Assessment for Production Risk Zones based on Clause 4.3.1 of BRC Issue 9

Hi all,

I am wondering if anyone can share anything on risk assessment of production zones based on clause 4.3.1 of BRC Issue 9.

Thanks,

Good day,
 
According to 4.3.1. you need to have a site map.
 
Attached an example I did on excel. I print each area and use laminating sheet / clear paper to draw the flow of the people / packaging / waste / product (each with a different color and each on a separate clear paper), then you can follow the processes to see where there is any over lap or were you need control points. 
 
Hope this helps...

Good day,
 
According to 4.3.1. you need to have a site map.
 
Attached an example I did on excel. I print each area and use laminating sheet / clear paper to draw the flow of the people / packaging / waste / product (each with a different color and each on a separate clear paper), then you can follow the processes to see where there is any over lap or were you need control points. 
 
Hope this helps...

Hi Lindsay,

thks input but the attachment seems to have failed. You need to click on "More Reply Options" box at bottom, right hand side then follow the instructions on the new page which appears.

@Omoware - Probably more useful/relevant to you to give your own requirement ? If a simple setup, might suggest you look at the model flowcharts given by BRC in previous Versions. They may have difficulties in some cases but are nonetheless probably still valuable.

Hi,

Thank you for that.  

Hi Omoware,

BRCGS Global Standard for Food Safety Issue 9 clause 4.3.1 states:

The site shall assess the production risk zones required for the products manufactured, processed or packed at the site, using the definitions in Appendix 2 of the Standard.

I can understand the previous posts but in actual fact Clause 4.3.2 is the requirement for a site map:

There shall be a map of the site. At a minimum, this map shall define:…. etc.

And in reality 4.3.1 will be looked at in conjunction with clause 4.3.2 site map

So, you will need to assess each of the areas/zones on site and consider which of the BRCGS zones they fall into. Clearly a map will assist in defining the area/zone.

From BRC Guidance:

The Standard recognises six zones:

• high-risk and high-care zones for chilled or frozen and ready-to-eat products where there is a risk of contamination

• ambient high care for products where there is a risk of contamination with vegetative micro-organisms originating from raw materials and the products are stored in ambient conditions (rather than chilled or frozen)

• low-risk areas

• enclosed product areas (e.g. storage areas where products are fully enclosed within

packaging and production areas where the product is fully enclosed within the equipment

or pipework)

• non-product areas (i.e. areas such as offices, where products are not taken at any stage in

their manufacture or storage).

It is important to note that the high-risk, high-care and ambient high-care production zones usually only apply to part of a factory’s production processes. These zones typically start when products exit a microbiological kill step and include all the processes and steps until the products are enclosed in packaging.

So, you might have these areas:

Goods In/Raw Storage – Raw Material Handling – Low Risk Areas (May be Enclosed Product Area if enclosed within packaging)

Mixing/Cooking – Low Risk but Cooked Product goes immediately into Cooling/Packing (High-Risk)

Cooling/Freezing/Packing - High-Risk Zone for Chilled or Frozen and Ready-To-Eat Product

Finished Product Storage/Dispatch - Enclosed Product Areas

From BRC Guidance:

The auditor will expect to see a documented assessment comparing the products manufactured, processed or packed on site with the definitions within Appendix 2 of the Standard.

Kind regards,

Tony

Good day,
 
According to 4.3.1. you need to have a site map.
 
Attached an example I did on excel. I print each area and use laminating sheet / clear paper to draw the flow of the people / packaging / waste / product (each with a different color and each on a separate clear paper), then you can follow the processes to see where there is any over lap or were you need control points. 
 
Hope this helps...

Thanks a lot! I think this is a risk assessment of production zones rather than map. Map Risk assessment is a separate clause.

Thanks!
 

Hi Omoware,

 

BRCGS Global Standard for Food Safety Issue 9 clause 4.3.1 states:

The site shall assess the production risk zones required for the products manufactured, processed or packed at the site, using the definitions in Appendix 2 of the Standard.

 

I can understand the previous posts but in actual fact Clause 4.3.2 is the requirement for a site map:

There shall be a map of the site. At a minimum, this map shall define:…. etc.

 

And in reality 4.3.1 will be looked at in conjunction with clause 4.3.2 site map

 

So, you will need to assess each of the areas/zones on site and consider which of the BRCGS zones they fall into. Clearly a map will assist in defining the area/zone.

