9. Inspection and testing
Testing methods
Once the risk assessment defines what testing is needed, the next step is to define what testing methods will be used.
Introduction to testing methods
Once the risk assessment has defined what testing must be carried out, the next step is to identify the testing methods to be used.
The standards
This article is written to meet the requirements for testing methods:
| BRCGS Food Safety Issue 9 | 4.5.1 Water supply |
| BRCGS Packaging Issue 6 | No specific clauses. |
| BRCGS Agents & Brokers Issue 3 | No specific clauses. |
| BRCGS Storage & Distribution Issue 4 | No specific clauses. |
| FSSC22000 Version 6 | No specific clauses. |
| IFS Food Version 8 | No specific clauses. |
| SQF Edition 9 | No specific clauses. |
| FSMA Preventive controls for human food (Final 2015) | No specific clauses |
| Additional standards | Not covered. |
The requirements
Most of the requirements for this section sit within customer standards. The main points which is relevant to BRCGS is water.
Water testing
The sampling points must be determined using risk assessment. They must consider:
- Testing the points of use at the far end of the circuit, as shown by the schematic.
- The source of the water.
- On-site storage and distribution facilities.
- Outlet points and the point of use.
- Previous sample history.
- The level and type of use of each outlet.
BRCGS Food Safety Issue 9
Clause 4.5.1 has been updated to state that stored water and water handling systems must be managed to minimise risk.
Water sampling plans must now also be based on legal requirements.
The interpretation has also been expanded to state that the water must be fit for purpose and that the testing methods must consider legal requirements. Where water storage systems are in use, the risk assessment must take into account risks posed from the equipment itself.
Water schematics
The purpose of the water schematic is to:
- To establish where the water comes into the site and therefore where the water infeed filter should be
- Identify and map out all the water pipe work leading off from this main infeed pipe, which allows us to:
- Identify if there are any dead legs in the system.
- Identify the furthest points in the water system.
- Identify all the water output points.
Dead legs
A dead leg is where a water pipe which once supplied water to a part of the factory, is capped off. For example, where a hand wash sink is removed, the water pipe is no longer needed and so, engineering come along and cap it off. This means that if there is still water held in this pipe, which no longer goes anywhere – it just sits there and stagnates. This stagnant water can then contaminate the mains water at the point at which the pipe connects to the main ring main.
Below is an example of a water schematic to explain how a dead leg can be created.
Example water schematic:
(click to open full view)
In this example, the site had recently removed a line from one of their units, in order to increase their storage capacity. During this process, they removed an unneeded sink from the area. The mains water comes in where the pink diamond is shown and the blue lines show the direction of travel around the site.
The sink was capped off at the point where the sink was, rather than removing the pipe back to the point where it meets the main ring main.
This means that the water in this pipe can’t go anywhere, so it sits there and stagnates. This then contaminates the water in the ring main, which is then picked up in the results of the water sampling micro.
Make sure that when old equipment is removed that requires water, that the water pipe work is removed and it is capped back at the ring main. If you have high results on your water micro, check your water schematic to make sure you’ve not got any historic dead legs.
Furthest points
Let’s use our example water schematic again to explain this.
The water in the ring main (the pipework that allows the water to go round and round) is constantly supplying other parts of the factory and it’s always on the move, so it’s unlikely that it’ll stagnate and become a micro problem.
Where the pipework routes away from ring main, we need to follow each route to see where it goes. The furthest part of the pipework away from the ring main, is where the water is most at risk.
Water output points
The water output points at the end of these routes, must be on the water sampling plan. That way we are confirming that all the water on that route is potable (safe to drink). So, check your water schematic to make sure that all of your pipework furthest away from the ring main is being sampled, at the very least at the very end output point.
Great article, Kassy, and very helpful. Is it possible to outline what the legal requirements in England are, please? Thank you!
There are a lot Susan, too many to mention here. I’m currently collating links to legislation here (but it’s work in progress!): https://techni-k.co.uk/legislation/food-industry-legislation/
Sorry
CIP water
CIP tanks
Hoses
water from the hoses we think is ‘clean’ at least or disinfected at least if the dosing pumps work!!
Phew! Worth a book!
Wow, that is a lot! It’s nearly as long as a Technical Managers ‘to do’ list! Thanks Chris. 🙂
Really good article!! Thanks…..water is key in a Food factory….
Waste Water
Rain Water – flow of it!!
Sterile water – or not
Filtered water – or not
Filters and cleanliness, changing regime, if they are sterile or not oh and what about the steam to sterilize!!
Steam – clean or dirty – uses??
Domestic water
Don’t forget condensate!!
So if Factories get the product flow sorted then that’s about 1/4 of the issue with the other 3/4 coming from the services – water been one so thanks Kassy for highlighting!
Great article.
Did I mention ‘stored water’???? mmmmmmm
Excellent. It helps me to explain the water sampling to the organization.
Simple, concise & easy to understand.
Another top article by the team.
Thank you 🙂
Another great article Kassy, and really given me some food for thought. It is so easy to leave a redundant pipe on the wall and simply cap it off, especially if access to the main ring can be cumbersome or troublesome. Engineers like to keep things simple for the most part, and that often means getting the job done just enough.
These articles are a great resource for learning. I hope you had a great Christmas and New Year. Thanks again Kassy!
I agree, everyone is under so much pressure ‘getting the job done just enough’ is a good way of putting it. Thanks for your kind words of feedback, it really helps keep me motivated! 🙂
Hi Kassy,
This is a really good example of what water schematics for a site should look like and is very clear on direction of flow. I will be reviewing ours to ensure it includes these points if not already. Certainly a tool if you have any issues with water micro from an investigation point of view. 🙂
Thank you, I’m glad you like it 🙂
Great article.
Thank you Kassy & Happy New Year!
HT
Thank you and you too!