BRCGS Global Food Safety Standard, Issue 9. The Top 5 Non-Conformities of 2024-2025. Plus, the key causes of product recalls and a guide to securing compliance.

BRCGS has released its top non-conformities for 2024-2025. The data highlights where food production sites are most at risk of falling short. From equipment design to chemical handling, these common issues can threaten both compliance and consumer safety.

In this article, we explore the top five non-conformities reported under the BRCGS Global Food Safety Standard, Issue 9, alongside the leading causes of product recalls, and how your site can stay ahead with practical steps for compliance.

Understanding the Top Non-Conformities of the BRCGS Food Safety Standard (2024-2025)

In its 2024-2025 report on Achievements, Progress, and Impact, BRCGS has shared the top five non-conformities across its key standards, including the Global Food Safety Standard, Issue 9.  

At the top of the list is Clause 4.11.1, which asks that a factory’s “premises and equipment shall be maintained in a clean and hygienic condition.” This clause accounted for 4,715 non-conformities. 

Second is Clause 4.6.2. “The design and construction of equipment shall be based on risk, to prevent product contamination.” This clause accounted for 3,322 non-conformities. 

Third is Clause 4.9.1.1. “Processes shall be in place to manage the use, storage and handling of chemicals to prevent chemical contamination.” This clause accounted for 3,284 non-conformities. 

Clause 4.4.8 states that “Doors (both internal and external) shall be maintained in good condition.” This clause accounted for 3,007 non-conformities. 

Finally, Clause 4.4.1 asks that “Walls shall be finished and maintained to prevent the accumulation of dirt, minimise condensation and mould growth, and facilitate cleaning.” This clause accounted for 2,933 non-conformities. 

BRCGS Product Recalls (2024-2025)

The BRCGS Standard requires that certificated sites report any product recalls to the certification body responsible for their most recent audit in a timely manner. Sites must provide sufficient information to allow the certification body to assess whether certification can be maintained. At a minimum, the report must include: 

  • A description of the corrective action taken 
  • A root cause analysis 
  • A preventive action plan 

These elements must be submitted within 21 days of the recall date. 

Throughout 2024-2025, BRCGS-approved certification bodies investigated over 1,600 product incidents, categorised as follows: 

  • 78% – Food safety 
  • 16% – Storage and distribution 
  • 4% – Agents and brokers 
  • 1.5% – Packaging materials 
  • 1.5% – Other 

Key Causes of Product Recalls 

Below are the primary causes of product recalls, ranked from most to least frequent: 

1. Microbiological contamination 

2. Chemical contamination 

3. Physical contamination 

4. Allergen-related incidents 

5. Packaging and labelling issues 

6. Other reasons

7. Quality control issues 

Where did these Incidents Originate? 

BRCGS also provided data relating to the origin of these food safety incidents, tracing recalls back to three main areas: site, supplier, and unknown.

  • Packaging/labelling, physical contamination, and quality issues: Over 50% originated on-site 
  • Allergen-related incidents and microbiological contamination: Just under 50% originated on-site 
  • Chemical contamination: Around 30% originated on-site, with most traced back to suppliers 

Avoiding the Top Non-Conformities of the BRCGS Food Safety Standard (2024-2025)

Clause 4.11.1: The cleanliness of premises and equipment.

Focus on hard-to-reach areas that are often overlooked during routine cleaning. Using Detail Cleaning Equipment can make these tasks more manageable, allowing you to access awkward spaces – such as behind machines, inside narrow gaps, or beneath equipment. Just as important is fostering a culture of accountability. Encourage team members to take personal responsibility, understand the importance of food safety, and commit to continuous improvement across the site.

Everything You Need to Know About Detail Cleaning

Clause 4.6.2: Design and construction of equipment.

Opt for equipment that is hygienically designed, with minimal welds, joints, or hidden crevices. Collaborate closely with your Original Equipment Manufacturer (OEM) to verify the construction quality and suitability of each purchase. It’s also important to formalise your procurement process, so decisions are based on hygienic design, not just cost. Make sure team members at every level understand the reasoning behind these choices and the standards required.

Clause 4.9.1.1: Use, storage, and handling of chemicals.

It’s critical to keep an up-to-date inventory of the chemicals at your site, including efficacy information and relevant test results. During your upcoming audits, you can use then this information to prove the chemicals are fit for purpose and safe when used correctly. You also need to make sure COSHH assessments are in place and accessible, and that only trained operatives are handling hazardous substances. Another important step is to equip your team with chemical-resistant PPE.

Help Guide: Using, Storing & Handling Chemicals

Clause 4.4.8: The condition of internal and external doors.

Doors should be close-fitting and fully pest-proof, with any damage addressed immediately. A Wireless Monitoring System will allow you to track door status in real time, ensuring critical doors remain closed. This will support compliance and help to prevent stock loss. You should also consider installing antimicrobial door handles, push plates, and levers, as these surfaces can eliminate up to 99.9% of bacteria, offering a quick and easy way to drive standards of hygiene across your site.

Clause 4.4.1: The condition of factory walls.

The materials used for your factory walls needs to be hygienic and suited to a food production site. Carry out regular inspections to identify any areas in need of maintenance – ideally with your Hygiene Manager in tow, as it will be the Hygiene Team’s responsibility to keep the walls up to standard. It’s also important to assess anything fixed to the walls. Have you used hygienic mounting methods (e.g. magnetic mounting) or are there potential harbourage points.

Help Guide: Maintaining Your Factory Doors and Walls

Taking the Next Steps

The data from BRCGS’s 2024-2025 reporting period reveals the most common non-conformities relate to core hygiene and maintenance practices.

By learning from these trends, your site can take proactive steps to strengthen compliance, protect consumers, and ensure audit readiness.

If you would like support in this area or want to explore our wide range of products and solutions, you can contact us directly on 01473461800 or sales@klipspringer.com. Alternatively, complete the contact form below and a member of our team will be in touch. 

Foram Mehta, Global Standards Technical Manager at BRCGS, and Klipspringer Director, Alex Carlyon discuss Issue 9 of the BRCGS Food Safety Global Standard.

Using BRCGS audit data, they explore the root causes of the most common hygiene non-conformities and discuss what this tells us about the challenges we face in today’s industry.

WEBINAR: Practical Tips to Overcome the Top Hygiene Non-Conformities

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