The BRC global standard for food safety a guide to a successful audit

P1: SFK/UKS P2: SFK BLBK426-fm BLBK426-Kill May 12, 2012 11:50 Trim: 244mm×172mm The BRC Global Standard for Food Safety P1: SFK/UKS P2: SFK BLBK426-fm BLBK426-Kill May 12, 2012 11:50 Trim: 244mm×172mm The BRC Global Standard for Food Safety A Guide to a Successful Audit Second Edition Ron Kill Micron2 Ltd Market Drayton Shropshire UK A John Wiley & Sons, Ltd., Publication P1: SFK/UKS P2: SFK BLBK426-fm BLBK426-Kill May 12, 2012 11:50 This edition first published 2012 First edition C 2008 by Ron Kill C Trim: 244mm×172mm 2012 by John Wiley & Sons, Ltd Wiley-Blackwell is an imprint of John Wiley & Sons, formed by the merger of Wiley’s global Scientific, Technical and Medical business with Blackwell Publishing Registered office: John Wiley & Sons, Ltd, The Atrium, Southern Gate, Chichester, West Sussex, PO19 8SQ, UK Editorial offices: 9600 Garsington Road, Oxford, OX4 2DQ, UK The Atrium, Southern Gate, Chichester, West Sussex, PO19 8SQ, UK 2121 State Avenue, Ames, Iowa 50014-8300, USA For details of our global editorial offices, for customer services and for information about how to apply for permission to reuse the copyright material in this book please see our website at www.wiley.com/wiley-blackwell The right of the author to be identified as the author of this work has been asserted in accordance with the UK Copyright, Designs and Patents Act 1988 All rights reserved No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, except as permitted by the UK Copyright, Designs and Patents Act 1988, without the prior permission of the publisher Designations used by companies to distinguish their products are often claimed as trademarks All brand names and product names used in this book are trade names, service marks, trademarks or registered trademarks of their respective owners The publisher is not associated with any product or vendor mentioned in this book This publication is designed to provide accurate and authoritative information in regard to the subject matter covered It is sold on the understanding that the publisher is not engaged in rendering professional services If professional advice or other expert assistance is required, the services of a competent professional should be sought Library of Congress Cataloging-in-Publication Data Kill, R C The BRC global standard for food safety : a guide to a successful audit / Ron Kill – 2nd ed p cm Includes bibliographical references and index ISBN 978-0-470-67065-1 (pbk : alk paper) Food industry and trade–Standards–Great Britain Food industry and trade–Standards I Title TX537.K54 2012 338.1 9–dc23 2012010600 A catalogue record for this book is available from the British Library Wiley also publishes its books in a variety of electronic formats Some content that appears in print may not be available in electronic books Cover design by www.hisandhersdesign.co.uk Set in 10/12pt Sabon by Aptara R Inc., New Delhi, India 2012 P1: SFK/UKS P2: SFK BLBK426-fm BLBK426-Kill May 12, 2012 11:50 Trim: 244mm×172mm Contents About the Online Training Resources Cast of Characters Abbreviations Acknowledgements xi xiii