Your Trusted Partner for BRCGS Certification

BRCGS Packaging certification applies to any operation that manufactures or converts packaging materials. This includes producers of food packaging (e.g. bottles, wrappers, cans), packaging for hygiene-sensitive products (like cosmetics or pharmaceuticals), and packaging for other consumer goods.

Whether you make flexible plastics, paper cartons, metal cans, glass containers, or any packaging material that will come into contact with food or other products, the BRCGS Packaging Standard is designed for you.

Notably, Issue 7 of the Packaging Standard (released October 2024) extended its focus to contemporary concerns like product authenticity, allergen management, and sustainability, while reinforcing fundamentals like risk assessment and traceability. All audits from April 2025 onward use Issue 7, ensuring the standard stays current with industry trends.

The BRCGS Packaging Standard outlines a comprehensive set of requirements in its protocol (primarily in Part II of the Standard). Major focus areas include:

• Senior Management Commitment: Top management must be fully committed to the standard. This includes establishing a clear food safety and quality policy, setting objectives, providing resources, and fostering a culture that supports safety. An effective product safety culture plan is required, and management should review it and continually improve it. (Lack of an effective culture plan is a common non-conformance in audits, so leadership involvement here is critical).

• Hazard and Risk Management: The facility must implement a documented hazard analysis and risk assessment (HARA) for its processes, equivalent to a HACCP plan for packaging. All potential hazards (physical, chemical, microbiological, and allergen risks related to packaging) need to be identified, and control measures must be put in place. This risk-based approach ensures that packaging materials are safe and meet legal requirements for food contact.

• Product Safety & Quality Management System: You need a robust management system that documents all policies, procedures, and records to show compliance. This includes document control, record-keeping, internal audits, corrective action processes, complaint handling, and incident management. The system should cover how you manage product quality from raw material sourcing through to finished packaging, ensuring traceability and consistent quality.

• Site Standards: The factory environment and infrastructure must be suitable and well maintained to prevent product contamination. This covers the construction and layout of buildings, cleaning and sanitation, pest control, waste management, and equipment maintenance. For example, facilities should have smooth, cleanable surfaces and proper separation of operations to avoid any contamination of packaging materials. (Auditors often find issues in this area, such as poor premises hygiene or temporary “quick fix” repairs like tape on equipment – these must be addressed with proper maintenance plans.)

• Product and Process Control: All process steps should be carried out under controlled conditions. You need documented process specifications and quality checks at appropriate stages (e.g. incoming material inspection, in-process quality checks, and final product testing). Any critical variables (like sealing temperatures, curing times, etc., depending on packaging type) should be monitored. Change control and control of non-conforming product (e.g. how you handle any packaging that falls out of spec) are also key.

• Personnel: Employees must be adequately trained, and high standards of personal hygiene must be enforced. The standard requires training programs for all staff whose work can affect product safety or quality – this includes training on GMP, allergen handling (if applicable), and product defense. Operators should understand the hazards associated with their tasks. Additionally, the standard specifies requirements for staff facilities (handwashing stations, hygiene zones, protective clothing, etc.) to ensure personnel do not contaminate products. (Note: In BRCGS Packaging audits, issues like poor personal hygiene or incomplete training records are frequently noted, so companies should pay close attention to this area.)

• Traded Goods (Brokered Products): If the packaging plant also trades finished packaging products that it did not manufacture on site, there are requirements to approve and monitor those suppliers. Essentially, you must ensure any outsourced or purchased-for-resale packaging meets the same safety and quality criteria, through supplier approval processes and specifications.

The audit protocol for BRCGS Packaging is similar to other BRCGS standards: an on-site audit (announced or unannounced) is conducted against all these requirements, and any non-conformities must be addressed to achieve certification. The result is a grade (AA to C) depending on the number and severity of non-conformities, and a certificate valid for 12 months (with re-audits annually). We will cover more on the audit process and grading in later sections.

Kiwa-asi provides a structured set of services to guide manufacturers through the preparation, audit, and maintenance phases of BRCGS Packaging certification:

• Certification Audits: They perform the official, on-site audit against the BRCGS Global Standard for Packaging Materials. Passing this rigorous audit—which reviews documentation, facility standards, staff practices, and product safety systems—is required to achieve certification.

