Employee Onboarding Guide

Welcome to Bernard Food Industries. This guide covers everything you need to know about working safely and effectively in our dry mix manufacturing facility.

Bernard Food Industries, Inc. • Confidential • Rev. February 2026

Contents

  1. Quick Start (Read This First)
  2. Welcome to BFI
  3. 30 Critical Mistakes to Avoid
  4. Safety Requirements
  5. Good Manufacturing Practices (GMPs)
  6. Personal Hygiene & Dress Code
  7. Allergen Awareness
  8. Our Products & Processes
  9. Sanitation Responsibilities
  10. Quality Control Basics
  11. Emergency Procedures
  12. Role-Specific Training Paths
  13. Your 30 / 60 / 90 Day Roadmap
  14. Day One Checklist & Acknowledgment

0. Quick Start (Read This First)

BFI Rule #1: Food Safety Comes Before Speed If you are ever unsure, STOP and ASK. We would rather lose 2 minutes than risk a recall.
1

Show Up Ready

Arrive on time. No jewelry. Closed-toe shoes. Clean clothes.

2

Wash + Gear Up

Hand wash + hairnet/smock before entering any production area.

3

Follow the Buddy

You will shadow a training buddy. Do not operate equipment until signed off.

Your Authority: STOP THE LINE Every employee has the authority and responsibility to stop production if food safety, allergen control, labeling, or employee safety is at risk. You will never be punished for stopping a line in good faith.

1. Welcome to BFI

Bernard Food Industries has manufactured shelf-stable dry mix products since 1947. Our products are used by schools, hospitals, military personnel, correctional facilities, and families nationwide. Because our products reach vulnerable populations, we operate with a simple standard:

The BFI Standard We produce every batch as if it will be eaten by someone in a hospital or a school cafeteria tomorrow. That is the level of care we expect from every employee, every shift, every day.

What “World-Class” Looks Like Here

  • Clean: Our facility stays clean enough to pass an audit any day — not just before inspections.
  • Controlled: We follow formulas, lot tracking, and allergen controls with discipline.
  • Consistent: Our product must perform the same every time, in every batch, for every customer.
  • Accountable: We document what we do, when we do it, and who did it.

Every employee plays a critical role in food safety. Your attention to detail and commitment to following procedures directly protects public health.

Your First Two Weeks You will be paired with an experienced team member who will walk you through daily operations. Do not operate any equipment until you have been trained and signed off by your supervisor. There are no “stupid questions” in food manufacturing — always ask if you are unsure.

2. The 30 Critical Mistakes to Avoid

Read This Twice Most recalls, injuries, and write-ups come from predictable mistakes — not bad intentions. New hires remember what to avoid even better than what to do.

Food Safety & GMP Mistakes

  • Bringing a phone, keys, or personal items onto the production floor. These are contamination sources and physical hazards.
  • Touching your face/hair and not washing hands before returning to work. Your hands are the #1 contamination vector.
  • Wearing jewelry or loose items that can fall into product. A single ring becomes a recall.
  • Propping exterior doors open “for just a minute.” Open doors break air pressure barriers and invite pests.
  • Using wet rags/tools near open dry mix product. Moisture creates microbial risk and caking.
  • Ignoring condensation, leaks, or standing water near product. Water is the enemy of dry mix.
  • Walking past powder buildup instead of cleaning/reporting it. Dust accumulation is a combustible hazard and a GMP failure.
  • Eating or drinking outside the break room. Food in production areas attracts pests and risks contamination.

Allergen & Labeling Mistakes (Recall Triggers)

  • Running products out of schedule without approval. Allergen sequencing exists for a reason.
  • Moving allergen ingredients without using designated areas/rules. Cross-contact can cause life-threatening reactions.
  • Assuming “same bag” means “same label.” Always verify — never assume.
  • Starting packaging before correct label verification and QA release. A wrong label is a recall, not a rework.
  • Not segregating rework or hold product immediately. Unsegregated hold product can ship accidentally.
  • Ignoring foreign material found during sifting or screening. Every contaminant gets documented and investigated.

Safety & Equipment Mistakes

  • Reaching into equipment without Lockout/Tagout (LOTO). This is how amputations happen.
  • Bypassing guards or sensors to “keep going.” Guards exist because someone was hurt before you.
  • Not wearing hearing/eye protection in required areas. Damage is cumulative and irreversible.
  • Lifting heavy bags improperly instead of asking for help. Back injuries end careers.
  • Using compressed air carelessly. It redistributes allergens and ignitable dust.
  • Not reporting spills, leaks, or foreign material immediately. Small spills become contamination events.