xv xvii Introduction to Second Edition Introduction to First Edition xix xxi Part One Before the Audit Chapter The Changes: Issue to Issue Reasons for Change Two-Part Auditing: Increased Focus on GMP Vertical Audits Unannounced Audits Enrolment Programme High Care and High Risk New Report Format Other Protocol Changes Changes to Requirements 4 4 5 Keys to Success Success Failure Embrace the Standard Preparation Documented Procedures and Records Evidence Track Record Team Building Internal Audit See Yourselves as Others See You Summary 8 9 10 10 10 11 11 12 Chapter P1: SFK/UKS P2: SFK BLBK426-fm BLBK426-Kill vi May 12, 2012 11:50 Trim: 244mm×172mm Contents Chapter Chapter Chapter Chapter Chapter Some Background 13 What is a Certification Body? Accreditation and Competency A CB’s Contract with the BRC Consistency Summary 13 13 15 15 18 Familiarity with the Standard: Part – Structure and Concepts 19 Why Choose the Global Standard for Food Safety? Global Food Safety Initiative Issue The Structure of the Standard Section I Section II: The Requirements Recurring Themes Section III: The Audit Protocol Section IV: The Appendices and the Glossary The BRC Guideline Series and Other Support Information Summary 19 20 20 20 20 21 25 29 29 30 30 Familiarity with the Standard: Part – The Protocol 31 Paragraph 1: Introduction Paragraph 2: Self-Assessment of Compliance with the Standard Paragraph 3: Selection of an Audit Option Paragraph 4: Selection of a CB Paragraph 5: Company/CB Contractual Arrangements Paragraph 6: Scope of Audit What About ‘Factored Goods’? Paragraph 7.1: Audit Planning Paragraph 7.2: Information to be Provided to the CB for Audit Preparation Paragraph 7.3: Duration of the Audit Paragraph 8: The On-Site Audit Paragraph 9: Nonconformities and Corrective Action Summary 31 32 32 37 37 38 38 38 38 39 39 39 43 Familiarity with the Standard: Part – Section IV and the Appendices 45 Section IV: Management and Governance of the Scheme The Appendices Summary 45 45 50 Final Steps to the Audit 51 Choosing a Certification Body The Application Form and Contract Agreeing the Scope 51 53 54 P1: SFK/UKS P2: SFK BLBK426-fm BLBK426-Kill May 12, 2012 11:50 Trim: 244mm×172mm Contents vii Registering with the BRC Fixing a Date Key Staff Availability of Records and Other Evidence Pre-Audits Facilities for the Auditor Summary 57 57 58 58 59 60 60 The Global Standards Website and Directory 63 The BRC Global Standards Website The Directory Summary 63 66 68 Training for the Standard 69 Official BRC Courses Approved Training Providers Other Training Requirements Finding the Right Course for You Summary 69 71 71 71 73 The Audit 75 Chapter 10 How to Survive the Audit 77 The Format of the Audit Keeping the Auditor Safe Preventing Interruptions Letting the Auditor Lead the Audit Listening to the Question Knowing When to be Quiet Being Positive and Co-operative Consultants Remembering the Obvious Correcting Nonconformities During the Audit May We Offer the Auditor a Gift? Summary 77 81 82 82 82 83 84 84 84 85 85 85 Chapter 11 Clause 1: Senior Management Commitment 87 Chapter Chapter Part Two Clause 1.1: Senior Management Commitment and