• Expert Auditors: They provide highly experienced and qualified auditors with deep knowledge of the BRCGS standards and industry regulations. These auditors are essential for evaluating compliance with criteria like Hazard Analysis and Risk Assessment (HARA), site standards, personnel training, and product safety management.

• Pre-Assessments/Gap Analysis: Kiwa-asi offers optional preliminary audits or pre-assessments. This service helps a company compare its current operations against the BRCGS requirements, identify non-conformities or "gaps" early, and fix them before the official, higher-stakes certification audit.

• Global Recognition and Listing: As an accredited CB (e.g., UKAS Accredited for Kiwa UK), a certificate issued by Kiwa-asi ensures the manufacturer is globally recognized and, upon successful completion, the facility is listed in the official BRCGS Directory. This helps the manufacturer access major global retailers and brands that require this certification.

• Ongoing Support and Compliance: They provide continuous support, resources, and guidance to help companies maintain compliance post-certification. This includes information on updates to the BRCGS standard (like the new Issue 7) and scheduling the required periodic surveillance audits (typically annual or semi-annual) to ensure ongoing adherence to the standard.

In essence, Kiwa-asi is the independent verification partner that assesses a packaging manufacturer's compliance, granting the certification that demonstrates their packaging is produced under safe, legal, and quality-controlled conditions, thus safeguarding consumers and brand reputation as outlined in the BRCGS scope.

Start by getting the most current issue of the BRCGS standard for your scope. For example, if you’re pursuing packaging, obtain BRCGS Packaging Materials Issue 7; for storage & distribution, get Issue 4. The standards can be purchased or downloaded from the official BRCGS website or obtained via training courses. This gives you the detailed requirements and protocols you'll be audited against.

Perform an internal review of your current practices versus the BRCGS requirements. This is essentially a gap analysis. Go clause by clause through the standard and identify where you meet the requirement and where you have gaps. It’s wise to involve a cross-functional team (quality, production, warehouse, etc.) in this exercise. Many companies use a checklist or hire a consultant to do a preliminary gap assessment. As part of this, ensure you have all prerequisite programs in place. For instance, confirm you have: a current, validated HACCP (or HARA) plan; a documented food safety & quality manual; records of internal audits with corrective actions completed; management review meeting minutes; a supplier approval program; traceability test results (e.g. a successful mock recall); allergen control procedures; staff training records; maintenance and calibration logs; and cleaning/sanitation programs. These foundational programs are expected to be functioning before your certification audit.

Based on your self-assessment, begin implementing changes to meet BRCGS requirements. This could involve writing or updating procedures, improving facility conditions, providing training to employees, upgrading equipment, or enhancing record-keeping.

For example, if you found a gap in traceability, you might implement more robust lot tracking software or conduct training on recall procedures. If allergen management was insufficient, you might segregate allergenic materials and update cleaning protocols. This step can take a few weeks to several months depending on how many changes are needed and the size of your operation.

In the U.S., you must use an accredited BRCGS certification body to perform the audit. Choose a CB that is licensed for BRCGS and has auditors knowledgeable in your industry. Many are available – for instance, ASI Food Safety (in partnership with Kiwa, a BRCGS-accredited certifier) offers BRCGS audits in the U.S. You’ll want to contact the CB and get a quote and proposal.

When selecting, consider factors like their availability, expertise in Packaging vs Distribution standards, and cost. Note that the auditor must be impartial – they cannot have consulted for you – and the CB will need details about your facility size, number of employees, and processes to determine audit duration.

Many companies opt for a pre-assessment audit (also known as a preliminary or practice audit) before the official certification audit. This is essentially a “mock audit” where an auditor (often from the CB, but in an unofficial capacity) or a consultant evaluates your readiness.

The benefit is that you can identify any remaining gaps without the results going on record. If any major issues are found, you can fix them prior to the real audit. Pre-assessments are optional but recommended – they give you a trial run and confidence. Importantly, findings in a pre-assessment do not affect your certification result; they’re for your improvement only.

