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AWARENESS TRAINING PROGRAMME Technical Standard for Companies Manufacturing and Supplying Food Packaging Materials for Retailer Branded Products. presented by David Burns.

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presented by david burns

AWARENESS TRAINING PROGRAMMETechnical Standardfor Companies Manufacturing and Supplying Food Packaging Materials for Retailer Branded Products

presented by

David Burns

slide2

INTRODUCTIONBRC / IOP Technical Standardfor Companies Manufacturing and Supplying Food Packaging Materials for Retailer Branded Products

development of the standard
Development of the Standard
  • This standard hails as a first for the packaging industry
  • It provides common ground on auditing
  • It underpins due diligence to users.
  • It brings quality and hygiene standards, and many manufacturers to new heights.
  • It means a single audit for packaging manufacturers
development of the standard4
Development of the Standard
  • The BRC / IOP Technical Standard was bench-marked to several existing standards during writing
  • It covers all packaging industry types, not just one, as are many codes of practices that are issued by trade associations
  • The BRC/IOP Standard encompasses all problem areas within packaging production.
development of the standard5
Development of the Standard
  • It is hoped that the Standard will cascade through the packaging industry
  • Retailers will require their packer fillers to ensure all of their packaging manufacturers are accredited
  • The Standard requires them to ensure their suppliers are up to an adequate standard
  • The best way to achieve this is by accredited certification
development of the standard6
Development of the Standard
  • The cascade effect will ensure all packaging manufacturers, converters and suppliers have the same standard.
  • Transparency of auditing will ensure companies will not be commercially disadvantaged by non compliant companies.
development of the standard7
Development of the Standard
  • The new Standard is designed to be dynamic
  • Regular Standard updates will be carried out
  • A Standard review body will sit every six months and look at problems that have arisen
background information
Background Information
  • Following the Food Hygiene Standard, it was agreed that the Packaging Standard had to be credible
  • It should be backed by the EN45011 standard
  • All standard audit bodies must be accredited under the EN 45011 standard requirements
  • Each evaluator will have to prove competence by examination in both hygiene and packaging.
standard integrity
Standard Integrity
  • Only bodies that are accredited to the EN45011 standard will be allowed to carry out audits
  • Audit bodies will not be allowed to carry out both consultations and audits
  • Individual Inspectors will need to have specific qualifications based on packaging, hygiene and audit management
why have a common standard
Why have a common Standard ?
  • Provides a level playing field
  • Being able to demonstrate Due Diligence
  • A single audit, one certificate that will be acceptable by all interested parties
  • Reduction in cost, speed up of auditing
what are the objectives
What are the objectives ?
  • To ensure all food packaging manufacturers are satisfactory in both hygiene and technical matters
  • To ensure all packaging users are able to trust their packaging materials to be hygienic and consistent
what are the objectives13
What are the objectives ?
  • The Standard is based on both pre-requisites and risk assessment
  • The Standard is prescriptive in many areas
  • Control of hygiene in every aspect of a production unit
  • Ensures consistent adherence to a specification
  • Covers high and low risk areas
  • Defines high and low risk
who were involved
Who Were Involved ?
  • Institutions
  • United Kingdom Accreditation Service (UKAS)
  • The Institute of Packaging (IOP)
  • The British Retail Consortium (BRC)
who were involved15
Who Were Involved ?
  • Others
  • The Standard has not been written by the retailers and then imposed on the packaging industry. The committee was made up from the following:
  • Audit bodies, Institute of Packaging, Academia, Manufacturing Trade Bodies, Packaging Manufacturers, Food Manufacturers (Packer Fillers) and Retailers
benefits of the standard
Benefits of the Standard
  • Accepted Standard based on best practise
  • Certification bodies accredited to EN45011 to achieve maximum consistency in application and interpretation
  • Open and transparent
  • Encourages continuous improvement
  • Cost effective, removes need for multiple customer inspections
benefits of the standard17
Benefits of the Standard
  • Removes “burden” of “routine” visits
  • Broad based standard, including; quality, hygiene, and safety
  • The standard addresses “due diligence”
  • Requirement for on-going surveillance
  • Focusing on process improvement
benefits of the standard18
Benefits of the Standard
  • The Standard covers issues that are also covered within an ISO9000 standard.
  • Provided your ISO9000 certification can be shown to be acceptable to the assessor much of the Packaging Technical Standard may be covered.
what does the standard cover
What does the Standard cover ?
  • Management Responsibilities
  • Risk Assessment
  • Documentation Requirements
  • Factory Standards
what does the standard cover20
What does the Standard cover ?
  • Quality Assurance/ Process Control
  • Contamination Control
  • Personal Hygiene
  • Glossary of Terms
what does the standard protocol cover
What does the Standard protocol cover ?
  • Audit Body Requirements
  • Frequency of Evaluation and follow up.
  • Evaluation Reporting.
  • Certification.
  • Competency of Inspectors.
  • Standard and Protocol development.
  • The Auditors Report
brc standard contents
BRC - STANDARD CONTENTS
  • 1. Scope
  • 2. Organisation
  • 3. Hazard and Risk Management System
  • 4. Technical Management System
  • 5. Factory Standards
  • 6. Contamination Control
  • 7. Personnel
  • 8. Risk Category Determination
brc technical standard
BRC - TECHNICAL STANDARD
  • The BRC Standard is divided into two levels, in consideration of the product supplied
  • Category A – Non Food Contact Packaging
  • Category B – Food Contact Packaging
  • The priority categories associated with your company’s requirements will beexplained, as follows:
the standard requirements
THE STANDARD REQUIREMENTS