Continual Improvement (Fundamental) Clause 1.2: Organisational Structure, Responsibilities and Management Authority Summary 96 99 Chapter 12 Clause 2: Food Safety Plan – HACCP 101 Clause 2.0: Food Safety Plan – HACCP (Fundamental) Codex Alimentarius 101 103 87 P1: SFK/UKS P2: SFK BLBK426-fm BLBK426-Kill viii May 12, 2012 11:50 Trim: 244mm×172mm Contents Other Aspects Clause 2.1 Clause 2.2 Clause 2.3 Clause 2.4 Clause 2.5 Clause 2.6 Clause 2.7 Clause 2.8 Clause 2.9 Clause 2.10 Clause 2.11 Clause 2.12 Clause 2.13 Clause 2.14 Summary 103 103 106 107 109 110 111 112 116 118 121 123 124 125 126 127 Chapter 13 Clause 3: Food Safety and Quality Management System 129 Clause 3.1: Food Safety and Quality Manual Clause 3.2: Documentation Control Clause 3.3: Record Completion and Maintenance Clause 3.4: Internal Audit (Fundamental) Summary of Internal Audit Clause 3.5: Supplier and Raw Material Approval and Performance Monitoring Clause 3.6: Specifications Clause 3.7: Corrective Action (Fundamental) Clause 3.8: Control of Nonconforming Product Clause 3.9: Traceability (Fundamental) Clause 3.10: Complaint Handling Clause 3.11: Management of Incidents, Product Withdrawal and Product Recall Summary 129 132 135 137 144 167 172 Chapter 14 Clause 4: Site Standards 173 Production Risk Zones Clause 4.1: External Standards Clause 4.2: Security Clause 4.3: Layout, Product Flow and Segregation (Fundamental) Clause 4.4: Building Fabric – Raw Material Handling, Preparation, Processing, Packing and Storage Areas Clause 4.5: Utilities – Water, Ice, Air and Other Gases Clause 4.6: Equipment Clause 4.7: Maintenance Clause 4.8: Staff Facilities 173 174 177 179 145 152 155 157 159 165 185 196 198 200 206 P1: SFK/UKS P2: SFK BLBK426-fm BLBK426-Kill May 12, 2012 11:50 Trim: 244mm×172mm Contents ix Clause 4.9: Physical and Chemical Product Contamination Control – Raw Material Handling, Preparation, Processing, Packing and Storage Areas Clause 4.10: Foreign Body Detection and Removal Equipment Clause 4.11: Housekeeping and Hygiene (Fundamental) Clause 4.12: Waste/Waste Disposal Clause 4.13: Pest Control Clause 4.14: Storage Facilities Clause 4.15: Dispatch and Transport Summary 215 225 235 241 244 253 257 262 Chapter 15 Clause 5: Product Control 263 Clause 5.2: Management of Allergens (Fundamental) Clause 5.1: Product Design/Development Clause 5.3: Provenance, Assured Status and Claims of Identity Preserved Materials Clause 5.4: Product Packaging Clause 5.5: Product Inspection and Laboratory Testing Clause 5.6: Product Release Summary 263 271 275 276 278 284 285 Chapter 16 Clause 6: Process Control 287 Clause 6.1: Control of Operations (Fundamental) Clause 6.2: Quantity – Weight, Volume and Number Control Clause 6.3: Calibration and Control of Measuring and Monitoring Devices Summary 287 292 295 300 Chapter 17 Clause 7: Personnel 301 Clause 7.1: Training – Raw Material Handling, Preparation, Processing, Packing and Storage Areas (Fundamental) Clause 7.2: Personal Hygiene – Raw Material Handling, Preparation, Processing, Packing and Storage Areas Clause 7.3: Medical Screening Clause 7.4: Protective Clothing – Employees or Visitors to Production Areas