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A Comprehensive Feed SafetyA Comprehensive Feed SafetyApproach for Rendered Products Approach for Rendered Products
FDA Public MeetingFDA Public MeetingDiscussion of Animal Feed Safety SystemDiscussion of Animal Feed Safety System
September 23, 2003September 23, 2003
David HarlanTaylor Packing Co., Inc An Excel Food Solutions Company
Food Animal Production
Pet Foods
RenderedCo-Products
Animal FeedManufacture
Meat Processing
Feed Ingredients
ConsumerFoods
Rendering Cycle Plays a Critical Role
Dressing Floor
Fabrication
Further Process
Edible Beef Products
Inedible Rendering
Beef ProcessingBeef Processing Typical Fed-Cattle PlantTypical Fed-Cattle Plant
Blood Drying
EdibleRendering
Feed & Technical
USDA Ante mortem
Dressing Floor
Fabrication
Edible Beef Products
Inedible Rendering
Beef ProcessingBeef ProcessingTaylor PackingTaylor Packing
Blood Drying
Feed & Technical
USDA Ante mortem
Further Process
CENTRIFUGE
Dressing Offal
COOKER
Taylor Rendering ProcessTaylor Rendering Process
MIX & GRIND
Fab Bone & Fat
PRESS (3)SCREENSolidLiquid
COOLER
STORAGE
GRIND/SCREEN
LOADOUT/BLENDING
TANK
FILTER
BEEF TALLOWTANKS
Comprehensive ProgramComprehensive Program
Philosophy & CommitmentPhilosophy & Commitment Raw Material Source, Specifications & AssurancesRaw Material Source, Specifications & Assurances Hazard Analysis & Critical Control Point programHazard Analysis & Critical Control Point program Good Manufacturing PracticesGood Manufacturing Practices Employee Training ProgramsEmployee Training Programs Transportation PolicyTransportation Policy Third Party Audits Third Party Audits
Philosophy & CommitmentPhilosophy & Commitment
Preventative MindsetPreventative Mindset Proactive vs. ReactiveProactive vs. Reactive Continuous ImprovementContinuous Improvement Commitment from Entire TeamCommitment from Entire Team
– LeadershipLeadership– ManagementManagement– ProductionProduction
Raw Material SpecificationsRaw Material Specifications
In-House Packer Source – 100% Bovine with mixed In-House Packer Source – 100% Bovine with mixed supply from 70% mature cows and 30% fed-cattle supply from 70% mature cows and 30% fed-cattle
100% from Cattle Passing Ante Mortem Inspection 100% from Cattle Passing Ante Mortem Inspection Conducted by USDA:FSIS VeterinarianConducted by USDA:FSIS Veterinarian
Packinghouse Training & Awareness Relative to Packinghouse Training & Awareness Relative to Potential Physical & Chemical ContaminantsPotential Physical & Chemical Contaminants
CNS Tissue Removed in PackinghouseCNS Tissue Removed in Packinghouse
Hazard Analysis and Critical Hazard Analysis and Critical Control Point (HACCP) Control Point (HACCP)
7 Principles7 Principles
1.1. Assess Hazards Assess Hazards
2.2. Determine Critical Control Points – CCPDetermine Critical Control Points – CCP
3.3. Establish Critical Limits for CCP’s – CCPCLEstablish Critical Limits for CCP’s – CCPCL
4.4. Procedures to Monitor CCP’sProcedures to Monitor CCP’s
5.5. Develop Corrective Action PlansDevelop Corrective Action Plans
6.6. RecordkeepingRecordkeeping
7.7. Verification Verification
Potential HazardsPotential Hazards3 Classes3 Classes
BiologicalBiological– MicrobiologicalMicrobiological
– Insect InfestationInsect Infestation
– TSE’sTSE’s
ChemicalChemical– Pesticides & PCB’sPesticides & PCB’s
– Lubricants, oils, etc.Lubricants, oils, etc.
