Staff Flow & Movement Procedures
Aligned with FSSC 22000 – Zoning and Control of Contamination Risk
Requirement Overview
FSSC 22000 requires that facilities establish and maintain clearly defined zoning protocols and controlled staff movement between production areas to prevent cross-contamination and ensure the integrity of food safety.
This is especially critical for areas handling ready-to-eat (RTE) products or other high-risk food items, where strict personnel hygiene and segregation protocols must be enforced to protect against the transfer of pathogens, allergens, or foreign materials.
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 cross-contamination through controlled staff movement
✓ Enforce physical and procedural barriers between zones
✓ Maintain compliance with zoning definitions and risk assessments
✓ Document all procedures and movement controls for audit readiness
Step-by-Step Compliance Implementation
1. Define Risk Zones and Entry Criteria
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Zone Types:
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• High Risk – exposed RTE product, sensitive to pathogens
• High Care – chilled RTE product, not fully sealed
• Ambient High Care – ambient-stable but sensitive to contamination
Evidence to Maintain:
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• Factory zoning maps
• Zoning justification documents
• Staff access level assignments
- • High Risk – exposed RTE product, sensitive to pathogens • High Care – chilled RTE product, not fully sealed • Ambient High Care – ambient-stable but sensitive to contamination
- • Factory zoning maps • Zoning justification documents • Staff access level assignments
2. Establish Controlled Entry/Exit Points
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Requirements Include:
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• Airlocks or hygiene lobbies
• Handwashing and disinfection stations
• Change of PPE, footwear, and tools before entry
Evidence to Maintain:
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• Entry logs or access badge records
• Hygiene station maintenance logs
• PPE changeover procedures
- • Airlocks or hygiene lobbies • Handwashing and disinfection stations • Change of PPE, footwear, and tools before entry
- • Entry logs or access badge records • Hygiene station maintenance logs • PPE changeover procedures
3. Implement Staff Flow Procedures
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Procedural Controls:
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• Designated routes to prevent crossing from high to low-risk areas
• No return to low-risk zones without full decontamination
• Staggered breaks to reduce congestion in hygiene areas
Evidence to Maintain:
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• Documented staff flow procedures
• Area signage and floor markings
• Staff induction and refresher training records
- • Designated routes to prevent crossing from high to low-risk areas • No return to low-risk zones without full decontamination • Staggered breaks to reduce congestion in hygiene areas
- • Documented staff flow procedures • Area signage and floor markings • Staff induction and refresher training records
4. Train and Enforce Compliance
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Training Must Cover:
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• Zoning awareness and color-coded zones
• Proper hygiene practices before moving between areas
• Reporting breaches or non-compliances
Evidence to Maintain:
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• Training completion logs
• Visual aids (e.g., posters, signs, zone maps)
• Disciplinary or corrective action reports for zoning breaches
- • Zoning awareness and color-coded zones • Proper hygiene practices before moving between areas • Reporting breaches or non-compliances
- • Training completion logs • Visual aids (e.g., posters, signs, zone maps) • Disciplinary or corrective action reports for zoning breaches
5. Monitor, Audit, and Review
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Oversight Activities:
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• Supervisory checks and hygiene audits
• Incident logs for unauthorized movements
• Regular review of staff feedback and incident data
Evidence to Maintain:
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• Internal audit reports and corrective actions
• Observation checklists and sign-off logs
• Zoning SOP updates and review records
- • Supervisory checks and hygiene audits • Incident logs for unauthorized movements • Regular review of staff feedback and incident data
- • Internal audit reports and corrective actions • Observation checklists and sign-off logs • Zoning SOP updates and review records
Common Audit Findings & Recommended Fixes
| Audit Finding | Recommended Action |
|---|---|
| No physical or procedural zoning controls | Install airlocks, barriers, and revise staff movement procedures |
| PPE not changed between zones | Enforce zoning-specific PPE and staff training |
| Inadequate signage or unclear zones | Install color-coded maps, floor markings, and area labels |
| No records of staff movement procedures | Develop documented SOPs and maintain training evidence |