18 03 Rigid Containers Selby BRC Report Rev 1

Audit
Report
Global Standard Packaging and Packaging Materials Issue 5: July 2015

Audit summary
Company name Rigid Containers Ltd BRC site code 1605181
Site name Selby
Hygiene Category Basic Hygiene

Audit scope
Scope of audit Manufacture of corrugated fibre board and Conversion and flexographic printing die‐
cutting, slotting, case making and gluing into cases and trays for secondary packaging for
food and other consumer products.
Exclusions from scope None
Justification for exclusion None
Voluntary modules included
Modules Result Details
Choose a module Choose an item
Choose a module Choose an item
Audit results
Audit result Certificated Audit type Announced
Audit grade AA Previous audit grade AA

Number of non‐conformities Major against SOI of Fundamental 0
Critical 0
Major 0
Minor 5

If you would like to feedback comments on the BRC Global Standard or the audit process directly to BRC, please contact
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P506: Packaging 5 Basic Hygiene, Issue 2 December 2015 Report No. UK/BRC/493 Auditor: Cameron Keith
QA International Certification Ltd, Dudley Court, Dudley Road, Darlington, Co. Durham, DL1 4GG Page 1 of 26

This report shall not be reproduced in part without the permission of QA International Certification Ltd

Company details
Address Denison Road
Selby
North Yorkshire
YO8 8AN
Country United Kingdom Telephone 01757 244600
Commercial Carol Murphy Email carolmurphy@rigid.co.uk

representative
Name
Technical Liz Roche Email lizroche@rigid.co.uk

representative
Name

Company profile
Plant size 10‐25K sq.m No. of 1‐50 No. of key 1‐3
(square metres) employees processes
Subcontracted processes Yes
Other certificates held ISO 14001 & FSC Chain of Custody
Regions exported to None
Choose a region
Choose a region
Choose a region
Choose a region
Major changes or auditor Within the last 12 months a new Site Director has been appointed Paul Hanley

observations since last BRC audit and the site has extended the mezzanine floor for additional storage and
installed a new Vega gluing machine
Company description The business Rigid originated in 1907 in Selby and moved to the current

location in the 2005. The plant was purpose built for manufacturing and
converting corrugated fibreboard. The business is now part of the VPK Group
based in Belgium. The group cell consists of four plants Selby, Wellington,
Limerick, & Desborough. There is a 2.5 Metre BHS Corrugator, 2 rotary die
cutters, 1 flat‐bed die cutters, 4 casemakers‐ die cutters, 3 folder gluers and
materials handling equipment. The premises manufacturing & storage areas
being 25,000m² with an established workforce of 183 personnel operating a
24hour three shift system Mon – Friday supplemented with 24 hr warehousing
– distribution facilities; 50 maximum personnel on site at any one time. The


Company profile
mission of the owners being to establish operations to meet the needs of
potential customers with excellent customer service principles.
They have concentrated on marketing the company’s strengths and providing
application expertise to resolve customer packaging and functional
requirements, whilst ensuring that all aspects of the product integrity, safety
and legality are properly maintained.
The management commitment and improvement plans ensure they are
competitive and retain their customer portfolio base.
The company makes product which it considers meets any existing or potential
customer need; either by direct approach from a potential customer or from
its own market research. The company has developed QMS systems with
appropriate procedures that meet the requirements of the BRC Global
standard for packaging and packaging materials.



Product and process characteristics
Field of Audit 02 ‐ Papermaking
(Glass 07 ‐ Print processes
Paper Category
Metal Category
Rigid plastic Category
Flexible plastic Category
Wood and other Category
material
Print
Chemical processes)
Products in production at the time C flute corrugated fibre board & Various printed fibreboard cases & trays from
of the audit FEFCO designs in production at the time of the audit

Audit duration details
Finish date 2018‐03‐15
Re‐audit due date 2019‐03‐19 Previous audit date 2017‐03‐06
On‐site duration 12 hours Duration of 4 hours

production facility
inspection
Reasons for deviation from typical or P509 Compliant
expected audit duration
Next audit type selected Announced

Audit duration per day
Audit days Date Audit start time Audit finish time
1 (start date) 2018‐03‐14 13:00 17:00
2 2018‐03‐15 08:30 16:30

Auditor information
Auditor number Auditor Name Role
110004 Cameron Keith Auditor



Present at audit
Note: the most senior operations manager on site should
be listed first and be present at both opening & closing Opening Site Procedure Closing
meetings (ref: clause 1.1.7) meeting inspection review meeting
Name / Job Title
Paul Hanley, Site Director X X
Ruth Vickers, Site Manager X X X X
Liz Roche, BRC & Environmental Co‐ordinator X X X
David Laverack, Quality Manager X X X
Aiden White, Health & Safety Manager X X
Darren Crossland, Corrugator Manager X X X X
Paul Langham, Conversion Manager X X X X
Rachel Gatenby, Continual Improvements Manager X X
Kath Lofthouse, Warehouse Manager X X
Ian Townend High Quality Process Print Manager X X
Peter Brown, Corrugator Supervisor X X
Mathew Cooper High Quality Process Print Supervisor X X
John Barwick, Clamp truck driver X X
Tony Carey, Electrician X X
Stuart Bagnall, Stores Controller X X



Non‐Conformity Summary

Major non‐conformity against statement of intent of a fundamental requirements
No. Requirement Details of non‐conformity Critical or Major ? Anticipated re‐
ref. audit date

Critical
No. Clause. Details of non‐conformity Anticipated re‐audit
date

Major
Proposed preventive action plan Evidence provided: document, Date Reviewed
No. Clause Details of non‐conformity Correction reviewed by
(based on root cause analysis) photograph, visit/other

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P506: Basic Hygiene Packaging 5, Issue 2 December 2015. Report No. UK/BRC/493 Auditor: Cameron Keith


