Part V Model HACCP Plans Medicate Dairy Cattle Feed Bulk Receiving CCP 1B, 1C Bagged Receiving Liquid Receiving Magnet Warehouse Stage Screen Bulk Stage bins Micro Ing. Bin Micro Ing. Bin Ing. Stage Containers Liquid Stage Bulk Scale Micro Scale Min Scale "Hand Adds" Check Scale Mixer Returned Product/ Rewk Holding Bin Automated Bagging Line Metal Detect Tote Filler Manual Palletizer Metal Detect Automated Palletizer Finished Prod. Stage Loadout 23
Product Description Fm Product Categy: Medicated Dairy Cattle Feed 1. Product name(s) Turbo-charged Golden Fluff 2. Product safety properties (Moist., Pro., etc) 3. How is the product to be used (intended use) and who is the intended consumer? Monensin concentration Iodine concentration Selenium concentration Low moisture to avoid mycotoxin Feed to dairy cattle per instructions on label under nutritionist directions 4. Type of packaging Bag & bulk 5. Shelf life Do not feed moldy insect infested feed. Do not exceed 75 days stage. Two weeks less is optimum. 6. Where will the product be sold? Retail wholesale 7. Labeling instructions In compliance with state and federal regulations. 8. Special distribution control Ensure and verify proper unload location Bulk: Recd lot numbers on shipping documents. Proper sequencing and/ flushing Bags: Recd lot numbers on shipping documents. KSU 1996 Approved: Date: 24
List of Product s and Incoming Materials Fm Product Categy: Medicated Dairy Cattle Feed Bulk s Cn, fine-ground Distillers Dried Grains By-Pass Protein Supplement Soybean Hulls Dried Bakery Product Limestone Sodium Bicarbonate east culture Potassium Chlide EDDI Salt Micro, Bag, and Hand Add s Magnesium oxide Monocalcium/Dicalcium phosphate Vitamin E premix Dairy TM Zinc Proteinate Vitamin ADE Premix Medications/Drugs Monensin Premix Liquids Packaging Materials Molasses KSU 1996 Approved: Date: 25
Product Categy: Supplement f ruminants Bulk ingredient receiving Prohibited animal protein Aflatoxin a significant Hazard Analysis Fm Cross contamination by prohibited animal protein (defined as a hazard in 21 CFR 589:2000) is a potential source of bovine spongifm encephalopathy (BSE) Hepatotoxicity and carcinogenesis Cross contamination by prohibited animal protein (defined as a hazard in 21 CFR 589:2000) resulting in BSE can cause the human disease variant Creutzfeldt Jakob disease (vcjd) Passed through milk as M1 carcinogen Receiving Bulk s SOP that includes directions f inspecting the cleanout certificate from carriers and LOG from supplier Test ingredients that can contain aflatoxin per Receiving Bulk s SOP 1B 1C Heavy Metals (Cd, Pb, Hg, As) Chronic toxicity to animal may occur Unlikely to accumulate in significant levels in human food Approve supplier program Metal Plastic Stones Glass Wood hazards can damage animal mouth and digestive system Low likelihood of passing through animal into food Equipment (screens, de-stoning device, metal detects and magnets) in place to eliminate hazard 26
Magnet a significant s Bulk stage Metal Other feign materials Low likelihood of additional feign materials introduced at this point Unlikely to enter 27
Bulk scale a significant s Bag ingredient receiving Mislabeled product Wrong potency of ingredient Mislabeled products wrong potency can negatively impact animal perfmance Low likelihood of passing through animal into food Approved supplier program; label inspection at receipt per Receiving Bagged s SOP; random testing Metal and other feign materials hazards can damage animal mouth and digestive system Low likelihood of passing through animal into food Equipment (screens, de-stoning device, metal detects and magnets) in place to eliminate hazard 28
Warehouse stage Micro bin a significant Loss of potency Potential loss unlikely to significantly affect animal health Cross Contamination Product placed in wrong bin Metal Other Feign Material Unlikely to occur in high enough concentration to affect animal health Items such as selenium could cause animal health problems if used improperly Low likelihood of additional feign materials introduced at this point Unlikely to enter since it isn t an animal hazard Unlikely to enter since it isn t an animal hazard Low likelihood of passing through animal into food Unlikely to enter s Batching Micro- Min-s SOP & personnel training 29
Min bin Cross Contamination stage container Product placed in wrong bin Unlikely to occur in high enough concentration to affect animal health Items such as selenium could cause animal health problems if used improperly Feign Material Low likelihood of additional feign materials introduced at this point Cross Contamination Product placed in wrong bin Metal and other feign materials Unlikely to occur in high enough concentration to affect animal health These ingredients likely will not present a significant animal health hazards Low likelihood of additional feign materials introduced at this point Unlikely to enter since it isn t an animal hazard Low likelihood of passing through animal into food Unlikely to enter ot a human food hazard since it isn t an animal hazard ot a human food hazard since it isn t an animal hazard Unlikely to enter Batching Micro- Min-s SOP & personnel training 30
