Part 3: Enhancing GMPs with Technology and Standards
Tiffany M. Donica
In Part 3, we dive into how food and beverage manufacturers can enhance their GMP programs by integrating cutting-edge technologies, leveraging analytics, and aligning with GFSI-certified standards such as SQF, BRCGS, and FSSC 22000. By exploring real-world examples and actionable insights, you’ll discover how to future-proof your GMP strategy while maintaining the highest levels of compliance and customer confidence.
The 10 Principles of Good Manufacturing Practices
The principles of GMP in food industry establishments can be broken down into ten key components:
1. Write detailed, step-by-step procedures
The first step of GMPs is to establish detailed, step-by-step standard operating procedures (SOPs) in writing. These will act as a roadmap for consistent performance. Written procedures also allow workplace standards to be established and ensure that tasks are performed the same way each time.
2. Follow established procedures
Written SOPs are only as effective as the people who perform them. To that end, it’s important that employees know not to take any shortcuts, make modifications, or deviate from written instructions in any way. Again, the goal is to achieve a consistent, high-quality product.
3. Document everything
Timely and accurate documentation promotes regulatory compliance and also ensures any issues can be traced to the source. Accurate recordkeeping also provides a way to evaluate issues to prevent them from happening again. Moreover, records are required for audits, so having an effective documentation system ensures that all of your necessary records will be easily accessible.
4. Validate the SOPs and specs
To make sure SOPs work as they should, you must validate your processes. This is also achieved through routine documentation and precise following of written procedures. When performed consistently, these activities ensure a quality and consistent output is achieved.
5. Integrate quality and safety into equipment and facilities
Productivity, quality, and safety should be incorporated into the design and construction of food manufacturing facilities and equipment. This prioritizes quality and consistency at every processing step.
6. Maintain equipment and facilities
A number of maintenance activities must be performed on equipment and facilities consistently. Records should be kept to back up the work performed. This reduces safety concerns and mitigates quality control issues.
7. Establish, develop, and demonstrate job competence
Job competency should be demonstrated by every team member. GMP requires employees to be thoroughly competent in their roles, but note that competency may mean different things to different people. For this reason, competency should be defined for every role so employees know exactly what’s expected of them.
8. Ensure cleanliness
Protect products against contamination by making sanitization efforts routine tasks. Different products will call for specific degrees of cleanliness, so outline the necessary steps and implement checks for each zone in the facility.
9. Build quality into the product
Systematic quality control of components and processes should be implemented in every step of production, from packaging and labeling to any cooking or handling processes. Set clearly defined controls and keep clear records to ensure quality is consistent. You can even automate some aspects of your quality control program with tactics such as real-time statistical process control (SPC) that can help you identify and correct non-conformances quickly with real-time data capture and specification verification.
10. Conduct audits
While you can perform checks in your own facility to verify that GMPs are working effectively, having a fresh set of eyes can uncover inefficiencies or other areas of opportunities internal parties may have overlooked. Audits are, therefore, an essential aspect of both GMP success and regulatory compliance.
What Are Examples of Good Manufacturing Practices?
Implementing GMPs may look different for every company and perhaps for even different plant locations. With that in mind, here are some examples of GMPs in food industry facilities you might consider implementing in your own plant:
A robust hygiene program that identifies and eliminates potential sources of contamination
A thorough maintenance schedule for equipment and facilities, including preventive activities
Detailed job descriptions that clearly define employees’ roles
A system for investigating and addressing complaints and following through to resolution
A clear documentation strategy, which might include best practices such as:
Documents should not be handwritten
Documents must be routinely reviewed and updated
Documents must be approved, signed, and dated by the appropriate party
Any modifications or corrections to documents must be signed and dated
Whenever possible, photographs should accompany documents indicating an observed issue
Inspections that are performed routinely to monitor GMP effectiveness
Audit checklists that can outline GMP guidelines
A company that is implementing GMPs well is Joyce Farms who uses SafetyChain for a broad range of programs, including:
External & Internal Audits: BRC 9, SQF, USDA, GMPs, Food Defense, Glass & Brittle Plastics
Food Safety Documentation: CCP, HACCP, SSOP, Pre-Op, Foreign Material, Temperatures
Operations: Quality Inspections, Shipping & Receiving, Preventive Maintenance & Work Orders
Related to GMPs, Jennifer Hamby, Joyce Farms QA Manager, said an example of a question your BRC auditor will ask is, “Where is the policy for your GMPs (Food Safety Policy)?” And you don’t want the stress of searching for your GMPs on the spot; instead, you want your auditor to be able to click on the program and navigate through the policy and associated records with ease, as seen here:
With the ease of SafetyChain, the auditor can click GMP and see records generated from implementation, associated policy, and each heading. There’s no need to track down paper forms or other electronic files when all of the data is conveniently linked for them.
