FOOD SAFETY

PAS 223:2011

The British Standards Institution, BSI, has launched a new standard to streamline food safety systems between food manufacturers and the packaging they use for their products.
Personal Hygiene in Food Preparation Areas: Key to Delivering a Safe Product
This PAS is intended to meet requirements for PRP's specified in ISO 22000:2005 and PAS is not a management system standard to be used as in isolation. 
Basic Information about PAS 223:2011 
The main contents are 

1. Scope
2. Normative references
3. Terms and definitions
4. Establishments
5. Layout and Work Space includes design
6. Utilities includes water, air quality, compressed air and other gases, Lighting
7. Waste includes drain and drainage
8.  Equipment suitability and maintenance
9. Purchased materials and services
10. Contamination and migration
11. Cleaning include programs
12. Pest control
13. Personnel hygiene and facilities
14. Rework include usage
15. Withdrawal Procedures 
16. Storage and transport
17. Food packaging information and consumer awareness
18. Food defense, bio-vigilance and bio-terrorism (FSSC 22000 Guidance on PAS 223 Section 16 & 18)
19.  Food packaging design and development
20. Specifications
21. Process Validation

More information about contents will be updated in coming days

Guidance on the FSSC scheme with respect to PAS 223 section 18: Food defence, biovigilance and bioterrorism 
Food Safety System Prerequisite Program PAS 223:2011 in Manufacture and Food Packaging
Competence criteria 
Bioterrorism is one of the potential hazards that, just like all of the other potential hazards need to be addressed in the manufacturers Hazard Analysis. The auditors have to review if this has been done and if effective control measures are in place. There are no additional qualification requirements required for the auditors. 

Where relevant the auditor shall have knowledge of the PAS 96 which gives guidance as to 
be able to deal with applicable issues properly. 

Method for Auditing 
Biovigilance and Bioterrorism has to be audited within the scope of the certificate. Where 
relevant the auditor shall have such knowledge as to be able to deal with these issues 
properly. 
Guidance on the FSSC scheme with respect to PAS 223 section 16: storage and 
transport 
Storage and transport are not part of the FSSC scope as a stand alone activity. However 
manufacturers have to address it in cases where it is part of the organizations own process 
and when they have agreements with external transport and storage companies. CBs have 
to review if the manufacturer has addressed this effectively. The PAS 223 covers 
requirements for storage and transport and to ensure related food safety risks are addressed 
effectively in the manufacturer’s food safety management system and that CB’s cover this in 
the audits. 

Disposable Glove

• Personnel must have training of raw materials handling, preparation, processing , packing and storage areas.
• Personnel hygiene shall be documented and communicated to all personnels.
• Jewelery policy and hand washing frequency will depend on product risk assessment.
• Fingernails shall be short, clear and unvarnished while no false nails are permitted.
• Perfumes and after shave not permitted.
• Smoking (where permitted under law), eating and drinking shall be permitted in designated areas segregated for food handling and storage areas.
• All cuts and grazes are covered by colored plasters (preferably blue) and containing metal detectable stripe. samples to be checked with metal detectors.
• Use of personnel medicines to be controlled to minimize the contamination risk.

BRC Food Safety Issue 6 Includes

• Staff compliance to hygiene rule to be checked regularly.
• Visitors to be controlled by wearing gloves/ non handling of food if not compiling to hygiene requirement of fingernails.
• Colored plasters e.g Blue( Different from product) to be available.

This document is illustration follow  BRC Food Safety Issue 6

More Reading

• Personal Hygiene in Food Preparation Areas: Key to Delivering a Safe Product  
• What is New BRC Standard issue 6  
• The BRC Global Standard for Food Safety Issue 6 with Checklist  
• Guide to the BRC Food Safety Standard  

