BRC - GLOBAL STANDARDS FOR FOOD SAFETY ISSUE 6

1. BRC - GLOBAL STANDARDS
FOR FOOD SAFETY
ISSUE 6
1
AWARENESS SESSION
ON
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2. HISTORY
• BRC – British Retail Consortium
• Originally Developed in 1998
• New Name – Global Standard for Food Safety
• Based on HACCP Approach
• Latest Issue – Issue 6 released on July, 2011
• Sections – IV
• Annexures – 10
• Clauses – 112
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3. Key Characteristics
• This is a process and product certification
• More emphasis on Quality, Hygiene and Product Safety
• Certification based on grading system
• Frequency of surveillance audit based on number of non-conformances
• Detailing in allergens and site security
• Option of un-announced audits to get A+
rating
• GFSI recognized standard
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4. Certification Scope
• Applicable to the manufactures of the food products, produced and supplied to
retailers (Market Shelves).
• Scope covers only the particular sites where BRC assessments conducted or the
facilities including storage, that are under direct control of the respective site
management.
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5. Grading
• The scoring system based on 5 grades (A+
, A, B, C & D).
• The frequency of the surveillance audit depends upon the number of non-
conformances (NCs) and their nature accordingly.
• The nature of NCs, are:
– Minor
– Major
– Critical
– Fundamental
• Certification will be granted with the specific grade obtained.
• Evidence of the corrective actions is required within 28 calendar days.
• Certification Body should justify in the Audit Report if minor NCs are more than 20
or more than 1 major NC.
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6. Summary of Grading Criteria, Action Required and
Audit Frequency
6
Grade Critical or Manor Non-
conformity against the
Statement of Intent of a
Fundamental Requirement
Critical Major Minor Corrective Action Audit
Frequency
A / A+
1 to 10 Objective evidence in 28 calendar days 12 months
B / B+
11 to 20 Objective evidence in 28 calendar days 12 months
B / B+
1 1 to 10 Objective evidence in 28 calendar days 12 months
C / C+
21 to 30 Revisit required within 28 calendar days 6 months
C / C+
1 11 to 30 Revisit required within 28 calendar days 6 months
C / C+ 2 1 to 20 Revisit required within 28 calendar days 6 months
No Grade 1 or more Certification not granted
Re-audit is required
No Grade 1 or
more
Certification not granted
Re-audit is required
No Grade 31 or
more
Certification not granted
Re-audit is required
No Grader 2 21 or
more
Certification not granted
Re-audit is required
No Grade 3 or
more
Certification not granted
Re-audit is required
Note: + grade only apply to un-announced audit scheme
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7. Fundamental Clauses in Standard
• Within the standard, certain requirements have been declared as
Fundamental Clauses
• These requirements relate to systems that are crucial to the establishment and
operation of an effective food quality and safety operation.
• In all cases where critical or major non-conformity is raised against fundamental
clauses, this will lead to further full evaluation to establish demonstrable evidence
of continued compliance.
• Failure to the fundamental clauses will require a further full audit to establish
demonstrable evidence of compliance.