Documentation Mistakes

  • Writing batch records from memory later. Must be real-time. Auditors detect backfilling instantly.
  • Using pencil or whiteout. Ink only, always.
  • Leaving blanks on batch records. Blanks create audit findings. Write “N/A” and initial if not applicable.
  • Not recording lot codes when moving ingredients. Traceability depends on every lot being tracked.

Culture & Communication Mistakes

  • Not speaking up when something seems wrong. If a product looks, smells, or behaves differently, say something.
  • Starting the line before QC clearance. Never start production until QA gives the go-ahead.
  • Treating rework casually. Rework is one of the biggest hidden contamination pathways.
  • Letting ingredient bags pile near blending areas. Cross-contact and pest risk increases quickly.
  • Assuming someone else already reported a problem. If you see it, you own it. Report it.
If You’re Not Sure — STOP If something feels “off” (wrong label, wrong ingredient, unusual smell/color, missing paperwork), stop and call your supervisor or QA immediately.

3. Safety Requirements

General Plant Safety

  • Walk, don't run. Floors may be slippery, especially near wash-down areas.
  • Keep aisles clear. Never block exits, fire extinguishers, eye wash stations, or emergency shut-offs.
  • Report all injuries immediately — no matter how minor. Tell your supervisor right away.
  • Know your emergency exits. Locate the two nearest exits from your work area on your first day.
  • Lockout/Tagout (LOTO): Never operate, clean, or reach into equipment that has not been properly locked out. Only trained, authorized personnel may perform LOTO procedures.

Dry Mix-Specific Hazards

Dust Explosion Risk Fine food powders are combustible. Airborne dust concentrations as low as 20 g/m³ can ignite. Never allow powder dust to accumulate on surfaces, equipment, or overhead structures. Report any malfunctioning dust collection systems immediately.
  • Dust control: All dust collection and ventilation systems must be running during production. Report any visible dust clouds, leaks from ducting, or blocked filters to your supervisor.
  • Grounding: All powder handling equipment must be properly grounded to prevent static electricity buildup. Never disconnect grounding wires. Report any sparking or static shocks.
  • Lifting: Ingredient bags can weigh 25–50 lbs. Use proper lifting technique (bend knees, keep back straight, hold load close). Ask for help or use a pallet jack for heavier loads.
  • Noise protection: Wear hearing protection in areas marked with signage (near blenders, mills, packaging lines).
  • Eye protection: Wear safety glasses when handling powders, cleaning chemicals, or operating equipment with moving parts.

Required Personal Protective Equipment (PPE)

AreaRequired PPEWhy
Production floor (all areas)Hairnet, beard cover (if applicable), clean smock, closed-toe shoes with slip-resistant solesPrevents hair/fiber contamination + slip injuries
Mixing / blendingAll above + safety glasses, hearing protection, dust mask when dumping powdersProtects eyes, lungs, and hearing from powder/noise exposure
Sanitation / chemical handlingAll above + chemical-resistant gloves, eye protection, apronChemical burn and splash protection
Warehouse / receivingSafety shoes/steel toes, high-visibility vest near forklift areasForklift impact and crush protection

4. Good Manufacturing Practices (GMPs)

Good Manufacturing Practices are federal regulations (21 CFR Part 117, Subpart B) that every food manufacturer must follow. At BFI, GMPs are not optional — they are a condition of employment.

Core GMP Rules (With the “Why”)

  1. No food, gum, candy, or beverages in production or warehouse areas. Eat and drink only in the break room. (Prevents contamination and attracts pests.)
  2. No tobacco products anywhere in the plant except designated outdoor areas. (Sanitation risk + product contamination.)
  3. No jewelry in the plant — no watches, rings, earrings, bracelets, necklaces, or exposed piercings. Exception: Medic Alert jewelry is permitted. (Jewelry can fall into product and trigger a recall.)
  4. No personal items (phones, keys, wallets) on the production floor. Store them in your locker. (Foreign material hazard + distraction risk.)
  5. No spitting anywhere in the facility. (Biological contamination.)
  6. Keep doors closed. Exterior doors must remain closed at all times. Never prop them open, even briefly. (Pest entry + humidity/air pressure control.)
  7. Report illness. If you have vomiting, diarrhea, fever, jaundice, open sores, boils, or infected cuts, you must report to your supervisor before entering any production area. You may be temporarily reassigned or sent home until cleared. (Protects customers; required by FDA food safety regulations.)
GMP Enforcement QA and production leads monitor GMPs before each shift and throughout the day. Violations result in retraining for first offenses and progressive discipline for repeated non-compliance, up to and including termination. Visitors and contractors are held to the same standards.

