Food

1. Patrick Bèle
December 1st 2014
Food Auditor Calibration course

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Bureau Veritas
AGENDA
► BRC
► Unilever SQA
► FSSC
► IFS
► Audit case studies
► AOB

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BRC Food Product changeover
Definition: The preparation of a production line or piece of equipment
from running the current product to being ready to produce another
product
BRC Food requirements:
6.1.6 Documented checks of the production line shall be carried out before commencing
production and following changes of product. These shall ensure that lines have been
suitably cleaned and are ready for production. Documented checks shall be carried out
at product changes to ensure all products and packaging from the previous production
have been removed from the line before changing to the next production.
6.1.7 Documented procedures shall be in place to ensure that products are packed into the
correct packaging and correctly labelled. These shall include checks at the start of
packaging, during the packaging run, following packaging changes and when changing
batches of packaging materials, in order to ensure that correct packaging materials are
used. The procedures shall also include verification of any code information or other
printing carried out at the packing stage.

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Categories of incidents dealt with by the Food Standards
Agency (UK)
Source: Food
Standards Agency
(UK) Annual Report
of Incidents 2013

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“Undeclared allergens top US food recalls in Q2”
Food Quality News, 22 August 2013

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What causes these incidents?
Unintentional presence of an allergen
► Cross-contamination during production
► Accidental addition of an allergen by using the wrong recipe
Mis-packing – the wrong packaging is used
► Insufficient or ineffective changeover controls
► Inadequate packaging management
Wrongly labelled packaging
► Specification errors
► Communication poor during packing development
► Ineffective change management when a recipe changes
► Ineffective sign-off of new packaging or print changes
► Error on printing

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But very few non conformities raised against this issue
Clause 6.1.6 93rd most frequently occurring
Clause 6.1.7 101st most frequently occurring
Raised on average as minors in 2 sites out of every 100

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Bureau Veritas
How to audit this topic?
Records, systems and documentation
► Documented procedures
► Records relating to cleaning, changeover, etc
► Records of line checks/verification
► Production schedules (e.g. time between product runs)
Good manufacturing practice
• Watch the procedure
• Question staff
• Assess effectiveness of processes alongside site verification
Audit report
• Comment on change over process in the audit report

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Good manufacturing practice
►Procedures and checks by trained, authorised staff
►Old packaging removed and disposed of/returned to
store
►Cleaning completed to defined methods
►Changes in product are matched by changes in
packaging
►New batches of packaging verified as correct
►All parts of the line appropriately set

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Auditor calibration exercise
Write down how you are assessing the product changeover
clause and whether you have identified some best practises
during your audits

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BRC Most common issues found in report
► 1 Find below an extract of a BRC Food audit report. Is it
compliant? If not why?
A: Yes
B: No
► 2 Find below an extract of a BRC Food surveillance audit report. Is
it compliant?
 A: Yes
 B: No

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BRC Most common issues found in report
► 3 Find below an extract of a BRC Food audit report. Is it
compliant? If not why?
A: Yes
B: No
► 4 Find below an extract of a BRC Food surveillance audit report. Is
it compliant? If not why?
 A: Yes
 B: No

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BRC Most common issues found in report
► 5 Find below an extract of a BRC Food audit report. Is it
compliant? If not why?
A: Yes
B: No

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BRC scope wording exercises
► 1 Processing of tomatoes
► 2 Production of cheese from receiving of raw material,
manufacturing, packing, storing and shipment of finished goods
► 3 Bottling of mineral water in plastic bottles
Exclusion: Mineral water bottles for domestic market
► 4 Manufacturing of ham
Exclusion: Manufacturing of sausages in workshop A

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BRC update
► BRC Food Issue 7 will be published in January 2015 with
implementation on July 1st 2015
► BRC Participate: http://www.brcparticipate.com/signin
 All auditors have received their Id + password
 All standards & guidance available

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BRC packaging calibration webinar
► Watch video named “Packaging Auditor Calibration 4 - October
2014 update” on:
http://brcglobalstandards.com/KnowledgeCentre/Webinars.aspx#.
VHMD98nrGKB
► Fill-in attached form & return it to me:

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UNILEVER SQA UPDATE
► SQA approved protocols: see attached file
► Make sure the Food supplier has a valid license delivered by local
authorities
► Visit ConnectionsCertification BLSales Large contractsUnilever
SQA program
► http://iww.connections.bureauveritas.com/communities/service/html/communityview?communityUuid=c26231c0-bc52-403a-
be0b-c5875bd4637b#fullpageWidgetId=W6cee88130dce_4ea5_98a7_16c94feee83b&folder=%257BE4821AB3-217B-4A47-9A31-
935191BAD834%257D

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FSSC update
► Feedback from Integrity program: top 5 NC
 Auditor qualification
 Certification scope
 Audit report content
 Audit duration
 Certification audits (witness audits)

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FSSC overall questions
► 1 The interval between stage 1 and stage 2 must be no longer than:
 A: 6 months
 B: 3 months
► 2 The date of the first surveillance audit following initial
certification shall not be more than:
 A: 12 months from the certification decision date
 B: 12 months from the last day of the stage 2 audit
► 3 PAS 223 can be used to certify organizations against FSSC
Packaging till January 1st 2015
 A: Yes
 B: No
► 4 Non applicable clauses:
 A: Shall be excluded from the audit report
 B: Shall be shown as not applicable in the audit report & clearly
motivated