1. SCOPE

2. Organisation

  • Responsibilities for implementation and maintenance of standard
  • Designated Manager (within structure)
    • Qualified
    • Suitably senior
    • Acknowledged deputy
  • Management review system
the standard requirements25
THE STANDARD REQUIREMENTS

4.Technical Management System

4.1 Technical Management Policy

  • Quality and Hygiene Policy Statement
  • Published and issued statement by the Senior Management:
  • Legal compliance
  • Commitment to consumer protection
  • Documented system implementation
  • Training and resource management
  • Review of system effectiveness
the standard requirements26
THE STANDARD REQUIREMENTS

4.2 Document Control

  • Demonstrate compliance with the standard
  • Documented management system (procedures / methods) shall be authorised (at all levels)
  • Formally issued and controlled
  • Obsolete documentation removed from use
  • Complete records controlled at all appropriate levels
the standard requirements27
THE STANDARD REQUIREMENTS

4.2 Document Control (Required Records)

  • Training
  • Cleaning Schedules
  • Foreign Body Incidents
  • Customer Complaints and Product Recall
  • Internal Audits
  • Pest Control (internal and external)
  • Maintenance / Engineering
  • Glass and Brittle Plastic Policies
  • Blades and Sharps Control
  • Non Conforming Products
  • Traceability
the standard requirements28
THE STANDARD REQUIREMENTS

4.3 Specifications

  • Raw Materials
  • Finished Goods
  • Suitable for food contact use
  • Adequate, accurate and legally compliant
  • Agreed with relevant parties
  • Trademark agreement
  • Review procedure
the standard requirements29
THE STANDARD REQUIREMENTS

4.4 Management Of Incidents And

Product Recall

  • Documented incident reporting procedure
  • Customer notification
  • Documented recall procedure
  • Product re-call at all stages of production
  • Control of non conforming products
  • Corrective and preventive actions
  • Verification of recall systems
the standard requirements30
THE STANDARD REQUIREMENTS

4.5 Traceability

  • Raw materials
  • Work in progress
  • Finished goods
  • Product identifiable at all stages of production
the standard requirements31
THE STANDARD REQUIREMENTS

4.6 Process Control

  • Hazard Analysis
  • Sufficient and appropriate controls
  • Segregation of raw materials, work in progress and finished goods
  • Process and equipment verification
  • Legal compliance and customer satisfaction
  • Equipment calibrated and traceable to National Standard
  • Control of raw material supply
the standard requirements32
THE STANDARD REQUIREMENTS

4.7 Internal Audits

  • Programme of audits in consideration of risk
  • Trained and independent auditors
  • Documented results of audit
  • Review of audit results
  • Corrective and preventive actions
the standard requirements33
THE STANDARD REQUIREMENTS

4.8 Complaint Procedure

  • Documented system for complaints
  • Effective management review
  • Implementation of corrective and preventive actions
  • Complete records of action taken
  • Approval of actions
the standard requirements34
THE STANDARD REQUIREMENTS

4.9 Supplier Monitoring

  • Evaluation and selection of suppliers
  • Selection criteria against procedures
  • Assess ability to supply conforming product
  • Maintain an approved supplier list
  • Measurement of supplier performance
  • Verification of supplier claims / approvals
the standard requirements35
THE STANDARD REQUIREMENTS

4.10 Sub Contracting Of Production

  • Effective control of sub-contracting
  • Include hazard analysis
  • Identify responsibility
  • Verification of Subcontractor Technical Systems
the standard requirements36
THE STANDARD REQUIREMENTS

4.11 Product Analysis

  • Hazard Analysis
  • Reliability of Test Results
  • Qualified Personnel
  • Accredited Sub Contracted Laboratories (or other body)
  • Agreed and Documented Test Methods
  • Compliance with Specifications
the standard requirements37
THE STANDARD REQUIREMENTS