Summary 313 319 Part Three After the Audit 321 Chapter 18 From Audit to Certification 323 Paragraph 9.2: Procedures for Handling Nonconformities and Corrective Action Paragraph 10: Grading of the Audit Paragraph 11: Audit Reporting Paragraph 12: Certification Summary 323 326 327 327 328 301 306 311 P1: SFK/UKS P2: SFK BLBK426-fm BLBK426-Kill x May 12, 2012 11:50 Trim: 244mm×172mm Contents Chapter 19 Correcting Nonconformities 329 Documentary Evidence Stating the Corrective Action Conclusion The Nature of the Evidence Corrective Actions: Follow Up Ways of Sending Evidence Other Ways of Helping the CB Returning to Your Site Root Cause Enrolment Programme Summary 329 330 346 346 347 348 349 349 350 352 352 Chapter 20 Certification and What Happens Next 353 Success! Paragraph 13: BRC Logos and Plaques Paragraph 14: The BRC Global Standards Directory Paragraph 15: Surveillance of Certificated Companies Paragraph 16: Ongoing Audit Frequency and Certification Paragraph 17: Communication with CBs Paragraph 18: Appeals Other Matters Summary 353 355 355 355 355 356 357 357 358 References Useful Websites 359 360 Appendices 361 Answers to Quizzes and Exercise Where Did Issue Go? New Clauses for Issue Changes to Product Categories from Issue to Issue 363 367 375 377 Index 379 Appendix Appendix Appendix Appendix P1: SFK/UKS P2: SFK BLBK426-RESOURCES BLBK426-Kill May 28, 2012 15:39 Trim: 244mm×172mm About the Online Training Resources BRC Update Course Issue to Issue This course guides the delegate through all the major changes of the BRC Global Standard for Food Safety from Issue to Issue in an easy-to-use e-training course The course has been developed to complement the book and provides a searchable database of all the changes To start using the course, just email info@micron2.com and request your username and password today, stating ‘BRC Global Standard Course’ in the subject line For more details on how to start using the course in conjunction with this book, just go to www.wiley.com/go/kill/brcglobalstandard Micron2 in conjunction with totrain are also providing other food-related courses; for more information go to the Micron2 web site at www.micron2.com and click on the e-learning link P1: SFK/UKS P2: SFK BLBK426-bapp02 BLBK426-Kill May 9, 2012 8:18 Trim: 244mm×172mm Where Did Issue Go? Issue clause Issue destination Section 3.5.6 3.6 3.6.1 3.6.2 3.6.3 3.6.4 3.7.1 3.7.1.1 3.7.1.2 3.7.1.3 3.7.1.4 3.7.2 3.7.2.1 3.7.2.2 3.7.2.3 3.7.2.5 3.7.3 3.7.3.1 3.7.3.2 3.7.3.3 3.7.3.4 3.7.3.5 3.8 3.8.1 3.8.2 3.8.3 3.8.4 3.9 3.9.1 3.9.2 3.9.3 3.9.4 3.10 3.10.1 3.10.2 3.10.3 3.11 3.11.1 3.11.2 3.11.3 3.11.4 3.11.5 3.11.6 3.11.7 3.4.4 3.5.1 and 3.5.3 3.5.1.2 and 3.5.3.1 3.5.1.2 3.5.1.3 Removed 3.2 3.2 3.1.3 3.2.1 3.2.1 3.6 3.6.1 3.6.2 3.6.4 3.6.5 3.3 3.3.1 3.3.1 Removed 3.3.2 3.3.2 3.7 3.7.1 3.7.1 3.7.1 3.7.1 3.9 3.9.1 3.9.2 5.3.2 3.9.3 3.10 3.10.1 3.10.1 3.10.2 3.11 3.11.1 3.11.2 3.11.2 3.11.2 3.11.3 3.11.3 3.11.4 (continued) 369 P1: SFK/UKS P2: SFK BLBK426-bapp02 370 BLBK426-Kill May 9, 2012 8:18 Trim: 244mm×172mm Appendices Issue clause Issue destination Section 4.1 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.3.1 4.3.1.1 4.3.1.2 