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The options for certification and the establishment of an operational QM system should be explored as early as possible. In particular, in order to eliminate impasses that arise when those involved are under time pressure.
A step towards the "big IFS"
In principle, the IFS programs („International Featured Standards“) fall into the category of product safety standards. These standards are therefore of overriding relevance for beverage manufacturers such as breweries or mineral water producers.
The IFS GMF serves as an entry-level program for smaller companies and can be completed in a basic or intermediate level. After successful implementation, a development to the „large IFS“ – the IFS Food – is planned. The two levels differ primarily in the scope of the catalog of requirements. As the standard already covers a large number of legal requirements, successful certification represents further proof of compliance with the legal requirements.
In the intermediate level, the IFS GMF comprises 185 requirements, which corresponds to around 80 percent of the requirements of IFS Food Version 8Revision 3 of the IFS GMF
The current version 3 of the program has been mandatory since October 2023. With the new version, the chapter structure has been based on the structure of IFS Food, making it easier to develop towards this major standard. The scope of the program has also increased significantly. The main changes are explained in more detail below, particularly for certification at intermediate level.
The framework
The audit is carried out annually by an accredited certification body. At the intermediate level, the audited company also has the option – but not the obligation – to have the audit carried out unannounced. The audit will take between four and eight hours, depending on the product and technology scopes used and the number of employees.
At the intermediate level, the IFS GMF comprises 185 requirements, which corresponds to approx. 80 percent of the requirements of IFS Food Version 8. While questions were asked in the previous version, clearer requirements are now formulated for the company.
The underlying assessment scheme of A, B, C and D assessment and the awarding of a major non-conformity, together with the resulting score, remains unchanged. In contrast to IFS Food, no k.o. criteria are defined that lead to immediate failure of the audit in the event of gross deviations. However, a major non-conformity can be awarded for each requirement, which leads to the deduction of ten percent of the possible total number of points and consequently to a denial of the confirmation letter.
The current version requires the implementation of a corporate food safety cultureThe new catalog of requirements of the IFS Global Markets Food
The main change in the new version is the chapter structure based on IFS Food. This results in the following chapters:
- Corporate governance and commitment;
- food safety and quality management;
- resource management;
- operational processes;
- measurements, analyses, improvements.
The requirement for the company management to implement an operational food safety culture is new. At this point, the requirements of EU Regulation 2021/382 take effect, which are aimed at the operational implementation of such a culture. The first chapter also includes an obligation to provide information in the event of changes to the name or production site, as well as product recalls and relevant official complaints. Furthermore, the person or department responsible for quality management in the company must report directly to the company management.
Implementation of an effective HACCP system
In the area of document management, it must be ensured in the future that records are stored securely. However, they must also be accessible. A key component here is the establishment and implementation of an effective HACCP system, based on the requirements of the Codex Alimentarius.
A new feature of the IFS GMF is a more comprehensive risk analysis. As before, microbiological, physical and chemical hazards that could realistically have an impact on the product are assessed. In addition, radiological hazards and hazards from materials with contact to food and from the working environment must be assessed.
Facilities for cleaning and disinfecting boots, shoes and protective clothing, as required in the resource management chapter, are usually not necessary in breweries and mineral water springs after risk-oriented consideration.
Companies must determine an appropriate shelf life for their productsOperational processes
New in the chapter on operational processes and infrastructure is the obligation for companies to provide evidence of product-related advertising claims. This applies, for example, to advertising claims about the regionality of the raw materials used.
Shelf life of the end products
Based on a validation and assessment of the microbiological, chemical and organoleptic properties, companies must determine an appropriate shelf life for their products. In addition to the specifications and declarations of conformity for the packaging materials used, the company must carry out tests and analyses that prove the suitability for contact with the manufactured food. This includes organoleptic tests, storage tests, chemical analyses and migration tests.
It is no longer sufficient to simply document the cleaning measures. With the new version, a concrete verification of the effectiveness of the carried out cleaning is requiredCleaning and disinfection
Whereas cleaning, disinfection and documentation were previously the main requirements, documented verification of the effectiveness of cleaning work is now also required. This includes visual inspections, rapid tests or analytical test methods.
Pest monitoring
The new version now requires the effectiveness of the measures taken to prevent pests to be verified for the first time. The contracted service provider should, for example, provide an annual trend analysis to verify this.
Food fraud and product protection in the IFS GMF
The areas of food fraud and food defense still played a subordinate role in the previous version. Risks must now be assessed in the intermediate stage and plans defined to minimize the identified risk. A product protection team must draw up a corresponding plan to protect against unauthorized access and manipulation of the products. The developed system must also be regularly tested for effectiveness.
New is the requirement for regular site inspectionsInspections, process analyses and sampling plans
The new version requires regular and documented inspections of all operational areas. The frequency of such inspections must be defined in a risk-oriented but binding manner. In addition to the structural condition, aspects such as operational hygiene, personnel hygiene and possible foreign body hazards must also be assessed.
This section of the standard also regulates process controls and analyses. The test equipment used for such checks must be monitored as part of a suitable test equipment management system. The requirement areas mentioned were already part of the previous version. New in version 3 of the IFS GMF, however, are detailed requirements for monitoring the filling quantity. A suitable sampling plan must be developed here that is representative of the batch in question.
The chapter on measurements, analyses and improvements also includes requirements for blocking and release processes, complaint and crisis management and the handling of corrective measures in the event of deviations. In particular, the necessary definition of correction and corrective action in the event of non-conformity should be mentioned as a significant innovation in this standard.
Report and confirmation letter
Once the audit has been completed, the company receives a detailed report. What is new here is the mandatory information provided by the auditor on the so-called mandatory requirements, which are intended to improve the transparency and traceability of the assessment.
In addition to the report, the company will be provided with an action plan within two weeks, which lists all deviations and non-conformities identified. The company also has two weeks to submit an action plan to the certification body.
An unlabeled spray bottle, as shown here, is a non-conformity that must be rectified within three monthsCorrections and corrective actions
New in the IFS GMF is the necessary definition of corrections and corrective actions for each deviation. A correction is the immediate elimination of a deviation, e.g. the labeling of unlabeled spray bottles with disinfectants. The company has three months to do this.
The corrective action, on the other hand, is aimed at eliminating the cause of the nonconformity. In the example mentioned, for example, demonstrable training of employees on the labeling of chemicals. The company has until the follow-up audit to implement such corrective measures.
After passing the audit and returning the fully completed action plan on time, the audited company receives a letter of confirmation from the certification body that it has successfully passed the audit in accordance with IFS GMF. It is valid for one year.
A corrective action is aimed at the cause of a nonconformity, in the case of the unlabeled spray bottle this would be, for example, training employees on the correct labeling of chemicalsSummary and outlook
The structure of the new version 3 of IFS GMF is closer to IFS Food than the previous version and makes the transition easier. However, this change in structure and the expansion of the requirements catalog pose greater challenges for already certified companies. The now more far-reaching requirements must be implemented in the company. Given the usually thin staffing levels in small and medium-sized companies, bottlenecks can occur at this point. The use of external expertise can be helpful to better understand the changes and to support their implementation in operational processes. This approach, combined with comprehensive support from the company and operations management, forms the basis for rapid and successful implementation of the new catalog of requirements in the company.