Minor
Proposed preventive action plan Evidence provided document, Date Reviewed
(based on root cause analysis) photograph, visit/other
A meeting was held on 16.03.18 to
An order was placed on discuss the NC that was raised, the crew
There is a potential risk of 19.03.18 to replace the had reported the issue verbally and
Photo to show the order of the
contamination from broken – damaged board, 28.03.18 LR nothing was logged. It was agreed that a
board placed for the corrugator.
splintered wood transfer board on checked and the board has log should be made for all issues so its
1 4.6 2018‐03‐29
top section of corrugator with arrived on site. The work is recorded. There is a maintenance C Keith
Photo of Maintenance request
corrugated board running directly been scheduled to be request form book in place, the
form located in corrugator booth.
over it completed over the first two corrugator manager has held a meeting
weeks of Apr 18. with his crew to communicate that all
issues should be logged to avoid
communication issues.
Planned PMI’s are scheduled to be
The machine was stopped
carried out every Mon and Wednesday.
with the whole area
Having checked the system, Piranha
High level area of corrugator needs thoroughly cleaned the Photographic evidence.
sheets are in place. That week no PMI’s
cleaning excessive debris and following day. A further check
2 4.8.1 was carried out due to board been 2018‐03‐29
flaking dried glue directly over has also been carried out on Copy of excel spreadsheet of C Keith
required. LR has added a
material pathway 28.03.18 to ensure that PMI’s audit.
check to the internal audit sheet to
are completed as scheduled
inspect the area when carrying out
with no issues found.
internal audits as she would not normally
check that area.
The plastic was picked up A meeting was held on 16.03 to discuss
immediately and the area further in detail, during equipment been
Glass breakage report supplied
checked during the audit. uninstalled and moved it is believed that
Piece of fractured brittle plastic A report was filled out and a holder may have broken and bits were
3 4.9.1.2 Details of engineering items 18‐03‐29
found in reel store filed. The following day a full missed. Engineering parts are being C Keith
being relocated onto Mezzanine
inspection was carried out of stored on a ledge away from the reels in
flooring
the site with no other traces the reel warehouse; these parts are
found. going to be re located to the new section
on the mezzanine floor, currently work in


progress, which has started since the
audit. This should eliminate and reduce
contamination.
A meeting was held on 16.03 to discuss
further in detail, We believe this is an
isolated incident as the blade was found
The blade was removed
on the ledge next to the engineering
immediately and placed in
parts. Engineering parts are being stored
Uncontrolled blade found in reel the sharps container in stores During the audit the blade was
on a ledge away from the reels, these
4 4.9.2.2 store adjacent to paper material during the audit. The removed & placed in the sharps 2018‐03‐29
parts are going to be re located to the C Keith
stocks following day a full inspection container in the stores dept.
mezzanine floor, currently work in
was carried out of the site
progress. A full audit was carried out
with no other traces found.
with no further issues found. We have a
system in place where blades are
exchanged, booked signed and the blade
placed in the sharps container.
Hygro tester {Moister meter} used
LR has arranged with AML to
for evaluating moisture content in For 2019 the meters have been added to
come on site 16.04.18 to Photo of PO No. 440005576 for
paper from suppliers has no an annual service that is carried out by
5 5.5.2 service the x3 meters that are Calibration of the Hygro tester 2018‐03‐29
quantifiable standard test method AML each year. We was not aware that C Keith
located on the corrugator {Moister meter}
of checking equipment, or the meters should be calibrated each
and reel warehouse.
calibrated to a national standard year hence never been done.
Comments on non‐conformities – not tagged, just free text. This is to explain where a large number of minor NCs have been raised without a major



Voluntary Modules Non‐Conformity Summary Sheet
Critical
No. Clause Details of non‐conformity Anticipated re‐audit date



Major
Proposed preventive action plan Evidence provided: document, Date Reviewed
(based on root cause analysis) photograph, visit, other



Minor
Proposed preventive action plan Evidence provided: Date Reviewe
No. Clause Details of non‐conformity Correction reviewed d by
(based on root cause analysis) document, photograph, visit, other



Detailed Section

1. Senior management commitment
1.1 Senior management commitment and continual improvement
Product Safety & Quality Management policy statement inclusive of Legal & Regulatory requirements dated
10.4.2017 signed by Group Managing Director Richard Coward. There is a commitment in the policy to
continual improvement established by targets & objectives.
The site is committed to maintaining the standard; discussions with the Site Director Paul Hanley & all senior
Manager present at the opening & closing meetings.
Site objectives & targets are referenced in the management review minutes.
Company objectives are derived with KPI targets and values allocated accordingly to the various
departmental tier levels.
2018 KPI’s
OTIF target >98%
OEE Plant efficiencies for all machines
Corrugator 69%
Conversion 50%
Waste rejected returns vs. Gross sales 2018 target <0.17%
Budgeted square metres 121 million square metres
The team review the KPI’s on a monthly basis to ensure compliance to targets is being attained.
The site regulatory compliance information is maintained by site Designated Manager Liz Roche & Group
Quality Manager. Managing Director is Chairman of CPI {Corrugated Paper Industry} that keeps abreast of
legislation; also use internet web sites and suppliers of raw materials to ensure legislation is maintained.
There is a register of legislation ref in file QMS 106 issue 4 dated 8.3.2017
The products produced are used within mainland UK; they are compliant for EU distribution.
Raw material paper stocks are procured from industry recognised suppliers in the EC and have declarations
of compliance demonstrating that they comply with Regulations 1935/2004, 2023/2006, Reach 1907/2006,
& Regulation 94/62/ EC re heavy metals. Water based Maize Starch & PVA adhesive in use.
Site manufactures Secondary packaging mediums for indirect food contact applications.
There is a statement re recycled content may be up to 100% dependant on paper grade and application.
Root cause analysis used to resolve non‐compliances raised internally or by customers as deemed
appropriate.
1.2 Management review
Management review held 1.2.2018 with senior personnel in attendance. There is an internal reporting
system of reporting issues of product safety, legality & product quality to senior management.
The review has covered the base elements as required there is reference to HARM study, site compliance,
training, Legislation review previous reviews action plans achievements & deficiencies, There is also
reference to use of root‐cause analysis & findings and changes implemented from customer audits.
1.3 Organisational structure, responsibilities and management authority
The management organisational structure is documented within the QMS manual Organisational structure
QMS 102; reporting structure of
Group Managing Director, BRC & Environmental Co‐Ordinator, Quality Manager, Site Director, Corrugator
Manager, Conversion Manager, Print Manager, Logistics Manager, Engineering Manager, Site Safety
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Manager, Cell Leaders & Supervisors, Production Operators & logistics personnel.
Personnel are trained in operational work instructions – procedures with the training system linked to job
functions and descriptions.
Designated BRC Manager Liz Roche BRC & EMS Co‐Ordinator
Deputy for BRC is Dave Laverack Quality Manager
Non‐applicable clauses