 Sources: BRC Food Safety Global Standard

Publicly Available Specification (PAS) 96 provides guidance to food businesses of all sizes and at all points in the food supply chain – from farm to fork. It provides guidance on approaches to the protection of business from all forms of malicious attack including ideologically motivated attack and the procedures to mitigate and minimize the impact of such an attack.
PAS 96:2010 Defending food and drink provides guidance and good practice for food businesses of all sizes and at all points in the supply chain. It is intended to be of particular use to managers of small and medium sized food enterprises who may not have access to specialist advice.
The food and drink industry is naturally vulnerable to attack but highly resilient. The main generic threats are malicious contamination with toxic materials, sabotage of the supply chain and misuse of food and drink materials for terrorist or criminal purposes. A successful attack could disrupt business and undermine brands, and could lead to illness and death. Even the threat of an attack could be problematic.
Reducing vulnerability and increasing resilience can be achieved by greater control of access to materials, processes, services and premises, and by undertaking regular review, and this revised edition of PAS96 offers guidance on deterring, detecting and defeating malicious attack on food and drink supplies.
Food businesses will be able to use the guidance in the context of an effective food safety management regime such as Hazard Analysis Critical Control Point (HACCP) or the Red Tractor. This PAS assumes and builds on effective operation of such protocols.
Source: 
 Download Free Copy PAS 96: 2010

•  Building should be designed , constructed and maintained in appropriate manner according to the nature of the processing operations  especially related food safety operation.
• Building should not pose any hazard to the product.
• Building roofs should be self draining and no leakage.

• Consideration shall be given for any potential source of contamination to the product from local environment.
• Reviewed periodically.

An Overview of new changes in BRC Global Standard for Food issue 6 1.
Management Commitment and Continual Improvement
This is a new section to the standard.

• ·         Requirement for clear communication channels.
• ·         Management Review is required annually.
• ·         Additional requirements specific to audit process.
• ·         Copy of current issue of BRC Standard is required.
• ·         Certification to the BRC standard must not lapse.
• ·         Most senior operations/production manager on site must be at audit meetings.
• ·         Non-conformities from previous BRC audit must be completed.

2. HACCP
This section now follows Codex Alimentarius steps and is more descriptive in its requirements:

• ·         More detailed product description and intended use is required.
• ·         Detailed flow diagram and verification of flow diagram.
• ·         Use of decision tree for CCP determination.
• ·         Critical limits to be validated.
• ·         More requirements for documentation e.g. monitoring records signed and dated, corrective action and procedures for handling of unsafe products.
• ·         HACCP Review required annually as a minimum.

3. Quality Management System
3.1 Now called Food Safety and Quality Policy

• ·         Requirement for Continual improvement.
• ·         Senior manager must sign and date policy

3.2 Now called Food Safety and Quality Manual

• ·         Requirement for review at planned intervals.

3.3 Organisational Structure, Responsibilities and Management Authority

• ·         Organisation chart must be available.

 3.4 Contract Review and Customer Focus

• ·         There is a new requirement for the staff responsible for communication with customers to be defined.
• ·         Customer requirements need to be identified and agreed and these are to be reviewed at predetermined frequencies.

3.5 Internal Audit

• ·         There is a specific requirement to audit system annually as a minimum.

3.6 Purchasing – Supplier Approval and Performance Monitoring No changes.
 3.7 General Documentation Requirements No changes
3.7.1 Documentation Control

• ·         Documents now need to be in the ‘appropriate languages’

 3.7.2 Specifications

• ·         Manufacturing instructions need to comply with recipes and be fully implemented.
• ·         Documented procedure required for specification amendment and approval.
• ·         Specifications need to be readily accessible to staff. 3.7.3 Record completion
• ·         Period of retention of records needs to be related to shelf life, legislation and customer requirements.

3.8 Corrective and Preventive Action * Procedures required for preventive action and verification.
3.9 Traceability

• ·         Traceability audit / test to include quantity check / mass balance reconciliation.
• ·         Traceability audit / test to be carried out annually.

3.10 Complaint Handling

• ·         There must be a system to effectively capture and record complaints.

3.11 Management of Incidents, Product Withdrawal and Product Recall

• ·         More detail is included on what to include and consider regarding incidents & the management of incidents.
• ·         Detailed contingency planning for all types of incidents is required.
• ·         Record timing of key stages of recall / withdrawal audit / test.
• ·         Traceability and recall systems to be tested at least annually.
• ·         Now a requirement to notify your certification body in the event of a product recall.

