Air Handling & Movement
Aligned with FSSC 22000 Requirements
Requirement Overview
FSSC 22000 requires that facilities implement environmental controls to prevent airborne contamination in processing and storage areas. This includes air handling systems, filtration, and airflow direction designed according to a risk assessment to protect product integrity, especially in areas where products are exposed and vulnerable to contamination.
Proper air control minimizes microbial and particulate transfer, maintains hygienic conditions, and supports compliance with food safety management system requirements.
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 defined processing zones
✓ Maintain air quality through effective filtration and controlled airflow direction
✓ Monitor and verify air pressure differentials where required
✓ Ensure air handling measures are based on documented risk assessments
Step-by-Step Compliance Implementation
1. Define Processing Zones and Air Control Requirements
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Processing Zone Types (Examples):
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• High Risk – Chilled ready-to-eat products after cooking
• High Care – Ready-to-eat products that bypass a kill step
• Ambient High Care – Ambient-stored RTE products vulnerable to contamination
Air Handling Must Include:
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• Positive air pressure where needed to protect high-risk areas
• HEPA or equivalent filtration for sensitive processing areas
• Independent air handling units (AHUs) to prevent cross-contamination from recirculated air
Evidence to Maintain:
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• Facility zoning map with air pressure indications
• HVAC system specifications and maintenance records
• Zoning validation or documented risk assessment
- • High Risk – Chilled ready-to-eat products after cooking • High Care – Ready-to-eat products that bypass a kill step • Ambient High Care – Ambient-stored RTE products vulnerable to contamination
- • Positive air pressure where needed to protect high-risk areas • HEPA or equivalent filtration for sensitive processing areas • Independent air handling units (AHUs) to prevent cross-contamination from recirculated air
- • Facility zoning map with air pressure indications • HVAC system specifications and maintenance records • Zoning validation or documented risk assessment
2. Implement Airflow Controls
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Required Controls:
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• Airflow direction from cleaner to less clean areas
• Pressure differential monitoring with set limits
• Alarms or automatic shut-off for airflow failures
Evidence to Maintain:
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• Airflow validation and balancing reports
• Pressure differential monitoring logs
• Calibration records for monitoring equipment
- • Airflow direction from cleaner to less clean areas • Pressure differential monitoring with set limits • Alarms or automatic shut-off for airflow failures
- • Airflow validation and balancing reports • Pressure differential monitoring logs • Calibration records for monitoring equipment
3. Validate Effectiveness and Prevent Failures
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Verification Activities:
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• Visual confirmation of airflow direction (e.g., smoke tests)
• Periodic microbiological air sampling in high-risk areas
• Review of trends and deviations related to air handling
Evidence to Maintain:
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• Air sampling test reports
• Corrective and preventive action (CAPA) logs
• Validation protocols and documented results
- • Visual confirmation of airflow direction (e.g., smoke tests) • Periodic microbiological air sampling in high-risk areas • Review of trends and deviations related to air handling
- • Air sampling test reports • Corrective and preventive action (CAPA) logs • Validation protocols and documented results
Common Audit Findings & Recommended Fixes
| Audit Finding | Recommended Action |
|---|---|
| No airflow validation or direction testing | Perform routine smoke tests or pressure differential checks |
| Filters not changed on schedule | Establish and follow a documented filter replacement plan |
| Shared HVAC system across sensitive and non-sensitive areas | Install separate air handling units or add appropriate filtration |
| Missing air pressure monitoring records | Record pressure readings daily and include in internal checks |