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AWARENESS TRAINING PROGRAMME Technical Standard for Companies Manufacturing and Supplying Food Packaging Materials for Retailer Branded Products

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Title: AWARENESS TRAINING PROGRAMME Technical Standard for Companies Manufacturing and Supplying Food Packaging Materials for Retailer Branded Products


1
AWARENESS TRAINING PROGRAMME Technical
Standardfor Companies Manufacturing and
Supplying Food Packaging Materials for Retailer
Branded Products
  • presented by
  • David Burns

2
INTRODUCTION BRC / IOP Technical Standardfor
Companies Manufacturing and Supplying Food
Packaging Materials for Retailer Branded Products
3
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

4
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.

5
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

6
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.

7
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

8
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.

9
UKAS Accreditation
10
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

11
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

12
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

13
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

14
Who Were Involved ?
  • Institutions
  • United Kingdom Accreditation Service (UKAS)
  • The Institute of Packaging (IOP)
  • The British Retail Consortium (BRC)

15
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

16
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

17
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

18
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.

19
What does the Standard cover ?
  • Management Responsibilities
  • Risk Assessment
  • Documentation Requirements
  • Factory Standards

20
What does the Standard cover ?
  • Quality Assurance/ Process Control
  • Contamination Control
  • Personal Hygiene
  • Glossary of Terms

21
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

22
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

23
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
    companys requirements will be explained, as
    follows

24
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

25
THE STANDARD REQUIREMENTS
  • 3. Hazard And Risk Management
  • Contamination risks
  • Packaging defects
  • Customer specific
  • Senior Management commitment
  • Documented management system
  • Internal Audits

26
THE STANDARD REQUIREMENTS
  • 3. Hazard And Risk Management
  • 3.1 Hazard analysis
  • Conduct hazard analysis
  • Determine hazards
  • Establish critical limits programme
  • Monitor against programme
  • Verification and validation records
  • Procedures and methods for execution

27
THE STANDARD REQUIREMENTS
  • 3. Hazard And Risk Management
  • 3.2 Hazard analysis
  • Establish process flows
  • Identify and record hazards
  • Assess the risk
  • Decide the action required
  • Procedures appropriate to the risk
  • Process controls
  • Regular review / audits of the risk areas

28
THE STANDARD REQUIREMENTS
  • 3. Hazard And Risk Management
  • 3.3 Following the completion of the analysis (as
    above), measure to monitor critical process steps
    shall be implemented, maintained and reviewed

29
THE STANDARD REQUIREMENTS
  • 3. Hazard And Risk Management
  • 3.4 Hazard analysis and procedures shall have Top
    Management approval and commitment
  • 3.4 Procedures and methods of control implemented
    through the companys documented management
    system
  • 3.5 Related procedures shall be included with
    audit programme (refer to section 4.7)

30
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

31
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

32
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

33
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

34
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

35
THE STANDARD REQUIREMENTS
  • 4.5 Traceability
  • Raw materials
  • Work in progress
  • Finished goods
  • Product identifiable at all stages of production

36
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

37
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

38
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

39
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

40
THE STANDARD REQUIREMENTS
  • 4.10 Sub Contracting Of Production
  • Effective control of sub-contracting
  • Include hazard analysis
  • Identify responsibility
  • Verification of Subcontractor Technical Systems

41
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

42
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
    companys requirements will be explained, as
    follows

43
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

44
THE STANDARD REQUIREMENTS
  • 5.2 Layout And Product Flow
  • Prevention of cross contamination
  • Control of work in progress
  • Product handling areas
  • Designated personnel routes

45
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

46
THE STANDARD REQUIREMENTS
  • 5.4 Maintenance Of Equipment
  • Well maintained
  • Cleaning schedules
  • Wooden equipment
  • Minimised use
  • Good condition
  • Properly sealed
  • Notice-boards

47
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

48
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

49
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

50
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

51
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

52
THE STANDARD REQUIREMENTS
  • 6.2 Chemical And Biological Control
  • Chemicals, cleaning materials, lubricants and
    adhesives controlled to prevent product
    contamination
  • Aseptic control systems

53
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

54
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

55
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

56
THE STANDARD REQUIREMENTS
  • 7. Personnel
  • 7.1 Access And Movement Of Personnel
  • Designated entrances
  • Site security
  • Designated walkways
  • Logical movements

57
THE STANDARD REQUIREMENTS
  • 7.2 Locker Rooms
  • Provision of lockers
  • Access to locker rooms and overall/protective
    clothing segregation
  • Control of eating, smoking and drinking
  • Food control
  • Visitors and contractor facilities

58
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

59
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

60
THE STANDARD REQUIREMENTS
  • 7.5 Personal Health
  • Illness notification/return to work
  • Medical questionnaire for visitors/contractors
  • Covering of cuts with appropriate dressings

61
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

62
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

63
THE STANDARD REQUIREMENTS
  • 7.8 Hygiene Training
  • Induction training
  • Formal basic hygiene training
  • Refresher hygiene training
  • Training records
  • Contractor and visitor hygiene procedures

64
PROTOCAL
65
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

66
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.

67
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.

68
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

69
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,

70
PROTOCAL
  • Evaluation Procedures (continued)
  • the number of employees related to food
  • (food safety)
  • size of random sampling
  • the number of non conformances as recorded in
    previous evaluation

71
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

72
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.

73
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
    products safety and legality is not in doubt

74
PROTOCAL
  • Recommendation
  • There is a failure to meet a recommendation of
    good practice.

75
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

76
BRC / IOP Technical Standardfor Companies
Manufacturing and Supplying Food Packaging
Materials for Retailer Branded Products
  • YOUR QUESTIONS

77
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
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