How to Comply with BRCGS Issue 7 in Packaging Manufacturing

Table of Contents

• Why BRCGS Issue 7 Training Is Essential for Packaging Manufacturers
• Modules Covered in the BRCGS Issue 7 Course
• Interesting Lessons and Key Takeaways from the Training
• Building Strong, Audit-Ready Packaging Teams

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Why BRCGS Issue 7 Training Is Essential for Packaging Manufacturers

BRCGS Issue 7 is one of the most globally recognized and widely demanded standards for packaging materials. Customers expect certified facilities to demonstrate strong system controls, risk-based thinking, consistent monitoring, and full traceability. The standard is far more than a document, it is a system that requires:

• Strong senior management commitment
• A well-structured Food Safety & Quality Management System
• Effective process control
• Documented risk assessments
• Clear evidence of implementation
• Continuous improvement

For packaging manufacturers, this is especially important because packaging plays a direct role in protecting food. Ink migration issues, foreign bodies, allergen cross-contact, artwork errors, incorrect labelling, and poor hygiene can all have major consequences.

This training helps packaging manufacturers understand their responsibilities, interpret clauses correctly, reduce operational risks, and improve audit performance.

Modules Covered in the BRCGS Issue 7 Course

Below is a clear summary of the modules covered during training, aligned with the BRCGS Issue 7 manual:

• Module 1: Senior Management Commitment
  
  Explains leadership responsibilities, communication, food safety policy development, reviews, resource allocation, and how management influences food safety and quality culture in a packaging environment.
  
• Module 2: Hazard & Risk Management (The Food Safety Plan)
  
  Covers HACCP principles required under BRCGS, including prerequisite programmes, and the 12 steps of HACCP using the Codex Alimentarius guidelines. Delegates learn how HACCP applies to packaging processes such as extrusion, printing, laminating, die-cutting, and conversion etc.
  
• Module 3: Food Safety & Quality Management System Requirements
  
  Covers documentation, record control, specifications, artwork and label control, internal audits, corrective action, traceability, and complaint handling, critical elements for packaging manufacturers supplying food producers.
  
• Module 4: Site Standards
  
  Explores building layout, environmental controls, foreign body prevention, pest management, equipment design, waste removal, cleaning programmes, and hygiene zoning specific to packaging plants.
  
• Module 5: Product Control
  
  Focuses on allergen management, product testing, chemical hazards (e.g., ink, adhesives, coatings), product release, authenticity, and provenance.
  
• Module 6: Process Control
  
  Covers machine start-up checks, in-process monitoring, calibration, verification, print control, die-cutting accuracy, and extrusion conditions, etc
  
• Module 7: Personnel Requirements
  
  Addresses training, hygiene rules, protective clothing, competencies, and staff behavior expectations relevant to packaging manufacturing.

These modules collectively help delegates understand how to implement the standard effectively while reducing risks across all manufacturing and converting operations.

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Interesting Lessons and Key Takeaways from the Training

One of the most eye-opening sections for packaging teams is the artwork and label control clause. Many non-conformances across the packaging industry are linked to incorrect labelling, outdated artwork, or poor control of printing plates, cylinders, and templates. Delegates gain insight into practical controls to prevent misprints and protect brand integrity.

Another powerful learning area is the risk assessment of inks, adhesives, coatings, and other chemical hazards. Packaging manufacturers often underestimate the role these components play in migration risks and product safety. Through real examples, we explore how chemical hazards move through packaging materials and how BRCGS expects facilities to control them.

Additionally, delegates appreciate the section on site standards, where we unpack practical issues like dust control in printing rooms, equipment design flaws, waste build-up, and poor segregation of raw materials. Many delegates realize that improving housekeeping and zoning can significantly reduce audit findings.

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Key facts

• BRCGS Issue 7 compliance rests on senior management commitment, a well-structured Food Safety and Quality Management System, effective process control, documented risk assessments, clear evidence of implementation, and continuous improvement.
• The ASC Implementation of BRCGS for Packaging Materials Issue 7 Course (FS18) covers seven modules: senior management commitment, hazard and risk management, the food safety and quality management system, site standards, product control, process control, and personnel requirements.
• Key packaging risks addressed include ink migration, foreign bodies, allergen cross-contact, artwork errors, incorrect labelling, and poor hygiene.
• Hazard and risk management applies HACCP principles and the 12-step Codex Alimentarius framework to packaging processes such as extrusion, printing, laminating, die-cutting, and conversion.
• The training helps packaging manufacturers understand their responsibilities, interpret clauses correctly, reduce operational risks, and improve audit performance.
• The course focuses on building strong, audit-ready packaging teams so that food safety and audit results improve and customer trust grows.

Frequently asked questions

What does BRCGS Issue 7 apply to?

BRCGS Issue 7 is the standard for Packaging Materials. The ASC course is titled the Implementation of BRCGS for Packaging Materials Issue 7 Course (FS18), and it is aimed at helping packaging manufacturers meet the standard's requirements.

What is required to comply with BRCGS Issue 7?

Compliance requires senior management commitment, a well-structured Food Safety and Quality Management System, effective process control, documented risk assessments, clear evidence of implementation, and continuous improvement. Together these elements form the foundation for meeting the standard and passing audits.

What modules does the ASC BRCGS Issue 7 course cover?

The course covers seven modules: senior management commitment, hazard and risk management, the food safety and quality management system, site standards, product control, process control, and personnel requirements. Each module maps to the standard's clauses so teams can interpret and apply them correctly.

What packaging-specific risks does BRCGS Issue 7 training address?

The training addresses risks such as ink migration, foreign bodies, allergen cross-contact, artwork errors, incorrect labelling, and poor hygiene. It also covers chemical hazards from inks, adhesives, and coatings, along with dust control, equipment design, waste segregation, and hygiene zoning.

How does BRCGS Issue 7 training help with audits?

The training helps packaging teams understand their responsibilities, interpret clauses correctly, reduce operational risks, and improve audit performance. ASC frames it as building strong, audit-ready packaging teams, noting that when teams understand the reasoning behind BRCGS, food safety and audit results improve and customer trust grows.

Who provides this BRCGS Issue 7 packaging course?

The course is provided by ASC Food Safety Consultants, a South Africa-based food safety consultancy. Interested organisations can contact ASC for more information or request a free quote.