January 22, 2026

Food Safety Every Day, Not Just Audit Day

A Practical Path to GFSI Certification for Small and Mid-Size Food Manufacturers

For many food manufacturers, Global Food Safety Initiative (GFSI) requirements show up as a customer demand or a regulator’s directive. The need is clear; the path is not. Peg Dorn, WMEP Consultant and food safety expert, says the biggest advantage of doing it right from the start is time and cost. “It’s so much easier—and cheaper—to set it up correctly than to fix a system that was done wrong,” Peg explains. “Do it right, and you’ll get certified faster and reach the markets you need quicker.”

Start with the Right Scope: What Level of Certification Do You Actually Need?

Peg recommends starting with a clear scope by identifying exactly what requirements you need to meet. “Do you need a full-scale certification, or can we take baby steps?” she adds. “The level of certification drives the work, the timeline, and the resources.” This first step prevents overbuilding a program that’s more complex than necessary and ensures the approach fits your goals and capabilities.

Find Your Starting Line with a Gap Assessment

An onsite gap assessment establishes the starting line. For many small and mid-size food manufacturers, the gap assessment is often the first moment of clarity—turning confusion or concern into a manageable, step-by-step plan toward certification. During the assessment, review current processes, documentation, and facility conditions to identify what’s working and what’s missing. “It gives you a clear picture of the goal and helps you build a realistic plan,” she says. “That way, you’re not wasting time or money fixing the wrong things and you know what to expect.” The output: a prioritized roadmap aligned to GFSI, identifying what to keep, what to fix, and what to add—without overbuilding.

Build the Foundation: Start with a Solid HACCP Plan

Peg emphasizes that the HACCP plan becomes the foundation of everything that follows. It identifies where potential hazards exist, determines how to control them, and ensures those controls are working. “The HACCP plan is a risk assessment of your entire process and ingredients—and it’s required by regulators,” she notes. From there, Peg describes a “layered” approach that builds the system’s strength over time through core programs that make it reliable and audit-ready:

• Prerequisite Programs: These are the everyday practices that support food safety, such as sanitation, pest control, and employee hygiene.
• Management Systems: Elements like recall procedures, supplier approval, and contingency plans that help the business respond quickly and confidently if an issue arises.

It’s Not Enough to Plan—You Have to Prove It

Identifying hazards is only half the job—controlling them and proving control is the rest. “The goal isn’t to pass a test once,” Peg emphasizes. “It’s to set up processes that work every time. Ineffective controls can lead to recalls later.” Preventive controls turn the HACCP plan into daily practice. These include standard operating procedures (SOPs), metal detection, pasteurization, and other safeguards that keep food safe and compliant. Just as important is the documentation that proves those controls are working—temperature logs, metal detector checks, sanitation records, and internal audits. “When your records show that your system is under control at all times,” Peg explains, “you’re not just compliant—you’re confident your product is safe.”

Build Internal Capability Through Training and Mentorship

Not every manufacturer needs full-time food safety hires; some just need a coach. “Take advantage of outside experts who can mentor internal staff,” Peg says. “If a younger team member wants to learn, provide the training opportunity so you can develop effective, confident internal food safety owners.” She adds, “Personally, mentoring is my favorite part.”

Practice Makes Perfect (and Safer)

To stay ready year-round, Peg strongly recommends conducting internal audits regularly—and well before the regulatory auditor arrives. “Run a full-blown audit just like a registrar would,” she advises. “The goal isn’t to cram for a test—it’s to run a safe plant every day.” Internal audits give manufacturers the opportunity to catch issues early, strengthen confidence, and sustain compliance. Peg describes them as a “safe, no-danger way to critically assess operations and experience the process without the risk.” She adds, “You can find weak spots, correct them, and make sure your processes are truly working before someone else walks in the door.” Ultimately, she says, it’s about building a culture of continuous improvement. “Keep learning, keep tightening your systems—and make sure your company name never ends up in the news for the wrong reasons.”

Keep It Simple, Safe, and Sustainable

Having a clear scope, a practical plan, and disciplined steps makes all the difference. Skipping those can delay certification, overcomplicate your program, or even shut you out of key customer markets. Worse yet, poor systems can create dangerous—and costly—food safety risks. “My favorite word is simplify,” Peg says. “Build what you need, maintain what works, and pass without panic. Too many companies try to do everything—or worse, just go through the motions—and still miss what really matters.”

WMEP is a nonprofit consulting organization with a simple mission: help Wisconsin manufacturers succeed. Our advisors bring real-world industry experience and deliver practical solutions across three key focus areas: Growth, Operations, and People. Contact us to simplify your path to certification, strengthen your food safety systems, and build a program that works every day—not just audit day.