4.3.1.3 4.3.1.4 4.3.1.5 4.3.1.6 4.3.1.7 4.3.1.8 4.3.1.9 4.3.1.10 4.3.2 4.3.2.1 4.3.2.2.1 4.3.2.2.2 4.3.2.2.3 4.3.2.3.1 4.3.2.3.2 4.3.2.4.1 4.3.2.4.2 4.3.2.5.1 4.3.2.5.2 4.3.2.6.1 4.3.2.6.2 4.3.2.7.1 4.3.2.7.2 4.3.2.7.3 4.4 4.4.1 4.4.2 4.5 4.5.1 4.5.2 4.1 4.1.1 4.1.2 Removed 4.1.2 4.1.3 4.2 4.2.2 4.2.2 4.2.2 4.2.1 Removed 4.2.3 4.3 4.3.4 4.3.4 4.3.4 Removed 4.3.7 4.3.1.5 4.3.8 4.3.5 4.3.6 4.3.5 4.4 4.4.1 4.4.2 4.4.3 4.4.3 4.4.5 4.4.6 4.4.7 4.4.8 4.4.9 4.4.9 4.4.10 4.4.11 4.4.12 4.4.13 4.4.13 4.5 4.5.1 4.5.4 4.6 4.6.1 Removed P1: SFK/UKS P2: SFK BLBK426-bapp02 BLBK426-Kill May 9, 2012 8:18 Trim: 244mm×172mm Where Did Issue Go? Issue clause Issue destination Section 4.5.3 4.6 4.6.1 4.6.2 4.6.3 4.6.4 4.6.5 4.6.6 4.6.7 4.6.8 4.6.9 4.7 4.7.1 4.7.2 4.7.3 4.7.4 4.7.5 4.7.6 4.7.7 4.7.8 4.7.9 4.7.10 4.7.11 4.8 4.8.1 4.8.2 4.8.3.1 4.8.3.2 4.8.3.3 4.8.3.4 4.8.4.1 4.8.4.2 4.8.4.3 4.8.5.1 4.8.6.1 4.9 4.9.1 4.9.2 4.9.3 4.9.4 4.9.5 4.9.6 4.10 4.10.1 4.10.2 4.6.2 4.7.1 4.7 4.7.1 4.7.4 4.7.2 4.7.3 4.3.3 4.7.4 4.7.5 4.7.6 4.8 4.3.2/4.8.1 4.8.2 4.8.3 4.8.6 4.8.7 4.8.8 4.8.9 4.8.10 4.8.9 Removed 4.8.5 4.9 Removed 4.9.1.1 4.9.2.1 4.9.2.1 Removed 4.9.2.2 4.9.3.1 4.9.3.2 4.9.3.3 4.9.4.1 4.10.2.2 4.11 4.11.1 4.11.6.1 4.11.3 4.11.5 4.11.2 Removed 4.12 4.12 4.12.1 (continued) 371 P1: SFK/UKS P2: SFK BLBK426-bapp02 372 BLBK426-Kill May 9, 2012 8:18 Trim: 244mm×172mm Appendices Issue clause Issue destination Section 4.10.3 4.10.4 4.10.5 4.11 4.11.1 4.11.2 4.11.3 4.11.4 4.11.5 4.11.6 4.11.7 4.11.8 4.12 4.12.1 4.12.2 4.12.3 4.12.4 4.12.5 4.12.6 4.12.7 4.12.8 4.12.9 4.12.1 4.12.3 4.12.4 4.13 Removed 4.13.1 4.13.3 4.13.4 4.13.5 4.13.6 4.13.7 4.13.9 4.14 and 4.15 4.15.1 4.14.2 4.15.4 4.14.4 4.14.5 4.15.7 4.15.2 4.15.5 4.15.6 Section 5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 5.1.6 5.1.7 5.1.8 5.2 5.2.1.1 5.2.1.2 5.2.1.3 5.2.1.4 5.2.1.5 5.2.1.6 5.2.1.7 5.2.1.8 5.2.2.1 5.2.2.2 5.3.1 5.3.2 5.1 5.1.2 5.1.3 5.1.4 Removed 5.4.1 Removed 5.1.6 Removed 5.2 5.2.1 5.2.2 5.2.3 5.2.5 5.2.7 5.2.8 5.2.9 5.2.10 5.3.1 5.3.3 4.10.3.1 and 4.10.3.2 4.10.1.2 P1: SFK/UKS P2: SFK BLBK426-bapp02 BLBK426-Kill May 9, 2012 8:18 Trim: 244mm×172mm Where Did Issue Go? Issue clause Issue destination Section 5.3.3 5.3.4 5.3.5 5.4 5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.5 5.5.1.1 5.5.1.2 5.5.1.3 5.5.1.4 5.5.2.1 5.5.2.2 5.5.2.3 5.5.2.4 5.6 5.6.1 5.6.2 5.6.3 5.7 5.7.1 4.10.3.3 4.10.3.4 4.10.3.6 5.4 5.4.1 5.4.2 5.4.2 5.4.3 Removed 5.5 5.5.1.1 5.5.1.2 5.5.1.3 5.5.1.4 5.5.2.1 5.5.2.2 5.5.2.3 5.5.2.4 3.8 3.8.1 3.8.1 3.8.1 5.6 5.6.1 Section 6 6.1 6.1.1 6.1.2 6.1.3 6.1.4 6.1.5 6.1.6 6.1.7 6.1.8 6.2 6.2.1 6.2.2 6.3 6.3.1 6.3.2 6.3.3 6.3.4 Removed 6.1 6.1.1 6.1.2 Removed 6.1.3 6.1.5 Removed 6.1.7 Removed 6.2 6.2.1 6.2.2 6.3 6.3.1 6.3.2 6.3.1 6.3.4 (continued) 373 P1: SFK/UKS P2: SFK BLBK426-bapp02 374 BLBK426-Kill May 9, 2012 8:18 Trim: 244mm×172mm Appendices Issue clause Issue destination Section 7.1 7.1.1 7.1.2 7.1.3 7.1.4 7.1.5 7.2 7.2.1 7.2.2 7.2.3 7.2.4 7.3 7.3.1 7.3.2 7.3.3 7.3.4 7.3.5 7.3.6 7.3.7 7.3.8 7.3.9 7.3.10 7.4 7.4.1 7.4.2 7.4.3 7.5 7.5.1 7.5.2 7.5.3 7.5.4 7.5.5 7.5.6 7.5.7 7.5.8 7.5.9 7.5.10 7.1 7.1.1 7.1.2 7.1.3 7.1.4 7.1.5 4.3.2 4.3.2 4.3.2 4.3.2 