17. Process control
Packing controls
Packing controls ensure that the product goes in the correct printed packaging and that the printing is accurate.
Packing controls
Incorrect printing and putting the product in the wrong packaging, is the one of the main causes for recalls and withdrawals. It’s a safety issue, as it means that the allergen information on the pack could be incorrect.
For this reason, the certification standards provide detail as to how these packing controls must be managed.
Customers apply even more requirements, as they don’t want their own brands to be put at risk. Many customers require automated equipment to, in theory, eliminate the risk.
The standards
This article is written to meet the print control requirements for the following standards:
| BRCGS Food Safety Issue 9 | 6.2.1 Allocation of packing materials 6.2.3 Packing controls |
| BRCGS Packaging Issue 6 | 5.3.3 – 5.3.7 Printed packaging controls |
| BRCGS Agents & Brokers Issue 3 | Not applicable |
| BRCGS Storage & Distribution Issue 4 | 15.3, 15.4, 15.6 Packaging controls |
| FSSC22000 Version 5.1 | 2.5.2 Product labelling and printed materials |
| IFS Food Version 7 | 5.6.1 Packaging materials – testing |
| SQF Edition 9 | 2.6.1.2 Packing procedures |
| FSMA Preventive controls for human food (Final 2015) | No specific clauses |
| Additional standards | M&S AIB Sainsburys Tesco |
The requirements
Printed packaging control
Where packaging such as labels, are printed away from the packing line, the print must be controlled by:
- Allocation of printed packaging to the line.
- Adjustment of the printing equipment is only carried out by authorised personnel.
- Verification of the print prior to allocation to the packing line.
Right product, right pack
Packaging checks must be completed to confirm that the correct packaging is being used:
- At the start of packing.
- During the packing run.
- When changing batches of packaging materials.
- At the end of each production run.
Samples of printed packaging must be retained, where requested by the customer, to prove that the print met specification.
Issuing and reconciliation
A process must be in place to issue printed packaging to the line. The quantity that has been used and the quantity left over must then be reconciled to establish if there is a discrepancy.
Records of issue, usage and return must be kept, to allow mass balance to be carried out.
Print checks
The appropriate checks must be carried out, to confirm that the print is correct:
- Product name.
- Date coding.
- Traceability coding.
- Quantity.
- Pricing and promotions.
- Bar code.
- Country of origin.
- Allergen information.
The above must also be carried out where printing takes place away from the packing line, for example where labels are printed offline.
BRCGS Food Safety Issue 9
Clause 6.2.1 has been expanded to state that a reconciliation must be completed, so that any inconsistencies can be investigated. The purpose of this is to reduce the risk of the wrong printed packaging being used by mistake.
The aim is to not to mass balance the packaging, but to be able to identify if a problem – which can then be investigated. This means that the reconciliation only has to be accurate enough to identify a problem, so this may be to the nearest (for example):
- Reel.
- Box of printed packaging.
Customer
This is a general overview of packing controls detailed in customer codes of practice, however your business must refer to your customer’s standards to identify the requirements that are applicable.
Automated coding and label checks
Many customers require their suppliers to have automated equipment in place, which check that the coding and packaging are correct. This is a requirement of doing business with them. The automation of these checks is designed to reduce the likelihood of packaging errors which may lead to recalls and withdrawals.
The customer standards specify how the equipment must be designed and the type of fail-safe systems that it must have.
Manual checks
Where automated equipment isn’t in place, the customer standards specify how manual checks must take place. These requirements are really detailed, due to the risks involved with doing the checks manually.
Packing controls
Documentation
Our documentation pack gives you a really robust structure to determine what your packing controls should be and implement a system which will ensure that non-conforming product doesn’t get sent to the customer. It includes a packing control record and a detailed packing work instruction you can use for training. The procedure in this pack covers the subject areas you need to include, such as print control, right packaging, offline printing, monitoring equipment and monitoring frequencies.
Find out more about what’s included in the documentation pack now
Packing controls
elearning
Our elearning course covers the packing controls for printed packaging and the role of the accountable manager and process controller. It includes the requirements and the interpretation of allocating printed packaging and printing checks. We teach how to allocate and reconcile packaging, carry out checks and provide documented instructions. The last part of the training covers monitoring for change control, supervision and trending for continuous improvement.
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