To assist food manufacturers in understanding why a BRC audit failure occurred, in finding the true reasons for a BRC audit failure, and in developing and implementing a BRC corrective action plan that results in recovery success, not repeat failure.
You open the audit report.
You scroll.
And then you see it:
Major non-conformity.
Another Major.
Grade dropped or certification denied.
Your first thought isn’t about clauses.
It’s about buyers, shipments, and credibility.
So, you search:
- “BRC audit failed.”
- “BRC audit failure reasons.”
- “How to recover from BRC audit failure.”
What you really want is clarity and a way to fast forward.
Problem Statement:
When a BRC audit failed, most food manufacturers believe they failed because they are “not compliant enough.”
That’s not true.
Most BRC audit failure reasons can be broken down into three groups:
- Misunderstood expectations
- Poor evidence alignment
- Weak corrective action planning
Without a proper BRC corrective action plan, food manufacturers jump into corrective actions that look great on paper but fail during the re-audit.
Helpful Guide:- Real BRCGS Non-Conformities Found in Indian Food Plants (With Fixes)
Why does this happen?
A BRC audit failure is not due to the standards being impossible to meet, but because:
- Manufacturers are preparing for documentation, not verification
- Internal audits do not reflect the depth of the BRC audit
- Site conditions are not considered until audit week
- Corrective actions are taken for symptoms, not causes
- No experienced BRC audit failure consultant expert is involved
BRC checks whether your systems actually work in real situations, not just whether policies exist on paper.
Founder Pain Points:
- The BRC audit failed unexpectedly.
- Buyers are checking the status of supplier approval.
- There is confusion about the reason for the BRC audit failure.
- All feel the pressure to submit corrective actions quickly.
- There is a fear of another failure in the re-audit.
- There is burnout among the teams from last-minute changes.
- And there is no clarity on how to recover from the audit failure.
Let’s strip this down.
A BRC auditor asks one core question:
“Can I trust this site to control food safety every single day?”
They don’t just read SOPs.
They walk the floor, talk to operators, and test traceability.
That’s why a BRC audit failed even when the documents looked perfect.
The gap is almost always between:
What’s written and what’s actually happening.
The Most Common BRC Audit Failure Reasons:
Five critical areas are common pitfalls in audits:
1) Site Standards & Housekeeping
– Bad zoning
– Temporary fixes
– Inconsistent sanitation practices
These are some of the leading worldwide causes of BRC audit failures.
2) Poor HACCP Implementation
– The CCP logic is not scientifically justified
– Monitoring records are incomplete
– Corrective actions are not closed
Auditors see HACCP failures as a systemic issue, not a minor problem.
3) Traceability & Recall Failures
– 4-hour traceability is not accomplished
– Mock recalls are not practical
– Supplier connections are weak
One of these alone can cause a BRC audit failure.
4) People Don’t Understand the System
– Operators don’t know the procedures
– Supervisors can’t explain the controls
– Training is only done “for the record”
Auditors believe in people more than procedures.
5) Poor Corrective Action Thinking
– Root cause is not determined
– Persistent problems from previous audits
– No preventive controls
This is why many companies fail again after “correcting” problems.
What a Real BRC Corrective Action Plan Looks Like?
A good and strong BRC corrective action plan has three levels:
- Immediate Containment
- Visible risks must be fixed immediately
- Product and process must be protected
- Actions must be documented honestly
- Root Cause Analysis
Ask:
- Why did this occur?
- Why wasn’t it detected earlier?
- Why did the controls fail?
This level distinguishes recovery correction from recurrence of failure.
- Preventive System Fix
- Procedures must be updated
- Teams must be retrained
- Monitoring must be improved and strengthened
A good, credible BRC corrective action plan demonstrates future control, not past regret.
Helpful Guide:- BRC vs FSSC 22000: Which Certification Buyers Prefer in 2026?
What Actually Works After a BRC Audit Failed?
Step 1: Pause & Analyze
Don’t be rushed with your responses.
Understand all non-conformities and their meaning.
Step 2: Prioritize Major & Critical NCs
Most BRC audit failure causes come from majors, not minors.
Step 3: Align Evidence with Reality
All corrections must be:
- Implemented
- Recorded
- Understood by staff
Step 4: Conduct a Focused Internal Re-Audit
Your site must be audited as a BRC auditor would.
Step 5: Get Expert Review
This is where the BRC audit failure consultant expertise comes in to prevent blind spots and recurrence of mistakes.
Legal4sure Role:
After the initial shock of the audit, we at Legal4sure engage with food companies.
We are a team whose role is to:
- Unravels the truth behind the real BRC audit failure reasons
- Creates auditor-credible BRC corrective action plans
- Gets systems in line with the shop-floor reality
- Assists in recovery without the use of cosmetic solutions
We don’t prepare companies to “look compliant.”
We prepare them to stay compliant.
Helpful Guide:- AI & Automation in BRCGS Internal Audits – The Future of Food Safety Compliance
Frequently Asked Questions (FAQs):
- What should we do as soon as the BRC audit fails?
The first step is to analyze the major non-conformities and identify the root cause of BRC audit failure before the submission of a corrective action plan.
- Is it possible to recover the BRC audit failure without repeating all the work?
Indeed. To get back into business after the failure of an audit by BRC, one will need to understand and fix the high-risk loopholes instead of starting the whole system over again.
- What is the significance of the BRC corrective action plan?
Crucial. A weak BRC corrective action plan is often followed by recurrent failures even after the facility is improved.
- Why do companies fail BRC audits again after rectifying problems?
This is because the underlying factors were not addressed. BRC auditors are not satisfied with superficial or cosmetic fixes.
- Should we take the BRC audit failure consultant support?
Yes. Hiring a skilled BRC audit failure consultant would assist in discovering the weak areas and being ready to have a successful re-audit.
Founder Takeaway:
A failure to pass a BRC audit does not automatically indicate that your business is unsafe.
It simply implies:
- Systems didn’t prove consistency
- Evidence didn’t match practice
- Corrective actions lacked depth
Recovery is indeed possible if you have a correct understanding of the reasons behind the BRC audit failure and a robust BRC corrective action plan.
After a failed BRC audit, a re-audit is scheduled. Don’t put yourself in the situation of losing buyer confidence or risking repeat failure.
Consult an expert to get a credible BRC corrective action plan and take the proper steps towards your quick recovery, sincere, honest, and auditor compliant.
