The responsibility for a dairy company Aspects of the food safety systems at DMK Group

Transcription

1 The responsibility for a dairy company Aspects of the food safety systems at DMK Group Burkhard Voss Head of QM-Systems and Suppliermanagement Beijing, 6th November 2015

2 DMK Group - Key figures (1) DMK Group is a German dairy 68 companies worldwide 28 locations in Germany No. 7 in Europe and No. 13 in the World (Source Rabobank 2014) Page 1

3 DMK Group - Key figures (2) Page 2

4 DMK Group - Key figures (3) Portfolio Dairy products Cheese Ingredients Baby food / dietetics Ice cream Health products International brands Page 3

5 Definitions of Food safety (1) Food safety is according to (the) assurance that food will not cause harm to the consumer when it is prepared and/or eaten according to its intended use. (Food hygiene - basic text 4 th edition section 2.3) Page 4

6 Definitions of Food safety (2) Food safety is stated to Chapter 1 of the Food Safety Law of the People's Republic of China (Release Date: 2015/04/24) Article 1 This Law is formulated to assure food safety and safeguard people's health and life. Article 3 Food safety work shall follow the principles of putting prevention first, risk management, whole-process control, and making efforts by the whole society, aiming to establish the science based and strict oversight system Page 5

7 Definitions of Food safety (3) Food safety is according to Article 2 (2) of the Regulation (EC) No 852/2004 of the Europaen Union: food hygiene ( ) the measures and conditions necessary to control hazards and to ensure fitness for human consumption of a foodstuff taking into account its intended use Page 6

8 Responsibility for a food business operator Also in the Regulation (EC) No 852/2004 you find in Article 3 the requirement for the responsibility of food safety: Food business operators shall ensure that all stages of production, processing and distribution of food under their control satisfy the relevant hygiene requirements laid down in this Regulation Page 7

9 Food safety transferred to systems of DMK Group Requirements European and German law International / trading standards Food law of export countries Scientific information Guidelines Directives and standard operating procedures gggg implemented in an Integrated Management System (IMS) Risk analyses Analyses Measures HACCP-Plan Sampling plans Monitoring plans IT-solutions Page 8

10 Risk-based Food safety system (1) Guidelines DMK Directive HACCP is progressive and very comprehensive. was composed over 1 year by a working group of specialists. was established for all companies of DMK Group. complies fully with the Regulation (EC) No 852/2004. meets the requirements of the Codex alimentarius and ISO expands existing standards and combines CCP s, CP s and PRP s in logical matters. Since 2015 a group of university professors has supported the working group in their further development of the food safety system Page 9

11 Risk-based Food safety system (2) Guidelines Flow-charts were revised within the implementation of the HACCP directive. point out a very high level of details. were all harmonised by the central quality management (approx. 500). are published in web-based process-models with additional information. and connection to the document libaries. The flow-charts are validated yearly or, by the change of the process, in every shift and every operating status Page 10

12 Risk-based Food safety system (3) Analysis Example of a flow chart Page 11

13 Risk-based Food safety system (4) Guidelines Risk analysis The risk analysis was newly published as an Excel-Tool. The tool is very comprehensive and consists of logics not covered by the Codex alimentarius so far. Identified risk are set as measures with a modified decision tree as CCP s CP s PRP s (Critical control points) (Control points) (Prerequisite programs) There are more than 4000 identified points based on the flow-charts in big plants, checked for hazards and risks with the Excel-Tool Page 12

14 Risk-based Food safety system (5) Guidelines Risk analysis Part of the Excel-Tool Page 13

15 Risk-based Food safety system (6) Guidelines Advanced directives In addition to the HACCP directive, following directives were published at DMK Group within the last 2 years, e.g.: Directive for Heat exchangers Directive for the prevention of foreign matters and detection systems Process for the residue monitoring of raw-milk Directives for the pathogen monitoring in dairy-, cheese- and powder plants Process and directive for process validation Directive for pest control Page 14

16 Examples of practical implementation (1) Measures Milk receipt (1) The cooperative farmers of DMK are contractually bound. The have to fullfil strict rules regarding animal keeping and the application of antibiotics. Beside the DMK regulation for milk supplies, DMK established the new MILKMASTER-programme, the contents of which go beyond legal requirements. In this regard DMK takes into account the requirements of export countries like e.g. China and Russia Page 15

17 Examples of practical implementation (2) Measures Milk receipt (2) Upon receipt of the raw milk the truck automatically collects and stores data (GPS, time, quantity, temperature). At the same time, the truck system proportionally takes single-samples of each farmer and a mixed-sample. These samples are used for further testing and also for traceability Page 16

18 Examples of practical implementation (3) Measures Milk receipt (3) Before receipt of the milk in the plant, an antibiotic testing (CCP) and an examination of the ph-content is done out of the mixed truck sample for the acceptance of the milk. Non-conforming raw milk is verifiable diposed of in accordance with the Regulation (EC) No. 1069/2009. The mixed-sample is used for further examinations while the single-samples are sent to an external lab in accordance with the German MilchgueteVO Page 17

19 Examples of practical implementation (4) Measures Milk receiption (4) In accordance with the risk-based plan (PRP) the samples are taken for the residue monitoring and sent to an external lab. Following resuidues are in scope (selection): PCP s, pesticides (603), Aflatoxin M1, heavy metals, veterinary drug residues, radionuclides, hormons Independently from DMK sampling, there are samples taken by the veterinary authorities Page 18

20 Examples of practical implementation (5) Measures Milk treatment (1) The specifications for the pasteurisation of raw milk were harmonised in all plants of DMK Group with the implementation of the directive for heat exchangers. The new specifications describe technical conditions that go further, comparable with state of art technology. The relevant CCP-parameter (temperature, pressure and flow) were also unified Page 19

21 Examples of practical implementation (6) Measures Milk treatment (2) DMK Group has started the implementation of a webbased platform to monitor all CCP s in the plants and to store the information in accordance with legal certainty Page 20

22 Examples of practical implementation (7) Measures Drying (1) A standardized zoning concept, based on a risk analysis, has been implemented in the powder plants. The extensive environmental monitoring was aligned to the zoning concept to prevent contamination of pathogens. Additionally, the plants use a method called MTA (microbiological trend analysis) to detect potential contaminations in the productat an early stage Page 21

23 Examples of practical implementation (8) Measures Drying (2) The examinations of end products are effected on the basis of risk-based sampling plans (PRP). Requirements of export countries like China are mentioned in the sampling plans. For the evidence of foreign matters, combinations of detectors (CCP), like x-ray-systems or metal detectors and magnets or sieves (CP) are mostly used in the bagging of the powder Page 22

24 Thank you for the attention! Page 23