2. Hazard and risk management system
2.1 Hazard and risk management team
The hazard and Risk Management Team consists of six team members with multifunctional expertise, across

whole the business operations. The HARM system is reviewed annually.
Harm Team
Liz Roche is Team Leader
Dave Laverack Quality Manager Deputy
Aiden White Health & Safety Manager
Chris Marshall Senior Cell Leader
Roy Hadden Maintenance Engineer
Paul Langham Conversion Manager
Liz trained in HACCP hazard & risk principles 12.5. 2009 by Elite Training & Consultancy.
Liz is supported by Deputy Dave Laverack trained in BRC hazard & risk principles by Liz
The team members have been trained in 2009 & 2016 in HACCP by Liz Roche.
Day to day updates at production briefing meetings to ensure any changes to manufacturing / customer
requirements are always attained.
HARM Team members have extensive knowledge of industry and all but 2 other members {New additions to
team} also attended the BRC hazard & risk principles training course on 13.7.2017.
2.2 Hazard and risk analysis
The company has carried out a HARM Hazard analysis study in accordance with the requirements of this

standard, section 2. Basic Hygiene Risk Category established / referenced by use of determination tree page.
The study was reviewed 23.11.2017. The scope covers all products manufactured in accordance with the
manufacture & conversion of corrugated fibre board intended as an indirect contact packaging medium for
various products such as food stuffs and consumer products. The site stipulates it sells their product for
indirect food contact. This is detailed in the analysis which is entirely suited to site manufacturing activities.
Products manufactured include printed and die‐cut cases and trays which are used as secondary packaging.
Products incorporate B, R, C, BC, RB flute in 2000‐2500 deckle in single and double wall configuration from
Kraft, Testliner and other grades from 85gsm to 170gsm to suit customer requirements.
The analysis covers all potential hazards and contamination sources within the process inclusive of allergens,
taint and odour, and component transfer. The study is inclusive of a risk assessment employing a
quantifiable rating system evaluating hazards and identification of potential CCP’s QCP’s and prerequisites.
The prerequisites and QMS procedural work instructions maintain product integrity to produce a safe and
legal product, meeting customer requirements. The plan considers functional & performance, potential legal
issue as well as microbial, physical, critical defects, potential for unintended migration of substances ref to
mineral oils, and chemical hazards & malicious intervention. The Printing at site utilises water‐based inks.
Pre requisites include raw material checks, Maintenance, Glass & foreign body controls, personal hygiene,


pest control etc. Post‐Consumer Recycled materials in products may be up to 100% content utilised in
process dependant on paper grades and application; detailed on supplier’s raw material specifications. The
identified hazards have been accessed to define the impact on the process and appropriate control
measures implemented accordingly Additional materials in the process being starch & PVA adhesives that
are water based. Storage conditions referenced as ambient.
The study has not identified any Critical Control Points in the process all hazards identified are controlled by
quality control procedures and work instructions; they are included in the internal audits and monitored for
effectiveness accordingly. Codes of practice for corrugated CPI Corrugated paper Industry & FEFCO
European Federation of Corrugated Board Manufacturers; organization of the European Corrugated Board
Industry. The HARM study is scheduled to be re vamped with assistance of industry Consultant on 26.4.2018
and also refresher HARM training.
2.3 Exemption of requirements based on risk analysis
No exemptions requested.
Non‐applicable clauses 2.2.8, 2.2.9

3. Product safety and quality management system
3.1 Product safety and quality management system
The company have a “Document Live System” that covers Product Safety and Quality Management with
procedures & work Instructions QMS 003 dated 12.8.2016, approved by designated manager, with
supporting Hazard & Risk Analysis Study. The electronic system read only is fully implemented and
monitored by continual review and internal audits. Printed copies from system are classified as not
controlled.
3.2 Documentation control
QMS 300 Doc & Data Control procedure issue 22 dated 7.3.2018

Documentation is generated by management process owners and authorised ‐ controlled by quality team.
Managing Director approves top level documents. System is computer based with printed documents
classed as uncontrolled; Personnel have read only central access to documentation. Control of documents
procedure incorporates control of records. The system was found to be working effectively and the
document reference library identifies changes.
Moisture Control Procedure RW130 issue 6 dated 22.2.2018
Document matched controlled register
3.3 Record keeping
QMS 300 Doc & Data Control issue 22 dated 7.3.2018 Incorporates control of records

Inspection records completed at each stage of manufacturing process. The KIWI MIS system is computer
based with bespoke software that holds specifications and product safety information. Retention times
listed with Quality records retained indefinitely electronically.
Computer electronic records are backed up daily to disc and replicated to data store in security hut on site.
Main systems are also backed up in Belgium to VPK Packaging servers as part of the group requirements.
3.4 Specifications


Specifications are created on the operating system design department at site. When a new product is
required, any change to the specification would generally require a new specification be generated. Once a
new specification has been generated, it is sent to the customer for approval before the job moves through
production.
Specification viewed as part of vertical audit
Spec No. 563480/AT
Design style Die Cut Case
Board Grade 140T 130KLG 100WB
Board Code 3026
Sheet size 1034 x 1054
Print No. 563480
Artwork No. P27409 {3 Colour}
Bundle 1600 per pallet
Pallet 4way entry
A declaration of compliance is in place dated 2017 on company web site, it covers the nature of materials
used, confirmation that it meets the requirements for the ’Essential requirements’ legislation, packaging and
packaging waste and heavy metals content 94/62.
Trademarks on products Scrapped by site for quality issues are destroyed in the recycling process shredder &
baled.
Specifications are reviewed as required by customer services as part of the contract review process.
Electronic specifications are stored on a password and permissions protected system that is backed up daily.
3.5 Internal audits
Internal audit procedure in place QMS301 issue 11 dated 8.3.2017 with a schedule in place for 2018.

