Maintenance and Repair
Aligned with FSSC 22000 Requirements
Requirement Overview
FSSC 22000 requires that buildings, processing equipment, and supporting facilities be maintained in a condition that supports food safety, minimizes contamination risks, and ensures reliable operation. Maintenance systems must be both proactive and responsive, with activities controlled, documented, and verified for effectiveness.
The goal is to prevent breakdown-related contamination, protect product integrity, and maintain the hygienic condition of the site and equipment throughout their lifecycle.
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
-
✓ Maintain structurally sound and hygienically designed facilities and equipment
✓ Prevent food safety hazards caused by damage or deterioration
✓ Ensure maintenance is documented, validated, and authorized
✓ Meet regulatory and certification requirements for food safety assurance
Step-by-Step Compliance Implementation
1. Develop a Planned Maintenance Program
-
Program Components Include:
-
• Scheduled servicing of equipment, utilities, and building fabric
• Risk-based prioritization of critical control points and high-risk areas
• Clear responsibilities, SOPs, and resource allocation
Evidence to Maintain:
-
• Preventive maintenance calendar or Gantt chart
• Maintenance logs by equipment and facility section
• Work instructions and technician work orders
- • Scheduled servicing of equipment, utilities, and building fabric • Risk-based prioritization of critical control points and high-risk areas • Clear responsibilities, SOPs, and resource allocation
- • Preventive maintenance calendar or Gantt chart • Maintenance logs by equipment and facility section • Work instructions and technician work orders
2. Control Reactive (Unscheduled) Maintenance
-
Control Measures Include:
-
• Authorization protocols before emergency repairs begin
• Isolation of food products, packaging, and production lines
• Mandatory cleaning and validation before resumption
Evidence to Maintain:
-
• Reactive maintenance log with incident notes
• Post-maintenance inspection and sign-off forms
• Records of sanitation and cleaning validation
- • Authorization protocols before emergency repairs begin • Isolation of food products, packaging, and production lines • Mandatory cleaning and validation before resumption
- • Reactive maintenance log with incident notes • Post-maintenance inspection and sign-off forms • Records of sanitation and cleaning validation
3. Manage Building Fabric and Utility Systems
-
Requirements Include:
-
• Routine inspection of walls, floors, ceilings, doors, and drains
• Prompt resolution of structural defects or degradation
• Maintenance of utilities including water, ventilation, compressed air, and lighting
Evidence to Maintain:
-
• Structural and utilities inspection checklists
• Photos of identified issues and post-repair status
• Contractor documentation (if outsourced)
- • Routine inspection of walls, floors, ceilings, doors, and drains • Prompt resolution of structural defects or degradation • Maintenance of utilities including water, ventilation, compressed air, and lighting
- • Structural and utilities inspection checklists • Photos of identified issues and post-repair status • Contractor documentation (if outsourced)
4. Monitor and Verify Maintenance Activities
-
Verification Steps:
-
• Conduct post-maintenance inspections and close-out reviews
• Include maintenance in internal audit scope
• Analyze trends in breakdowns or repeated issues
Evidence to Maintain:
-
• Maintenance performance reviews or KPIs
• Internal audit findings and corrective action reports
• Downtime and failure trend analysis
- • Conduct post-maintenance inspections and close-out reviews • Include maintenance in internal audit scope • Analyze trends in breakdowns or repeated issues
- • Maintenance performance reviews or KPIs • Internal audit findings and corrective action reports • Downtime and failure trend analysis
Common Audit Findings & Recommended Fixes
| Audit Finding | Recommended Action |
|---|---|
| No documented maintenance schedule | Create a preventive maintenance program with detailed tracking |
| Repairs near exposed products | Implement area isolation and protective barriers during maintenance |
| Missing cleaning records post-repair | Document sanitation and revalidation of affected areas |
| Poor structural upkeep | Schedule periodic fabric inspections and execute timely repairs |
