Based on BRC/IOP global standard for the packaging

and packaging materials.

SOME RULES……….
1. Kindly switch off your cell
phones – or put them on silent

2. This is a smoke free course –

kindly no-smoking during the
training

3. Emergency rules and regulations

4. Facilities

8/3/2023 Food Safety Systems Certification - FSSC 22000 2

 COURSE INTRODUCTION

The objective of this course is to enable

the delegates to gain knowledge on the
Good Manufacturing Practices (GMP)
in the manufacture of packaging and
packaging materials.

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 About the Standards

Packaging Consumer Storage &

Food Products Distribution
Introduction to BRC
 BRC is a trade association representing retail trade in
the UK – established in 1992
 IOP is a professional membership body for the
packaging industry. Established in 1947.
 The BRC/IoP Global Standard for Packaging and
Packaging is a logical extension of the already
established BRC Global Standard for Food.
 Background

Issue 1
2004 2011
Issue 3 Packaging
Global Standard and Packaging
for Food Issue 2 released Materials Issue 4 released
Packaging

2002 2008
 Objectives of the Standard

To ensure the quality, safety and legality of packaging and

packaging materials

To assure the users of packaging that the packaging

producer has robust quality and safety systems

Maintain customer confidence in their supply base through

audit and certification

Provides a basis for approval of suppliers by

customers
 The Requirements

Senior Management Hazard & Risk

Commitment Management

Product Safety & Site Standards

Quality Management

Product & Process

Personnel
Control
Product Safety
Assurance that products have been designed and
manufactured in a manner that ensures they do
not represent harm or hazards to consumers

10
HAZARDS ASSOCIATED WITH PACKAGING
MATERIALS
 hazards fall into 3 main categories.
 Biological
 Chemical
 Physical

11
PHYSICAL CONTAMINATION/HAZARDS
A. Inherent
(i) In containers
• Heavy metals
• Dust
• Iron filings from equipment
(ii) Dried products
• Grit
• Insects

12
PHYSICAL CONTAMINATION/HAZARDS
B. (i) Introduced
From the environment
 Glass fragments
 Metal pieces i.e. nuts, bolts, screws and pins
 Stones
 Paint chippings
 Rust
 Pieces of wood & plastic

13
HAZARDS ASSOCIATED WITH PACKAGING
MATERIALS
 B. Introduced
(ii) From handlers
• Jewellery
• Buttons
• Hair
• Nail fragments and nail varnish
• Cigarettes etc.

14
HAZARDS ASSOCIATED WITH PACKAGING
MATERIALS
2. Chemical Contamination
 Common examples of chemical contamination in product
include: -
 Cleaning chemicals and disinfectants
 Oil and machine lubricants
 Paint fumes and chippings
 Line cleaning fluids
 Adhesives, Inks etc
Toxic metals present in nature in the environment, e.g. tin,
cadmium, mercury, lead arsenic etc.

15
HAZARDS ASSOCIATED WITH PACKAGING
MATERIALS
 Microbiological Hazards
 Bacteria
 Yeasts & Moulds
 Viruses

16
Product Safety Control
 Manufacturers must maintain control of
product safety/quality hazards
 This can be effectively achieved through
implementation of Good Manufacturing
Practices.
Is Product Safety and Quality Important?
YES!

▪ It protects you,
your customers and
your co-workers.

▪ It’s required by law.

▪ It’s good business.
How Product Become Contaminated/Unsafe

▪ Poor Personal Hygiene

▪ Cross Contamination

▪ Poor Site Standards

▪ Improper Cleaning and Sanitizing

What’s Wrong?

I ate something bad, I have…..

Food Poisoning!
How do people get Food Poisoning?
Because of Bad Bacteria

What is Bad Bacteria?

Where does bad bacteria come from?