There is a team of 6 internal auditors trained by 17.1.2018 via IHC. The team are multi‐disciplined and able
to be sufficiently independent of the area being audited.
Designated Manager Quality Manager, H&S Manager, Conversion Manager, Corrugator Manager.
Internal audits for 2018 checked: Compliance as well as non‐compliance is noted. Any NCR’s raised are sent
to the responsible manager for action, where root cause analysis will used to determine effective preventive
and corrective actions.
Example of audits viewed
Product Withdrawal audit by Paul Langham, audit 31.5.2017 with 2 NCR’s raised Minor position job titles
incorrect {viewed evidence of close out actions from the report}
Contamination control audit by Ian Townend 1.11.2017 carried out; 4 minor NCR’s raised. {viewed evidence
of close out actions from the report}
There is an action log in place that utilises root cause analysis
Hygiene audits in place
Viewed corrugator hygiene audit 25.1.2018
3.6 Supplier approval and performance monitoring
Supplier Assessment & Approval is in place QMS303 Issue 13 dated 7.3.2018.

The criteria for approval is defined in the procedure, BRC Certificated, approved subject to confirmation of
certification, check BRC website. If not a BRC certificated a supplier is required to complete a supplier self‐
assessment questionnaire, ISO 9001 will be approved, non‐certificated suppliers may be subject to a physical
audit conducted by the BRC team.
Exceptions will be permitted with the receipt of a Declaration of compliance for the materials and then the
completion of a Supplier Self‐Assessment.


Paper suppliers are managed by head office Desborough
Smurfit Kappa paper supplier evaluation dated 4.5.2016
BSEN 15593:2008 Packaging. Management of hygiene in the production of packaging for foodstuffs
Certificated via AJA Registration Cert No. AJA15/1074 Expiry date 13.3.2018

Mondi Swiecie Poland paper supplier evaluation dated 15.4.2017
ISO9001:2015 Certificated by Bureau Veritas Cert No. PL007587/P Expiry 25.9.2020

Pafra Adhesives supplier of water based PVA adhesive Aquapal9791HV UV Aqueous polyvinyl acetate
copolymer emulsion with details of food safety referenced in DOC 2.3.2017 EU10/2011, 1935/2004,
2023/2006; There is also a supplier evaluation on file for 27.10.2017
3.7 Management of sub dated contracted processes
The site sub‐contract die cut cases which are out of their capability range with their customers knowledge
One sub contract company being Cap cases who are BRC Certificated
3.8 Management of suppliers of services
Supplier Assessment & Approval is in place QMS303 Issue 10 dated 11.2.2018, which identifies that the
relevant managers shall be responsible for the monitoring of the service performance, copies of service level
agreements are held on site
Advanced Logistics haulier agreement – declaration of carriage in place approved at senior level 28.6.2012
There is a contract in place for pest management at site as supplied by M J Backhouse Pest Control
3.9 Traceability
Product & Identification procedure QMS304 issue 7 dated 24.1.2018
Process in place for tracing raw materials back to sources and through to finished product is in place. Raw
materials have a unique reel number provided by the suppliers, this is recorded on the computer system, to
the program number of the job on the corrugator, the job numbers of the various finished products are
linked to the program number of the materials, the job number of the finished product from the corrugator
is then the traceability key for the remainder of the process. The finished job number is also the traceability
key that is number supplied on pallet labels to the customer.

Reverse traceability test carried out 16.2.2018
Customer R&R Ice Cream UK Ltd
Customer Order No. 584167/I & 580451/K
Delivery Note No.1754730
Qty Delivered two items 4,500 & 22,800
Corrugator program numbers 90694 {15.2.2018} 90622 {14.2.2018}
2 Jobs delivered 584167/I 580451/K
Board grade code 115T 100WB 115T & 140WTK 100WB 140T
Despatch date 16.2.2018 Haulier BTS Trailer No. 62 both jobs

Paper Reel No’s used on 584167/I
Papers used Roll id Supplier
Outer Liner 595895 Saica 115T


Fluting 595883 Smurfit 100 WB
Inner Liner 595892 Saica 115T

Paper Reel No’s used on 580451/K
Outer Liner 595945 Mondi 140WTK
Fluting 595388 DS Smith 100 WB
Inner Liner 596978 DS Smith 1409T
Traceability achieved by computer and hardcopy data, records checked, and a successful test completed.
Forward traceability exercise carried 9.3.2018 out on a reel of raw material
Paper delivery Note 882677 on 6.3.2018
Paper reel No. 600765 from supplier Smurfit 186gsm test liner
Ran on corrugator programme 91392 on 8.3.2018
Case maker 618 Martin 8.3.2018
Die cuter Bobst 2.3.2018
Gluing Super Nova 5.3.2018
Reel was run on 5 jobs
Job No. Customer Despatched D Note No.
534715/O BCM Ltd 6.3.2018 1757676
519800/BW Sherwin Williams 9.3.2018 1758242
445936/BC Sherwin Williams 8.3.2018 1758190
547463/AW Daniels Group in Stock
547463/AV Daniels Group 9.3.2018 1758426

Traceability was challenged at evaluation as part of vertical audit
Customer Heck Foods
Job No. 569938/BO/0/A0
Spec No. C1124149
Customer No. 201867
Customer Order No. 2543
Qty Ordered 31,000
Qty produced 35,700 over 3 shifts
Design No. 569337
Tool No. C535239
Board Code 5058 140WKT/RP/140T
Corrugator programme 86946
Sheet size 867 x 806
Dimensions 240 x 135 x 185
Print No. 535239 {3 Colour}
Bundle 20 Tied
Pallet 4way entry
Delivery Note No. 1736434
Load No. 47868
Qty Delivered to Customer 35,700 on 6.11.2017
Reel No. 7108127101 Kiwi No. 580278 VPK Paper 140gsm test liner
Material arrived on Delivery Note No. 80065336 on 23.10.2017
Full traceability achieved
3.10 Customer focus and contract review


Sales & Contract Review procedure QMS305 issue11 dated 6.2.2018
Customer contact is controlled via Desborough site.
Sales Director, Carol Murphy Group Customer Services Manager & Customer Services personnel in
conjunction with & external area sales managers. A contract review is carried out to establish requirements
and a generation of an agreed approved specification is held in bespoke MIS computer software programme
KIWI. An order is then put on system and Selby site planner generates a production schedule every morning
3.11 Complaint handling
Customer Complaints & Corrective/ Preventative Actions procedure QMS307, Issue 16 Dated 3.10.2017,
Complaints logged on receipt via Customer Service personnel; investigated by Quality dept in conjunction
with dept team leader. Coordination & close out of complaints by Compliance Manager. Any credits are
authorised by Site Director. Corrective/preventative measures documented with company response to
customers as applicable.
Viewed
Complaint No. 12495
Customer Park Cake Bakeries
Issue design problem on carton bottom knives in tooling being incorrect
Root cause CAD file and PDF inconsistency on knives and perf requirements; New re designed tooling
ordered, returned product destroyed via baler, and remainder of stock at Rigid inspected and destroyed.

