Measuring, Analyzing, and Improving for IFS Standards

When it comes to food safety, hoping for the best simply isn’t good enough. The International Featured Standards (IFS) Food certification requires manufacturers to implement rigorous systems for measuring, analyzing, and improving every aspect of their operations. These continuous monitoring practices ensure that food safety and quality aren’t just maintained-they’re constantly enhanced. From conducting internal audits to managing product recalls, these systems form the backbone of a robust food safety culture that protects both consumers and brands.

Why measurement and analysis matter in food safety 🔗

The IFS Food Standard is built on the principle that what gets measured gets managed. IFS Food is a globally recognized certification system benchmarked by the Global Food Safety Initiative (GFSI), and it emphasizes continuous improvement through systematic measurement and analysis. Version 8 of the standard, which became mandatory in 2024, places even greater emphasis on proactive approaches to food safety, requiring companies to integrate measurement and analysis into their corporate culture.

These practices aren’t just about checking boxes for certification. They create a framework where problems are identified before they reach consumers, corrective actions are implemented swiftly, and lessons learned prevent future issues. This approach transforms food safety from a reactive process into a proactive system.

Internal audits as the foundation of compliance 🔗

Internal audits represent one of the most critical requirements in the IFS standard-so critical, in fact, that effective internal audits are designated as Knock-Out requirement number 8. This means failure to conduct proper internal audits automatically results in non-certification, regardless of performance in other areas.

What makes an internal audit effective 🔗

An effective internal audit program must be documented, implemented, and maintained to ensure all IFS Standard requirements are audited within a 12-month period, with execution not exceeding 15 months. The audit frequency should be risk-based, meaning that activities critical to food safety and product quality require more frequent auditing.

Companies preparing for IFS certification should conduct regular internal audits that simulate the official audit environment. These audits help identify lingering issues before external auditors arrive, allowing time for corrective actions. Mock audits provide practical rehearsals for staff and demonstrate to external auditors that the company takes a proactive approach to compliance.

Internal audits should cover all aspects of the production process, including food safety management systems, quality control measures, and compliance with regulatory requirements. The findings from these audits drive continuous improvement and help build a culture where food safety is everyone’s responsibility.

Process control and quality control systems 🔗

Process control ensures that every step of food production follows established procedures consistently. This includes maintaining standard operating procedures (SOPs) that clearly define how each production step should be carried out, using real-time monitoring systems with sensors and automated controls at critical control points, and implementing immediate corrective actions when deviations occur.

Quality control throughout production 🔗

Quality control operates at three key stages. Incoming material inspection examines raw materials for quality before they enter production, catching potential issues at the earliest possible point. In-process inspection conducts regular checks during production to ensure consistency and quality throughout the manufacturing process. Finally, final product inspection involves rigorous testing of finished products to verify they meet all quality standards before reaching consumers.

These quality control measures work together to create multiple checkpoints where potential problems can be identified and corrected, preventing defective products from advancing through the production chain.

Foreign body detection and prevention 🔗

Foreign body contamination remains one of the most common causes of food recalls. Over the past 20 years, foreign materials have been responsible for about one out of ten food recalls, with plastic fragments being the most frequent complaint. The IFS standard addresses this through Knock-Out requirement number 6, which mandates procedures to avoid contamination with foreign objects.

Detection technologies 🔗

Modern food manufacturers employ multiple detection technologies to catch foreign materials. Metal detectors use electromagnetic fields to identify ferrous and non-ferrous metals in food products, serving as a final line of defense before packaging. X-ray machines provide more comprehensive detection, identifying not just metals but also glass, stone, dense plastics, and bone fragments.

Visual inspection by trained personnel remains important for catching items that automated systems might miss. Sifters and screens create physical barriers to remove foreign materials based on size, particularly important for dry ingredients and powdered products.