 Poor Personal Hygiene

Dirty Hands Dirty Finger Nails

Dirty Uniforms

Smoking in Food Areas Being Sick at Work Open Cuts

By Practicing Good Personal Hygiene

Wash your hands regularly Especially after

going to the
bathroom

Have a Clean Uniform

Available

If Sick Stay Home

Place a Band Aid on Cuts
The Importance of Washing your Hands
 Hand washing
All employees must wash their hands thoroughly:
 when they enter product handling areas
 before starting work
 after handling contaminated materials
 after breaks
 after using toilet facilities
Hand washing facilities
Hand washing facilities
 Must be accessible to all product handlers.
 To be used only for the washing of hands.
 Provide unscented liquid soap and warm potable
water.
 Provide disposable towels for drying hands.
 Provide a bin for the disposable towels.
 Display hand washing procedure/instructions
What is wrong with this hand
wash area?
HAND WASHING
PROCEDURE
Wash hands before
entering production
areas

Signs in areas (e.g.

changing rooms)
Remember to always…
After……
Medical screening
 The company to monitor and control health
conditions likely to adversely affect product quality
and safety.
 Visitors to fill health questionnaires prior to entering
production areas.
 Visitors Should always be accompanied.
 Visitors Must be appropriately dressed - hair
coverings, booties over street shoes, gloves, sleeve
covers, etc.
 Illness
 Doctor’s certificate on hiring (for high risk contact
products)
 Inform your supervisor or HR if you are ill with
symptoms that could contaminate ingredients or
products
 No medication allowed in factory
 Ensure that a clean bandage covers any open
wounds
What symptoms of foodborne illness
should establishments be most
concerned about?
 Establishments should be most concerned about
the following symptoms:
 Vomiting
 Diarrhea
 Jaundice (yellow skin or eyes)
 Sore throat with fever
 Infected cuts and burns with pus on hands and
wrists
What should employees do when they
have symptoms of vomiting or
diarrhea?
 If at work:
 Stop work immediately;
 Report to management; and
 Go home and return after at least 24 hours have passed
since the vomiting and diarrhea symptoms ended.
 If the symptoms occur before the employee arrives to
work, he or she should:
 Notify the manager by telephone; and
 Do not report to work until at least 24 hours have passed
after the diarrhea and vomiting symptoms have ended.
Cont’d
 What should employees do if they are not feeling
well and their skin or eyes turn yellow?
 What should employees do if they have an
infected wound or cut on their hand or arm?
 What should employees do if they have a sore
throat with fever?
 Personnel
 Any behavior that could result in product
contamination such as eating, use of tobacco, chewing
gum or other unhygienic practices, is not allowed in
product handling areas
Production employees
 Bathe daily
 No perfume, aftershave, fragrant creams
 No jewellery
 No false nails or nail polish
 Fingernails should be trimmed short
 Use metal detectable bandages covered with gloves
 No eating, drinking or chewing gum
 Clothing
 Everyone must wear clean protecting clothing
 Separate shoes (no open toes or high heels) are to
be worn in the factory.

 Personal belongings and street clothing must be

stored in locker rooms.
Protective clothing
 Appropriate PPE to worn in production and storage
areas to minimize the risk of contamination.
 Where high-risk contact products are made, clothing
shall have no external pockets on the external body
garments or sewn on buttons.
 Laundry of clothing
 Professional laundry service
 In-house
 Controlled laundry facilities or self-care
Personnel
 All employees should be adequately trained (including
induction training).
 A training program to be maintained.
 The effectiveness of training to be evaluated and
records maintained to demonstrate effectiveness.