PhysicalPhysical– MetalMetal
– Plastic Plastic
HACCP Example HACCP Example Microbiological - PasteurizationMicrobiological - Pasteurization
1.1. Assess HazardAssess Hazard• Raw material contains potential pathogensRaw material contains potential pathogens
2.2. Determine Critical Control Points – CCPDetermine Critical Control Points – CCPa.a. Cooker discharge temperature - Cooker discharge temperature - TEMPTEMPb.b. Raw material grind - Raw material grind - GRINDGRINDc.c. Processing rate - Processing rate - RATERATE
3.3. Establish Critical Limits for CCP’s – CCPCLEstablish Critical Limits for CCP’s – CCPCLa.a. TEMPTEMP - Minimum 270 - Minimum 270oo F based on validation study F based on validation study b.b. GRINDGRIND - Maximum 30 mm anvil gap on pre-breaker - Maximum 30 mm anvil gap on pre-breakerc.c. RATERATE - Maximum 36,000 pounds/hour feed rate - Maximum 36,000 pounds/hour feed rate
HACCP – MicrobiologicalHACCP – MicrobiologicalContinuedContinued
4.4. Procedures to Monitor CCP’sProcedures to Monitor CCP’sa.a. TEMPTEMP - Continuous monitoring by certified - Continuous monitoring by certified
thermocouplethermocouple
b.b. GRINDGRIND - Inspection, Weekly measurement of anvil gap - Inspection, Weekly measurement of anvil gap
c.c. RATERATE - Computer tracking of cooker feed auger - Computer tracking of cooker feed auger
5.5. Develop Corrective Action PlansDevelop Corrective Action Plansa.a. TEMPTEMP - Alarm notification, automated discharge shutoff - Alarm notification, automated discharge shutoff
b.b. GRINDGRIND - Repair, Rebuild when gap reaches 30 mm - Repair, Rebuild when gap reaches 30 mm
c.c. RATERATE - Reduce feed rate if over 36,000 pounds/hour - Reduce feed rate if over 36,000 pounds/hour
HACCP – MicrobiologicalHACCP – MicrobiologicalContinuedContinued
6.6. RecordkeepingRecordkeepinga.a. TEMPTEMP - Computer tracking of CCP and alarm log - Computer tracking of CCP and alarm log
b.b. GRINDGRIND - Operations & maintenance logs - Operations & maintenance logs
c.c. RATERATE - Computer tracking of CCP and alarm log - Computer tracking of CCP and alarm log
7.7. Verification Verification • Clostridium perfringens testing – indicator organismClostridium perfringens testing – indicator organism
• 15 day intervals 15 day intervals
• Rotate shift and time within shiftRotate shift and time within shift
Plant Operator Screen
RecordkeepingCooker TemperatureTrending and Statistical Analysis
Good Manufacturing Practices Good Manufacturing Practices (GMP)(GMP)
Housekeeping IssuesHousekeeping Issues RecordkeepingRecordkeeping Pest Control ProgramPest Control Program Facility Design & RepairFacility Design & Repair Sanitation ProgramSanitation Program Startup & Shutdown Procedures Startup & Shutdown Procedures
GMP ExampleGMP Example Prevent Salmonella RecontaminationPrevent Salmonella Recontamination
APPI model adopted by +99% of industryAPPI model adopted by +99% of industry Process zones in facilityProcess zones in facility Work habits & policiesWork habits & policies Startup procedures Startup procedures Reprocessing of product spillsReprocessing of product spills Dry cleaning of finished product areasDry cleaning of finished product areas Sanitation practices that target “hot spots”Sanitation practices that target “hot spots” Facility design & equipment maintenanceFacility design & equipment maintenance Effectiveness verified by finished product testingEffectiveness verified by finished product testing
No CCP available except formaldehyde additionNo CCP available except formaldehyde addition
Employee TrainingEmployee Training Specific Modules on HACCP, GMP’s and SOP’sSpecific Modules on HACCP, GMP’s and SOP’s New Hires New Hires
– Entry at Trainee positionEntry at Trainee position– Individualized training over several monthsIndividualized training over several months
Career Advancement Career Advancement – Training program for each positionTraining program for each position– Certified by written & verbal testing Certified by written & verbal testing
All Employee’s All Employee’s – Quarterly quality trainingQuarterly quality training– Immediate team review of feed safety issuesImmediate team review of feed safety issues
Transportation PolicyTransportation Policy Certification of regulatory compliance by carriersCertification of regulatory compliance by carriers Trucks are only to haul agricultural commoditiesTrucks are only to haul agricultural commodities Trucks are to be clean Trucks are to be clean priorprior to arrival to arrival Visual inspection of empty trucks upon arrivalVisual inspection of empty trucks upon arrival
– No visible carryover regardless of past ingredient hauledNo visible carryover regardless of past ingredient hauled– Will the integrity of our product be maintained?Will the integrity of our product be maintained?
Assurance of cleanout after delivery Assurance of cleanout after delivery – Included in policy signed by carriers & driversIncluded in policy signed by carriers & drivers– Prominent reminder to driver attached to Bill of LadingProminent reminder to driver attached to Bill of Lading
Clean Conveyances and Inspection Prior to LoadingIs the Responsibility of Every Ingredient Supplier!!
Third Party AuditsThird Party Audits21 CFR 589.200021 CFR 589.2000
APPI Certification via Cook & ThurberAPPI Certification via Cook & Thurber– Found high compliance in Rendering IndustryFound high compliance in Rendering Industry– Confirmed by FDA Inspections Confirmed by FDA Inspections – Discontinued because of high complianceDiscontinued because of high compliance
Facility Certification Institute - FCIFacility Certification Institute - FCI– Requirements are based upon FDA ruleRequirements are based upon FDA rule– Must prove compliance with FCI programMust prove compliance with FCI program– Ingredient supplier and transport certificationsIngredient supplier and transport certifications– Must demonstrate adequacy of flushing when co-Must demonstrate adequacy of flushing when co-
mingling restricted use productsmingling restricted use products– Annual audits to maintain status in programAnnual audits to maintain status in program
Thank YouThank You
Special Thanks To:Special Thanks To:Debby Capela, Taylor Packing Debby Capela, Taylor Packing
The Taylor & Excel Rendering TeamThe Taylor & Excel Rendering Team