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QUALITY MANAGEMENT SYSTEMS FOR FOOD AND BEVERAGES INDUSTRY 4 - Coggle…

- - - - BRC benefits--> easy entry for new customers, easy management for companies that comply with ISO 9001 and HACCP, continuous commitment, management of raw materials and packaging, layout, product flow and segregation, order and hygiene, allergen management
      - BRC managed in 9 sections--> commitment to management and continuous improvement: external and internal audit results, feedback and complaint management, effectiveness of HACCP systems
        
        2 HACCP → food safety plan
        An effective hazard and risk analysis allows you to identify and manage hazards that can compromise
        product safety, quality, and integrity → Required by BRC -> food safety policy, forming HACCP teams, defining product scope and description by identifying target customers, analyzing hazards and critical limits with monitoring, defining corrections with verification procedures, and reviewing or updating the HACCP plan.
        
        Prerequisites HACCP--> cleaning and disinfection plan, required documentation, cleaning and disinfection procedure, inspection plan, control of unwanted animals, control of potable water
        
        Operational control procedure--> purpose: start work under optimal hygienic and sanitary conditions, method--> completion of checklist as everything must function properly, including all applicable regulations. High level of personal hygiene is required, respecting recommended clothing and work areas.
        
        3 BRC food quality system and management--> internal audits, raw material supplier management, corrective and preventive actions, traceability
        
        Audits -> verifications by third parties -> impartiality, responsibility, competence. UNI ISO 19011 has three types of audits: First-part – internal, conducted by the company on itself → self-declaration of conformity. Second-part – customer audits on suppliers, for quality control → correct product labeling, production hygiene, traceability. Third-part – independent body to obtain official certifications.
        
        Quality assurance -> assessment to be chosen based on the most suitable ones. Supplier -> approval system for managing authenticity risks related to allergens; foreign body risk; microbiological contamination; chemical contamination; cross-contamination; substitution or fraud; risks associated with raw materials. Risk assessment of raw materials when changing, the company must know the final producer
        
        4 Site standards--> suitability for cleaning of the building, layout--> risk assessment, access points for personnel and raw materials, predefined personnel routes
        
        defined routes for movement and processing, service positions for personnel, areas with time segregation for risky activities, as well as additional requirements such as contractors and visitors informed of the risks, filters, sieves, metal detectors, x-rays
        
        Production control--> Product control with safe and authentic controls. List of main allergens, identification and risk assessment of allergens (which also depend on the physical state or even on flavorings, additives, cross-contamination, or compound ingredients).
        
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- - - - 8 High-risk products zone -> ready-to-eat, main microbiological risks -> Listeria monocytogenes, Salmonella, E. coli → in the relevant product sections. Control measures (High-risk and high-care areas). Hygienic design. Separation of raw/cooked areas. Separate flows for personnel, raw materials, and equipment. Environmental microbiological control. Regular sampling.
        
        Unidirectional routes (from clean to cleanest); ambient temperature control (<10°C if required);
        dedicated or sanitized equipment between uses. Increased maintenance and cleaning frequency. Hygiene testing.
        
        Suppliers: only qualified and certified.
        Traceability: clear records (batch, date, quantity, origin). Safe storage: temperature, hygiene, adequate separation. Inspections: acceptance and shipping (labels, intact packaging). Non-compliance: recall and complaint procedures. Communication: clear labeling to avoid confusion.
  - - - Objectives: A single standard for large-scale retail trade, fewer multiple audits and greater supplier consistency, and regulatory compliance. Key points: Site location, accumulation, collection, and disposal of waste materials, hygiene standards and staff organization, and process control.
      - benefits--> Reduction in the number of second-party audits, i.e. those carried out on behalf of the supplier's customers, with lower costs, both direct (audit costs) and indirect
      - IFS standards: Currently comprise six standards, which have been developed for and by stakeholders involved in all parts of the supply chain--> they define quality
        
        10 IFS requirements→ are KO requirements. If they aren't followed, the company won't obtain certification, and if they aren't complied with, it loses certification.
        
        Management Responsibilities → Management must ensure that employees understand their
        responsibilities regarding safety and quality.
        
        CCP Monitoring→ Each CCP must have documented monitoring procedures with method, frequency and records to ensure control and detect any leaks.
        
        Personal Hygiene → Personal hygiene requirements must be understood and applied by all relevant personnel, contractors, and visitors..
        
        Raw Material Specifications → Specifications for all raw materials must be documented,
        updated, clear, and compliant with legal and customer requirements.
        
        Traceability Systems → There must be a documented traceability system linking product batches, raw materials, and packaging, including records of receipt, processing, rework, and
        distribution, up to delivery to the customer.
        
        Foreign body management → There must be documented procedures to prevent contamination by foreign bodies; contaminated products are considered non-compliant.
        
        Recipe Compliance → All agreements with the customer regarding the recipe, process,
        controls, packaging, and labeling must be respected.
        
        Internal Audits → An internal audit program covering all IFS requirements is mandatory, scheduled every 12 months (maximum 15), with more frequent intervals for critical activities and including external warehouses.
        
        Withdrawal and recall procedures → There must be a documented procedure for recalls, withdrawals, and emergencies that defines responsibilities, training, decision-making, a 24/7 contact person, up-to-date contact information, and a communication plan with customers, authorities, and, if necessary, consumers.
        
        Corrective actions→ Corrective actions must be rapid, documented, with defined responsibilities and timeframes to prevent new non-conformities.
        
        IFS is divided into 5 sections: 1 Corporate governance and management commitment. 2 Food safety and quality management system. 3 This section ensures documented management systems, resource management
        
        4 Operational processes--> essential controls, product development, raw materials, production and storage, transportation, site, packaging suppliers, water, traceability. Outsourced suppliers approved by the GFSI or documented audits verifying food safety, quality, legality, and authenticity.
        
        FOOD DEFENSE must have:
        Managers with specific skills.
        A documented plan to identify threats and define protective measures (legal requirements, critical areas and access, visitor/inspection management, additional controls). Testing and review at least annually or after significant changes.
        
        Cross-contamination risks must be minimized through effective measures--> 5 measurement, analysis and improvement, and process control. An internal audit program covering all IFS requirements is mandatory: each area must be audited
        at least every 12 months (maximum 15), with more frequent visits for critical activities based on risk.
        
        Quality and safety parameters monitored and recorded regularly or continuously--> A= 20 points (complete compliance), KO B (small part of the requirement is not implemented without impact on food safety). C score not possible. D--> requirement is not implemented--> non-compliance KO
        
        PRP (Prerequisite Programs) according to ISO/TS 22002-1. Appropriate facility design and layout. Effective cleaning and sanitation, pest control and prevention, proper waste management and disposal. Regular and safe equipment maintenance. Personal hygiene of staff. Water and air quality control. Safe handling of raw materials, ingredients, and packaging. Prevention of cross-contamination. Alert system and management of non-compliance.
        
        BRC
        
        Highly prescriptive and detailed standard.
        
        Rigorous documentation and traceability.
        
        Preferred by large retailers in the UK and US. - Strong focus on layout, staffing, cleanliness, allergen management, etc.
        
        IFS Food
        • Similar to BRC but more flexible.
        • Designed for European manufacturers, especially private labels. • Scoring system (A, B, C, etc.), audits may also be announced. • More open to risk-based interpretations, if well-documented.
        
        ISO 22000: A system standard that doesn't delve into production details like BRC or IFS. Applicable to any food company along the entire supply chain. Based on ISO standards (easily integrated with ISO 9001 and ISO 14001). To be recognized at GFSI level, it must be integrated with ISO/TS 22002-1.