8/3/2023 Food Safety Systems Certification - FSSC 22000 41

 Personnel
 Do not leave gloves, masks, etc. lying around
while on break or at shift end.
 Crates, boxes, containers or buckets must not
be placed directly on the floor.
 Store brooms and dust pans at stations
provided.
 Personnel Practices
 Do not lean, sit or step on product surfaces.
 Do not handle materials or products with either
cut or infected hands.
 Do not engage in horseplay.
Access and movement of
personnel
 The company shall ensure that movement of
personnel, visitors and contractors does not
compromise product safety and quality.
 Availability of a site Plan showing the traffic of
personnel
 Access points to be clearly identified.
External Standards
 All grounds within the site shall be furnished and
maintained to an appropriate standard.
 External areas
 Buildings designed to minimize pest entry and ingress
of other contaminants
 Proper and adequate drainage
 External storage of refuse in designated areas.
 External storage area
Building fabric
 Internal design, layout and traffic patterns - adequate
space, partitions, walls, barriers etc.
 Internal structures and fittings – washable or
cleanable.
 Floors designed to avoid standing water.
 Drains shall be trapped and covered
 Insect screening of all external openings.
 Location of equipment – should facilitate good
hygienic practice and monitoring.
 Design of Premises

 Design
Walls, floors, ceilings, ledges, drains, air supply,
dust extraction
 Prevention of build-up of dirt and dust to avoid
unnecessary risks of contamination
Cleaning programme, appropriate cleaning,
cleaning records
 Effective cleaning and disinfection
choice of materials and chemicals, validation
 Drains – prevent backflow
 Staff facilities
 Adequacy of facilities to accommodate numbers of
personnel
 Suitable and sufficient hand washing facilities
 For high risk contact products, hand washing facilities
to be located at the entrance to the production area.
 Locker rooms to be accessed without need to enter
production unless appropriate segregated walkways
are provided
 Staff facilities
 Company issued protective clothing and personal
clothing not to be stored in the same locker or shall be
effectively segregated within the locker.
 Eating, drinking and smoking not allowed in the
locker and change rooms.
 No food to be taken into manufacturing premises (
production and storage areas)
 HOUSE KEEPING
 House keeping and cleaning systems shall be in place.
 Implementation of a clean as you go policy
 Establishment and implementation of cleaning
schedule
 Cleaning equipment and materials to be kept in secure
designated areas.
 House Keeping
 Keep contact surfaces clean and free of
contamination from tools, cords, cleaning
utensils, machine parts, lubricants and paper.
 Clean all spills promptly.
 Keep everything off the floor and the area
clean and floors swept.
 House Keeping
 Work areas should be cleaned regularly
throughout the shift.
 Keep your immediate working area swept or dust
mopped. Wipe or mop up spilled liquids
promptly.
 Scrape the floor around the work area after
completing a job.
 Leave your work area clean at the end of your
shift.
Utilities – air, water, energy
 Utilities quality shall be monitored to minimize product
contamination risk.
1. Water supply
 The supply of potable water shall be sufficient to meet
the needs of the production process (es).
 The microbiological and chemical quality of water,
steam, ice, air, compressed air or other gases, which do
not constitute an ingredient but come in direct contact
with packaging, shall be regularly monitored.
 Non portable water to be conveyed separately in labelled
systems which prevent reflux into potable system

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Utilities – air, water, energy
2. Boiler chemicals
Shall be approved food additives or approved by
relevant regulatory authority.
Boiler chemical to be stored separately in secured places.

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Utilities – air, water, energy
3. Air quality and ventilation
 Establish requirements for filtration, humidity and
microbiology of air used as an ingredient or for direct
product contact.
 Where temperature and/or humidity are critical,
control system shall be put in place and monitored.
 Exterior air intake ports shall be examined periodically
for physical integrity.

8/3/2023 Food Safety Systems Certification - FSSC 22000 56

Utilities – air, water, energy
5. Compressed air and other gases
 Compressed air, carbon dioxide, nitrogen and other
gas systems used in manufacturing and/or filling shall
be constructed and maintained so as to prevent
contamination.
 Where oil is used for compressors and there is a
potential for the air to come into contact with the
product, the oil used shall be food grade.

