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Top 10 Reasons for BRCGS Audit Non-conformities

Helen Timothy
January 6, 2020

On Demand Webinar: BRC Issue 8

Watch the Recording

On Demand Webinar: BRC Issue 8

Nadia Narine, President of Lumar Food Safety Services, shares the key changes made to BRC’s Issue 8 in this on demand webinar. Version 8 focuses on product safety culture, environmental monitoring, food security and defense, separation and clarification to high risk, high care and ambient high care production risk zones and specific requirements on pet food.

Watch the Recording

BRCGS is a leading brand and consumer protection organization, used by more than 30,000 certificated suppliers in over 130 countries. Their international network of accredited certification groups issues certifications, guaranteeing the standardization of quality and safety.

Becoming certified proves manufacturers' dedication to their consumers and the safety of the supply chain. Beginning in February 2019, food manufacturers pursuing recertification or certification to the BRCGS Global Standard for Food Safety will be audited by criteria and clauses in Issue 8 of the Standard.

When preparing for a BRCGS audit, it can help to know what trips up other companies the most. BRCGS's annual report offers useful insights.

Top 10 Non-conformities 

1 - 3.4 Internal Audits

There shall be a scheduled program of internal audits. At a minimum, the program shall include at least four different audit dates spread throughout the year. The frequency at which each activity is audited shall be established in relation to the risks associated with the activity and previous audit performances. All activities shall be covered at least once each year. 

At a minimum, the scope of the internal audit program shall include the:

  • HACCP or food safety plan, including the activities to implement it (e.g., supplier approval, corrective actions, and verification)

  • prerequisite programs (e.g., hygiene, pest control)

  • food defense and food fraud prevention plans

  • procedures implemented to achieve the Standard. 

Each internal audit within the program shall have a defined scope and consider a specific activity or section of the HACCP or food safety plan. 

2 - 4.11 Housekeeping & Hygiene

Housekeeping and cleaning systems shall be in place which ensures appropriate standards of hygiene are maintained at all times, and the risk of product contamination is minimized. 

3 - 4.4.8 Door Condition

Doors (both internal and external) shall be maintained in good condition. At a minimum: 

  • external doors and dock levelers shall be close fitting or adequately proofed

  • external doors to open product areas shall not be opened during production periods except in emergencies

  • where external doors to enclosed product areas are opened, suitable precautions shall be taken to prevent pest ingress.

4 - 2.6 Verify HACCP Flow Diagram

The HACCP food safety team shall verify the accuracy of the flow diagrams by onsite audit and challenge at least annually. Daily and seasonal variations shall be considered and evaluated. Records of verified flow diagrams shall be maintained.

5 - 4.4.1 Walls Condition

Walls shall be finished and maintained to prevent the accumulation of dirt, minimize condensation and mold growth, and facilitate cleaning. 

6 - 3.9 Traceability

The site shall be able to trace all raw material product lots (including primary packaging) from its suppliers through all stages of processing and dispatch to its customers and vice versa. 

7 - 4.9.3 Procedure for Glass Handling

4.9.3.1 through 4.9.3.5, all caused non-conformities. 

8 - 1.1.2 Management Objectives

The site's senior management shall define and maintain a clear plan for the development and continuing improvement of a food safety and quality culture. 

This shall include: 

  • defined activities involving all sections of the site that have an impact on product safety

  • an action plan indicating how the activities will be undertaken and measured, and the intended timescales

  • a review of the effectiveness of completed activities  

9 - 4.7.3 Temporary Repairs

Where temporary repairs are made, these shall be documented and controlled to ensure that the safety or legality of products is not jeopardized. These temporary measures shall be permanently repaired as soon as practicable and within a defined timescale. 

10 - 4.7 Equipment Maintenance

An effective maintenance program shall be in operation for plant and equipment to prevent contamination and reduce the potential for breakdowns. 

Are you working on version 8 certification? Nadia Narine, President of Lumar Food Safety Services, shares the key changes made to BRCGS's Issue 8 in our on-demand webinar. Version 8 focuses on product safety culture, environmental monitoring, food security and defense, separation and clarification to high risk, high care, and ambient high care production risk zones, and specific pet food requirements. Watch the recording here

GFSI BRCGS
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