 

From BRC Guidance:

The Standard recognises six zones:

• high-risk and high-care zones for chilled or frozen and ready-to-eat products where there is a risk of contamination

• ambient high care for products where there is a risk of contamination with vegetative micro-organisms originating from raw materials and the products are stored in ambient conditions (rather than chilled or frozen)

• low-risk areas

• enclosed product areas (e.g. storage areas where products are fully enclosed within

packaging and production areas where the product is fully enclosed within the equipment

or pipework)

• non-product areas (i.e. areas such as offices, where products are not taken at any stage in

their manufacture or storage).

 

It is important to note that the high-risk, high-care and ambient high-care production zones usually only apply to part of a factory’s production processes. These zones typically start when products exit a microbiological kill step and include all the processes and steps until the products are enclosed in packaging.

 

So, you might have these areas:

Goods In/Raw Storage – Raw Material Handling – Low Risk Areas (May be Enclosed Product Area if enclosed within packaging)

Mixing/Cooking – Low Risk but Cooked Product goes immediately into Cooling/Packing (High-Risk)

Cooling/Freezing/Packing - High-Risk Zone for Chilled or Frozen and Ready-To-Eat Product

Finished Product Storage/Dispatch - Enclosed Product Areas

 

From BRC Guidance:

The auditor will expect to see a documented assessment comparing the products manufactured, processed or packed on site with the definitions within Appendix 2 of the Standard.

 

Kind regards,

 

Tony

Hi Lindsay,

 

thks input but the attachment seems to have failed. You need to click on "More Reply Options" box at bottom, right hand side then follow the instructions on the new page which appears.

 

@Omoware - Probably more useful/relevant to you to give your own requirement ? If a simple setup, might suggest you look at the model flowcharts given by BRC in previous Versions. They may have difficulties in some cases but are nonetheless probably still valuable.

Thanks, I was able to create a production zones risk assessment. I would have loved to share it just in case any one needs it, but I don't know how to share document here.

Hi Omoware,

 

BRCGS Global Standard for Food Safety Issue 9 clause 4.3.1 states:

The site shall assess the production risk zones required for the products manufactured, processed or packed at the site, using the definitions in Appendix 2 of the Standard.

 

I can understand the previous posts but in actual fact Clause 4.3.2 is the requirement for a site map:

There shall be a map of the site. At a minimum, this map shall define:…. etc.

 

And in reality 4.3.1 will be looked at in conjunction with clause 4.3.2 site map

 

So, you will need to assess each of the areas/zones on site and consider which of the BRCGS zones they fall into. Clearly a map will assist in defining the area/zone.

 

From BRC Guidance:

The Standard recognises six zones:

• high-risk and high-care zones for chilled or frozen and ready-to-eat products where there is a risk of contamination

• ambient high care for products where there is a risk of contamination with vegetative micro-organisms originating from raw materials and the products are stored in ambient conditions (rather than chilled or frozen)

• low-risk areas

• enclosed product areas (e.g. storage areas where products are fully enclosed within

packaging and production areas where the product is fully enclosed within the equipment

or pipework)

• non-product areas (i.e. areas such as offices, where products are not taken at any stage in

their manufacture or storage).

 

It is important to note that the high-risk, high-care and ambient high-care production zones usually only apply to part of a factory’s production processes. These zones typically start when products exit a microbiological kill step and include all the processes and steps until the products are enclosed in packaging.

 

So, you might have these areas:

Goods In/Raw Storage – Raw Material Handling – Low Risk Areas (May be Enclosed Product Area if enclosed within packaging)

Mixing/Cooking – Low Risk but Cooked Product goes immediately into Cooling/Packing (High-Risk)

Cooling/Freezing/Packing - High-Risk Zone for Chilled or Frozen and Ready-To-Eat Product

Finished Product Storage/Dispatch - Enclosed Product Areas

 

From BRC Guidance:

The auditor will expect to see a documented assessment comparing the products manufactured, processed or packed on site with the definitions within Appendix 2 of the Standard.

 

Kind regards,

 

Tony

Thanks Tony. This is exactly what I did.

I have the risk assessment according to Appendix 2.

Here is the map (for example) that goes with it.

Marshall

Thanks, I was able to create a production zones risk assessment. I would have loved to share it just in case any one needs it, but I don't know how to share document here.

Hi Omoware,/Lindsay

Did my previous suggestion not work ?

Hello everyone - the requirement clearly states: "The site shall assess production risk zones, required for the products manufactured, processed or packed at the site..." 
There needs to be a type of assessment or risk assessment involved in this clause prior to the site maps. 

I am in an audit with low risk products only and need this. 
 

Please provide examples on such Risk Zone Risk Assessment. 

Thanks