Part 2: Implementing GMPs in the Food Industry
Tiffany M. Donica
Good Manufacturing Practices (GMPs) form the backbone of food safety and quality assurance, but implementing them effectively in a food manufacturing facility is no small task. With unique challenges ranging from resource constraints to evolving regulations, even the most well-intentioned efforts can face roadblocks.
This article explores practical strategies to overcome common GMP implementation challenges and introduces the five essential components of successful GMP programs. Whether you're addressing sanitation gaps, managing cross-contamination risks, or streamlining documentation, these insights will help you transform GMPs from a compliance checkbox into a competitive advantage.
Top 10 GMP Implementation Challenges (And How to Overcome Them)
Implementing GMPs is essential, but not always easy. Here’s where food manufacturers often get stuck, and how to move forward:
1. Inconsistent Training
Challenge: High turnover and varied experience levels lead to uneven GMP knowledge.
Solution: Create role-specific training with regular refreshers to build confidence and consistency.
2. Limited Resources
Challenge: Smaller teams or tight budgets make it hard to implement GMPs fully.
Solution: Focus on high-impact areas first and scale efforts with digital tools and automation.
3. Poor Documentation
Challenge: Paper-based logs and spreadsheets are prone to errors and hard to manage.
Solution: Move to digital recordkeeping for real-time tracking, easy audits, and centralized access.
4. Sanitation Gaps
Challenge: Inconsistent hygiene practices increase contamination risk.
Solution: Standardize sanitation SOPs and assign accountability with routine inspections.
5. Keeping Up With Regulations
Challenge: Rules evolve—and vary by region and certifying body.
Solution: Use compliance software to stay current and auto-update processes when standards shift.
6. Cross-Contamination Risks
Challenge: Shared spaces and poor zoning create contamination hazards.
Solution: Physically separate zones, color-code tools, and enforce strict workflows.
7. Resistance to Change
Challenge: Employees may be hesitant to adopt new systems or processes.
Solution: Involve frontline staff early, show benefits, and reward adoption.
8. Monitoring & Enforcement
Challenge: Manual oversight can miss non-conformances.
Solution: Leverage real-time monitoring and alerts to spot and fix issues faster.
9. Supplier Compliance
Challenge: Suppliers vary in their adherence to GMPs.
Solution: Conduct regular audits, require documentation, and build quality into sourcing contracts.
10. Overlapping Standards
Challenge: Juggling GMPs with SQF, GFSI, or customer-specific rules creates complexity.
Solution: Use an integrated compliance platform to manage all requirements in one system.
Addressing these challenges requires a proactive and strategic approach, leveraging modern technology, effective training, and a culture of accountability to ensure GMP compliance becomes a seamless part of daily operations.
The 5 Main Components of Good Manufacturing Practices
GMPs in food industry establishments should focus on the five main categories below.
People
The foundation of any strong GMP program is people. If the individuals on the plant floor (and those in managerial roles) aren’t properly trained, they can’t be expected to implement processes and procedures effectively. Therefore, food companies must invest in training, so employees know GMP quality control standards and how to carry them out. It cannot be a “one-and-done” activity. However, training methods should be assessed and reassessed regularly.
Premises
Having a clean, safe environment is essential in food manufacturing, where products routinely come into contact with surfaces. The premises should be designed in a way that allows for effective cleaning and a reduced risk of cross-contamination.
In the food industry, “premises” also refers to equipment. All machines should be validated and calibrated, and there should be procedures, schedules, and records in place for cleaning and maintenance.
Processes/Paperwork
GMP processes refer to the documentation that proves that procedures are followed. Auditors will use this documentation to check facilities and ensure GMP procedures are being carried out effectively. Therefore, thorough documentation can benefit food manufacturers, though it certainly doesn’t have to mean keeping binders, notebooks, or other handwritten paperwork. In fact, digitizing your GMPs with plant management software can simplify your approach by ensuring all employees have access to pre-op and sanitation programs at their fingertips, record sign-offs can be completed easily in one convenient platform, and food safety checks can be carried out, and reviewed for thorough recordkeeping.
Products & Primary Materials
Among the most important aspects of food manufacturing are products and primary materials. Products refer to the end goods sold to customers, such as retailers and restaurants, which will ultimately reach the consumer. Primary materials, on the other hand, are raw or semi-processed ingredients. If primary materials aren’t properly inspected prior to entering production, dangerous products could wind up on the market. GMPs must therefore incorporate quality tactics to monitor for and address deviations in incoming materials.
Procedures
Procedures themselves must be closely analyzed, updated routinely, and implemented effectively. They must also be well-documented so that if a problem occurs, it can be quickly and easily traced to the cause through measures such as root cause analysis.
Conclusion: Get Ready for Part 3
Implementing GMPs is only the beginning of the journey toward operational excellence. To ensure their success, a proactive approach to monitoring, continuous improvement, and fostering a culture of accountability is essential.
In Part 3: Monitoring and Improving GMP Compliance, we’ll explore how to evaluate the effectiveness of your GMPs, use real-time data for actionable insights, and sustain a culture of excellence across your organization. Don’t miss it!
