Staff Flow & Movement Procedures
Aligned with BRCGS Food Safety Issue 9 – Clause 8.2: Zoning and Control of Contamination Risk
Requirement Overview
BRCGS Food Safety Issue 9 requires clearly defined zoning protocols and controlled staff movement between production risk zones to prevent cross-contamination and ensure food safety integrity.
Clause 8.2.2: “The process flow, factory and equipment layout, and movement of staff shall be designed to minimize the risk of product contamination.”
This is especially critical for High Risk, High Care, and Ambient High Care areas, where strict personnel hygiene and segregation protocols must be enforced to protect against the transfer of pathogens or allergens.
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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✓ Prevent cross-contamination through controlled staff movement
✓ Enforce physical and procedural barriers between risk zones
✓ Maintain compliance with BRCGS zoning definitions
✓ Document all procedures and movement controls for audit readiness
Step-by-Step Compliance Implementation
1. Define Risk Zones and Entry Criteria
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Zone Types:
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• High Risk – exposed RTE product, sensitive to pathogens
• High Care – chilled RTE product, not fully sealed
• Ambient High Care – ambient-stable but sensitive to contamination
Evidence to Maintain:
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• Factory zoning maps
• Zoning justification documents
• Staff access level assignments
- • High Risk – exposed RTE product, sensitive to pathogens • High Care – chilled RTE product, not fully sealed • Ambient High Care – ambient-stable but sensitive to contamination
- • Factory zoning maps • Zoning justification documents • Staff access level assignments
2. Establish Controlled Entry/Exit Points
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Requirements Include:
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• Airlocks or hygiene lobbies
• Handwashing and disinfection stations
• Change of PPE, footwear, and tools before entry
Evidence to Maintain:
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• Entry logs or access badge records
• Hygiene station maintenance logs
• PPE changeover procedures
- • Airlocks or hygiene lobbies • Handwashing and disinfection stations • Change of PPE, footwear, and tools before entry
- • Entry logs or access badge records • Hygiene station maintenance logs • PPE changeover procedures
3. Implement Staff Flow Procedures
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Procedural Controls:
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• Designated routes to prevent crossing from high to low-risk areas
• No return to low-risk zones without full decontamination
• Staggered breaks to reduce congestion in hygiene areas
Evidence to Maintain:
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• Documented staff flow procedures
• Area signage and floor markings
• Staff induction and refresher training records
- • Designated routes to prevent crossing from high to low-risk areas • No return to low-risk zones without full decontamination • Staggered breaks to reduce congestion in hygiene areas
- • Documented staff flow procedures • Area signage and floor markings • Staff induction and refresher training records
4. Train and Enforce Compliance
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Training Must Cover:
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• Zoning awareness and color-coded zones
• Proper hygiene practices before moving between areas
• Reporting breaches or non-compliances
Evidence to Maintain:
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• Training completion logs
• Visual aids (e.g., posters, signs, zone maps)
• Disciplinary or corrective action reports for zoning breaches
- • Zoning awareness and color-coded zones • Proper hygiene practices before moving between areas • Reporting breaches or non-compliances
- • Training completion logs • Visual aids (e.g., posters, signs, zone maps) • Disciplinary or corrective action reports for zoning breaches
5. Monitor, Audit, and Review
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Oversight Activities:
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• Supervisory checks and hygiene audits
• Incident logs for unauthorized movements
• Regular review of staff feedback and incident data
Evidence to Maintain:
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• Internal audit reports and corrective actions
• Observation checklists and sign-off logs
• Zoning SOP updates and review records
- • Supervisory checks and hygiene audits • Incident logs for unauthorized movements • Regular review of staff feedback and incident data
- • Internal audit reports and corrective actions • Observation checklists and sign-off logs • Zoning SOP updates and review records
Common Audit Findings & Recommended Fixes
| Audit Finding | Recommended Action |
|---|---|
| No physical or procedural zoning controls | Install airlocks, barriers, and revise staff movement procedures |
| PPE not changed between zones | Enforce zoning-specific PPE and staff training |
| Inadequate signage or unclear zones | Install color-coded maps, floor markings, and area labels |
| No records of staff movement procedures | Develop documented SOPs and maintain training evidence |