5. Personal Hygiene & Dress Code

Hand Washing — The Single Most Important Thing You Do

Proper hand washing prevents contamination of every product we make. You must wash your hands:

  • Before starting work
  • After every break, including restroom visits
  • After touching your face, hair, or any non-food-contact surface
  • After handling raw materials or waste
  • After sneezing, coughing, or blowing your nose
  • Whenever your hands become soiled for any reason
1

Wet

Wet hands with warm running water

2

Soap

Apply soap and lather thoroughly

3

Scrub

Scrub all surfaces for at least 20 seconds

4

Rinse & Dry

Rinse clean, dry with single-use towels

After drying, use the hand sanitizer dip station before entering the production floor.

Dress Code

  • Hairnets: Must cover all hair. Put on before entering production or warehouse areas. Remove before going outside or to the restroom.
  • Beard covers: Required for any facial hair, including stubble.
  • Company smocks: Provided by BFI. Wear a clean smock at the start of each shift. Change immediately if it becomes soiled. Remove before going outside or to the restroom.
  • Shoes: Closed-toe, slip-resistant. No sandals, canvas shoes, or open-back shoes.
  • Gloves: When required, gloves must be impermeable, intact, and clean. Change gloves frequently and wash hands before putting on new gloves.

6. Allergen Awareness (Zero-Tolerance Risk Area)

Federal law (FALCPA) requires clear labeling of 8 major allergens. Cross-contamination between allergenic and non-allergenic products can cause life-threatening reactions in consumers.

The 8 Major Allergens

#AllergenCommon in BFI Products
1Milk (dairy, whey, casein, lactose)Puddings, custards, some drink mixes
2EggsCake mixes, brownie mixes
3Wheat (flour, gluten)Cake mixes, brownie mixes
4Soy (lecithin, soy flour)Various mixes
5Tree nutsSome specialty products
6PeanutsSome specialty products
7FishRare
8Crustacean shellfishRare

Your Non-Negotiable Allergen Rules

  • Never run products out of schedule without approval. Allergen sequencing exists for a reason — violating it creates cross-contact risk.
  • Complete allergen changeover cleaning and verification between products with different allergen profiles. Do not start the next product until cleaning is verified and signed off by QA.
  • Keep allergen ingredients segregated. Never store allergenic ingredients next to or above non-allergenic ingredients. Never “temporarily” move them.
  • Verify labels before every run. Confirm the packaging matches the product being packed. A wrong label is a recall, not a rework.
  • Stop the line immediately if you suspect a label/code mismatch or cross-contact.
Allergen Cross-Contact = Potential Recall A single allergen mix-up can trigger a Class I recall (risk of death) and cost the company hundreds of thousands of dollars. If you suspect cross-contact has occurred, stop the line immediately and notify your supervisor.

7. Our Products & Processes

BFI manufactures dehydrated dry mix products. Understanding how our products work helps you understand why procedures matter.

Product Categories

Drink Mixes

Powdered beverage blends designed to dissolve quickly in water. Ingredients include sugars, citric acid, flavors, colors, and sometimes dairy components. Must maintain fine, free-flowing consistency.

Dessert Mixes

Mousses, custards, and puddings. Contain starches, sugars, dairy powders, and stabilizers. Shelf life depends on controlling moisture — even small amounts of water absorption cause caking and spoilage.

Bakery Mixes

Cake and brownie mixes. Contain flour, sugar, leavening agents, cocoa, eggs, and dairy. Particle size consistency is critical — uneven blending causes quality defects in the finished baked product.

Why Moisture Is the Enemy

Dry mix products are shelf-stable because they have very low water activity (below 0.85). When moisture gets in — through a leaky seal, humid air, a wet scoop, or condensation — the powder absorbs water and begins to degrade:

  • Caking: Powder clumps into hard masses that won't dissolve properly
  • Browning: Sugar and protein components react (Maillard reaction), causing off-colors and off-flavors
  • Microbial growth: If water activity rises above 0.85, bacteria and mold can grow
Practical Rule Never use wet scoops, wet containers, or damp cleaning cloths near open product. If you see condensation on equipment or packaging, stop and report it. Every drop of water is a potential quality failure.

