BRCGS Production Risk Zones Explained

Today, we’ll explore the production risk zones according to the BRCGS standard. These zones are essential for ensuring that production facilities are designed to prevent pathogen contamination, thereby safeguarding food safety and protecting consumer health.

The BRCGS provides a comprehensive framework to ensure food safety by preventing pathogen contamination during production. A key aspect of this framework is the classification of Production Risk Zones, which are specifically established to maintain the appropriate conditions and controls based on varying contamination risk levels.

The categorisation of these zones considers not only the product itself but also how and where it is handled during the production process. Proper understanding and implementation of these zones are vital for any facility striving to maintain high hygiene standards and product integrity.

The BRCGS standard defines four main production risk zones, each with its own set of hygiene and control measures:

1. High-Risk Zone: This zone demands the strictest hygiene standards and is used for products with a high potential for contamination.

▶️ Key Requirements:

• Physical segregation from other areas to prevent cross-contamination.

• Positive air pressure and filtered air control, such as HEPA filters, are required.

• Finished products must undergo chilling or freezing to ensure safety, not just quality.

• Before entering this area, all components must be fully cooked (minimum 70°C for 2 minutes or equivalent).

▶️ Products in this zone:

• Ready-to-eat, ready-to-heat, or those likely to be consumed without further cooking.

• Vulnerable to the growth or survival of pathogens.

2. High-Care Zone: This zone provides slightly more flexibility than the high-risk zone but prioritises microbiological safety for vulnerable products.

▶️ Key Requirements:

• Products require chilling or freezing to maintain safety.

• Susceptible components must undergo a validated micro-kill step but do not necessarily need to be fully cooked.

▶️ Products in this zone:

• Ready-to-eat, ready-to-heat, or those likely to be consumed without adequate cooking.

• It can support the growth or survival of pathogens.

3. Ambient High-Care Zone: This category is similar to the high-care zone but applies to products stored at ambient (non-chilled) temperatures.

▶️ Key Requirements:

• Raw materials must be susceptible to contamination by vegetative pathogens (e.g., Salmonella).

• A microbiological reduction step (e.g., drying, heating) must be applied to the product.

▶️ Products in this zone:

• Ready to eat or those likely to be consumed without further cooking.

• Capable of supporting pathogen growth or survival during storage.

4. Low-Risk and Enclosed Product Areas: These zones are used for products with a lower risk of contamination or are fully enclosed, preventing environmental exposure. While not covered in great detail here, these zones form a critical baseline for many manufacturing processes.

Identifying and implementing the appropriate risk zone is essential for ensuring food safety, maintaining compliance, and protecting consumer health.

By adhering to these requirements, manufacturers can create robust systems that minimise contamination risks and promote a culture of hygiene excellence throughout the production process.

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