Food Manufacturing Glass and Brittle Material Audit Checklist [FREE PDF]

Glass and brittle material contamination is one of the most significant physical hazard risks in food manufacturing, capable of causing serious consumer injury and triggering costly product recalls. FDA FSMA 21 CFR 117, BRC Global Standard Issue 9, and SQF Code Edition 9 all mandate documented glass and brittle material control programs as a fundamental prerequisite program. This audit checklist provides a systematic approach to identifying, documenting, and controlling glass and brittle materia

  • Industry: Food Processing
  • Frequency: Monthly
  • Estimated Time: 45-60 minutes
  • Role: QA Manager
  • Total Items: 35
  • Compliance: FDA FSMA 21 CFR 117.135 - Preventive Controls for Human Food, BRC Global Standard for Food Safety Issue 9 Section 4.9.3, SQF Code Edition 9 Module 11.2.8, GMP 21 CFR 110.20 - Plant and Grounds, HACCP Codex Alimentarius CAC/RCP 1-1969 Rev 4 Principle 1

Glass and Brittle Material Register Verification

Confirm the glass and brittle material register is current, complete, and accurately reflects all items present in the facility.

  • Is a documented glass and brittle material register maintained and available for all production and support areas?
  • Has the glass and brittle material register been reviewed and updated within the last 30 days?
  • Does the register accurately reflect the current number and location of all glass and brittle material items in the audited area?
  • Are glass items categorized in the register by risk level (e.g., high risk - direct contact areas; low risk - enclosed non-contact areas)?
  • Are brittle plastics, ceramics, and other brittle materials included in the register in addition to glass?

Production Area Glass and Brittle Material Physical Inspection

Physically inspect all production areas for unauthorized glass items, damaged items, or items not on the register.

  • Are all light fittings in production areas fitted with shatterproof covers or shatterproof bulbs?
  • Are all glass light fittings, covers, and tubes free from cracks, chips, or damage that could lead to breakage?
  • Are there any unauthorized glass items (e.g., personal items, food containers, glassware) present in the production area?
  • Are all registered glass gauges, sight glasses, and instrument covers in good condition and free from cracks or chips?
  • Have any new glass or brittle material items been introduced to the production area since the last audit that are not on the register?
  • Are glass-containing windows or viewing panels in production areas either absent, protected with shatterproof film, or secured against breakage?

Packaging Area Glass and Brittle Material Control

Inspect packaging lines and areas for glass-containing packaging materials, equipment components, and brittle material risks.

  • Are glass packaging materials (e.g., glass bottles, jars) stored separately from non-glass packaging with defined segregation controls?
  • Is there a documented glass breakage procedure specific to the packaging area that is known by all operators?
  • Are glass bottle inspection systems (e.g., empty bottle inspectors, full bottle inspectors) operational and recently verified?
  • Are conveyors and guides in glass packaging areas free from metal-on-glass contact points that could cause chipping?
  • Are brittle plastic components on packaging equipment (e.g., timing screws, star wheels, guides) inspected for cracks or breaks?

Glass Breakage Incident Response and Procedures

Verify breakage procedures are documented, known by staff, and have been properly followed for any incidents since the last audit.

  • Is a written glass breakage response procedure posted or accessible in all production and packaging areas?
  • Have any glass or brittle material breakage incidents occurred since the last audit, and have they been documented in the incident log?
  • For any glass breakage incident since the last audit, was the minimum 3-foot (1-meter) contamination zone quarantined immediately?
  • Was a line clearance and supervisor sign-off completed before production restarted following any glass breakage incident?
  • Have all operators in this area been trained on the glass breakage response procedure in the last 12 months with training records on file?

Laboratory and QA Area Glass Control

Inspect quality control and laboratory areas for glass control measures and ensure lab glass does not migrate to production areas.

  • Is laboratory and QA area glassware maintained in a dedicated inventory with items individually identified or numbered?
  • Is laboratory glassware prohibited from being taken into production areas without a documented risk assessment and approval?
  • Are laboratory glassware items free from chips, cracks, or damage, and is damaged glassware disposed of in a dedicated sharps/glass waste container?
  • Are sample containers used for product sampling in production areas made from plastic or other non-glass, food-safe material?

Maintenance and Engineering Glass Controls

Verify that maintenance activities involving glass or brittle materials are controlled to prevent introduction of physical hazards.

  • Is there a permit-to-work or work order system in place that requires glass/brittle material risk assessment before any maintenance work in production areas?
  • Are gauge glasses, sight glasses, and flow indicators on process equipment registered, covered, or fitted with protective guards where possible?
  • Are maintenance staff aware of and trained on the glass and brittle material control policy and breakage response procedure?
  • Are engineer and maintenance tool kits inspected for glass or brittle material items before entry into production areas?
  • Are glass thermometers prohibited from production areas, with digital or stainless-steel thermometers used exclusively?

Audit Closeout, Non-Conformances, and Corrective Actions

Document all findings, non-conformances identified during the audit, and assign corrective actions with responsible parties and due dates.

  • Were any non-conformances or unregistered glass/brittle material items identified during this audit?
  • Have corrective actions been assigned to responsible parties with specific due dates for all identified non-conformances?
  • Has the glass and brittle material register been updated during or immediately following this audit to reflect current conditions?
  • Have photographs been taken of any damaged, unregistered, or non-conforming glass or brittle material items found during the audit?
  • Please provide a summary of all findings, non-conformances, corrective actions assigned, and any immediate actions taken during this audit.

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Why Use This Food Manufacturing Glass and Brittle Material Audit Checklist [FREE PDF]?

This food manufacturing glass and brittle material audit checklist [free pdf] helps food processing teams maintain compliance and operational excellence. Designed for qa manager professionals, this checklist covers 35 critical inspection points across 7 sections. Recommended frequency: monthly.

Ensures compliance with FDA FSMA 21 CFR 117.135 - Preventive Controls for Human Food, BRC Global Standard for Food Safety Issue 9 Section 4.9.3, SQF Code Edition 9 Module 11.2.8, GMP 21 CFR 110.20 - Plant and Grounds, HACCP Codex Alimentarius CAC/RCP 1-1969 Rev 4 Principle 1. Regulatory-aligned for audit readiness and inspection documentation.

Frequently Asked Questions

What does the Food Manufacturing Glass and Brittle Material Audit Checklist [FREE PDF] cover?

This checklist covers 35 inspection items across 7 sections: Glass and Brittle Material Register Verification, Production Area Glass and Brittle Material Physical Inspection, Packaging Area Glass and Brittle Material Control, Glass Breakage Incident Response and Procedures, Laboratory and QA Area Glass Control, Maintenance and Engineering Glass Controls, Audit Closeout, Non-Conformances, and Corrective Actions. It is designed for food processing operations and compliance.

How often should this checklist be completed?

This checklist should be completed monthly. Each completion takes approximately 45-60 minutes.

Who should use this Food Manufacturing Glass and Brittle Material Audit Checklist [FREE PDF]?

This checklist is designed for QA Manager professionals in the food processing industry. It can be used for self-assessments, team audits, and regulatory compliance documentation.

Can I download this checklist as a PDF?

Yes, this checklist is available as a free PDF download. You can also use it digitally in the POPProbe mobile app for real-time data capture, photo documentation, and automatic reporting.

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