4.3.3 7.2 7.2.1 7.2.1 7.2.1 7.2.2 7.2.1 7.2.1 4.8.8 7.2.3 7.2.4 7.2.5 7.3 7.3.1 7.3.2 7.3.3 7.4 7.4.1 7.4.2 4.8.3 7.4.3 Removed 7.4.2 7.4.2 Removed 7.4.5 4.8.4 P1: SFK/UKS P2: SFK BLBK426-bapp03 BLBK426-Kill May 9, 2012 8:13 Trim: 244mm×172mm Appendix New Clauses for Issue The following table shows the completely new clauses for Issue Clause Clause Clause Clause Clause Clause Clause None 2.2 3.4.4 4.3.1 5.1.1 6.1.4 7.4.4 3.5.1.1 4.4.4 5.1.5 6.1.6 7.4.6 3.5.2 4.5.2 5.2.4 6.3.3 3.5.2.1 4.5.3 5.2.6 3.5.3 4.8.4 3.5.3.1 4.9.1.2 3.5.3.2 4.9.3.4.1 3.5.4 4.9.3.4.2 3.5.4.1 4.9.3.4.3 3.5.4.2 4.10 3.5.4.3 4.10.1.1 3.5.4.4 4.10.1.2 4.10.1.3 4.10.1.4 4.10.2.1 4.10.3.5 4.10.4.1 4.10.5.1 (continued) The BRC Global Standard for Food Safety: A Guide to a Successful Audit, Second Edition Ron Kill c 2012 John Wiley & Sons, Ltd Published 2012 by John Wiley & Sons, Ltd P1: SFK/UKS P2: SFK BLBK426-bapp03 376 BLBK426-Kill May 9, 2012 8:13 Trim: 244mm×172mm Appendices Clause Clause Clause Clause Clause Clause Clause 4.10.6.2 4.11.6.2 4.11.6.3 4.12.2 4.13.2 4.13.8 4.14.3 4.15 Note: There are also several clauses that have been greatly revised or augmented for Issue 6, which are described in the relevant chapter An example is 3.6.3 concerning finished product specifications They were referred to in the previous SOI and were implicit in the clauses; however, the extra detail and new focus on branded product specifications make this almost a new clause Another example is 4.4.13 with the specific emphasis on positive air pressure and number of air changes for high-risk zones There are others P1: SFK/UKS P2: SFK BLBK426-bapp04 BLBK426-Kill May 9, 2012 8:42 Trim: 244mm×172mm Appendix Changes to Product Categories from Issue to Issue Issue reference Issue reference Appendix – product categories Appendix – product categories Category Changes High-care/low-risk principles omitted Comminuted fish products added from Category 4 High-care/low-risk principles omitted Comminuted fish products moved to Category 3, for example fish pie omitted Storage conditions now only ‘fresh’ Butter added, cheese food added Hot and cold eating pies removed to Category 10 10 Hot and cold eating pies added 12 Milk and cereal beverages omitted 14 ‘Frozen’ added to storage conditions 15 Sugar and flour added Gases omitted 16 Sugar removed 17 Now includes ‘Porridge’ oats 18 Butter moved to Category The BRC Global Standard for Food Safety: A Guide to a Successful Audit, Second Edition Ron Kill c 2012 John Wiley & Sons, Ltd Published 2012 by John Wiley & Sons, Ltd P1: SFK/UKS P2: SFK BLBK426-IND BLBK426-Kill May 25, 2012 12:54 Trim: 244mm×172mm Index accreditation bodies, 14, 16 air changes, 196 air filtration, 195–6, 198 allergens, 165, 263–71 claims, 269 labelling, 271 appeals, 357 application form, 53–4 approved training providers, 71–2 auditor qualifications, 47 auditor selection, 38 audits (to the global standard) announced, 33 closing meeting, 81 date, 57 delayed, 94 duration, 39, 81 facilities, 60 format, 77–82 frequency, 355–6 grading, 326–7 head office, 5, 48–9 initial, 33 internal (see internal audit) multiple sites 5, 48–9 opening meeting, 77–8 plan, 79 planning, 