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8. Fundamental Clauses in Standard
The requirements deemed as being fundamental are:-
• Senior Management Commitment and continual Clause 1.1
improvement
• The Food Safety Plan - HACCP Clause 2
• Internal Audits Clause 3.4
• Corrective Action Clause 3.7
• Traceability Clause 3.9
• Layout, Product Flow and Segregation Clause 4.3
• Housekeeping and Hygiene Clause 4.11
• Management of Allergens Clause 5.2
• Control of Operations Clause 6.1
• Training Clause 7.1
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9. CONTENTS
• Section I – Introduction
• Section II - Requirements
1. Senior Management Commitment
2. The Food Safety Plan- HACCP
3. Food Safety & Quality Management System
4. Site Standards
5. Product Control
6. Process Control
7. Personnel
• Section III – The Audit Protocols
• Section IV – Management & Governance of the Scheme
• Appendixes
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10. Section II - The Requirements
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11. 1.Senior Management
Commitment
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12. FUNDAMENTAL CLAUSE
1.1.1 Documented Policy
• Signed by Concerned Overall responsible
• Communicated to all
1.1.2 Clear Objectives. These objectives shall be:
• Documented and include measures of success
• Clearly communicated
• Monitored / reviewed the results al least quarterly
New format of the objective to be used
1.1.3 Management Review Meeting, annually as a
minimum
1.2 Organization Structure, Responsibilities and
Management Authority
Job Description to be amended for CCP & OPRP
responsibilities
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13. FUNDAMENTAL CLAUSE
1.2 Organization Structure, Responsibilities and
Management Authority
Job Description to be amended for CCP & OPRP
responsibilities
⁻ Clear structure and defined responsibilities
⁻ Organisation chart in place
⁻ Details of deputy personnel
⁻ System for keeping updated of legal and technology changes
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14. 2. The Food Safety Plan - HACCP
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15. FUNDAMENTAL CLAUSE
2. The Food Safety Plan – HACCP
• Systematic
• Comprehensive
• Thorough
• Fully implemented & maintained
• Follows Codex Alimentarius
• Reference to legislation
• Reference to Company’s own Processes or guidelines
15

16. 2.1 Codex Alimentarius Steps
Step 1 – Assemble the HACCP team
Step 2 – Describe the product
Step 3 – Identify the intended use
Step 4 – Construct a process flow diagram
Step 5 – Verify the flow diagram
Step 6 – Conduct the hazard analysis
Step 7 – Determine the CCPs
Step 8 – Establish the critical limits
Step 9 – Establish a monitoring system for each CCP
Step 10 – Establish a corrective action plan
Step 11 – Establish verification procedures
Step 12 – Establish documentation
Step 13 – Review the HACCP plan
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17. 2.1 The HACCP team
• Multi-disciplinary
• Designated and qualified leader
• Records of training
Training of HACCP Team in mandatory
• Use of consultants
If required
• Senior management support
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18. 2.2 Pre-Requisite Programs (PRPs)
• Pre-requisite program includes, but not limited to:
⁻ Cleaning and sanitization
Recognized MSDS of cleaning chemicals
⁻ Pest Control
Statistical analysis, hazard assessment for frequency and
reference of internationally recognised usage of chemicals
⁻ Maintenance Program for equipment and buildings
Preventive / corrective maintenance plan for building. SOP to be
amended
⁻ Personal hygiene requirements
Hygiene cap, mask, gloves, access control, trimming of nails,
amendments in instructions.
⁻ Staff training
CCP, OPRP, PRPs, Hygiene and food defence
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19. 2.2 Pre-Requisite Programs (PRPs) – Continued…
• Purchasing
⁻ For all food contact materials and equipment, food grade
certificated is required
• Transportation arrangements
⁻ Hazard assessment for the selection and inspection
• Processes to prevent cross contamination
⁻ Clear identification, segregation and containment
• Allergens control
⁻ Known allergens to be mentioned on labels
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20. 2.3 Describe the product
• Team to describe products and processes
• Relevant information collected and maintained
• Full description of the product
⁻ It includes by-products, ingredients, packaging and other
incoming raw materials used
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21. 2.4 Identify intended use
• Define Users
⁻ Infants
⁻ Elderly persons
⁻ Allergy sufferers
• Define Next Process
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22. 2.5 Construct the Flow Diagram
• For each product, category or process
⁻ Plan of premises (Plant / Equipment Layout, area wise)
⁻ Raw materials
⁻ Process steps and parameters
⁻ Outsourcing
⁻ Any delays
⁻ Reworking
⁻ Low/high risk segregation
⁻ Identification of CCP / OPRP
2.6 Verify Flow Diagram
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23. 2.7 Conduct Hazard Analysis
• List all hazards associated with each process step
⁻ Hazard analysis for each incoming Raw Material used
• Consider the control measures
• Evidence of control of each PRP, OPRP
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2.8 Determine the CCPs
• Logical approach
• Risk Assessment criteria & Decision tree
• Must eliminate or reduce to safe level
• Mandatory to be checked by a Validation Team

24. 2.9 Establish Critical Limits
• Must be measurable
• Take into account legal aspects
• Refer to Company’s own Procedures
• Validate each CCP
• Rational for critical limits should be taken from Codex
Alimentarius / Internally recognized specifications
• Mandatory to be checked by a Validation Team
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25. 2.10 Establish Monitoring System
• Must be able to detect loss of control
• On-line, off-line or continuous measurement
• Must include results and date
• Periodic verification of results for all OPRPs and CCPs from
ISO 17025 Accredited Laboratory.
