brc food6 - checklist
TRANSCRIPT
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