Site Standards: Utilities – Water, Air, and Energy
Aligned with FSSC 22000 Requirements
Requirement Overview
FSSC 22000 requires that all utilities—including water, air, gases, and energy sources—that may have a direct or indirect impact on food safety be identified, controlled, and maintained to prevent contamination. This includes utilities that come into contact with food, food-contact surfaces, packaging, or the surrounding environment.
Utilities are often overlooked in daily operations, yet failure to properly manage them can result in microbial, physical, or chemical contamination, potentially compromising product safety and integrity.
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
-
✓ Prevent contamination from water, air, gas, or energy sources
✓ Ensure utilities meet safety and quality standards for food production
✓ Maintain utility systems to prevent failures, leaks, and hygiene risks
✓ Monitor, document, and verify the performance of all utility systems
Step-by-Step Compliance Implementation
1. Assess and Map All Utility Sources
-
Utilities to Include:
-
• Potable and non-potable water (e.g., processing, handwashing, CIP)
• Compressed air and gas systems
• Steam systems (for culinary use or sanitation)
• Electrical and mechanical energy (if indirectly affecting food safety)
Evidence to Maintain:
-
• Utility schematics or layout maps
• Utility identification by zone (food-contact vs. non-contact)
• Supplier records for water, air, and gas quality (if outsourced)
- • Potable and non-potable water (e.g., processing, handwashing, CIP) • Compressed air and gas systems • Steam systems (for culinary use or sanitation) • Electrical and mechanical energy (if indirectly affecting food safety)
- • Utility schematics or layout maps • Utility identification by zone (food-contact vs. non-contact) • Supplier records for water, air, and gas quality (if outsourced)
2. Verify Utility Safety and Quality
-
Control Measures Include:
-
• Water: Conduct potability tests and verify supply line integrity
• Air/Gases: Install filters, monitor for oil/moisture/microbial contamination
• Steam: Use food-safe boiler chemicals and monitor for condensate quality
Evidence to Maintain:
-
• Water testing lab reports
• Air and gas monitoring and filter change logs
• Steam treatment documentation and maintenance records
- • Water: Conduct potability tests and verify supply line integrity • Air/Gases: Install filters, monitor for oil/moisture/microbial contamination • Steam: Use food-safe boiler chemicals and monitor for condensate quality
- • Water testing lab reports • Air and gas monitoring and filter change logs • Steam treatment documentation and maintenance records
3. Prevent Utility-Based Contamination
-
Risk Reduction Actions:
-
• Install air and water filters suitable for food-contact use
• Ensure utility contact surfaces are hygienically designed and maintained
• Use backflow preventers and isolate non-potable lines
Evidence to Maintain:
-
• Utility maintenance records and component inspections
• Calibration logs for monitoring devices
• Corrective actions and incident reports (if contamination risk identified)
- • Install air and water filters suitable for food-contact use • Ensure utility contact surfaces are hygienically designed and maintained • Use backflow preventers and isolate non-potable lines
- • Utility maintenance records and component inspections • Calibration logs for monitoring devices • Corrective actions and incident reports (if contamination risk identified)
4. Maintain and Monitor Utility Infrastructure
-
Maintenance Activities:
-
• Scheduled cleaning and inspection of utility points and connections
• Continuous or periodic monitoring of utility flow, pressure, and cleanliness
• Rapid fault repair systems for leaks or equipment malfunction
Evidence to Maintain:
-
• Preventive maintenance schedules
• Performance logs for water, air, steam, and gases
• Service orders and technician reports
- • Scheduled cleaning and inspection of utility points and connections • Continuous or periodic monitoring of utility flow, pressure, and cleanliness • Rapid fault repair systems for leaks or equipment malfunction
- • Preventive maintenance schedules • Performance logs for water, air, steam, and gases • Service orders and technician reports
Common Audit Findings & Recommended Fixes
| Audit Finding | Recommended Action |
|---|---|
| Unfiltered compressed air in food zones | Install suitable filtration and document maintenance protocols |
| No water potability testing | Initiate regular sampling and retain results from accredited labs |
| Steam lines lack food-grade treatment | Transition to approved boiler chemicals and validate supplier compliance |
| No documented utility layout or risk zones | Develop a utility map and identify potential contamination touchpoints |