• Signed by person responsible
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26. 2.11 Establish Corrective Action Plan
• Specify and document
• Identify authorised personnel
• Procedures for unsafe products
• Release procedures
• Procedure for correction against immediate issues
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27. 2.12 Establish Verification Procedures
• Internal Audits
• Review of hazards levels
• Review of complaints
• Review of withdrawals or recalls
• Results to be recorded
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2.13 HACCP Documentation & Record Keeping
• Records sufficient

28. 2.14 Review the HACCP Plan
• The review of HACCP Plan will be conducted by Cross
Functional Team at least once a year, viewing the
following parameters
⁻ Raw Material
⁻ Supplier of Raw materials
⁻ Ingredients / recipe
⁻ Processing conditions
⁻ Processing equipment
⁻ Packaging
⁻ Storage
⁻ Distribution conditions
⁻ Consumer Usage
⁻ New Risk
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29. 3. Food Safety & Quality Management System
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30. 3.1 Food Safety & Quality Manual
• Development and maintenance of a formal documented
management system
• Fully implemented and reviewed
• Outline of working practices
• Readily available to key staff
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31. 3.2 Document Control
• A master list of all controlled documents is required with
current revision and issue date
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3.3 Record Completion and Maintenance
• Back-up of the Electronic record is mandatory
• Records for product conformity should be maintained for
shelf life + 12 months

32. FUNDAMENTAL CLAUSE
3.4 Internal Audit
• Programme of audits critical to safety, quality and legality
• Scheduled and frequency by risk assessment
• Competent, independent personnel
• Documented results of audit positive and negative
• In addition to internal audits, following inspections, at least
monthly, are mandatory:
⁻ Hygiene inspection for cleaning and housekeeping
performance
⁻ Fabrication inspection to identify risks to the product for
building and equipment
• Corrective and preventive actions verified
• Record of audits and actions must be maintained
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33. 3.5 Supplier and Raw Material Approval & Performance
Monitoring
• Control of all purchasing processes based on risk assessment
• Risk assessment of each raw material or group of raw
materials to identify potential risks to product safety. This
shall take the potential for:
⁻ Allergen contamination
⁻ Foreign body risks
⁻ Microbiological contaminations
⁻ Chemical contaminations
• Procedures for exemptions if not audited
• Clear procedures for on-going assessment
• Review within specified “trial” period
• Traceability of raw materials to be maintained
• Questionnaire based approval shall be re-issued at least
every 3 years
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34. 3.5.3 Suppliers of Services
• A documented procedure for approval and monitoring of
suppliers of services is required
• Such services includes as appropriate:
⁻ Pest Control
⁻ Laundry Services
⁻ Contracted Cleaning
⁻ Contracted Maintenance
⁻ Transport and Distribution
⁻ Off-site Storage
⁻ Laboratory Testing
⁻ Catering Services
⁻ Waste Management
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35. 3.5.4 Management of Out-Sourced Processing
• The intermediate process step which is included within
the scope of certification
• Selection of site on the basis of documented site audit
• Maintain product traceability
• Maintain procedure of inspection and testing for
outsourced product on:
⁻ Release
⁻ Return
⁻ Storage
⁻ Traceability
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36. 3.7 General Documentation Requirements
• Document Control
• Specifications
• Record Keeping
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3.6 Specifications
• Adequate and accurate
• Manufacturing instructions comply with recipes
• Formally agreed
• Procedure for amendment and approval
• Accessible to relevant staff

37. FUNDAMENTAL CLAUSE
3.7 Corrective Action
• Investigation of cause
• Corrective actions completed in a timely manner
• Implementation of corrective actions
• Review of corrective actions
• Verification of actions
• Actions must be documented and assign accountability
• Identification of the corrective action to address the
immediate issues
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38. 3.8 Control of Non-Conforming Products
• Clear identification of non-conforming products
• Secure storage e.g.; isolation of area
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39. FUNDAMENTAL CLAUSE
3.9 Traceability
• Raw materials to finished product and vice versa
• Testing including mass balance
• Testing procedures for IP products
• Product identifiable at all stages of production
• Traceability during rework
• Test the Traceability at least annually.
