Know: Equipment Calibration

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Equipment Calibration

Definition

Equipment calibration is the process of assessing and adjusting measuring devices to ensure their accuracy and reliability within predetermined limits. In food manufacturing, calibration is essential for maintaining the safety, legality, and quality of products, as required by both regulatory and certification standards, such as the BRCGS Food Standard. By calibrating equipment, manufacturers can achieve confidence in their measurements and maintain compliance with industry expectations.

Practical Application

Effective calibration and control of measuring and monitoring devices is critical for ensuring food safety and compliance. The key applications include:

1. Documenting Equipment
   Food manufacturers must maintain a comprehensive, documented list of all measuring devices used to monitor critical control points (CCPs) and ensure product safety, legality, and quality. Each device should include:

• A unique identification code.
• Its physical location within the facility.
• The calibration due date.

This documentation not only allows for reliable calibration to schedule, but aids traceability and also ensures readiness for audits and inspections.

2. Protection from Misuse and Damage
   Measuring equipment must be protected from unauthorised adjustments, physical damage, and deterioration. To meet these requirements, manufacturers should:

• Implement security measures, such as locking mechanisms or software restrictions, to prevent unauthorised adjustments.
• Install physical barriers or designated storage locations to minimise the risk of damage or misuse.
• Train employees on the proper handling, use, and storage of sensitive equipment.

3. Calibration Frequency and Risk Assessment
   Calibration schedules must be defined based on risk assessments that account for:

• The frequency of equipment use.
• The potential impact of measurement inaccuracies on product safety or quality.
• Environmental conditions that could influence measurement performance.

For example, thermometers used at CCPs in a HACCP plan might require monthly or even weekly calibration (or verification), while less critical equipment may be calibrated annually.

4. Traceability and Standards Alignment
   Calibration methods should be traceable to recognised national or international standards wherever possible. For example:

• Temperature sensors can be calibrated using reference thermometers traceable to UK’s National Physical Laboratory (NPL) standards.
• pH meters might use certified buffer solutions traceable to ISO or NIST standards.

This ensures consistent and reliable measurements across all facilities.

5. Documentation of Calibration Results
   All calibration activities must be thoroughly documented, including:

• The calibration date and results.
• The person or organisation responsible for the calibration.
• Details of any adjustments made and the subsequent results.

These records are essential for demonstrating compliance during audits and provide evidence of due diligence in the event of product safety issues.

6. Corrective Actions for Out-of-Limit Results
   Procedures must be in place to address instances where measuring devices are found to operate outside specified limits. These should include:

• Immediate recalibration or replacement of the faulty device.
• Evaluation of any products produced since the last successful calibration to assess potential safety or quality risks.
• Implementation of corrective and preventive actions to avoid recurrence, such as more frequent calibration or enhanced staff training.

For instance, if a miscalibrated weighing scale leads to underfilled product packages, the affected batch must be reviewed to ensure compliance with labelling laws, and subsequent calibrations should be conducted more frequently.

Related Concepts

Measurement Uncertainty: The uncertainty of calibration must be assessed and documented, especially when the device is used to monitor critical limits.
Preventive Maintenance: Calibration should be integrated with routine maintenance schedules to maintain the performance and reliability of equipment.
Validation and Verification: Calibration confirms that equipment operates within its intended specifications, supporting overall validation and verification processes in food production.

Conclusion

By aligning equipment calibration practices with national and international standards, food manufacturers can enhance confidence in their measurement systems, maintain compliance with regulations, and protect product integrity. Systematic calibration practices not only reduce the likelihood of product non-conformances but also strengthen overall operational efficiency and consumer trust.

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