Complaint No. 12533
Customer BCM Ltd
Complaint date 23.2.2018
Issue Gluing missing from tab
Qty effected 115
Root cause Sensor on glue tab not working effectively due to tab knife requiring replacing.
Cell leader spoken to crew and requested additional inspections of tab knives for wear and more frequent
replacement.
3.12 Management of product withdrawals, and incidents and product recalls
Product recall – withdrawal procedure QMS308 issue 3 dated 7.6.2017

All personnel advised on Induction and at appropriate intervals on incidents and actions to be taken; records
of training on file.
Contact details for customers are held on system database. The system can be activated during normal
working hours & customers have contact telephone details of Sales Area Managers & appropriate Business
contacts for out of hour’s situations.
Product withdrawal carried out 24.1.2018 as part of complaint 12495
Customer Park Cake Bakeries.
Call Off C1150677
Issue design problem on carton bottom knives in tooling being incorrect Qty delivered 31500
Qty affected 1500
Goods returned 5.1.2018
Complaint No. 12495 confirms returned product baled
Remaining stock put on hold for inspection then baled
Customer managed to use majority of items but is was more time consuming in erecting the carton
A documented record of the exercise is held on file, Quality Manager & BRC ‐Environmental Co‐ordinator in
conjunction with Site Director being responsible for any recall or product withdrawal decision. Production


Administrator re co‐ordination for uplift of product from customer. Compliances Manager has overall
responsibility to ensure suitable preventative action is implemented.

4. Site Standards
4.1 External standards
The site is was purpose built on an industrial estate with neighbours that do not have any activities that
could harm their products. The perimeter has a concourse of concrete & tarmac & an area with a pond to
the rear; drainage is via mains systems with suitable gratings in place. Refuse and materials for recycling are
stored in designated areas and skip containers away from main buildings. The external grounds are
maintained by in house provision. Perimeter areas being well maintained. The building fabric of steel
cladding and brick is well maintained with no access for pest ingress. External pipework passes through
sealed apertures. Raw materials are not stored outside.
4.2 Building fabric and interiors
The plant was purpose built for manufacturing and converting corrugated fibreboard.
There is a 2.5 Metre BHS Corrugator, 2 rotary die cutters, 1 flat‐bed die cutters, 4 casemakers‐ die cutters, 3
folder gluers and materials handling equipment. There are separate storage for finished goods, reel store
and pallet finished goods store. The roof is corrugated sheeting incorporating sky lights. Floors are
constructed of concrete with painted walkways; internal walls are steel clad & brick, and painted. Protected
LED lighting in production & storage areas. Ventilation is of natural provision with dust extraction systems in
place.
4.3 Utilities
Water is specifically used for generation of steam in corrugator process with temperatures of 1600C; It is also
utilised for cleaning purposes it is via mains supplies provided by local water authority Yorkshire Water it is
of potable quality. Compressed air is utilised on machinery for operational control of valves & cylinders that
is dried & oil separated.
4.4 Security
There are two site security risk assessment on file
1 conducted by Duval Third party security company at site dated 2.6.2018
2 Sites own product security risk evaluation dated 2.6.2017
The site is protected with Security CCTV camera monitoring, manned security gatehouse in operation,
security fencing ‐ hedges, security barriers, security lighting. Electronic fobs for employees; signage is clearly
displayed on reception. All visitors sign in on entry and staff are encouraged to report or challenge any
unidentified or un accompanied personnel. Transport personnel have use of site welfare facilities but do not
enter main production facility.
4.5 Layout and product flow


The site has a plan of the site that shows;
Personnel entrances, Staff facilities, Travel routes, Process flow, Storage areas. The process flow is linear and
protects the products from contamination or damage, the site has sufficient space and storage capacity to
enable all operations to be carried out correctly. Access through the production area is via designated
walkways.
4.6 Equipment
The equipment is designed specifically for its intended purpose and is maintained in a suitable condition
applicable to its application. The company have the knowledge and expertise required to ensure compliance
with this requirement. Any new equipment is fully specified prior to purchase and installed and
commissioned by the manufacturer. The machinery is maintained in very good condition
4.7 Maintenance
QMS402 Preventive Maintenance & Machine Cleaning procedure issue 11 dated 6.2.2018
The site maintenance is controlled by Pirana PPM system. Managed by specialist machine cell technicians.
The incorporates an asset care process with schedules of work/identified repairs for each machine, there are
general lubrication schedules & ppm schedules, with electronic records of maintenance files for each
machine up to date. Food safe oil oils H1 used on slitter scorer blades supplied by Solent Lubricants
Compressor services by third party inclusive of dryer filters by Roton Air 21.2.2017
Viewed maintenance of Corrugator W/Order No. 58814 as part of vertical audit at evaluation
Viewed maintenance records of Gopfert die cutter W/O No. 51859 as part of vertical audit at evaluation
Viewed maintenance records of Vega gluer W/O No.58763 as part of vertical audit at evaluation
Woodthorn Air conditioning certificate 13.1.2016 re inspection 10.12.2020
Houseman Environmental Legionella certificate Cert No. 2013/2289 Valid to 31.8.2018
4.8 Housekeeping and cleaning
QMS402 Preventive Maintenance & Machine Cleaning procedure issue 11 dated 6.2.2018
Good standards of hygiene were seen during the audit with a ‘Clean as You Go Policy’ in place.
Cleaning schedules in place for general areas which include
Task/areas to be cleaned, Frequency, Method and materials. Machinery is cleaned by the operatives to a
schedule that covers daily, weekly and monthly requirements, that are recorded both electronically and hard
copy. Cleaning chemicals are of a domestic type {Selden multipurpose cleaner MSDS on file} and used within
the manufacturers guidelines. Toilet and other materials are segregated. Welfare areas cleaned by site
cleaners.
Machine cleaning records of Corrugator carried out 23.10.2017 viewed as part of vertical audit
Machine cleaning of Gopfert die cutter carried out 23.10.2017 viewed as part of vertical audit
Machine cleaning records of Vega gluer carried out 24.10.2017 viewed as part of vertical audit
High level cleaning 19 zones with schedule in place using vacuums
Conversion machine cleaning zones carried out 3rd to 17th Feb 2018
There is a section of a zone cleaned monthly.
Toilets cleaned 14.2.2018
4.9 Product contamination control