• Full traceability should be achievable within 4 hours
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40. 3.10 Complaint Handling
• Documented system for complaints
• Investigation and recording
• Implementation of actions by trained staff
• Trend analysis to be undertaken to be used continual
improvement.
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41. 3.11 Management of Incidents, Product Withdrawal and
Product Recall
• Documented incident reporting procedure
• Business continuity plan
• Written guidance to staff
• Documented recall & withdrawal procedure
• Regularly tested at least annually
– Results of the test shall include timings of key activity
• Results of test to effect improvements
• Notification to customer, consumer, CB, Laboratories,
logistic handler and regulatory authorities
• Certification body to be informed within 3 working days
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42. 4. Site Standards
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43. 4.1 External Standards
• Compliance with local regulations
• Location away from “offensive” trades
• External areas maintained
• Drainage
• Suitably surfaced traffic routes
• Maintenance of building fabric
• Prevention of contamination from OFF-SITE sources
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44. 4.2 Security
• Prevent access by unauthorised persons
• Visitor reporting system in place
• Designated access areas
• Procedures for secure storage
• Registration of the site, if required
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45. FUNDAMENTAL CLAUSE
4.3 Layout, Product Flow & Segregation
• Designed to control risk of contamination
• Process flow suitably arranged
• Control of laboratories
• Segregated cleaning operations
• Lack of congestion
• Control of temporary structures
• Transfer points to minimise contamination
• Segregation for high risk and high care areas
• Site Plan shall define:
– Access point for personnel and travel routs
– Location of staff facilities
– Production process flow
– Routs for the removal of waste
– Routs for the movement of re-work
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46. 4.4 Building Fabric
4.4.1 Walls
• Suitable for intended purpose
• Surface finishes for removal of dirt, mould
and bacteria
4.4.2 Floors
• Impervious and in good repair
• Water/drainage flow away from “high risk”
• Clean and well maintained
• Should have adequate falls to cope with the flow of any
water or effluent towards suitable drainage.
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47. 4.4.5 Ceilings/Overheads
• Clean and well maintained
• Should be appropriate design
• Finished surfaces
• Prevent dirt, mould, bacteria
• Falling items/dirt
4.4.6 Suspended Ceilings
• Avoid suspended ceilings in the process areas, especially,
laboratories and ingredients / mixing areas
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48. 4.4.7 Windows
• Glass window be avoided in process areas, warehousing
and laboratories.
4.4.9 Doors
• Prevention of entry by pests
• Good condition
• Easy to clean
• External doors and dock levellers shall be closed fitting or
adequately proofed.
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49. 4.4.11
• Glass (bulb, strip lights) to be protected
• Electric Fly Killers tubes to be protected
4.4.12 Air Conditioning/Ventilation
• Of appropriate design
• Adequate ventilation and extraction
• Use of filters where appropriate
• Positive air pressure where appropriate
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50. 4.4 Utilities
• Water, ice, steam, air and other gases used directly in contact with or
as an ingredient, shall be monitored for possible contamination.
• Water for process or cleaning to be potable or pose no risk
• Contact materials monitored to prevent risk of contamination
• Layouts of water distribution system including:
⁻ Holding tanks
⁻ Water treatments
⁻ Water re-cycling
⁻ Water sampling point should be identified
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51. 4.6 Equipment
• Suitably designed Properly specified before purchase
• Tested and commissioned before use
• Positioned for access
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4.7 Maintenance
• Maintenance based on risk assessment
• Care during maintenance operations
• Regular inspections
• Contractors supervised
• Post maintenance clearance
• Materials to be food grade
• Control of temporary repairs
• Control of workshops
• Work order to be amended for Hygiene Clearance after maintenance.