 4.1 External Site Standards

• ·         Your site to be of suitable size, construction and design.
• ·         External yards and roads must be suitably surfaced and maintained.
• ·         Building fabric must be well maintained 4.2 Site Security
• ·         There must be controlled access and training of staff.
• ·         Secure storage of materials to be demonstrated.
• ·         Premises must be registered and approved.

4.3.1 Layout, product flow and segregation

• ·         Temporary repairs and structure must be controlled 4.3.2 Fabrication – walls, floors etc
• ·         Waste to go directly to drain.
• ·         Where floor falls are required is clarified.
• ·         Risk assessment of windows.
• ·         Doors to be maintained in good condition and cleanable.

 4.4 Services – now called Utilities No new requirements
4.5 Equipment

• ·         Requirement for Certificates of Conformity for suitability for use of food contact materials e.g. conveyor belt material.

 4.6 Maintenance

• ·         Specific control of maintenance contractors required.
• ·         Formal clearance / sign off required following maintenance work.
• ·         Maintenance consumables to be suitable for use.
• ·         Engineering workshops to be controlled to prevent contamination risks e.g. swarf mats.

4.7 Staff Facilities

• ·         There must be sufficient storage facilities available for personal items.
• ·         Waste must be controlled at outside designated eating areas.
• ·         Water, liquid soap, towels or air drier must be provided at handwash stations.
• ·         Hand wash instructions must be available.
• ·         Hand free operation taps and disinfection and high risk areas.
• ·         Water, liquid soap, drying facilities and signage must be provided at toilet handwash stations
• ·         At smoking areas the must be waste bins & signage for handwashing.

 4.8 Chemical and Physical Contamination Control

• ·         Specific requirements for non-food chemicals e.g. approved purchase, data sheets, suitability for food use, identified containers, secure and used by trained staff.
• ·         Procedures required for sharps e.g. knives and blades etc.
• ·         Glass breakage procedures e.g. quarantine, cleaning and release of area and Personnel controls. * ?Inspection procedures & documentation for sieves, filters and magnets
• ·         Procedures & control of foreign body contamination of packaging during filling operations e.g. use of inverters, air jets on line. 4.9 Housekeeping and Hygiene
• ·         Specific requirement for cleaning procedures to include responsibility, frequency, method, etc. * CIP to be monitored & controlled.
• ·         Cleaning chemicals and equipment to be fit for purpose, identified and stored to prevent contamination.

 4.10 Waste / Waste Disposal

• ·         Waste to be categorised based on legislative requirements.
• ·         Identified waste containers & rooms.
• ·         Waste containers & rooms cleanable and maintained.

 4.11 Pest Control

• ·         Risk assessment required to establish pest control programme and frequency of visits.
• ·         Clear specification for documentation required.
• ·         Bait station design and use specified e.g. tamper proof & tethered.
• ·         Corrective action required in the event of infestation.
• ·         Company to action recommendations.
• ·         Catch tray analysis required.

4.12 Storage and Transport

• ·         Covers storage as well as transport
• ·         Storage must be off floor and away from walls, use of bulk tankers, pre-loading and unloading inspection required.
• ·         Storage areas to be kept dry and well ventilated.
• ·         Global Standard for Storage and Distribution recommended for suppliers of these services.
• ·         Traceability to be ensured during storage and transport.

5.1 Product Design / Development

• ·         Shelf life trials required to confirm compliance with microbiological, chemical and organoleptic criteria.
• ·         NPD to control special handling requirements e.g. allergens.
• ·         Packaging to be confirmed as suitable for use and legal.
• ·         Validation of product claims e.g. nutrition.
• ·         Communication of changes to formulation or process.

5.2 Handling Requirements for Specific Materials – Materials containing Allergens and Identity Preserved Materials

• ·         All allergen containing materials, intermediate and finished products need to be listed.
• ·         Document a risk assessment to identify and control routes of contamination.
• ·         Develop procedures of segregation, use of dedicated equipment and staff policies.
• ·         Any claims to be fully validated.
• ·         Cleaning methods, waste handling & spillage controls to be validated.
• ·         Staff training required in allergen handling.
• ·         Non-conformities specifically involving allergens to be reviewed.
• ·         Risk assessment is required for raw materials requiring ID preservation.
• ·         Risk assessment is required of routes of contamination of ID preserved materials.