4.9.1 Glass, brittle plastics, ceramics and similar materials control
QMS404 Glass & Brittle Plastics Policy issue 4 dated 1.12.2016 & QMS405 Glass & Brittle plastic Control issue

12 dated 8.11.2017 identifies how to deal with a breakage / incident reporting. Glass and Brittle plastic
register inspected monthly with any issues repaired accordingly. High level LED lights protected & low level
fluorescent lighting with protected covers in production & storage areas, shatterproof EFK tubes. Any
breakages will be reported on the Glass Log which is signed off by the dept. leader to confirm that
everything has been suitably cleaned and checked before production restarts.
Viewed glass & brittle plastics inspection report 6.4.2017
4.9.2 Sharps control
QMS406 Sharps policy issue 7 dated 9.11.2017 in place with associated Sharps registers, Procedure also
forbids that snap off blades are permitted on site.
Knives seen were in good condition Stanley type.
4.9.3 Chemical and biological control
QMS408 Chemical Control Procedure issue 9 dated 9.1.2017
Chemicals are controlled via COSHH & Reach MSDS sheets readily available. PRP programmes, GMP
procedures manage any potential microbiological contamination. No Aseptic controls applicable; Food grade
lubricants in use. Chemicals stored in designated locations.
Selden FO10 Multipurpose Cleaner on register with MSDS sheet readily available
4.10 Waste and waste disposal
Process cardboard trim waste is extracted & compacted for recycling via Chambers & Cook Ltd an upper tier
waste carrier; defective board rejected compacted / baled for recycling.
General waste removed by Mytuns of Selby
Waste License Mytuns No CBDU82700 Exp 11.2.2019
Waste Licence No. CBDU183008 Chambers & Cook Expiry date 2.8.2020
4.11 Pest control
M J Backhouse Pest Control at site holds NPTA membership No. 0233 to 15.4.2018; 8 routine, 4 EFK visits & 2

biologist visit. Specification covering, rats, mice, crawling insects & ants. Shatterproof EFK bulbs, pesticide list
of baits in use.
Ratimor toxic blocks & Detex non‐ toxic blocks in use
Technician visit 15.2.2018; Levels of activity in reports ref predominantly to external areas with mice and
moles. Site bait plan dated Sept 2017. The site is proofed with various door strips & seals.
Competency certificates for technician Craig McCormack & Biologist Nick Wright on file. Operatives are
made aware of the need to report any sightings of pest activity conveyed as part of hygiene training.
Biologist visit 26.10 2017 noted proofing issues now closed out
Non‐applicable clauses 4.11.3

5. Product and process control
5.1 Product development


QMS500 Graphics & Structural design issue 7 dated 9.1.2018
There is no product development at site {managed at head office Desborough}
Product Development is managed by Desborough sister site
Selby Site receive approved cutter layout and artwork from the sister site
Sales and estimating also at Desborough site {Selby is a manufacturing facility}
5.2 Graphic design and artwork control
QMS500 Graphics & Structural design issue 7 dated 9.1.2018
There is no Artwork control at site {managed at head office} by Desborough sister site
Selby Site receive approved artwork from the sister site & also printing plates
5.3 Packaging print control
Procedures covering Print Controls are in place. The printing process is routinely reviewed at the HARM
Review Meeting and via internal audits, although the loss of essential information such as allergens is not
applicable in this instance as this is printed on the primary packaging. Printing plates are controlled during all
production runs & are fully traceable through unique reference numbers. Plates are suitably stored in
designated free hanging racking systems around the site.
Master samples or approved Customer proofs to match to are supplied with every Works Order. A first off
sample is scanned into an X‐rite spectrophotometer (with Delta 2 as the standard acceptable reading) and
samples of printed board are checked against the approved scan at regular intervals throughout the run.
First off samples must be signed off by the Printers or the dept. Manager. Samples are taken at pre‐
determined frequencies throughout the run to identify any printing errors and include ink coverage,
registration and colour match. Composite printing is not undertaken at the site. Checks were in evidence for
the W/O’s in production during the time of the site tour. Samples are retained in accordance with Customer
requirements. Unused print is treated as waste shredded and baled.
5.4 Process control
QMS501 Production Planning & Process Control procedure Issue 5 dated 7.3.2018
The senior management constantly review all processes to ensure consistency of product is maintained.
Controls in place include product integrity production procedures with manufacturing work instructions at
point of use to ensure products meet the specification and maintain standards of hygiene. The process is
also maintained via the reviews of the Hazard & risk study and implemented prerequisite controls.
Production specifications are available for products. Specifications are approved internally by production &
technical personnel. There are manufacturing control points identified in process; managed by QMS
procedures – work instructions & prerequisite controls. Various quality inspections carried out as per work
instructions for each job task. Typical machine settings are dimensions, pressures, and speeds. Inspection
regime defined by quality manufacturing plan Warp 0.3% tolerance. Viscosity checks at Wet end. First off
inspections verified by production machine operatives at start of run.
Line clearance process as part of set up for new job to required parameters and per customer specification.
New specification is raised and new unique spec ref put on system. Revalidation of quality plan to ensure
conformity to specification, verification via inspection regime.
5.5 Calibration and control of measuring devices
QMS502 Inspection, Measuring & Test Equipment procedure issue 9 dated 11.5.2017 applies.
The parameters of items manufactured are controlled by precision cutting forms made to specification. Basic
dimensional measuring 3mm + / ‐ tolerance is verified by steel measures. Steel measures are calibrated on


purchase are replaced as and when required or damaged.
There are a selection of X rite spectrophotometers used on site calibrated 6 ton 8 weekly cycle by Quality
Manager
Last calibrations 21.1.2018
Moisture meter serial No. 41688 not Calibrated NC
5.6 Product inspection, testing and measuring
Quality checks are undertaken at the start of every run and through every stack of cases throughout the run.
Checks include case make up, dimensions, glue and print quality. Checks are recorded at the start and end
of the run by sign off on the conversion log sheet. All product inspection takes place on‐site by trained
operatives and follows procedures appropriate to product. The production team leaders verify the accuracy
of checks where applicable. No laboratory testing is carried out on site.
Viewed quality checks completed at time of audit
Description Food to Go Die Cut Tray
Artwork No. P27409
Print No. 563480
Job No. 563480/AT for Greencore
5.7 Control of non‐conforming product
QMS503 Control & Disposition of non‐conforming product issue 11 dated 5.10.2017

Defect material or suspect material is reported to dept. manager or team leader; it is labelled and
segregated accordingly awaiting disposition i.e. resort, rework is generally not possible, or destroy and
recycle. Corrective actions to prevent re‐occurrence are determined through the use of root cause analysis.

