Processing equipment

The requirements

Automated monitoring

Automated equipment must be considered where the process control risk assessment identifies a high risk of defects.

Where automated equipment is used to carry out process control checks, there must be a risk assessment in place to define what equipment tests are needed, to ensure that the equipment is working. The testing procedure must confirm that the equipment is working for each of the checks that it’s used for.

The equipment must be checked to ensure that it is working at:

• The start of the packing run.
• The end of the packing run.
• A frequency which ensures that any affected product is still on site if the equipment is found to be defective.

The equipment must highlight defective product or divert it out of the process flow (e.g. onto a reject line). The procedure must define the corrective action process and what to do with the rejected packs.

Interchangeable equipment

Interchangeable equipment used to process the product must be stored to minimise damage.

Interchangeable equipment includes:

• Product tins, trays.
• Printing plates, cylinders, cutting dies.
• Change parts.
• Packaging moulds.
• Packing containers, baskets.

Where interchangeable equipment looks similar and using the wrong type can have a direct impact on the quality or safety of the product produced – the equipment must be labelled.  Where the equipment is labelled, confirmation that the correct equipment has been used, must be recorded for each run.

BRCGS Food Safety Issue 9

Clause 6.3.3 now states that a procedure must define what happens to packs that have been rejected from checkweighers. The interpretation now includes the minimum expectations for the procedure for online checkweighers, which include:

• Stating the legislation that the procedure complies with.
• Detailing the process for testing the equipment (including frequency of testing and who will complete it), or reference to the work instruction/ procedure where this information is held.
• Identifying any products that need to be handled differently and what you do about these. For example, if certain pack sizes are too large for the machine to cope with.
• Detailing how rejects are handled and corrective action to be taken.
• Stating how the tests of the machine are recorded.

Customer

Processing equipment – containers and utensils (including trays)

Equipment used for work-in-progress, part-used raw materials, rework or finished product must:

• Be fit for purpose.
• Not be placed directly on the floor.
• Only be placed on pallets which are clean.
• Visually distinctive and different from those used for waste materials.

Ingredient scoops, tools, and utensils must be risk assessed to determine the cross-contamination controls, such as:

• Color-coding or labelling.
• The use of one scoop per ingredient container.

Containers must be fit for purpose and designed from appropriate materials.

Single use containers must not be re-used.

Plastics must be of the correct strength for their use (e.g. cold temperature).

Processing equipment – packaging containers

Packaging, including customer packaging must not be used to hold anything other than product, this includes:

• Waste.
• Nuts, bolts, tools.
• Chemicals.

Stored processing equipment

Equipment which is not being used must be stored hygienically.

Product contact equipment that’s not used daily must be sanitised before it’s used.

New equipment

Where new equipment is purchased, the equipment and the supplier must be assessed through the supplier management system. This includes a purchase specification and checks on receipt.

Filters and sieves

Filters and sieves must:

• Be stored hygienically and, in a dust-free environment.
• Be made of materials which won’t contaminate the material.
• Verified before use, this includes prior to pumping to bulk tankers.