Work with your chosen CB to schedule the audit. You can choose an announced audit (you agree on a date with the auditor) or go for the unannounced audit option. In an announced audit, you’ll have a set date to prepare for, but keep in mind that at least once every 3 years an unannounced audit is mandatory for GFSI schemes like BRCGS. Some companies choose unannounced audits to demonstrate extra transparency (or because certain customers require it).

On the audit day(s), the auditor will review documents, tour the facility (storage areas, production lines, warehouses, trucks, etc.), and interview employees. The audit covers all sections of the standard. For Packaging and Storage/Distribution, audits typically last 1-3 days depending on facility size and scope.

After the audit, the auditor will issue a report with any non-conformities (NCs) found. These are categorized usually as minor, major, or critical. You typically have a limited timeframe (e.g. 28 days) to address all non-conformities and submit evidence of corrections to the CB.

Corrective actions might include revising a procedure, providing missing records, fixing a facility issue, or retraining staff – whatever is needed to fix the problem. It’s crucial to not just fix the issue but perform a root cause analysis so that it doesn’t recur. The auditor (or CB review team) will evaluate your corrective action responses to decide if they are satisfactory.

Once all NCs are addressed, the certification body will issue your BRCGS Certificate and assign a grade (AA, A, B, C, etc., based on how many NCs and whether it was announced or unannounced). Grades range from AA (no or very few minor NCs) down to C.

The certificate is valid for 12 months, and your facility will be added to the official BRCGS Directory of certified sites. This directory listing is important because many buyers check it to confirm a supplier’s certification status.

Certification is not one-and-done; you must maintain compliance and prepare for annual audits to remain certified. This means continuing your internal audits, management reviews, updating your programs for any changes (e.g. new equipment or products), and generally fostering an environment of continuous improvement. Surveillance or recertification audits will occur roughly every 12 months.

If you received a lower grade (e.g. B or C), the audit frequency might increase (sometimes 6 or 9 months) until you improve your grade. Also, remember that one audit every 3 years will be unannounced – so always be “audit-ready” by keeping your programs in daily practice, not just for show when an audit is coming.

Throughout this process, communication with the certification body and utilization of resources like BRCGS webinars, guidance documents, and training courses can be invaluable. BRCGS publishes interpretation guidelines and has an FAQ for new issues – these can help clarify expectations. Additionally, consider joining industry forums or groups, as many U.S. companies share their BRCGS audit experiences and can provide insight into what to expect.

By following these steps diligently, getting BRCGS certified in the USA can be a smooth process. Many facilities report that the preparation journey itself greatly strengthens their operations, even before the auditor arrives. And once certified, you’ll have a robust food safety/quality system that not only passes audits but truly improves your business.

Challenge: Demonstrating an active, effective food safety and quality culture is now a focus area in BRCGS audits. Auditors often cite companies for failing to evaluate the effectiveness of their culture plan (for example, not tracking culture improvements or lacking employee feedback mechanisms).

Tip: Engage senior management to champion a Culture Improvement Plan. Set clear objectives (e.g. improve training participation or decrease safety incidents), monitor progress (through surveys, KPI trends, etc.), and adjust your plan annually. Encourage employee involvement and recognition in food safety practices. Being able to show the auditor tangible evidence, like culture survey results or meeting notes where culture is discussed, goes a long way.

Challenge: Supplier management is a common weak point. BRCGS expects robust supplier approval and monitoring programs, yet some companies have gaps like incomplete supplier documentation or not conducting regular supplier performance reviews. Clause 3.5/3.7 issues (depending on standard) for supplier approval are frequently cited.

Tip: Maintain a documented list of approved suppliers for all materials (including packaging raw materials or items stored). Collect up-to-date certifications or audits for those suppliers. Implement a schedule to review supplier performance (e.g. annually check for any recalls, quality issues, on-time delivery). Also, have contingency plans for unapproved supplier use (with risk assessment). Being thorough here not only avoids NCs but also prevents upstream problems that could affect your product.