Noted a reel of paper in quarantine area with Label Do Not Use {reel ref Royal Cote Plus 180kg} The reel had
been made unselect able via the electronic management system for scanning material in and out of stock.
5.8 Incoming goods
All incoming raw materials, including pallets, are checked by Warehouse Personnel against the relevant
paperwork and entered into the KIWI MIS system ready for production. Incoming deliveries are inspected
for hygiene standards and damage. Any defective materials are reported, photographed and returned.
Viewed incoming load from Smurfit Paper
Shipment O/No. 883687
Product Recycled based fluting 85gsm x 2500 deckle
Delivery Note No. 0082188718 dated 15.3.2018
Reel No. 9181100131 weight 2.828kg part of shipment was allocated KIWI No. 602499
Inspected for moisture content between Min 5% & Max 12% {Actual 8.2%}
5.9 Storage of all materials and intermediate and finished products
All raw materials and finished goods are suitably identified with labels and finished product is banded with
top coverings as a minimum criteria, some is wrapped to avoid contamination depending on customer
requirements. During the assessment it was observed that raw materials and finished product were kept
segregated. Stock is stored and used in conjunction with FIFO batch principles. There are no hazardous
chemicals on site. No instances of unidentified WIP noted during evaluation. There is no offsite storage.
Materials intended for recycling are baled and stored internally until collected by sister VPK site based in
Belgium. The process is paper is delivered from Belgium site, and baled material is returned for recycling on


the same trailer
5.10 Dispatch and transport
Finished goods are transported by hauliers; there is a preload hygiene inspection. Contract haulier BTS
transport used, Transport agreement & supplier evaluation in place. Only suitable non contaminated &
adequate construction pallets are used in the process. Vehicle delivery drivers comply with the site rules
relevant to this standard. Loading is carried out under cover
Viewed vehicle loading at evaluation, and also documentation completed with hygiene inspections as part of
vertical audit
Customer R&R Ice Cream UK Ltd
Customer Order No. 584167/I & 580451/K
Delivery Note No.1754730
Qty Delivered two items 4,500 & 22,800
Despatch date 16.2.2018 Haulier BTS Trailer No. 62 both jobs
Non‐applicable clauses 5.9.2, 5.10.3

6. Personnel
6.1 Training and competence
Employees including temporary personnel employed in business are subjected to an induction process to
cover all aspects of the standard. Competency training records include induction, machine / job training,
quality and product inspections, hygiene, safety. BRC hygiene training information hand out with tool box
talk via team leaders. Induction includes hygiene rules conducted by designated manager.

Viewed competency records of;
Peter Brown Corrugator Supervisor
Corrugator supervisor training 20.2.2014
Module facer training 7.12.2015
Corrugator S/Facer 24.7.2009
Reel loading on corrugator training 5.10.2015
Key behavioural safety training 14.6.2016
Internal auditor training 15.7.2011
SSOW BHS Corrugator 15.6.2015
Job Task risk assessment training 29.4.2017
BRC Hygiene code of practice 2.11.2017
Chemical handling training 30.9.2015

David Liversidge Gluing machine operative
Operator training Sept 2014 via Bobst
Hygiene training 3.11.2017
Pallet wrapper training 30.11.2016
Conversion machine training 27.1.2016
Multi point folder gluer training 27.1.2015
BRC Hygiene code of practice 17.1.2017



All records viewed were suitably maintained to establish competency of employee
6.2 Personal hygiene
QMS601 Hygiene code of practice issue 8 dated 20.10.2017
All personnel receive an induction course including the hygiene and jewellery policies before starting work in
the shop floor, which address the wearing of jewellery and hand washing. Personal items are not permitted
on the shop floor and have to be kept in lockers.
6.3 Staff facilities
Eating and drinking is restricted to the canteen areas and is not permitted in production, storage or locker
areas. Toilets with 2person stainless steel handwash trough, unperfumed liquid antibacterial soaps, paper
towels, hand dryers, hand wash signage and easy cleanable tiled flooring. This is supplemented with
strategic located sanitiser units.
There are sufficient facilities for visitors and contactors to comply with the sites requirements. Water
dispensers with conical cups positioned around site perimeter; the drinking of water in sports type bottles is
also permitted away from production equipment.
6.4 Protective clothing
Workware risk assessment in place dated 12.1.2018
Company issued protective garments consist of Polo shirts, trousers, sweat shirts, sweat shirts, safety boots,
hearing protection & Hi visibility vest that is suitable & sufficient. Workwear is maintained by self‐care
laundering provision with self‐care guidance {clean at 40°C} in site hygiene rules & hygiene training
programme. Additional supplies of clothing available held on site for unplanned circumstances. The
condition of clothing is monitored for compliance via production management.
Engineers have a contract laundering of garments with supply source currently under review of contract



Traded Goods Module
Scope
7.1 Approval and performance monitoring of manufacturers/packers of traded food products

7.2 Specifications

7.3 Product inspection and laboratory testing

7.4 Product legality

7.5 Traceability




18 03 Rigid Containers Selby BRC Report Rev 1

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Audit

Audit grade AA Previous audit grade AA

P506: Packaging 5 Basic Hygiene, Issue 2 December 2015 Report No. UK/BRC/493 Auditor: Cameron Keith

QA International Certification Ltd, Dudley Court, Dudley Road, Darlington, Co. Durham, DL1 4GG Page 1 of 26

Country United Kingdom Telephone 01757 244600

Commercial Carol Murphy Email carolmurphy@rigid.co.uk

Technical Liz Roche Email lizroche@rigid.co.uk

Other certificates held ISO 14001 & FSC Chain of Custody

Major changes or auditor Within the last 12 months a new Site Director has been appointed Paul Hanley

Company description The business Rigid originated in 1907 in Selby and moved to the current