5. Factory Standards

  • As indicated within earlier slides, the Standard is divided into two categories:
  • Category A,(indicated in orange)and;
  • Category B(indicated in green)
  • The priority categories associated with your company’s requirements will beexplained, as follows:
the standard requirements38
THE STANDARD REQUIREMENTS

5. Factory Standards

5.1 Perimeter And Grounds

  • Unobstructed Access and Debris Free
  • Defined External Eating Area
  • Access Points Proofed
  • Protected Appropriate Drainage Systems
  • Traffic Routes Surfaced
  • Protected External Storage
  • Designated Refuse Collection Areas
the standard requirements39
THE STANDARD REQUIREMENTS

5.2 Layout And Product Flow

  • Prevention of cross contamination
  • Control of work in progress
  • Product handling areas
  • Designated personnel routes
the standard requirements40
THE STANDARD REQUIREMENTS

5.3 Building Fabric

  • Sound construction
  • Suspended ceilings accessible
  • Adequate lighting
  • Cleaning schedules for internal surfaces
  • Walls capable of being cleaned
  • Drainage protection
  • Sufficient ventilation
  • Proofing of ventilation openings
  • Proofed against pest ingress
the standard requirements41
THE STANDARD REQUIREMENTS

5.4 Maintenance Of Equipment

  • Well maintained
  • Cleaning schedules
  • Wooden equipment
    • Minimised use
    • Good condition
    • Properly sealed
  • Notice-boards
the standard requirements42
THE STANDARD REQUIREMENTS
  • Maintenance Of Equipment
  • Planned maintenance programmes
  • Control of compressed air
  • Use of tape engineering
  • Operate to hygiene, health and safety requirements
  • Control of contractors
  • Post maintenance checks
  • Documented post maintenance checks
the standard requirements43
THE STANDARD REQUIREMENTS

5.4 Housekeeping And Cleaning

  • Clean as you go policy
  • Cleaning schedules
    • Item to be cleaned
    • Frequency
    • Method
    • Cleaning materials
    • Responsibility
    • Cleaning record checks
  • Use of approved cleaning detergents
  • Monitoring of effectiveness
the standard requirements44
THE STANDARD REQUIREMENTS

5.4 Housekeeping And Cleaning

  • Storage of cleaning equipment
  • Toilet cleaning products segregated
  • Control of tools and maintenance equipment
  • Control of workstations to prevent product contamination
  • Suitable storage facilities for workstations
the standard requirements45
THE STANDARD REQUIREMENTS

5.6 Waste And Waste Disposal

  • Minimise accumulation of waste in production
  • Use of appropriate containers
  • Disposal of putrescible waste (lined and lidded)
  • Disposal of Trademarked waste
  • Use of licensed waste contractors
  • Collection of recycling waste
the standard requirements46
THE STANDARD REQUIREMENTS

6. Contamination Control

6.1 Foreign Body Control

  • Staff training
  • Written policy for glass and brittle plastic
  • Glass and brittle plastic register
  • Written policy for “sharps” control
  • Issue and control of “sharps”
  • Snap off knife blades
the standard requirements47
THE STANDARD REQUIREMENTS

6.2 Chemical And Biological Control

  • Chemicals, cleaning materials, lubricants and adhesives controlled to prevent product contamination
  • Aseptic control systems
the standard requirements48
THE STANDARD REQUIREMENTS

6.3 Pest Control

  • Formalised preventative programme
  • Use of approved contractors for pest control
  • Records and location of pest control baits
  • Correctly sited EFKs
  • Follow up actions
the standard requirements49
THE STANDARD REQUIREMENTS

6.4 Transport, Storage And Distribution

  • Finished product protected
  • Product movements between premises
  • Checking of wooden pallets
  • Control of contract haulage
  • Written contract with hauliers
  • Integrity checks of raw materials
  • Documented checks of raw materials
the standard requirements50
THE STANDARD REQUIREMENTS

6.4 Transport, Storage And Distribution

  • Non conforming products
  • Vehicle drivers
  • Clean and suitable transport
  • Cleaning programme for vehicles
  • Pre loading checks of vehicles
  • Control of off site storage
the standard requirements51
THE STANDARD REQUIREMENTS

7. Personnel

7.1 Access And Movement Of Personnel

  • Designated entrances
  • Site security
  • Designated walkways
  • Logical movements
the standard requirements52
THE STANDARD REQUIREMENTS

7.2 Locker Rooms

  • Provision of lockers
  • Access to locker rooms andoverall/protective clothing segregation
  • Control of eating, smoking and drinking
  • Food control
  • Visitors and contractor facilities
the standard requirements53
THE STANDARD REQUIREMENTS

