Production Risk Zones & Segregation
Aligned with BRCGS Food Safety Issue 9 – Sections 8.1 & 8.2 High Risk • High Care • Ambient High Care
Requirement Overview
BRCGS Food Safety Issue 9 defines production risk zones based on the risk of product contamination. Facilities must identify, segregate, and manage areas designated as High Risk, High Care, and Ambient High Care to prevent cross-contamination, protect product integrity, and comply with food safety standards.
Clause 8.1.1: “The production of products in high-risk, high-care or ambient high-care areas shall be managed to prevent contamination.”
Clause 8.2.1: “Premises and process flows shall be designed, constructed, and maintained to segregate effectively manufacturing zones and minimize the risk of product contamination.”
Proper zone classification and segregation are essential for hygiene control, especially for ready-to-eat (RTE) or high-sensitivity products.
Aligned with BRCGS for Storage & Distribution Issue 4 – Clause 4.3.1 & 4.3.3
Requirement Overview
BRCGS for Storage & Distribution requires that products moved via cross-docking are traceable and controlled at all times, even when they are not held in storage for extended periods.
Clause 4.3.1: “The company shall ensure that traceability is maintained at all stages, including during cross-docking operations.”
Clause 4.3.3: “Procedures shall be in place to ensure that all products handled, including those not stored on-site, remain under control and are not subject to contamination or substitution.”
Cross-docking operations must not compromise product traceability, safety, or integrity. Even with minimal handling and temporary presence, each product must be accurately identified, documented, and protected.
Key Compliance Objectives
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✓ Identify and validate risk zones based on product and process risk
✓ Implement physical and procedural segregation measures
✓ Control movement of personnel, equipment, and air
✓ Maintain zoning maps, cleaning protocols, and verification records
Step-by-Step Compliance Implementation
1. Identify and Classify Risk Zones
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Zone Classifications:
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• High Risk – RTE products with high exposure risk (e.g., cooked meats)
• High Care – RTE products requiring protection from recontamination (e.g., sandwiches)
• Ambient High Care – Shelf-stable products requiring strict hygiene (e.g., flow-wrapped snacks)
Evidence to Maintain:
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• Risk zone assessment documentation
• Product classification and process flow diagrams
• Justification for each area’s risk level
- • High Risk – RTE products with high exposure risk (e.g., cooked meats) • High Care – RTE products requiring protection from recontamination (e.g., sandwiches) • Ambient High Care – Shelf-stable products requiring strict hygiene (e.g., flow-wrapped snacks)
- • Risk zone assessment documentation • Product classification and process flow diagrams • Justification for each area’s risk level
2. Design Effective Physical Segregation
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Segregation Measures Include:
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• Separate rooms, walls, barriers, or airlocks
• Positive air pressure in High Risk areas
• Controlled drainage flow from clean to dirty zones
Evidence to Maintain:
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• Facility zoning layouts with marked barriers
• Air pressure monitoring logs
• Maintenance records of doors, filters, and seals
- • Separate rooms, walls, barriers, or airlocks • Positive air pressure in High Risk areas • Controlled drainage flow from clean to dirty zones
- • Facility zoning layouts with marked barriers • Air pressure monitoring logs • Maintenance records of doors, filters, and seals
3. Implement Procedural Segregation Controls
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Key Controls:
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• Staff zoning with uniform color coding
• Dedicated tools, utensils, and PPE per zone
• Entry controls (e.g., handwashing, boot wash, change areas)
Evidence to Maintain:
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• SOPs for personnel and material movement
• Zone-specific equipment logs
• Uniform and hygiene compliance checks
- • Staff zoning with uniform color coding • Dedicated tools, utensils, and PPE per zone • Entry controls (e.g., handwashing, boot wash, change areas)
- • SOPs for personnel and material movement • Zone-specific equipment logs • Uniform and hygiene compliance checks
4. Validate and Monitor Risk Zone Effectiveness
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Verification Methods:
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• Environmental swabbing (e.g., Listeria, pathogens)
• Internal audits and inspections
• Staff training assessments on zone protocols
Evidence to Maintain:
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• Microbial test results by zone
• Audit checklists and CAPAs
• Training attendance and evaluations
- • Environmental swabbing (e.g., Listeria, pathogens) • Internal audits and inspections • Staff training assessments on zone protocols
- • Microbial test results by zone • Audit checklists and CAPAs • Training attendance and evaluations
Common Audit Findings & Recommended Fixes
| Audit Finding | Recommended Action |
|---|---|
| Undefined or inconsistent zoning | Conduct a risk assessment and create zoning maps |
| Cross-use of utensils or PPE across zones | Implement color-coded equipment and strict segregation policies |
| Airflow issues in High Risk areas | Install pressure controls and maintain HVAC filters |
| No validation of hygiene effectiveness | Start routine environmental monitoring in each zone |