Prevention strategies 🔗

Prevention is always better than detection. Best practices include inspecting equipment between batches, maintaining detailed procedures for opening ingredient packaging to prevent paper or plastic contamination, using color-coded and detectable utensils that can be easily identified if they enter the product stream, and conducting regular glass and brittle plastic audits to minimize breakage risks.

Product analysis and testing 🔗

Product analysis ensures that food products meet both safety and quality specifications through comprehensive testing. Microbiological testing identifies harmful bacteria, viruses, and fungi that could pose health risks to consumers. Chemical testing verifies the product is free from harmful chemicals and meets nutritional requirements. Allergen testing detects the presence of allergens to ensure accurate labeling and protect sensitive consumers.

These tests provide objective data about product safety and quality, supporting informed decisions about whether products can be released to the market.

Complaint handling systems 🔗

Effective complaint handling is essential for maintaining consumer trust and driving improvement. A robust complaint handling system includes several key steps. First, acknowledgment ensures consumers feel heard by promptly acknowledging complaints. Investigation follows, with a thorough examination to determine root causes rather than just symptoms.

Documentation creates detailed records of each complaint and the actions taken, building a database for trend analysis. Corrective action addresses immediate issues to resolve the specific complaint. Finally, improvement implements changes to prevent similar complaints in the future, turning problems into opportunities for enhancement.

This systematic approach transforms complaints from mere problems into valuable sources of information for continuous improvement.

Product recall procedures 🔗

Product recalls represent one of the most serious events a food manufacturer can face. IFS Knock-Out requirement number 9 mandates effective procedures for product withdrawal and recall. Companies must be prepared to act swiftly and decisively when a food safety issue is identified.

Elements of an effective recall plan 🔗

A comprehensive recall plan starts with identification, clearly defining the affected product and the reason for recall. Notification follows, with prompt communication to retailers, distributors, and consumers about the recall. Removal ensures affected products are quickly taken from shelves and inventory.

Disposal procedures safely eliminate recalled products to prevent further risk. Follow-up monitoring verifies the recall process was effective and implements corrective actions to prevent recurrence. The FDA explains that food recalls may be initiated due to contamination with disease-causing microorganisms, foreign objects, or failure to list allergens.

Companies must maintain detailed traceability systems that allow them to quickly identify which batches are affected and where they were distributed. This traceability is itself a critical IFS requirement, enabling rapid response when issues arise.

Control of non-conforming products 🔗

Non-conforming products are those that don’t meet required standards, and controlling them prevents unsafe or substandard products from reaching consumers. This includes identification through clear marking and segregation of non-conforming products, evaluation to determine whether products can be reworked, reprocessed, or must be disposed of, and disposition with documented decisions about what happens to non-conforming products.

Investigation identifies root causes to prevent similar non-conformities in the future, while documentation maintains detailed records of all non-conforming products and actions taken.

Building a culture of continuous improvement 🔗

The IFS standard isn’t about achieving a static state of compliance-it’s about fostering continuous improvement. This means regularly reviewing and updating procedures based on audit findings and new information, training employees consistently on both existing and new procedures, analyzing trends in audit findings, complaints, and non-conformities to identify systemic issues, and implementing corrective and preventive actions that address root causes rather than just symptoms.

Companies that excel in IFS certification view it not as a burden but as a framework for building operational excellence. They use the measurement and analysis requirements to drive genuine improvements in food safety and quality, creating value for their businesses while protecting consumers.

What do you think? How effectively does your organization integrate measurement and analysis into daily operations rather than treating them as separate audit requirements? What barriers prevent food manufacturers from moving beyond compliance to truly embrace continuous improvement culture?

References

1. https://www.ifs-certification.com/en/food-standard
2. https://www.qassurance.com/international-food-standard-ifs-information/
3. https://goaudits.com/blog/ifs-audits/
4. https://pmc.ncbi.nlm.nih.gov/articles/PMC10558841/
5. https://www.food-safety.com/articles/8501-controlling-foreign-object-hazards-in-food
6. https://www.fda.gov/food/buy-store-serve-safe-food/food-recalls-what-you-need-know