The Manufacturing Flow

  1. Receiving: Incoming ingredients are inspected, verified against purchase orders, and stored in designated areas.
  2. Weighing & Batching: Ingredients are measured according to the batch formula. Accuracy is critical — even small errors change the finished product.
  3. Blending: Ingredients are combined in ribbon blenders, V-type blenders, or other mixing equipment. Blend time and sequence follow the batch record exactly.
  4. Quality Check: QC samples are pulled for testing (moisture, particle size, appearance, taste).
  5. Packaging: Blended product is filled into bags, pouches, or cases. Sifting/screening for foreign material and sealing verification happen at this stage.
  6. Warehousing: Finished product is palletized, labeled, and stored in climate-controlled conditions until shipment.

8. Sanitation Responsibilities

Sanitation is the foundation of food safety. It is a prerequisite to our HACCP plan — without effective sanitation, nothing else works. Every employee shares responsibility for maintaining sanitary conditions.

Your Daily Sanitation Duties

  • Clean as you go. Wipe up spills immediately. Don't leave ingredient bags or debris on the floor.
  • Follow cleaning schedules. Your work area has a posted cleaning schedule. Know what needs to be cleaned at the end of each shift and between product changeovers.
  • Report sanitation issues. Cracked floors, peeling paint, damaged equipment, standing water, or pest signs (droppings, gnaw marks, dead insects) must be reported immediately.

Equipment Cleaning — The 7-Step Process

  1. Disassemble equipment as required
  2. Remove all product debris (dry sweep, vacuum, scrape)
  3. Rinse with clear water to remove remaining residue
  4. Apply cleaning chemical per manufacturer instructions
  5. Rinse with clean potable water
  6. Apply sanitizer at proper concentration
  7. Reassemble equipment and re-sanitize contact surfaces
Dry Cleaning for Dry Mix Operations Many of our blending and packaging areas use dry cleaning methods (vacuuming, scraping, compressed air) rather than wet wash-down. This is intentional — introducing water into dry mix areas creates moisture that damages product and can promote microbial growth. Follow your area's specific cleaning SOP.

9. Quality Control Basics

Quality is built into the process, not inspected into the product afterward. Here's how you contribute:

What to Watch For

  • Foreign material: Metal fragments, plastic pieces, glass, personal items, insects. If you see anything that doesn't belong, stop and segregate the product.
  • Off-colors or unusual appearance: Product that looks different from normal may indicate a formulation error or contamination.
  • Wrong labels or packaging: Verify that packaging matches the product code before every run.
  • Equipment malfunctions: Unusual sounds, vibrations, or performance from blenders, fillers, or sealers.
  • Sifter/screen rejects: If foreign material (metal particles, clumps, debris) is found during sifting, segregate the affected product and notify QC immediately.

Batch Records

Every batch has a written record. If you are responsible for filling in any part of a batch record:

  • Use ink only (never pencil, never whiteout)
  • Record information in real time (never backfill from memory)
  • If you make an error, draw a single line through it, initial, date, and write the correction next to it
  • Sign and date every entry you make

10. Emergency Procedures

Fire

  1. Activate the nearest fire alarm pull station
  2. Evacuate via the nearest exit — do not use elevators
  3. Assemble at the designated meeting point in the parking lot
  4. Do not re-enter the building until cleared by fire department or management

Chemical Spill

  1. Evacuate the immediate area
  2. Notify your supervisor
  3. Do not attempt to clean chemical spills unless you have been trained and have proper PPE
  4. Locate the Safety Data Sheet (SDS) for the chemical involved

Injury / Medical Emergency

  1. Call for help — notify your supervisor and dial 911 if serious
  2. Administer basic first aid if trained (first aid kits are marked with green crosses)
  3. Eye wash stations and safety showers: know where they are in your area. Flush eyes or skin for at least 15 minutes if exposed to chemicals.
  4. Report all injuries to your supervisor and fill out an incident report the same day

Product Contamination / Food Safety Event

  1. Stop the line. Do not continue running product.
  2. Isolate and segregate the affected product — do not discard it.
  3. Notify your supervisor and QA immediately.
  4. Document what happened, when, and what product was involved.
Stop the Line Policy Every employee has the authority — and the responsibility — to stop production if food safety or employee safety is at risk. No employee will be disciplined for stopping a line in good faith. If you see something wrong, stop the line and speak up. This is one of the most important things you can do at BFI.

