Meet Diamond Pet Foods

Transcription

1 Recall to Supplier of the Year in 18 months? The Diamond Pet Food Story Told from the perspective of: Michele M. Sayles Ph.D. Meet Diamond Pet Foods A family-owned company Founded in 1970 Driven by the philosophy that superpremium pet food should be affordable and available to all pets 1000 employees in five locations Committed to caring for our employees Diamond Pet Foods brands used in 50 states and in more than 70 countries Our business has grown from wordof-mouth; retailers are our partners 2 Where We Make Our Products Presentation Overview Set the Stage What happened? How did Diamond react: Commitment Immediate changes Control Programs New Technology / Innovation Culture Change 2005 Aflatoxin Recall 2007 Melamine 3600 pet deaths over 5300 products recalled 2007 Mars Pet Care Salmonella Schwartzengrund 62 people in 18 states 2012 Diamond Pet Foods Salmonella Infantis 49 people in 20 states 2012 Hatchery in Ohio Salmonella Infantis, Newport, and Lille infections linked to live chicks & ducklings 195 people, 27 states and 2 deaths Interesting to Note: Pet Food Recall Mail Order Poultry Recall 1

2 What Happened? What happened? April 2012 Michigan Dept. Ag found Salmonella in an unopened bag during routine inspection This isolate was put into Pulse Net This yielded a match of 28 illnesses 22 of 28 had contact with a dog 1 week prior to becoming ill 17 of 28 had purchased dog food; 11 people had purchased Diamond During additional state surveillance S. infantis strain with a different pattern was found, put into Pulse Net and an additional 16 illnesses linked Canada also reported 2 illnesses from non-outbreak strain How Did Diamond React How did Diamond react: Immediately shut plant down Plant was down for 40 days FDA was in the plant for 7 days conducting investigation Outbreak strain was never found No single source identified Immediate Reaction: Company Commitment! Some Immediate Reactions Strict Plant Separation Tore every thing apart! Installed strict area segregation Installed Air Handling Units per production area Eliminated potential harborage Made equipment more accessible to clean Implement Test and Hold and a micro program Became DATA DRIVEN! DATA DRIVEN Control Programs Multi Hurdle Approach: Microbiological monitoring Cleaning and sanitation Effective pre-requisite programs Innovation technologies Pre-Requisite Programs Pre-Production Specifications HACCP Program Food Defense Vendor Approval Equipment Sanitary Design Standards Production Training Documentation Mycotoxin Control Water Quality Air Quality Cleaning and Sanitization GMPs Foreign Material Control Glass and Brittle Plastic Chemical Control Pest Control Raw Material Receiving Micro Environmental Finished Product Post Production Recall / Withdrawal Product Retrieval Warehouse and Distribution Center Customer Complaints Taking these programs to new levels: Example: Air Quality, Water Quality 2

3 Microbiological Monitoring Microbiological Monitoring Within 2 weeks onsite modular micro labs Implemented: Finished product testing Environmental monitoring program Ingredient testing / COA verification DATA DRIVEN Major Challenges Legacy equipment Equipment Design Sanitary design standards originally non existent Cleaning and Sanitation SSOP s how do we clean? Establishing frequencies C&S verification, validation 3

4 OLD Dryer room NEW Extruder Room OLD NEW Cleaning and Sanitization Strategies Cleaning and Sanitization: How and When?? Wet clean vs. dry clean New technology Dry fog Ozone / Chlorine dioxide Probiotics New chemicals vs. old chemicals Peracetic acid Acidified Calcium Sulfate Lactic Acid New Monitoring Technology 16 s? Innovation technologies Cleaning and Sanitization New technology, improved chemicals Sampling and Monitoring Improved testing 16 S metagemnomics Ingredients Probiotics Processing Technology Radio frequency, UV light WGS vs 16s Metagenomics WGS 16s Metagenomics Traditional (PFGE) Traditional Investigations with 16s Overview Sample multiple sites Sample multiple raw materials Compare spoiled vs. normal Understand facility microbiota Root cause analysis WGS 16s metagenomics 4

5 Data set # 1 What Are Probiotics? Commonly Used Strains Lactobacillus Bifidobacterium Enterococcus Vials What Do Probiotics Do? Aid in digestive health Competitive inhibition Competitive exclusion Receptor binding Antagonistic behavior Secondary benefits Antimicrobial characteristics in product Key Benefits of Probiotics Improve pet GI heath Food Safety Effect Competitive Inhibition of Pathogens (i.e.salmonella) Competitive Exclusion of Pathogens Probiotics are effective against pathogens: In the laboratory In the human or animal In the environment Diamond s cutting edge Environmental Application research project Culture Change Company - internal Customers Suppliers/vendors Trade Organization Professional Affiliations Regulatory Agencies No Really HOW??? 5

6 The Diamond Pet Food Story How did the story end? Customers: Recall to Supplier of the Year in 18 months Regulators: Invite us to teach and present our story Industry Peers: Ask for advice and input 6