Hazards to Human through Food Chain Bacterial Viral Toxins Drug Residues

Hazards to Human through Food Chain

• Bacterial

• Viral

• Toxins

• Drug Residues

Possible Sources

Bacteria• Breeder Farms

• Hatchery

• Broiler Growing Farms

• Processing Plant

Toxins• Feed

• Farms

Drug Residues:• Broiler Growing Farms

Poultry Breeding

• A team of qualified and experienced Veterinarians to manage entire operations

• Controlled Environment Housing

• All in All out flock placements

• Shower in and Shower out practice for all personnel

• Clean, Pure sanitized water served through automatic drinkers

• Immunization against Viral Diseases

• Regular Serology and Bacteriological Examination at K&N’s Poultry Research and Diagnostic Laboratory established in collaboration with PARC

• Culling of Positive Flocks

• Frequent Histological Examination

Poultry Breeding

• Frequent Egg Collection, Grading and Sanitization

• Integrated Pest Control

• Complete disinfection for a Zero Bacterial Count of houses before each flock replacement

Hatchery Operations

• Controlled Environment for temperature, humidity and air exchange

• Dedicated Incubators for each Breeding farm/flock

• All in All out setting in Hatchers

• Regular Disinfection of entire Hatchery Environment through automatic foggers

• Testing of Air, Floors and Fluffs for bacterial contamination

• Grading of Day Old Chicks

• Vaccination

• Transfer to Farms

Broiler Growing

• Same Practices as followed at Breeding Farms

• Complete Drug Withdrawal 10 days before Harvesting / Slaughtering

Feed Milling

• Testing of each raw material for Bacteria and Toxins and other contaminants

• Storage of Grains in Silos equipped with aeration to prevent buildup of fungus and toxins

• Testing of finished feed for nutritional profile

• Palletization of feed at high temperatures to kill molds and bacteria, if any

• Lab test for Nutritional Profile and Phyto-sanitary Testing before dispatch to the farms

Processing

• Operations include Primary Poultry Processing, production of Ready-to-Cook and Fully Cooked Value Added Chicken Products

• Air conditioned environment to prevent bacteria build up

• Thorough wash down of entire plant and machinery each day followed by Lab tests for confirmation of bacteria free equipment

• Personnel Hygiene and Health monitoring – Salmonella and Hepatitis

• In-house laundry for daily washing of uniforms

• In process chilling of carcass to prevent build up of bacteria

Processing

• Blast Freezing at -35°C to ensure food safety and maintain freshness

• Value Added Products from fryer at 60°C to -18°C core temperature, Individually Quick Frozen (IQF) in 30-40 minutes to enhance food safety, product taste and appearance with better retention of all essential nutrients

Quality Assurance

• Periodic supplier audits and strict raw materials inspection and lab testing

• QC checks on all operational facilities, processes and finished products

• Open to International Customers quality audit for compliance

Sample Test

Item Description Frequency Name Frequency

PRIMARY PROCESSING

Raw Meat Daily

TPC

On daily basisSalmonella

E.Coli

Coliform

Once a week

Mold

Yeast

Staph

Clostridium

In Process Chilled Carcass

Daily

TPC

On daily basisE.Coli

Salmonella

Microbiological Tests Conducted and their Frequency

Sample Test

Item Description Frequency Name Frequency

FURTHER PROCESSING

Value-Added Products (Ready-to-Cook and Fully

Cooked)

Daily

TPC (For Parfried)For each sample

TPC (For Cooked)

Salmonella

Alternate for each cooked product

E.Coli

Coliform

Staph

ListeriaCooked products

(Once a week)

Clostridium Once a month

Mold For each parfried product

Yeast For each parfried product

Sample Test

Item Description Frequency Name Frequency

FURTHER PROCESSING

Retail Outlets Once a Month

TPC (For Parfried)

For each sample

TPC (For Cooked)

Salmonella

E.Coli

Coliform

Staph

Clostridium

Mold

Yeast

Quality Assurance

• Monitoring and recording of temperature during various stages of processing for compliance to HACCP guidelines

• Constant update and conducting prerequisite internal QA audits to gear up for bi-annual HACCP and ISO 9001:2000 audits

• Implementation and reviewing the integrated pest control program

• Waste water treatment before discharging out

• Dedicated outdoor QA team

• Regular team visits to retail market for verifying freezer temperatures and evaluating product storage condition

Distribution

• Fleet of company owned refrigerated trucks and distribution centers in major cities for complete control over distribution of products to K&N’s Chicken Stores and other retailers and institutions for better quality control

• Strict temperature monitoring and control through computerized data loggers in delivery trucks to ensure proper cold-chain management