38 reporting, 327 scope, 38 unannounced, option 1, 34–5 option 2, 4, 35–6 beard snoods, 315 BRC directory, 63–8 BRC global standard for food safety, 19 obtaining a copy, protocol, 29, 31–44, 323–8 registration, 57 requirements, 21 review, 20 BRC guidelines, 30 breakdown procedures, 291 vehicles, 260 brittle materials, 220–24 calibration, 295–300 frequency, 297 records, 300 ceilings, 187–9 false, 189 certification, 327 certification body, 13 accreditation, 13–14 approved, 52 choosing, 37, 51–3 competency, 15, 17–18 contract with BRC, 15 requirements for, 14 resources, 53 changing facilities, 209–10 high risk, 210 cleaning, 239 of food containers, 234 closing meeting, 81 The BRC Global Standard for Food Safety: A Guide to a Successful Audit, Second Edition Ron Kill c 2012 John Wiley & Sons, Ltd Published 2012 by John Wiley & Sons, Ltd P1: SFK/UKS P2: SFK BLBK426-IND 380 BLBK426-Kill May 25, 2012 12:54 Trim: 244mm×172mm Index codex alimentarius, 101, 103 colour coding of clauses, 25 complaint handling, 165–7 complaints analysis, 166 consultants, 58, 84 contract with certification body, 53–4 contractors, 150, 302 co-operation groups, 15 corrective action, 27, 85, 155–7, 323–6, 329–53 critical control points, 116–18 customer focus, deputies, 87 documentation, 132–5 control, 132–5 obsolete, 135 reasons for changes to, 134 retention, 136–7 documentation control, 132–5 doors, 191–3 drainage, 186–7 plan of, 187 duration of audit, 39, 58 electric fly killers, 249–51 enclosed product area, 46 enrolment programme, 4–5, 8, 32–3, 352 equipment, 198–200, 202 evidence, 10, 348–9 external standards, 174–7 factored goods, 5, 38 filters, 227 floors, 185–6 footwear, 209–10 foreign body detection, 225–35 FTCG, 15–16 fundamental requirements, 22–5 genetically modified, 275 glass breakage, 222–3 glass control, 220–25 glass register, 220–22 Global Food Safety Initiative, 20 gloves, 318 GMP, grading of certificate, 8, 326–7 HACCP, 26, 101–28, 226, 272, 287 CCPs, 116–18, 288, 295–7, 303–4 corrective action, 123–4 critical limits, 118–21 decision tree, 117 flow diagram, 110–12 hazard analysis, 114–21 monitoring, 121–3 records, 117, 125–6 review, 126–7 team, 104 team leader, 124–5 verification, 124–5 hand washing, 209–10, 308 hazard analysis, 112–16 head coverings, 315 high care areas, 5, 46–7, 317 high risk areas, 5, 46–7, 317 housekeeping (see hygiene) hygiene, 235–41 personal, 306–11 rules, 306–8 vehicles, 258–9 identity preserved materials, 275–8 inspection and analysis, 278–84 internal audit, 11, 137–44 jewellery, 307 key staff, 58, 97 labelling, 271, 273–4, 291–2 laboratory facilities, 281 accredited, 282–3 laundry, 316–17 layout of site, 179–85 lighting, 194–5 Listeria monocytogenes, 47 low risk area, 46, 181 maintenance, 200–206 magnets, 233–4 management review, 90–93 mass balance, 162, 275 medical screening, 311–13 metal control, 219–20 metal detectable plasters, 308–10 metal detection, 226–33 reject mechanisms, 229–30 testing, 230–33 P1: SFK/UKS BLBK426-IND P2: SFK BLBK426-Kill May 25, 2012 12:54 Trim: 244mm×172mm Index nonconforming product, 157–9 nonconformities, 40–43 correcting, 323–6, 329–53 critical, 40, 326 major, 40–1, 326 