2. Food Safety Management System 14 Section II: The Requirements 14 The BRC Guideline Series and Other Support Information 15 The Fundamental Requirements 15 Recurring Themes 18 Section III: How to Gain Certifi cation – Understanding the Protocol 21 Unannounced Audits 28 Position Statements 29 Section IV and the Appendices 29 Chapter 3 Planning for the Audit 30 Choosing a Certifi cation Body 30 The Application Form and Contract 35 Agreeing the Scope 36 Registering with the BRC 37 Fixing a Date 38 Key Staff 38 Internal Audit 39 Availability of Records and Other Evidence 39 Facilities for the Auditor 40 Pre-Audits 41 Pre-Audit Checklist 41 Chapter 4 How to Conduct Yourself at the Audit 42 The Format of the Audit 42 Keeping the Auditor Safe 43 Preventing Interruptions 44 Letting the Auditor Lead the Audit 44 Listening to the Question 45 Knowing When to be Quiet 46 Being Positive and Co-operative 46 Consultants 46 Remembering the Obvious 47 Correcting Nonconformities during the Audit 47 The Closing Meeting 47 Part Two The Requirements of the Standard: What the Auditor Will Be Looking For 49 Chapter 5 Clause 1: Senior Management Commitment and Continual Improvement 51 Clause 1 51 Clause 1.1 52 Clause 1.2 52 Clause 1.3 53 Clause 1.4 54 Clause 1.5 54 Clause 1.6 55 Clause 1.7 56 Clause 1.8 57 Clause 1.9 57 Clause 1.10 58 Clause 1.11 59 Clause 1.12 59 Clause 1.13 59 Chapter 6 Clause 2: Food Safety Plan – HACCP 61 Clause 2.0: Food Safety Plan – HACCP 61 Codex Alimentarius 63 Other Aspects 63 Clause 2.1 63 Clause 2.2 68 Clause 2.3 70 Clause 2.4 70 Clause 2.5 71 Clause 2.6 72 Clause 2.7 77 Clause 2.8 79 Clause 2.9 82 Clause 2.10 85 Clause 2.11 86 Clause 2.12 88 Clause 2.13 88 Chapter 7 Clause 3: Food Safety and Quality Management System 91 Clause 3.1: Food Safety and Quality Policy 91 Clause 3.2: Food Safety and Quality Manual 93 Clause 3.3: Organisational Structure, Responsibilities and Management Authority 96 Clause 3.4: Contract Review and Customer Focus 100 Clause 3.5: Internal Audit 102 Clause 3.6: Purchasing 109 Clause 3.7: General Documentation Requirements 113 Clause 3.8: Corrective and Preventive Action 123 Clause 3.9: Traceability 125 Clause 3.10: Complaint Handling 130 Clause 3.11: Management of Incidents, Product Withdrawal and Product Recall 132 Chapter 8 Clause 4: Site Standards 140 Clause 4.1: External Standards 140 Clause 4.2: Security 143 Clause 4.3: Internal Site Standards 146 Clause 4.4: Utilities 165 Clause 4.5: Equipment 166 Clause 4.6: Maintenance 168 Clause 4.7: Staff Facilities 175 Clause 4.8: Physical and Chemical Product Contamination Control – Raw Material Handling, Preparation, Processing, Packing and Storage Areas 182 Clause 4.9: Housekeeping and Hygiene 192 Clause 4.10: Waste/Waste Disposal 198 Clause 4.11: Pest Control 200 Clause 4.12: Storage and Transport 207 Chapter 9 Clause 5: Product Control 215 Clause 5.1: Product Design/Development 215 Clause 5.2: Handling Requirements for Specifi c Materials – Materials Containing Allergens and Identity Preserved Materials 220 Clause 5.3: Foreign Body Detection 226 Clause 5.4: Product Packaging 232 Clause 5.5: Product Inspection and Laboratory Testing 235 Clause 5.6: Control of Non-Conforming Product 240 Clause 5.7: Product Release 242 Chapter 10 Clause 6: Process Control 244 Clause 6.0: Process Control 244 Clause 6.1: Control of Operations 244 Clause 6.2: Quantity – Weight, Volume and Number Control 250 Clause 6.3: Calibration and Control of Measuring and Monitoring Devices 252 Chapter 11 Clause 7: Personnel 257 Clause 7.1: Training – Raw Material Handling, Preparation, Processing, Packing and Storage Areas 257 Clause 7.2: Access and Movement of Personnel 261 Clause 7.3: Personal Hygiene – Raw Material Handling, Preparation, Processing, Packing and Storage Areas 263 Clause 7.4: Medical Screening 270 Clause 7.5: Protective Clothing – Employees or Visitors to Production Areas 272 Part Three After the On-Site Audit 279 Chapter 12 Correcting Nonconformities 281 Documentary Evidence 281 Stating the Corrective Action 281 Conclusion 296 Minor Nonconformities 296 The Nature of the Evidence 297 Corrective Actions: Follow Up 297 Ways of Sending Evidence 299 Other Ways of Helping the CB 299 Returning to Your Site 300 Chapter 13 What Next? 302 Failure 302 Success 302 References 305 Useful Websites 305 Appendices 307 Appendix 1 What Happened to Issue 4? 309 Appendix 2 Pre-Audit Checklist 319 Index 337

About the Author :
Dr Ron Kill is Managing Director, Micron Laboratories Ltd, UK

Review :
"Overall, this is a very useful book to use a guide to the BRC Global Standard for Food Safety, in preparing for and following up on a BRC audit. Its price is reasonable and should be good value, and a worthwhile acquisition, particularly for food businesses starting on the road to achieve accreditation to that standard." (International Journal of Dairy Technology, February 2011) “This book offers companies in the food industry the first comprehensive guide to preparing for the Global Standard Audit.” (Beverage and Food World, May 2009)