Challenge: Incomplete traceability is often noted as a non-conformance. You must trace products from raw input to finished goods and distribution, and conduct test recalls. Companies sometimes fail to code products properly or can’t retrieve records quickly during an audit.

Tip: Implement a lot coding system that links materials to finished product and to customer shipments. Do mock recalls at least annually and ensure you can retrieve necessary data (like which lots went to which customers) within the 4-hour window BRCGS mandates. Document these tests and any improvements made. During the audit, when the auditor does a traceability challenge, have staff practiced in pulling records from your ERP or files quickly. Good traceability not only meets BRCGS requirements but is crucial under FDA regulations too, so it’s doubly important for U.S. firms.

Challenge: A significant portion of non-conformities (in BRCGS Packaging, over half) relate to facility and equipment issues – e.g. building fabric, cleaning, and sanitation failures. Common problems include accumulation of dust on overheads, use of temporary fixes like duct tape on equipment, inadequate cleaning schedules, or pest control lapses. Storage facilities might be cited for damaged walls or improper separation of goods.

Tip: Adopt a preventive maintenance program that quickly addresses any damage – if you must do a temporary repair, document it and set a due date for permanent fix. Include ceilings, overhead structures, and hard-to-reach areas in your master sanitation schedule (cobwebs or peeling paint overhead are red flag). Keep detailed cleaning records and verify that cleaning chemicals are used correctly per their instructions. Also, ensure an effective pest management program with regular monitoring by a licensed pest control provider – auditors will check for any signs of infestation and how you respond.

Challenge: Auditors often find that documentation isn’t properly controlled – for example, uncontrolled copies of procedures, or forms with missing information and signatures. Incomplete record-keeping (missing dates, not following your own record review procedures) is another frequent issue.

Tip: Treat your documents and records like gold – implement a document control procedure (version numbers, approvals, distribution lists) and regularly audit it. Train staff on how to fill out records completely (every field, every time). Supervisors should routinely review records for accuracy and completeness (e.g. production logs, sanitation records). Keep a checklist of required records and do internal spot-checks. For any critical control or monitoring logs, ensure there’s a verification signature. Good documentation not only passes audits but also helps you run the business better with less risk.

Challenge: In packaging or distribution, you might handle a variety of materials, and if any pose allergen risks or could contaminate others (e.g. strong odors, powders, etc.), auditors will look at how you control that. Common gaps are lack of allergen cleaning validation or storing allergenic product next to non-allergen without separation.

Tip: Identify any allergens in your facility (e.g. if you’re a packaging printer using soy-based ink, or a warehouse storing products containing peanuts). Implement clear labeling and segregation for allergenic materials. If you change over from an allergen to non-allergen product (more applicable in food production, but sometimes in packaging if using shared equipment for different markets), have cleaning procedures that are validated to remove allergen residues. Even for non-allergen contamination, consider cross-contact controls – e.g. odor barrier, dust containment, etc., as relevant. Demonstrating a proactive approach to prevent cross-contamination will satisfy many requirements that might otherwise be findings.

Challenge: Auditors frequently interview employees on the floor. A common challenge is when front-line staff can’t answer basic questions about policies (like “What do you do if glass breaks?” or “Where do you wash your hands?”) or when observed practices don’t match the written procedure. Personal hygiene issues (no hairnet, jewelry, etc.) are also frequently cited.

Tip: Train and rehearse with your team before the audit. Do mini “mock interview” sessions with employees so they aren’t nervous and can confidently describe their job’s impact on product safety. Emphasize key rules like handwashing, foreign material control, and reporting problems to supervisors. Enforce dress code and hygiene rules consistently – not just on audit day. A strong culture (as noted earlier) will mean employees naturally follow rules and take ownership of safety. Also ensure any required training (like HACCP awareness, food defense, etc. for supervisors) is up to date and documented. During the audit, a confident and knowledgeable team leaves a great impression and often prevents minor issues from escalating to major ones.

Challenge: The possibility of an unannounced audit can be daunting – it means you must be in compliance at all times, not just when expecting the auditor. Companies have struggled when surprise audits occur and key staff are on vacation or records are not readily available.