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FSSC overall questions
► 5 Is the use of the FSSC logo by a certified client to be assessed
and recorded in the audit report?
 A: Yes
 B: No
► 6 The audit report has to be signed by a representative of the
audited organization:
 A: Yes
 B: No
► 7 Major NC must be cleared within 90 days
 A: Yes
 B: No
► 8 In case of major NC, an on-site follow-up audit has to be
performed:
 A: Yes
 B: No

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FSSC overall questions
► 9 Is it allowed to mentioned on product label “Manufactured in an
FSSC certified company”?
 A: Yes
 B: No
► 10 Is it allowed to use the FSSC logo on the certified company
website?
 A: Yes
 B: No
► 11 The FSSC logo can only be used in conjunction with BVC
certification
 A: Yes
 B: No
► 12 To maintain its qualification, each FSSC auditor must perform at
least 5 FSSC audit per year
 A: Yes
 B: No

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FSSC overall questions
► 13 Is it possible after an FSSC audit to recommend certification
against ISO 22000 but not against FSSC 22000?
 A: Yes
 B: No

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FSSC scope wording exercises
► 1 Storage & distribution of liquid CO2 for food & beverages
applications
► 2 Receiving of raw materials, processing of wheat up to packing,
storage, loading and dispatch of product
► 3 The production of meals and meal components
► 4 Manufacture of disposable tableware
► 5 The production of crude sunflower oil for further refinery /
processing. It includes the byproduct of the process: sunflower
cake for animal feed.
► 6 The grinding, mixing, blending and bagging of organic and
conventional wheat flour
► 7 Manufacture of liquid CO2
► 8 Manufacture and delivery of biscuits
► 9 Manufacturing of cane sugar

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FSSC Team leader recommendation exercises
► 1 During stage 1, you have identified some areas of concern but
not too many & not too severe. Your recommendation is then:
 A: Proceed to stage 2
 B: Address identified areas of concern detailed further in the report
and proceed to stage 2
► 2 During surveillance audit 1, you raise 3 minor NC. During closing
meeting, your recommendation is:
 A: Continued
 B: Continued subject to a satisfactory action plan / evidence is
received within 90 days

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FSSC Most common issues found in report
► 1 Find below an extract of an FSSC Food surveillance audit report.
Is it compliant? If not why?
 A: Yes
 B: No
► 2 Find below an extract of an FSSC Food surveillance audit report.
Is it compliant? If not why?
 A: Yes
 B: No

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FSSC Most common issues found in report
► 3 Is below sentence a relevant opportunity for improvement? If not
why?
“There were 2 uncontrolled instruction documents in packing line”
 A: Yes
 B: No
► 4 Is below mention a relevant opportunity for improvement? If not
why?
“Infrastructure”
 A: Yes
 B: No

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IFS standards: Food vs. Distribution

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IFS Global market

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IFS Integrity Program

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IFS written exam

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IFS oral exam

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IFS scope 7: combined products

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Audit case studies
► For each audit situation, assess whether a non-conformity / deviation
must be raised and if so mention standard & clause number
► Justify your decision
► Fill in attached form & return it to me

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Food audit case studies
► 1 Soup canning: In the soup preparation workshop, some condensation
water is observed on the ceiling and could fall into the product
► 2 Pork sausage manufacturing: There is no written procedure for checking
metal detector. Nevertheless, hourly checks are performed according to
best practices & well recorded.
► 3 Ice cream manufacturing: In the strawberry formula, a coloring is added
at 0,5 % rate. The lot number of this coloring is not recorded, hence
traceability of this ingredient not ensured.
► 4 Processing of dried fruits & nuts: A new product containing soy, sesame
and gluten is packed on the same line that packs other product not
containing those allergens. Intermediate cleaning is performed. The
company checks that there is no gluten left but cannot provide any test
results for soy & sesame.

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Food audit case studies
► 5 Wine bottling: The company bottles 75 cl glass bottles. When looking at
volume checks, you see that some batches with average of 0,70 cl have
been shipped without notifying the customers.
► 6 Roasting & grinding of coffee beans: The company located in Kenya
exports its product to the USA. No list of US Food safety regulation
applicable to coffee beans is available.
► 7 Hard cheese manufacturing: A maintenance contractor is working in
production area. You find out that he has not signed the appropriate form
for acknowledging hygiene & safety rules that he is supposed to follow.
► 8 Ice cream manufacturing: The product recall procedure includes a list of
key contacts. Certification body is not identified on this list.

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Packaging audit case studies
► 1 Paper label printing: You check a label that is being printed for canned
soup. The label as approved by the customer mentions an ingredient
(powdered milk) that is missing on the label being printed during your
audit.
► 2 Glass jars manufacturing: Previous month dimensions checks records
show that one production batch of jars was shipped to customer despite
not meeting agreed specifications for inner diameter.
► 3 Cardboard manufacturing: Pest control records are OK but there is no
trend analysis available.
► 4 Plastic closure manufacturing: A new resin supplier is being used but
has not been formally approved by QA Department as described in the
supplier approval procedure.

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Logistic & other audit case studies
► 1 Frozen food warehousing: None of temperature probes located in the
freezer are calibrated against an international standard.
► 2 Fresh food warehouse: One of the customer requires to have at
minimum 10 days of product shelf life remaining. Checking a pallet in a
trailer ready to leave for this customer, you find some products with only
5 days of remaining shelf life.
► 3 Medicated feed manufacturing: To avoid cross contamination between
production batches, a cleaning step is performed. There is no
documentation validating that this cleaning step is sufficient to avoid
cross-contamination.
► 4 Storing of grain: The company receives bulk grain in trailers. There is no
checking of previous load content.

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