52. 4.8 Staff facilities
• Designated changing facilities prior to entry
• For visitors, contractors and staff entering in processing, storage and
packing area
• Provision for personal storage
• Separation of outdoor clothing
• Suitable and sufficient hand-wash facilities
• Segregation of toilets
• Smoking only in designated areas
• Control of catering facilities
• Facilities for storage of food
• Facilities for visitors
• High risk changing procedures
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53. 4.9 Chemical & Physical Contamination
• Appropriate storage of chemicals
• List of Purchased chemicals
• Metal Control
• Work Instructions
• Glass and plastic listed on register
• Policy & Work Instructions
• Procedures for glass breakages
• Incident reports for breakages
• Use of wood restricted
• In the open product area
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54. 4.10 Foreign Body Detection and Removal Equipment
• A Documented Hazard Assessment required to identify the potential use of
equipment. These maybe;
⁻ Filters
⁻ Sieves
⁻ Metal Detectors
⁻ Magnets
• The type, location and sensitivity of the detectors shall be specified and
documented
• Filters and sieves shall be regularly (frequency) inspected / tested on the basis of
a risk assessment
• Unless a risk assessment eliminate, metal detection equipment shall be in place
• A corrective action system shall be in place in case of unidentified failure of the
foreign body detector
• For magnets, the type, location and strength shall be inspected and integrity
checks to be made. Records of all checks shall be maintained
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⁻ Optical Sorting equipment
⁻ X-ray detection equipment
⁻ Gravity separation
⁻ Fluid bed technology

55. FUNDAMENTAL CLAUSE
4.11 Housekeeping & Hygiene
• Cleaning procedure shall be in pace for the building, plant and
equipment
• A schematic plan of the layout of CIP system
• The process parameters of CIP shall be validated
• Documented cleaning schedules
• Control of CIP systems
• Carried out by trained personnel
• Documented procedures and records
• Strict control of chemicals
• Monitoring of effectiveness of cleaning
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56. 4.12 Waste / Waste Disposal
• Minimise accumulation of waste
• Categorisation of waste
• Disposal must meet legal requirements
• Management of external waste
• Secure disposal of trademarked waste
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57. 4.13 Pest Control
• Maintain preventive control system
• Use of contractors or trained personnel
• Detailed record & procedures
• Hazard Assessment, Pest-wise, to be carried out for the
frequency of monitoring
• Robust tamper resistant bait stations
• Correct siting of fly control devices
• Immediate corrective action after infestation
• Detailed records of all actions
• Trend analysis at least annually
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58. 4.14 Storage Facilities
• Protection for outside storage
• Correct stock rotation
• Evidence of Mass Balance check is required
• Documented Procedure to maintain product safety and
quality during storage
• Temperature control procedures
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59. 4.15 Dispatch and Transport
• Documented maintenance and hygiene procedures for all vehicles
including sub-contractors
• Contract in place with sub-contractor
• Procedures for breakdown
• Record of vehicles / container inspection
• Traceability shall be ensured during transportation
• In case of temperature control vehicles, operation of refrigeration
shall be verified and recorded
• Contract of vehicles to be amended for
⁻ Restriction of mixed loads
⁻ Security of product during transit
⁻ Clear instructions in case of vehicle breakdown, accident or
refrigeration system
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60. 5. Product Control
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61. 5. PRODUCT CONTROL
5.1 Product Design/Development
• New products must under-go production trials – HACCP based
• Shelf life to be confirmed
• Shelf life trials shall be undertaken using documented protocol.