Micro scale Min scale a significant 31
Hand adds Cross contamination of monesin a significant Unlikely to impact animal health Too low of concentration to be present in milk Wrong missed ingredient Weighing err Adding the wrong ingredient increct weight can affect safety of animal feed Feign Materials Low likelihood of additional feign materials introduced at this point Unlikely to be present in animal tissue in high enough concentration to affect human Unlikely to enter Hand Add SOP & employee training f both wrong ingredient, missing ingredient, and weighing err Liquid receiving 32
Liquid stage Check scale a significant 33
Mixer Cross contamination from previous batch a significant Fmulas produced are similar & unlikely to cause animal health problems if carryover occurs Low likelihood since not significant f animals Feign Material Low likelihood of additional feign materials introduced at this point Unlikely to enter Holding bin 34
Automated bagging line Metal Detect a significant Mislabeling Mislabeled product can affect safety of animal feed Low likelihood of passing through animal into human food Bagging SOP & employee training 35
Tote filler Metal Detect a significant Mislabeling Mislabeled product can affect safety of animal feed Low likelihood of passing through animal into human food Tote SOP & employee training 36
Manual palletizer Automated palletizer a significant 37
Finished product stage Loadout a significant Loss of utrient Potency Lost nutrient potency could affect animal growth perfmance but less likely to impact animal health Enteric pathogens (Salmonella and E coli) Wrong product loaded on truck Cleanliness of truck pri to loading Low likelihood of rodent and/ insect contamination contaminating bagged products on pallets Low likelihood that using wrong product could affect animal perfmance Debris such as glass not likely to enter bagged products ot likely to affect ot likely to affect ot likely to affect ot likely to affect 38
Return product and rewk Prohibited animal protein a significant Unlikely if no open containers (bags) are accepted f return ot a if controlled f animals Cross contamination of ingredients Fmulas produced are similar & unlikely to cause animal health problems if carryover occurs Low likelihood of passing through animal into human food OTSC-TAMU 2005 Approved: Date: 39
HACCP Plan Summary Fm Product Categy: Medicate Dairy Cattle Feed Process Critical Moniting and Hazards Limits f What How Frequency Who CCP each CCP Crective Action Verification Activities Recdkeeping procedure Bulk Ing. Receiving Pit, 1B Prohibited animal protein Zero Tolerance Cleanout certificate f carriers, Bill of Lading from supplier, Product labeling, Letter of Guarantee (LOG) from supplier, Presence of prohibited animal protein Visual observation of documentation, Purchase only from approved supplier, Use of eogen test strips Every load received into the facility Receiving employee -Reject load in the absence of documentation, test failure, nonapproved supplier -otify supplier that documentation must be received at delivery -Potential removal of supplier from Approved Supplier List -Training of purchasing personnel if product purchased from non-approved supplier and appropriate disciplinary action - Daily review of receiving log and paperwk by QA/QC department - Operational audit perfmed by designated management personnel to make sure Receiving Bulk s SOP is followed -Receiving Bulk s SOP, -Cleanout certificate from carrier -Bill of lading from supplier -Product labeling -Letter of Guarantee from supplier -Receiving log -Approved supplier list -Recd of testing (test strips) -Training log (f purchasing personnel if product came from a nonapproved supplier) FPI 1999 Approved Date: 40
Product Categy: Medicate Dairy Cattle Feed Process Critical Moniting and Hazards Limits f What How Frequency Who CCP each CCP Crective Action Verification Activities Recdkeeping procedure Bulk Ing. Receiving Pit, 1C Aflatoxin 20 ppb Approved supplier, Aflatoxin <20 ppb Visual Use of USDA- FGIS quick test Every load received into the facility Receiving employee -Reject load if test failure, nonapproved supplier -otify supplier that grain contained aflatoxin in excess of 20 ppb -Potential removal of supplier from Approved Supplier List - Daily review of receiving log and paperwk by QA/QC department - Operational audit perfmed by designated management personnel to make sure Receiving Bulk s SOP is followed -Receiving Bulk s SOP, -Receiving log -Approved supplier list -Recd of testing -Training log (f purchasing personnel if product came from a nonapproved supplier) FPI 1999 Approved Date: 41