Position warehouse hygiene controls against HACCP principles and the BRCGS Storage and Distribution standard.
Warehousing & Procurement
Food-Grade Warehousing with Allergen Segregation, FEFO Rotation and Mock Recalls
Manage food-grade warehousing through allergen risk assessment and segregation, FEFO date rotation, lot traceability and mock recall exercises aligned with HACCP and BRCGS Storage and Distribution principles.
🗓️Duration5 training days
📚Content4 modules · 8 sessions
🎓On completionAccredited attendance certificate
About the programme
Course Overview
A single mis-picked allergen-containing pallet or a date-rotation shortcut that lets older stock sit behind newer deliveries can turn into a full product recall within days, and the difference is usually a control that was assumed rather than tested. This course builds food-grade warehouse management from hazard analysis and the BRCGS Storage and Distribution standard through to the daily discipline of allergen segregation, first-expired-first-out rotation and full lot traceability. Delegates assess allergen cross-contact risk across receiving, storage and picking, apply physical and procedural segregation matched to their own site layout, and configure rotation and traceability controls so the system enforces good practice rather than relying on memory. The course culminates in planning and running a mock recall, tracing a chosen lot from goods-in to consignee against a time target, and using the gaps it exposes to strengthen supplier assurance and hygiene controls before a real incident or external audit finds them first.
Expected Learning Outcomes
Assess allergen cross-contact risk across receiving, storage and picking and classify products by risk tier.
Apply physical, zone or time segregation, colour-coding and dedicated equipment to keep allergen lines apart from the general range.
Configure putaway and picking rules that enforce first-expired-first-out rotation instead of relying on operator memory.
Maintain one-up-one-down traceability that links inbound lot numbers to outbound consignments at pallet level.
Plan and run a mock recall that traces a chosen lot from goods-in to consignee within a set time target.
Convert mock recall and audit findings into supplier assurance checks and prioritised hygiene improvements.
Who Should Attend
Warehouse and technical managers responsible for food safety in a food or drink storage operation.
Quality assurance and quality control staff supporting a food-grade distribution centre.
Warehouse supervisors managing allergen segregation and stock rotation on a daily basis.
Third-party logistics providers handling food, drink or ambient grocery products for multiple customers.
Technical and compliance auditors preparing a site for a food safety standard assessment.
New product introduction and supply chain staff assessing allergen and shelf-life impact on storage.
Course Modules
Select any module to see its sessions and points.
01Food-Grade Warehousing and Hygiene Foundations
2 sessions · 8 points
Session 1Regulatory and Standards Framework
- Apply HACCP-based hazard analysis to warehouse activities such as receiving, storage, picking and dispatch.
- Map site controls against the requirements of the BRCGS Storage and Distribution standard.
- Define the roles of a technical manager and warehouse hygiene champion within the site's food safety structure.
- Document a food safety and quality management system that fits a storage and distribution operation rather than manufacturing.
Session 2Site, Building and Pest Control Standards
- Assess building fabric, sealed floors and loading bay design against food-grade storage requirements.
- Run a pest control monitoring programme and review trend data to catch a developing problem early.
- Set cleaning schedules and validation checks appropriate to a food storage rather than production environment.
- Manage maintenance and non-food activity on site without compromising hygiene zoning or product protection.
02Allergen Management and Segregation
2 sessions · 8 points
Session 1Allergen Risk Assessment
- Identify allergen-containing products and their cross-contact risk points across receiving, storage and picking.
- Map the 14 major allergens recognised in food information law against the site's current product range.
- Assess where shared equipment, totes or pick faces create a realistic cross-contact risk between products.
- Classify products into allergen risk tiers to drive segregation and handling decisions across the site.
Session 2Physical and Procedural Segregation
- Apply physical, zone or time segregation methods matched to the site's layout and available space.
- Use colour-coding and dedicated equipment to keep allergen-containing lines apart from the general range.
- Control changeover and cleaning procedures when the same area handles different allergen profiles at different times.
- Verify segregation effectiveness through periodic swab testing or a documented physical check regime.
03Stock Rotation, Traceability and Date Management
2 sessions · 8 points
Session 1FEFO Rotation and Date-Code Control
- Apply first-expired-first-out rotation rather than first-in-first-out wherever shelf life varies within a SKU.
- Configure putaway and picking rules so the warehouse system enforces FEFO rather than relying on operator memory.
- Manage mixed date codes within a single location and define the exception process when FEFO cannot be followed.
- Set short-shelf-life alerts that flag stock approaching its use-by or best-before date for priority release.
Session 2Traceability and Lot Genealogy
- Maintain one-up-one-down traceability that links inbound lot numbers to the outbound consignments they supplied.
- Record lot and batch data at goods-in, storage and dispatch so a pallet can be traced within a defined time.
- Reconcile traceability records against physical stock through a periodic test trace exercise.
- Design traceability data capture so lot identity survives a relabelling, repack or cross-dock step.
04Recall Readiness and Continuous Assurance
2 sessions · 8 points
Session 1Planning and Running a Mock Recall
- Build a recall plan that defines trigger criteria, roles and communication steps for a warehouse-level incident.
- Run a mock recall exercise that traces a chosen lot from goods-in through to consignee within a set time target.
- Identify gaps exposed by the mock recall, such as missing lot data or slow system queries.
- Report mock recall performance and corrective actions to technical and quality management.
Session 2Supplier Assurance and Continuous Improvement
- Verify inbound supplier allergen and quality declarations before goods are put away into storage.
- Schedule internal audits of allergen segregation, rotation and traceability controls between external assessments.
- Use non-conformance and near-miss data to prioritise the next hygiene or segregation investment.
- Brief warehouse teams on lessons learned from mock recalls and audits to keep controls current.
What the participant receives
4 course modules
A structured syllabus
8 training sessions
across 5 days
32 detailed points
Applied, detailed content
Accredited attendance certificate
On completing the programme
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