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Utilities – air, water, energy
5. Lighting
 Light fixtures shall be protected to ensure that the
materials, product or equipment are not
contaminated in the case of breakages.

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 Security
 Access to the site shall be controlled
 Visitors reporting and clearance
 Supervision of contractors
 Security of site IT systems and back up
Equipment suitability,
cleaning and maintenance
 Product contact equipment shall be designed and
constructed to facilitate cleaning, disinfection and
maintenance.
 Hygienic design
 Product contact surfaces
 Measurement and monitoring equipment
 Cleaning plant and equipment
 Preventive and corrective maintenance

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Equipment
 Return tools and attachments to their proper
place after use.

 Check product surfaces before starting

equipment. Remove any foreign objects or dirt.

 Replace brushes that lose bristles.

Maintenance and Repairs
Ensure area is segregated from production
Do not leave maintenance supplies in the
product zone.
Return all tools and attachments to their proper
place after use.
Ensure the production area is clear of all tools
and hazards before production starts
Measures for prevention of
contamination
 Careless employee practices can cause
product contamination.

 The best way to avoid contamination is to

prevent it.

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Measures for prevention of
contamination
 Programs shall be put in place to prevent, control and
detect contamination.
 Where glass or brittle material are used, periodic
inspections shall be carried out and records
maintained.
 A preventive maintenance program shall be in place

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Measures for prevention of
contamination
 Maintenance and repair
activities inevitable in manufacturing area
Should present no risk to product
 Whenever possible, all planned maintenance
outside normal operating hours
 Emergency work in working area followed by
thorough clean down and disinfection before
manufacturing recommences
 Area clearance by QC
8/3/2023 Food Safety Systems Certification - FSSC 22000 65
PEST CONTROL
 Keep them out – seal the premises.
 Starve them out – keep premises clean.
 Throw them out – conduct regular pest
inspections or services.
 Don’t give them a home - remove all unnecessary
equipment and items.
Report all pest sightings or evidence of pest activity
to your supervisor.
Pest Control

Pest Control should be done on a REGULAR basis

No Pest Control

Flies on the Food Cockroaches Rats and Mice

In the Kitchen
Be pro-active
 Report or prevent all suspected breaches of
product safety.
 Report all evidence of pest activity.
 Implement a cleaning schedule.
 Obtain and read a copy of the BRC Standards.
 Always remember - prevention is better than
cure.
WASTE MANAGEMENT
 Place waste in plastic lined bins.
 Remove all waste from the premises as
required.
 Empty and clean waste bins regularly.
 Ensure all external bins are covered.
 Protect external waste bin area from
pests and birds.
Rubbish Bins not Emptied Regularly
Transport, storage and
distribution
 Materials and products to be stored in clean, dry, well
ventilated spaces protected from dust, condensation,
fumes, odours or other sources of contamination.
 Where products are stacked, measures should be
taken to protect lower layers.
 Correct stock rotation shall be practiced
 Inspection of incoming goods

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 Receiving and Storage
 Ensure that all pallets and materials are kept at
least 18” away from the walls.
 Inspect torn reels and materials for damage
 Brush off bags and boxes before opening them.
 Store materials and products in designated
areas.
Transport, storage and
distribution
 Separate store for hazardous substances like cleaning
products, lubricants and pesticides.

 Designated area (s) for segregating materials

identified as non conforming.

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Transport, storage and
distribution
Vehicles, conveyances and containers.
Availability and implementation a vehicle cleaning
schedule.
Vehicles, conveyances and containers shall be maintained
in a state of repair and cleanliness.

Hygiene checking of vehicles and shipping containers

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Conclusion
It is essential that handlers have the required skills
and knowledge of safety and handling controls to
minimise the risk of food poisoning.

As a Product handler, it is your responsibility to

ensure that Product for your customers is safe and
suitable to eat.
Product safety starts
with
YOU!
ASSESSMENT
Quiz
Spot the Hazards:
Personal Hygiene Practices