Result shall be recorded
• Legal requirements for labelling
• Verify the ingredient and allergen labelling is correctly based on
the product recipe
• Control of product claims
• Nutritional claims shall be validated
• Process to be documented and effectively communicated
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62. FUNDAMENTAL CLAUSE
5.2 Management of Allergens
• Risk assessment for specific allergens
• List of all allergens on site
• Including raw materials, processing aids,
intermediate and finished product
• Cross contamination during processing
• Documented procedure is required
• Training for allergen handling
• Re-working
• Identity preserved materials
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63. 5.3 Identification and assurance of origins
•Identity preservation of raw materials used, status of
each batch shall be verifiable
•Traceability of all claims mentioned on the label to be
maintained from purchasing, processing, raw materials
and final packaging. Records to be maintained
•Documented Mass Balance Test shall be conducted at
least every 6 months
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64. 5.4 Product Packaging
• Procedures to confirm specification
• Compliance with food safety legislation
• Food Grade Certificates for all direct contact packing material
• Storage away from food products
• Protection of re-usable packaging
• Contact liners to be coloured
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65. 5.5 Product Inspection & Laboratory Testing
• Provision of certificates of validation
• Monitoring of incoming, in-process & finished goods
• Laboratories accredited or complying with ISO 17025
• Procedures to ensure reliability of test results
• Suitably qualified personnel
• Test results recorded
• Appropriate organoleptic testing and records
• On-going shelf-life assessment
5.6 Product Release
• Finished product shall not be released unless all agreed procedures
have been followed
• In case of positive release, procedure shall be in place to ensure all
released criteria have been completed and release authorized
• Procedures based on risk assessment to ensure safe release
• Only by authorised staff
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66. 6. Process Control
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67. FUNDAMENTAL CLAUSE
6.1 Control of Operations
• Validation prior to production and according to “worst case
scenario”
• On-going validation according to risk assessment
• Control of additives, pressure and temperature
• On-line quality control including correct code verification
• Temperature, pressure monitoring equipment
• Re-establish characteristics when changes occur
• Procedure for equipment or process failure
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6. PROCESS CONTROL

68. 6.2 Quantity Control
• Legal requirements of the destination countries or the
country where product is going to be sold
• Where no legal requirements must conform to
customer specification
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69. 6.3 Calibration and Control of Measuring and Monitoring
Devices
• Traceable calibration of all test and measurement equipment
• Accuracy within agreed parameters
• Records of results maintained
• Identification of devices
• Prevention from adjustment
• Protection from damage or misuse
• Corrective action procedures
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70. 7. Personnel
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71. Copyright © 2008 BRC - Issue 28508
FUNDAMENTAL CLAUSE
7.1 Training
• Training to all staff prior to commencing of work
• Additional training for CCP(s) handlers, Cross Functional Team and
Validation Team
• Documented procedures and full training records
• Routine review of training procedures
• Refresher training to all employees including contractor’s
employees
• Evidence of periodic review of the competencies of employees
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72. 7.2 Personal Hygiene
• Work Instructions and on-the-job trainings
• Requirements documented and communicated
• Risk assessed jewellery policy
• No watches and only specified jewellery
• Hand cleaning at appropriate frequencies
• Hand free taps and disposable towel tissues
• Short fingernails, no varnish, no false ones
• No excessive perfume or aftershave
• Monitoring of hand cleaning
• Smoking / eating only in designated areas
• Covering of cuts and lesions with company issued and
monitored dressings
• Testing of first-aid dressings (different from the product colour)
if applicable
• Control of personal medicines
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73. 7.3 Medical Screening
• Reporting procedures for infections
• Steps to ensure product safety
• Visitors/contractors, where appropriate must be medically
screened prior to visiting production process areas
• Access & Movement of Personnel
⁻ Plan of site
⁻ Designated walkways
⁻ Simple logical routes
⁻ Control of visitors and drivers
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74. 7.4 Protective Clothing
• Full protective clothing for employees, contractors and visitors
working in / entering production / processing areas
• Segregation of laundry
• A documented procedure is required
• Periodic testing for the verification of hygienic condition of
protective clothing
• No smoking or eating
• Hair covered
• Control of beards
• Suitable footwear
• Gloves/aprons adequately controlled
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75. THANK
YOU
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