How GMP & GFSI Work Together
In the complex landscape of food and beverage manufacturing, the synergy between Good Manufacturing Practices (GMP), Global Food Safety Initiative (GFSI) certification, and modern analytics plays a pivotal role in driving compliance, quality, and operational efficiency. Here's how these elements interconnect:
Good Manufacturing Practices (GMP)
Good Manufacturing Practices form the foundation of food safety, providing detailed operational standards for everything from sanitation to equipment maintenance. While regulatory bodies such as the FDA and GFSI schemes like SQF each have their own GMP requirements, they share significant overlaps. Facilities certified under a GFSI scheme like SQF often align with the FDA's GMPs naturally, simplifying compliance efforts. This alignment ensures that the highest standards of safety and quality are consistently upheld.
BRCGS Global Standard Food Safety
The BRCGS (British Retail Consortium Global Standards) Global Standard for Food Safety is a GFSI-recognized certification program that emphasizes food safety and quality management. It is particularly well-suited for facilities seeking to demonstrate compliance with stringent global standards and retailer expectations.
This certification focuses on key elements such as:
Implementing a Hazard Analysis and Critical Control Points (HACCP)-based food safety plan.
Establishing robust quality management systems (QMS) to monitor and control risks.
Enhancing traceability and transparency throughout the supply chain.
Achieving BRCGS certification not only reinforces customer confidence but also supports continuous improvement, helping companies adapt to evolving industry challenges while maintaining a competitive edge.
FSSC22000
FSSC 22000 (Food Safety System Certification 22000) is another prominent GFSI-recognized scheme, rooted in ISO standards and tailored for organizations across the food supply chain. It combines ISO 22000 for food safety management systems with additional requirements specific to GFSI compliance.
Key components of FSSC 22000 include:
A strong focus on risk management and preventive controls.
Integration with ISO 9001 for organizations seeking a unified quality and safety system.
Flexibility to address the unique needs of diverse food manufacturing and processing facilities.
FSSC 22000 provides a comprehensive framework for ensuring food safety and operational excellence. It is ideal for companies operating in highly regulated or international markets, offering a universal approach to compliance and quality assurance.
Safe Quality Food (SQF)
SQF, shorthand for the Safe Quality Food Institute's certification program, is one of the most widely recognized Global Food Safety Initiative (GFSI) schemes in the U.S. Achieving SQF certification helps food and beverage companies align with industry best practices, enhance customer confidence, and maintain a competitive edge. The SQF code encompasses stringent food safety and quality standards that facilities must meet, ensuring consistency and credibility in their operations.
The Role of Analytics
In today’s food manufacturing environment, data is a powerful asset. Facilities generate vast amounts of information from process monitoring, inspections, and compliance tracking. While traditional offline systems like spreadsheets often limited the value of this data, modern analytics solutions unlock its potential.
By leveraging mobile forms and automated data collection, companies can centralize their data and harness real-time analytics to:
Monitor compliance with BRCGS, FSSC 22000, and SQF requirements.
Track adherence to GMP standards across the facility.
Receive alerts for immediate corrective action when non-conformances arise.
Benchmark performance and identify opportunities for continuous improvement.
This data-driven approach ensures seamless compliance while improving operational efficiency and product quality. Whether managing complex global certifications or foundational GMPs, integrating real-time analytics empowers food and beverage companies to maintain high standards and drive sustained success in a competitive market.
In Conclusion
Establishing, implementing, and routinely performing GMPs is an extensive undertaking. Yet, it’s among the most important things any food and beverage facility can do to ensure safe, consistent products and compliance. By adhering to the five components and ten principles of GMPs outlined above, you can ensure every aspect of your manufacturing process is designed to mitigate food safety events.