minor, 41, 326 objectives, 89–90 opening meeting, 77–8 optical sorting equipment, 234 organisational structure, 96–7 outsourced processing, 151–2 packaging, 276–8, 291 storage, 277 traceability, 159–65 perfume, 307 personal medicines, 310–11 personnel, 301–19 pest control, 244–53 position statements, 15–16 pre-audits, 59 pre-requisites, 106, 125–7 procedures, 167–9 process control, 287–300 product categories, 47 product development, 271–4 production zones, 46–7, 173–4 product recall and withdrawal, 167–72 corrective action, 171 procedures, 167–9 review, 171 test, 169–71 product release, 284 protective clothing, 313–18 high risk, 317 quality manual, 129–32 quality policy, 94–6 quantity control, 292–5 raw materials, 145–50 records, 58, 135–7 referrals, 18 report format, 5, 327 resource management, 88 review, 28–9, 90–93 rework, 164–5 381 risk assessment, 26, 145, 149, 178, 182, 196, 207, 228, 234, 246, 254, 266 for allergens, 265–6 root cause, 5, 28, 94, 157, 323–4, 350–51 scope of audit, 38, 54–6 scope exclusions, 56 scope extension, 49, 357 scope of global standard, 20–21 seasonal products, 36, 356 security of site, 177–9 vehicles, 260 segregation, 179 allergens, 268 high risk, 182–3 shelf life, 272–3, 280–81 sieves, 227 site plans, 27, 180 smoking, 212–13 specifications, 152–5 formal agreement, 154 review, 155 staff catering, 214–15 staff facilities, 206–15 staff toilets, 211–12 statements of intent, 21 stock rotation, 256–7 storage, 253–7 controlled atmosphere, 255 temperature control, 254–5 supplier approval, 146 exceptions, 148 monitoring, 146 suppliers of services, 150–51 taint, 218, 258 temporary repairs, 203–4 temporary structures, 184 traceability, 159–65, 258, 275 test, 78–9, 162–4 training, 29, 69–73, 140, 301–5 allergens, 270 chemical control, 218 cleaning, 239 complaint handling, 166 induction, 302–3 internal audit, 140 laboratory, 284 official courses, 69–73 P1: SFK/UKS P2: SFK BLBK426-IND 382 BLBK426-Kill May 25, 2012 12:54 Trim: 244mm×172mm Index training (Continued ) pest control, 246–7 security, 179 transport, 257–62 utilities 196–200 vehicle temperatures, 259 ventilation, 195 vertical audits, 4, 78–9 visitors, 181 volume control (see quantity control) walls, 185 waste, 241–4 water, 196 non-potable, 197–8 plan, 197 weight control (see quantity control) windows, 189–90 witnessed audits, 17 wood, 224–5 work instructions, 98 x-ray, 227–9 P1: SFK/UKS BLBK426-IND P2: SFK BLBK426-Kill May 25, 2012 12:54 Trim: 244mm×172mm P1: SFK/UKS BLBK426-IND P2: SFK BLBK426-Kill May 25, 2012 12:54 Trim: 244mm×172mm ... shall refer to it as the Global Standard or simply the Standard Issue of the Global Standard for Food Safety was published in January 2008 and introduced some significant changes to the Certification... definitions For issues and of the Standard, we became used to using the terms ‘Evaluation’ and ‘Evaluator’ to describe the process of auditing against the Standard and the person carrying out the audit. .. Standard: Part – The Protocol Familiarity with the Standard: Part – Section IV and the Appendices Final Steps to the Audit The Global Standards Website and Directory Training for the Standard P2: SFK