Site Standards: Equipment Suitability, Maintenance & Calibration
Aligned with FSSC 22000 Requirements
Requirement Overview
FSSC 22000 requires that all equipment used in food processing, handling, storage, or measurement be suitable for its intended purpose, hygienically designed, properly maintained, and accurately calibrated. These controls are essential to prevent contamination, ensure product safety, and maintain process integrity.
Improper equipment selection, poor maintenance practices, or inaccurate calibration can significantly impact food safety performance, regulatory compliance, and certification outcomes.
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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✓ Ensure equipment is designed for food safety and hygiene
✓ Implement a documented preventive maintenance program
✓ Calibrate measurement devices critical to food safety
✓ Maintain full traceability and supporting documentation for audits
Step-by-Step Compliance Implementation
1. Assess Equipment Suitability
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Evaluation Criteria:
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• Food contact surfaces made of food-grade, non-toxic, and corrosion-resistant materials
• Hygienic design to allow effective cleaning, disinfection, and inspection
• Equipment functionally suited to its intended use in processing, packaging, or measurement
Evidence to Maintain:
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• Equipment specifications and hygienic design documentation
• Risk assessments identifying contamination hazards associated with equipment
• Approval and validation records prior to equipment use
- • Food contact surfaces made of food-grade, non-toxic, and corrosion-resistant materials • Hygienic design to allow effective cleaning, disinfection, and inspection • Equipment functionally suited to its intended use in processing, packaging, or measurement
- • Equipment specifications and hygienic design documentation • Risk assessments identifying contamination hazards associated with equipment • Approval and validation records prior to equipment use
2. Establish a Preventive Maintenance Program
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Program Elements:
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• Maintenance schedules based on risk levels and manufacturer instructions
• Clearly assigned responsibilities and procedures for servicing
• Rapid response protocols for unexpected equipment failures
Evidence to Maintain:
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• Preventive maintenance calendars and logs
• Maintenance work orders and completion records
• Corrective action reports for breakdowns or performance deviations
- • Maintenance schedules based on risk levels and manufacturer instructions • Clearly assigned responsibilities and procedures for servicing • Rapid response protocols for unexpected equipment failures
- • Preventive maintenance calendars and logs • Maintenance work orders and completion records • Corrective action reports for breakdowns or performance deviations
3. Implement Calibration Controls
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Calibration Requirements:
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• Identify all measurement devices used to monitor CCPs, temperatures, weights, pH, etc.
• Calibrate devices at defined intervals against certified or traceable standards
• Label calibrated equipment and store associated certificates
Evidence to Maintain:
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• Device calibration schedule
• Calibration certificates (internal or third-party)
• Records of non-conformance for out-of-tolerance readings
- • Identify all measurement devices used to monitor CCPs, temperatures, weights, pH, etc. • Calibrate devices at defined intervals against certified or traceable standards • Label calibrated equipment and store associated certificates
- • Device calibration schedule • Calibration certificates (internal or third-party) • Records of non-conformance for out-of-tolerance readings
4. Monitor and Review Equipment Programs
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Monitoring Activities:
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• Conduct internal audits of maintenance and calibration programs
• Observe equipment functionality during operations
• Periodic management review to assess equipment performance and program effectiveness
Evidence to Maintain:
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• Audit reports and review summaries
• Justifications for equipment replacement or upgrade
• Trends in equipment-related non-conformities or downtime
- • Conduct internal audits of maintenance and calibration programs • Observe equipment functionality during operations • Periodic management review to assess equipment performance and program effectiveness
- • Audit reports and review summaries • Justifications for equipment replacement or upgrade • Trends in equipment-related non-conformities or downtime
Common Audit Findings & Recommended Fixes
| Audit Finding | Recommended Action |
|---|---|
| Poorly designed or deteriorating equipment | Conduct a risk assessment; repair or replace non-compliant equipment |
| Incomplete maintenance records | Centralize and digitize logs; require signatures for each completed task |
| Missed or overdue calibrations | Use automated scheduling or alerts for calibration due dates |
| No traceable calibration standards | Use certified calibration providers or verified reference-grade equipment |