Tip: Build an “always ready” mindset. This includes cross-training staff so there’s always someone who can cover key roles (e.g. if the QA manager is out, who can talk to the auditor?). Keep critical documentation organized and accessible at all times – consider digital document management for easy retrieval. Conduct regular internal audits on random dates to simulate an unannounced visit. Also, maintain a notification protocol: for example, if an auditor shows up, reception notifies management immediately, and your pre-assigned audit team gathers. When your daily practices align with BRCGS requirements as routine, an unannounced audit becomes much less scary. Remember, unannounced audits are required at least every 3 years, so it’s not “if” but “when”.

A: BRCGS offers different standards for different parts of the supply chain. The Packaging standard is for manufacturers of packaging materials – it focuses on factory GMP, product quality, and safety of packaging products themselves. In contrast, the Storage & Distribution standard is for companies that store, handle, or transport products – it ensures safety and quality during warehousing and transit, without altering the product.

If your business makes food packaging or any type of packaging, you’d pursue BRCGS Packaging certification. If your business is a warehouse or logistics provider for food/consumer goods, you’d pursue BRCGS Storage & Distribution certification. Some companies might need both (for example, a packaging manufacturer might also have a separate distribution operation), but typically the scope of each certificate is distinct. Choose based on your role in the supply chain: producers get Packaging, logistics providers get Storage & Distribution.

A: The cost can vary depending on your facility size, number of employees, and complexity of operations (which drive the audit duration), as well as the certification body’s day rates. Generally, you should budget for auditor daily fees, travel expenses, and an annual BRCGS administrative fee (registration fee). According to industry guidance, expect to pay for the audit itself (often an audit is 2 days on-site plus report writing off-site), plus any consultant or training costs you incur preparing. As a rough estimate, small single-site audits might range a few thousand dollars, while larger multi-day audits can be more.

Costs depend on scope and audit length, and you should expect daily audit fees, travel, and the BRCGS fee as components. It’s best to request a quote from a certification body; many will provide a free quote tailored to your site.

A: The timeline includes preparation and the audit process. Preparing for the first certification can take anywhere from a couple of months to over a year – it largely depends on your starting point. If you already have a robust food safety system (like ISO 22000 or another GFSI certification), it could be quicker. If starting from scratch, give yourself at least 6-12 months to implement all requirements comfortably.

Once you feel ready and schedule the audit, the audit itself might be 1-3 days. After the audit, if there are non-conformities, you typically have up to 28 days to address them. Once you submit corrections, the certification decision and certificate issuance might take a couple of weeks.

In total, from the audit date, certification is usually issued within weeks after successful closure of any findings. The key variable is the prep time before the audit – don’t rush that; it’s better to postpone an audit than to undergo one unprepared and possibly fail.

A: If you have critical non-conformities (or too many majors), you might not achieve certification on the first try. In such cases, you will need to fix the issues and usually undergo a partial or full re-audit on those failed elements. For less severe outcomes, you might still get certified but with a lower grade (B, C) and a shorter certificate validity (meaning another audit sooner).

The good news is BRCGS allows you to take corrective actions and still succeed – you are typically given a chance to address all non-conformities after the audit. If you respond adequately and in time, you can still get certified without a re-audit (except if a critical is issued – critical = automatic failure). Major non-conformities must be corrected and evidence provided; sometimes a follow-up visit is required for verification.

If you completely fail, you can reapply for certification once you’ve improved (there may be a slight waiting period). It’s not uncommon for initial audits to have several findings – the key is responding effectively. Engage your auditor in understanding each problem and seek their guidance on what will be acceptable as a fix. Remember, the goal is improvement, not punishment.

A: Audit grades in BRCGS range from AA, A, B, C, D (for announced audits) and slightly different for unannounced (AA* for unannounced top grade). The grade is based on the number and level of non-conformities found. Grade AA means very few minors (5 or fewer minors and no majors), A allows a few more minors, B might indicate a couple of majors or a larger number of minors, etc. In general, AA is the highest (excellent compliance) and C is the lowest pass grade (meaning many issues were found but corrected). If you have too many non-conformities, you might not certify at all (D or uncertified). Lower grades also shorten the time until the next audit – for example, an A or B grade might get 12 months, whereas a C grade often requires a re-audit in 6 months.

