Air Handling & Movement
Aligned with BRCGS Food Safety Issue 9 – Section 8: Production Risk Zones
(High Care, High Risk, and Ambient High Care Areas)
Requirement Overview
BRCGS Food Safety Issue 9 defines zoned production areas—High Risk, High Care, and Ambient High Care—as requiring controlled air movement and filtration systems to prevent cross-contamination between zones.
Clause 8.5.1: “Air handling systems shall be designed to prevent airborne contamination (e.g. filtered air, positive air pressure, airflow direction, segregation).”
Proper air control minimizes microbial and particulate transfer, maintains hygienic conditions, and ensures environmental compliance in sensitive processing areas.
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 airborne cross-contamination between zones
✓ Maintain air quality through filtration and directional airflow
✓ Verify air pressure differentials in High Risk and High Care areas
✓ Ensure alignment with risk-based environmental controls
Step-by-Step Compliance Implementation
1. Define Risk Zones and Air Control Requirements
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Production Risk Zones:
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• High Risk – Chilled RTE products post-cook
• High Care – RTE products that bypass a kill step
• Ambient High Care – RTE products stored ambient, vulnerable to cross-contamination
Air Handling Must Include:
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• Positive air pressure (especially High Risk/High Care)
• HEPA or equivalent filtration
• Independent air handling units (AHUs) to avoid recirculated contamination
Evidence to Maintain:
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• Site zoning map with air pressure zones
• HVAC specifications and maintenance logs
• Zoning validation or risk assessment
- • High Risk – Chilled RTE products post-cook • High Care – RTE products that bypass a kill step • Ambient High Care – RTE products stored ambient, vulnerable to cross-contamination
- • Positive air pressure (especially High Risk/High Care) • HEPA or equivalent filtration • Independent air handling units (AHUs) to avoid recirculated contamination
- • Site zoning map with air pressure zones • HVAC specifications and maintenance logs • Zoning validation or risk assessment
2. Implement Airflow Controls
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Required Controls:
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• Airflow direction from clean to less clean areas
• Pressure differential monitoring equipment
• Automatic shut-off or alarms for airflow failure
Evidence to Maintain:
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• Airflow validation reports
• Pressure differential logs
• Sensor calibration certificates
- • Airflow direction from clean to less clean areas • Pressure differential monitoring equipment • Automatic shut-off or alarms for airflow failure
- • Airflow validation reports • Pressure differential logs • Sensor calibration certificates
4. Validate Effectiveness and Prevent Failures
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Verification Activities:
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• Visual inspections of airflow direction (e.g., smoke pens)
• Periodic microbiological air sampling (especially in High Risk areas)
• Trend analysis on air-related deviations
Evidence to Maintain:
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• Air sampling reports
• Corrective/preventive action logs
• Validation protocols and outcomes
- • Visual inspections of airflow direction (e.g., smoke pens) • Periodic microbiological air sampling (especially in High Risk areas) • Trend analysis on air-related deviations
- • Air sampling reports • Corrective/preventive action logs • Validation protocols and outcomes
Common Audit Findings & Recommended Fixes
| Audit Finding | Recommended Action |
|---|---|
| No airflow validation or direction test | Conduct smoke tests or differential pressure assessments routinely |
| Filters not changed as scheduled | Implement documented filter maintenance schedule |
| Shared HVAC across zones | Use separate air handling for High Risk/High Care or install filters |
| Missing pressure monitoring records | Log air pressure daily; include in internal checks |