11. Role-Specific Training Paths

Your training plan depends on your department. Your supervisor will walk you through your specific requirements, but here is an overview of what each role covers:

DepartmentKey Training TopicsRequired PPEEquipment Authorization
Production Batch records, blender operation, packaging lines, sifter/screen verification, blend uniformity Hairnet, beard cover, smock, safety glasses, hearing protection, slip-resistant shoes Assigned equipment only after supervisor sign-off
Warehouse FIFO rotation, lot tracking, receiving inspection, forklift certification, shipping verification Steel/composite-toe shoes, high-visibility vest, hairnet in production-adjacent areas Forklift only after certification; pallet jack after training
Quality Assurance Sampling procedures, allergen swab testing, sifter mesh inspection, batch record review Lab coat, safety glasses, gloves (nitrile), hairnet, beard cover Lab instruments after training; production floor QC equipment after sign-off
Sanitation 7-step cleaning process, chemical handling, SDS review, equipment disassembly/reassembly, dry vs. wet cleaning Chemical-resistant gloves, splash goggles, chemical-resistant apron, slip-resistant shoes, hearing protection Cleaning equipment after training; chemical mixing only after HazCom certification
Maintenance LOTO procedures, food-grade lubricants, post-maintenance line clearance, tool accountability, electrical safety Safety glasses, steel-toe shoes, hearing protection, arc-flash PPE (qualified electrical work) Individual equipment LOTO authorization required for each machine

Skill Sign-Off Matrix (Supervisor Use)

Your supervisor will initial each line when you have been trained and can demonstrate correctly:

  • Handwashing + sanitizer station procedure demonstrated
  • GMP rules explained + employee Q&A completed
  • Allergen awareness: can name major allergens + explain cross-contact risk
  • Label verification: can match code/label/product correctly
  • Stop-the-line authority understood and acknowledged
  • Batch record rules: ink only, real-time, corrections method
  • Hold product procedure: how to tag and segregate product
  • Sifter/screen: foreign material reject handling procedure
  • Emergency exits, eyewash, fire extinguisher locations identified
Training Rule You are not authorized to perform a task alone until your supervisor signs you off. This protects you, the product, and the company.

12. Your 30 / 60 / 90 Day Roadmap

First 30 Days (Safety + Basics)

  • Zero GMP violations
  • Understands allergens and follows sequencing rules
  • Can complete assigned tasks with buddy supervision
  • Knows emergency exits, eyewash, first aid kit, assembly point
  • Demonstrates proper hand washing every time

Days 31–60 (Consistency + Documentation)

  • Can run assigned station with minimal supervision
  • Can document batch record entries correctly (ink, real-time, no blanks)
  • Understands hold/release and escalation process
  • Consistently follows cleaning SOPs for assigned area

Days 61–90 (Independence + Ownership)

  • Independently follows SOPs without reminders
  • Reports issues early (dust, leaks, label risk, equipment problems)
  • Demonstrates “BFI Standard” behavior consistently
  • Can explain why each rule exists — not just what the rule is
What Success Looks Like By 90 days, you should be safe, consistent, and reliable — not fast. Speed comes after mastery.

13. Day One Checklist & Acknowledgment

Complete each item with your supervisor or training buddy:

  • Received and reviewed this Employee Onboarding Guide
  • Toured the facility — know the location of exits, fire extinguishers, eye wash stations, first aid kits
  • Received locker assignment and stored personal items
  • Issued hairnet, smock, and any required PPE
  • Completed hand-washing demonstration with supervisor sign-off
  • Reviewed GMP rules and signed GMP acknowledgment form
  • Reviewed allergen awareness and signed allergen training form
  • Identified your work area's cleaning schedule and SOPs
  • Introduced to your training buddy / shift lead
  • Emergency assembly point identified and understood
  • Completed all HR paperwork (employment forms, direct deposit, benefits)
  • Scheduled for 6-month GMP refresher training
You're Part of the Team Food safety is a shared responsibility. Every product that leaves our facility carries our name and our promise. By following these guidelines, you protect our customers, our company, and each other. Welcome aboard.

Acknowledgment

I confirm I have received and reviewed the BFI Employee Onboarding Guide. I understand I must follow GMPs, safety rules, allergen controls, and documentation procedures as a condition of employment. I understand that failure to follow these procedures may result in disciplinary action, up to and including termination.

Employee Name____________________________
Employee Signature____________________________
Date____________________________
Supervisor / Trainer____________________________
Supervisor Signature____________________________
Date____________________________

Bernard Food Industries, Inc. • 1125 Hartrey Ave, Evanston, IL 60204 • (847) 869-5222

This document is confidential and intended for BFI employees only. Do not distribute externally.

Last updated: February 2026