In summary: AA = 5 or fewer minors, A = 6-10 minors, B = some majors (1-3) or more minors, etc., and anything critical = fail. BRCGS grades are a quick snapshot of how well you met the standard on audit day. Many companies aim to improve their grade over time. But even at a lower grade, you are considered certified – you just need to work on those deficiencies.

A: You have options. For your initial certification audit, it will almost always be announced (scheduled). After that, you can continue with announced annual audits, however BRCGS (aligned with GFSI rules) requires that at least every 3rd audit be unannounced if you stay in the announced program.

There is also an unannounced audit program you can voluntarily opt into, where your audits are randomly unannounced within a window each year (and you often get a grade with a “+” or asterisk to denote the distinction, which some retailers view favorably). In the U.S., most companies do the announced audits for convenience and prepare for the one unannounced every 3 years. When it’s time for an unannounced audit, the certification body will simply arrive during a specified timeframe (you usually provide blackout dates for when you’re not operational).

It’s important to always be prepared and maintain the system so that an unannounced audit can be passed any day. If an unannounced audit attempt happens and the site refuses (e.g. you send the auditor away), typically your certificate is downgraded or suspended, so planning for it is key. In short: yes, unannounced audits are a reality, but you can manage the process with your CB to minimize disruption.

A: BRCGS audits are comprehensive and consultative in nature. Unlike FDA inspectors who are enforcing regulations, BRCGS auditors are assessing against a private standard that often goes above regulatory minimums. Many U.S. companies find that if they perform well in a BRCGS audit, an FDA FSMA inspection or other customer audit tends to go smoothly because you’ve already implemented rigorous controls (HACCP, sanitation, allergen control, etc.).

However, BRCGS audits are typically more in-depth on documentation and process detail than a basic FDA GMP inspection. They also result in a certification (if you pass) and a grade, whereas FDA inspections result in a report of observations (or none if all is well). One should not replace the other, but being BRCGS-certified usually means you are in excellent shape compliance-wise.

Do note that BRCGS audits, being third-party, are scheduled events (except the unannounced aspects), while FDA can show up at any time. It’s wise to train your team to handle both with confidence. But certainly, the BRCGS framework aligns with FDA food safety plans and good practices – for example, both require a form of hazard analysis and preventive controls, both care about sanitation, etc., so there is synergy in meeting both.

A: After getting certified, you’ll need to undergo audits at least annually to renew your certification before it expires. Maintenance involves several ongoing activities:

• Internal audits: Conduct your own internal audits covering the entire standard at least yearly (many do it in sections throughout the year). This catches issues early.

• Management review: Have management review meetings at least annually to go over the performance of the system (complaints, audit results, KPIs, etc.), as required by the standard.

• Corrective actions: Promptly address any minor issues before they grow. If you got non-conformities in your last audit, ensure those areas are solidly fixed and monitor them.

• Stay informed: Keep up with any BRCGS standard updates or position statements. (For instance, BRCGS occasionally releases Position Statements that clarify rules – like the P618 mentioned in a top 10 NC lists. Staying updated on those is important.)

• Training and refreshers: Continue training new employees and refreshing current ones on food safety practices. Maybe have annual refreshers on allergen control, hygiene, or forklift safety – whatever is pertinent.

• Surveillance audits: Some certification bodies might do a mid-year check (not always for BRCGS, but if you had many issues, they might). Always address any observations they note.

• Essentially, embed BRCGS requirements into daily operations. The companies that do best are those that treat BRCGS as part of how they operate, not a once-a-year project. If you do that, each audit will feel more like a validation than an examination.

Maintaining certification is an ongoing commitment, but it becomes second-nature as your food safety management system matures. Many U.S. companies use the discipline of BRCGS to drive continuous improvement – by the time the next audit comes, they’ve already tackled previous gaps and perhaps even implemented new best practices, keeping them on the forefront of food safety and quality.