P506: Packaging 5 Basic Hygiene, Issue 2 December 2015 Report No. UK/BRC/493 Auditor: Cameron Keith

QA International Certification Ltd, Dudley Court, Dudley Road, Darlington, Co. Durham, DL1 4GG Page 2 of 26

P506: Packaging 5 Basic Hygiene, Issue 2 December 2015 Report No. UK/BRC/493 Auditor: Cameron Keith

QA International Certification Ltd, Dudley Court, Dudley Road, Darlington, Co. Durham, DL1 4GG Page 3 of 26

Re‐audit due date 2019‐03‐19 Previous audit date 2017‐03‐06

On‐site duration 12 hours Duration of 4 hours

110004 Cameron Keith Auditor

P506: Packaging 5 Basic Hygiene, Issue 2 December 2015 Report No. UK/BRC/493 Auditor: Cameron Keith

QA International Certification Ltd, Dudley Court, Dudley Road, Darlington, Co. Durham, DL1 4GG Page 4 of 26

P506: Packaging 5 Basic Hygiene, Issue 2 December 2015 Report No. UK/BRC/493 Auditor: Cameron Keith

QA International Certification Ltd, Dudley Court, Dudley Road, Darlington, Co. Durham, DL1 4GG Page 5 of 26

P506: Basic Hygiene Packaging 5, Issue 2 December 2015. Report No. UK/BRC/493 Auditor: Cameron Keith

QA International Certification Ltd, Dudley Court, Dudley Road, Darlington, Co. Durham, DL1 4GG Page 6 of 26

P506: Basic Hygiene Packaging 5, Issue 2 December 2015. Report No. UK/BRC/493 Auditor: Cameron Keith

QA International Certification Ltd, Dudley Court, Dudley Road, Darlington, Co. Durham, DL1 4GG Page 7 of 26

P506: Basic Hygiene Packaging 5, Issue 2 December 2015. Report No. UK/BRC/493 Auditor: Cameron Keith

QA International Certification Ltd, Dudley Court, Dudley Road, Darlington, Co. Durham, DL1 4GG Page 8 of 26

P506: Basic Hygiene Packaging 5, Issue 2 December 2015. Report No. UK/BRC/493 Auditor: Cameron Keith

QA International Certification Ltd, Dudley Court, Dudley Road, Darlington, Co. Durham, DL1 4GG Page 9 of 26

P506: Basic Hygiene Packaging 5, Issue 2 December 2015. Report No. UK/BRC/493 Auditor: Cameron Keith

QA International Certification Ltd, Dudley Court, Dudley Road, Darlington, Co. Durham, DL1 4GG Page 10 of 26

P506: Basic Hygiene Packaging 5, Issue 2 December 2015. Report No. UK/BRC/493 Auditor: Cameron Keith

QA International Certification Ltd, Dudley Court, Dudley Road, Darlington, Co. Durham, DL1 4GG Page 11 of 26

P506: Packaging 5 Basic Hygiene, Issue 2 December 2015 Report No. UK/BRC/493 Auditor: Cameron Keith

QA International Certification Ltd, Dudley Court, Dudley Road, Darlington, Co.Durham, DL1 4GG Page 12 of 26

The hazard and Risk Management Team consists of six team members with multifunctional expertise, across

The company has carried out a HARM Hazard analysis study in accordance with the requirements of this

P506: Packaging 5 Basic Hygiene, Issue 2 December 2015 Report No. UK/BRC/493 Auditor: Cameron Keith

QA International Certification Ltd, Dudley Court, Dudley Road, Darlington, Co.Durham, DL1 4GG Page 13 of 26

QMS 300 Doc & Data Control procedure issue 22 dated 7.3.2018

QMS 300 Doc & Data Control issue 22 dated 7.3.2018 Incorporates control of records

P506: Packaging 5 Basic Hygiene, Issue 2 December 2015 Report No. UK/BRC/493 Auditor: Cameron Keith

QA International Certification Ltd, Dudley Court, Dudley Road, Darlington, Co.Durham, DL1 4GG Page 14 of 26

Internal audit procedure in place QMS301 issue 11 dated 8.3.2017 with a schedule in place for 2018.

Supplier Assessment & Approval is in place QMS303 Issue 13 dated 7.3.2018.

P506: Packaging 5 Basic Hygiene, Issue 2 December 2015 Report No. UK/BRC/493 Auditor: Cameron Keith

QA International Certification Ltd, Dudley Court, Dudley Road, Darlington, Co.Durham, DL1 4GG Page 15 of 26

3.7 Management of sub dated contracted processes

P506: Packaging 5 Basic Hygiene, Issue 2 December 2015 Report No. UK/BRC/493 Auditor: Cameron Keith

QA International Certification Ltd, Dudley Court, Dudley Road, Darlington, Co.Durham, DL1 4GG Page 16 of 26

P506: Packaging 5 Basic Hygiene, Issue 2 December 2015 Report No. UK/BRC/493 Auditor: Cameron Keith

QA International Certification Ltd, Dudley Court, Dudley Road, Darlington, Co.Durham, DL1 4GG Page 17 of 26

Product recall – withdrawal procedure QMS308 issue 3 dated 7.6.2017

P506: Packaging 5 Basic Hygiene, Issue 2 December 2015 Report No. UK/BRC/493 Auditor: Cameron Keith

QA International Certification Ltd, Dudley Court, Dudley Road, Darlington, Co.Durham, DL1 4GG Page 18 of 26

P506: Packaging 5 Basic Hygiene, Issue 2 December 2015 Report No. UK/BRC/493 Auditor: Cameron Keith

QA International Certification Ltd, Dudley Court, Dudley Road, Darlington, Co.Durham, DL1 4GG Page 19 of 26

P506: Packaging 5 Basic Hygiene, Issue 2 December 2015 Report No. UK/BRC/493 Auditor: Cameron Keith

QA International Certification Ltd, Dudley Court, Dudley Road, Darlington, Co.Durham, DL1 4GG Page 20 of 26

QMS404 Glass & Brittle Plastics Policy issue 4 dated 1.12.2016 & QMS405 Glass & Brittle plastic Control issue

M J Backhouse Pest Control at site holds NPTA membership No. 0233 to 15.4.2018; 8 routine, 4 EFK visits & 2

P506: Packaging 5 Basic Hygiene, Issue 2 December 2015 Report No. UK/BRC/493 Auditor: Cameron Keith