Feed Quality Assurance and Certification Programs. Representing the Total Feed Industry

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1 Feed Quality Assurance and Certification Programs

2 Quality Programs ISO Food Industry HAACP System Certification Program Comprehensive Quality Assurance Programs New US Food Safety Laws Animal Feed Safety System Good Manufacturing Practices

3 American Feed Industry Association Safe Feed/Safe Food Certification Program November 17, 2008

4 What is Safe Feed / Safe Food? Raise Own Bar Right Thing to Do Developed by top industry experts (FDA input) Comprehensive Risk-based Process Control Program Audited by Independent 3 rd Party Non-profit Industry Service Program Show leadership to consumers & regulators

5 Safe Feed/Safe Food History Began 2003, as a Feed Safe initiative to recognize those practices that are correct and that firms are utilizing. It began as the right thing to do to put down on paper and in a program those practices that keep feed and food safe.

6 Safe Feed/Safe Food History Assembled a very large task force from every segment and invited AAFCO and FDA to send observers. Finalized in mid-2004 and launched in September 2005, now has over 300 facilities participating.

7 Safe Feed/Safe Food Mission To establish and promote generally accepted safe feed/safe food guidelines designed to ensure continuous improvement in the delivery of a safe and wholesome feed supply for the growth and care of animals.

8 Safe Feed/Safe Food Description The program is designed to be a proactive program to help facilities evaluate possible areas of concern in regard to feed safety and help prevent a feed safety problem. To recognize those firms that have met the guidelines established by the industry and allow use of a certification brand or seal that is authorized by the program.

9 HAZARD ID

10 Safe Feed Safe Food Components A. Policy, Management, Control of Documents & Records, Communication and Review B. Human Resources Training C. Facility Planning and Control D. Manufacturing & Processing E. Monitoring Devices

11 Safe Feed Safe Food Components F. Infrastructure - Building, Equipment and Grounds G. Ingredient Purchasing Process & Controls H. Identification and Traceability I. Customer Related Processes J. Control of Nonconforming Product

12 A. Safe Feed/Safe Food Policy, Management, Control of Documents & Records, Communication and Review 1. A Food/Feed Safety policy has been defined, reviewed and implemented by top management. Has the policy been communicated to each employee? 2. Document control procedures are in place, and documents are accessible to appropriate personnel. 3. The physical and chemical Feed Safety Hazards in the AFIA Hazard Guide have been identified, reviewed, and have control procedures, where applicable. 4. Records retention procedures are defined and followed. Records must be maintained for one year from date of manufacture of finished product or receipt of ingredients.

13 A. Safe Feed/Safe Food Policy, Management, Control of Documents & Records, Communication and Review 5. The following records are maintained as appropriate to the product: (BSE feed rule, medicated feed, formula/mixing instructions, production records, drug assays, and label files). 6. Responsible personnel review the following: audit results, customer feedback, process performance and product conformity, status of preventive and corrective actions, follow-up action from previous management reviews, planned changes that could affect the food/feed system and recommendations for improvement.

14 B. Human Resources -Training 1. Personnel are competent for assigned tasks and received initial training and at least annual recertification. 2. Job descriptions are maintained that include the responsibility and skills required by the employee to complete the job. The employee is evaluated to determine knowledge of the required skill. 3. Personnel are properly trained in SOP's for restricted areas, and where appropriate, to avoid contamination or carryover from internal or external sources.

15 C. Facility Planning and Control 1. A team has been formed to identify, evaluate, and control feed and food safety hazards. 2. Check points where hazards may enter the facility are identified and controlled. 3. Verification, monitoring, inspection, and test activities have been determined specific to the need of the product.

16 Critical Control Points HACCP Principle 2 Points, procedures, or operational steps that can be controlled to prevent or eliminate the hazard or minimize its likelihood of occurrence (i.e., critical control points ).

17 Potential Critical Control Points/Checkpoints Receiving Documentation, Visual inspection, Mycotoxins Batching/Mixing Scale checks, Drug recon, Mixer uniformity Pelleting/Cooling Roll grease (food grade) Packaging & Delivery Sequencing and flushing

18 Critical Control Points to Avoid Ingredient analysis on every load Cost and time Scale over and under amounts on all ingredients Not all ingredients create a hazard Pellet temperature Start-up and shutdowns will require action Finished feed pellet quality Not a hazard to animals

19 D. Manufacturing & Processing 1. Records are maintained for each product which includes the supplier approval process, product specifications, formulation, label, and special manufacturing instructions. 2. Procedures exist to monitor and measure the manufacturing processes. 3. Procedures exist and are implemented to compare expected and theoretical results and to reconcile any differences. [see section J.].