5.3 Foreign Body Detection

• ·         Foreign body detection is required unless it is otherwise justified.
• ·         Monitoring check frequency and sensitivity to be defined with trained personnel and documentation.

 5.4 Product Packaging

• ·         Evidence to confirm suitability for use e.g. certificates of conformity required.
• ·         Coloured liners of sufficient gauge to prevent contamination are required.

5.5 Product Inspection and Laboratory Testing

• ·         Test results to be recorded.
• ·         Test results to be analysed for trends and action taken.
• ·         There is a requirement for organoleptic tests.
• ·         Ongoing shelf life assessment is required.
• ·         Laboratory testing for pathogen testing to be subcontracted or laboratory must be remote from manufacturing.
• ·         Minimise risk of cross contamination from laboratory e.g. security, access, colour coding workwear, waste controls etc.
• ·         Procedures for reliability of results – recognised methods, documented methods, staff training, ring testing, equipment calibration.

5.6 Control of Non-conforming Product No major changes.
5.7 Product Release No major changes. 6.1 Control of Operations

• ·         All CCPs to be transferred to day to day production controls.
• ·         Process monitoring to be carried out by trained staff.
• ·         Procedure to be in place to ensure product is packed into correct packaging.

 6.2 Quantity – Weight, Volume and Number Control No major changes.
 6.3 Calibration and Control of Measuring and Monitoring Devices

• ·         Details of calibration procedures has been clarified e.g. list of equipment, identified & labelled, checked & adjusted based on risk assessment.

7.1 Training

• ·         Competency for specific roles to be documented.
• ·         Monitoring of training requirement and effectiveness.
• ·         Training in relevant language.
• ·         Specific details to be recorded on training records – name, date, duration, course contents, training provider.

 7.2 Access and Movement of Personnel

• ·         Site plan required showing access points and travel routes.
• ·         There are specific design and layout requirements.
• ·         Staff / visitor training on site access, movement and hazard procedures.

7.3 Personal Hygiene

• ·         Staff compliance to hygiene rules to be checked regularly.
• ·         Visitors to be controlled by wearing gloves / non handling of food if not complying to hygiene requirement of fingernails.
• ·         Coloured plasters e.g. blue (different from product) to be available.

7.4 Medical Screening

• ·         Procedure for action to be taken in the case of infectious disease to be communicated to staff. 7.5 Protective Clothing
• ·         Policy to be documented.
• ·         Protective clothing to be provided in sufficient numbers.
• ·         Design to prevent product contamination.
• ·         Clean and dirty clothing to be segregated
• ·         If laundering in-house, validate the effectiveness of process.
• ·         Gloves to be suitable for food use, disposable, distinctive colour, intact.
• ·         High risk clothing shall be removed and stored in a designated changing area.

The BRC Global Standard for Food Safety Issue 6 has been extensively revised in consultation with senior representatives from major retailers and food service companies, ensuring that it continues to meet the requirements of manufacturers and retailers.


The Standard was first introduced by the BRC in 1998 and now has almost 14,000 certificated sites in over 100 countries across the world.

Issue 6 places increased emphasis on good manufacturing practice, including a change in the balance of the number and depth of requirements in favour of the implementation of good manufacturing systems within the factory and greater focus on standardising best practices for auditing the Standard.

Key changes for Issue 6 include:

*

Expanded sections on foreign body control, hygiene and housekeeping, and allergens
*

Introduction of a new voluntary 2 stage unannounced audit scheme
*

A reduced number of clauses to ensure each expresses a significant idea, this will contribute to consistency of grading as requirements are now of similar significance

Issue 6 will come into effect in January 2012. Issue 5 can still be used for audits until January 2012.
Source:www.brcglobalstandards.com
Checklist can be Downloaded from
IFSQN.COM