7.3 Toilets And Hand Washing

  • Hand wash facilities
  • Advisory signs
  • Hand wash disciplines
  • Hand-wash disciplines entering production areas
  • Hand-wash facilities at entrances to production areas
the standard requirements54
THE STANDARD REQUIREMENTS

7.4 Facilities For Eating, Drinking And Use Of Tobacco Products

  • Prohibited within direct production areas
  • Provision of facilities
  • Facilities for smoking – internal or external
the standard requirements55
THE STANDARD REQUIREMENTS

7.5 Personal Health

  • Illness notification/return to work
  • Medical questionnaire for visitors/contractors
  • Covering of cuts with appropriate dressings
the standard requirements56
THE STANDARD REQUIREMENTS

7.6 Jewellery And Personal Items

  • Jewellery policy – plain band rings, sleeper earrings and wristwatches
  • Jewellery policy – plain band rings and sleeper earrings only
  • False nails and nail varnish
the standard requirements57
THE STANDARD REQUIREMENTS

7.7 Protective Clothing

  • Appropriate clothing
  • Appropriate clothing (spares)
  • Hair covered to prevent contamination
  • Self care of protective clothing
  • Approved laundry services (contractors)
  • Segregation of clean and dirty clothing
the standard requirements58
THE STANDARD REQUIREMENTS

7.8 Hygiene Training

  • Induction training
  • Formal basic hygiene training
  • Refresher hygiene training
  • Training records
  • Contractor and visitor hygiene procedures
protocal60
PROTOCAL
  • Certification Bodies
  • Only Accredited Certification bodies to EN45011* with the appropriate scope, shall carry out evaluations against the BRC Standard, and issue certificates, or;
  • Until 31st May 2003, to include those Certification Bodies actively seeking accreditation to EN45011
protocal61
PROTOCAL
  • Before the initial evaluation
  • The Supplier is required to review the BRC Standard
  • Make any necessary amendments or improvements to its operation and systems
  • Provide background information on the site concerned, by completion of a pre-evaluation questionnaire or pro-forma information sheet.
protocal62
PROTOCAL
  • The scope of the evaluation shall be defined between the Supplier and the Certification Body
  • The scope shall be identified in the evaluation report and any certificate of inspection.
  • The Supplier may contract the Certification Body to evaluate matters beyond the scope of the BRC Standard, but no relevant elements of the BRC Standard shall be omitted.
protocal63
PROTOCAL
  • Any additions to evaluation scope may or may not fall within the scope of the Certification Bodies accreditation
  • A supplier may be advised to check with either the Certification Body or UKAS before contracting such additional work
protocal64
PROTOCAL
  • Evaluation Procedures
  • Duration of evaluations will be dependant upon a number of factors but due regard must be given to;
  • size of the site
  • the types of processes to produce and store product
  • number of product lines,
protocal65
PROTOCAL
  • Evaluation Procedures (continued)
  • the number of employees related to food

(food safety)

  • size of random sampling
  • the number of non conformance’s as recorded in previous evaluation
protocal66
PROTOCAL
  • At all evaluations there are four elements, which shall be carried out;
  • opening meeting
  • review of quality systems and procedures
  • site inspection
  • closing meeting
protocal67
PROTOCAL
  • Major
  • There is substantial failure to meet the requirements of a statement of intent and any mandatory clause of the Standard.
  • Depending upon the level of certification sought (Foundation or Higher), the mandatory clauses will differ.
  • The mandatory clauses for Foundation Level are all those listed in the Foundation Level column.
  • The mandatory clauses for Higher Level are as for Foundation Level, and in addition, all the clauses in the Higher Level column.
protocal68
PROTOCAL
  • Minor
  • This is where absolute compliance to the statement of intent and a mandatory clause has not been demonstrated, but on the basis of objective evidence the conformity of the product’s safety and legality is not in doubt
protocal69
PROTOCAL
  • Recommendation
  • There is a failure to meet a recommendation of good practice.
protocal70
PROTOCAL
  • The report contains the following sections:
  • evaluation details
  • evaluation summary- overview of performance
  • details of non-conformance and corrective action plan
  • detailed evaluation report
slide71
BRC / IOP Technical Standardfor Companies Manufacturing and Supplying Food Packaging Materials for Retailer Branded Products

YOUR QUESTIONS

the standard requirements72
THE STANDARD REQUIREMENTS
  • What to do next:
  • Make sure your factories are up to the requirements of the Standard
  • Become accredited under the Packaging Technical Standard
  • Ensure your suppliers are as good as you require by insisting they become accredited