20 D. Manufacturing & Processing Liquid metering/timing devices (e.g. fat, molasses, binders) Mixer testing results Automatic dry matter feeders (e.g. salt, micro ingredient feeds, etc) Scale(s) maintenance and testing Maintenance records and schedule checklists for various equipment and process controls. Computer generated records are backed up and stored away from the facility

21 E. Monitoring Devices 1. Monitoring procedures have been established to evaluate incoming raw materials and finished products, where appropriate. 2. Scheduled monitoring activities have been established and should include incoming raw material evaluation and finished product evaluation. 3. Ingredient and finished product assays are performed on a scheduled basis, where appropriate.

22 F. Infrastructure - Building, Equipment and Grounds 1. Procedures exist for the review and evaluation by the feed safety team of feed and food safety hazards in the event of new or changed facilities or equipment. 2. Buildings, equipment and grounds are adequately and routinely maintained. 3. Scales and liquid metering devices are tested/calibrated upon installation and at least annually thereafter.

23 F. Infrastructure - Building, Equipment and Grounds 4. Buildings are of suitable construction to minimize access by pests. A written pest control program exists and a record of pest control products used in the facility is maintained. 5. Buildings provide adequate space and lighting. 6. Equipment possesses the capability to produce a homogenous product that prevents, eliminates, or reduces identified food/feed safety hazards. A procedure to test the mixer has been developed and includes corrective action to be taken when necessary. Mixers are tested/calibrated upon installation and annually thereafter.

24 F. Infrastructure - Building, Equipment and Grounds 7. All equipment is of suitable size, design, construction, precision, and accuracy for its intended use. 8. All equipment is maintained to prevent lubricants and coolants introduction as unapproved additives to finished products. Where contact may be possible food grade products are used.

25 F. Infrastructure - Building, Equipment and Grounds 9. All equipment is designed, constructed, and maintained to facilitate inspection by the operator and the use of cleanout procedures when required. 10. Work areas and equipment used for the manufacture and storage of ingredients and feed are kept separate from agrichemicals. 11. Procedures exist and are implemented to insure all equipment is routinely and properly cleaned to prevent contamination of feed and ingredients.

26 F. Infrastructure - Building, Equipment and Grounds 12. Adequate procedures are established and used for all equipment in the production and distribution of ingredients and products to avoid contamination of feed and ingredients. 13. Procedures are established to ensure a biosecure workplace and the firm is following the AFIA "Guide to Biosecurity Awareness" program.

27 G. Ingredient Purchasing Process & Controls 1. Certification for compliance to 21 CFR is provided by suppliers where appropriate. (BSE Rule) 2. Procedures are in place to monitor, qualify, and disqualify suppliers on a scheduled basis and an approved supplier lists exist.

28 G. Ingredient Purchasing Process & Controls 3. Procedures for conveyance of raw materials to plant are in place to ensure identification of food/feed safety hazards. Suppliers and transportation companies have agreed to cleanout procedure requirements for transportation vehicles. A truck receiving log is maintained documenting cleanout and prior cargo in the truck. 4. Suppliers are required to place a safety seal on incoming rail cars or trucks. A policy to handle broken bags has been developed and is being followed.

29 H. Identification and Traceability 1. Finished product is properly packaged and labeled for traceability (e.g. production codes), and other label regulatory requirements. 2. Procedures for product traceability as required by the AFIA Safe Feed/Safe Food Guidelines are documented and implemented and the firm is complying with the FDA's Bioterrorism Act recordkeeping rules.

30 H. Identification and Traceability 3. Bagged ingredients are stored in either original containers or containers with lot numbers for traceability and identification and controlled in mixing areas. Bulk ingredients are controlled in a similar manner, as appropriate. 4. A sample retention program is defined and implemented. Retained samples are stored in an area away from production that minimizes the potential for contamination.

31 H. Identification and Traceability 5. Daily inventories of drugs are maintained. 6. Procedures for proper storage to avoid contamination are established for both raw materials, ingredients and finished products.

32 I. Customer Related Processes 1. Product specifications are defined within customer and regulatory requirements. 2. Procedures for customers feedback and complaints are in place.

33 J. Control of Nonconforming Product 1. Procedures to control non-conforming product have been established and implemented.

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