Doane Pet Care CompanyDoane Pet Care Company

Pet Food Safety System (PFSS)Pet Food Safety System (PFSS)

M.W. MerkelM.W. MerkelSeptember 23, 2003September 23, 2003

Animal Feed Safety System Public MeetingAnimal Feed Safety System Public Meeting

Our MissionOur Mission - ‘ the trusted partner of - ‘ the trusted partner of choice for our customers brands ’choice for our customers brands ’

Our Primary ResponsibilityOur Primary Responsibility - assure all - assure all pet foods & treats we manufacture and pet foods & treats we manufacture and distribute are safe & wholesome for petsdistribute are safe & wholesome for pets

Our Means of AssuranceOur Means of Assurance - DPC’s Pet - DPC’s Pet Food Safety System (P.F.S.S.)Food Safety System (P.F.S.S.)

DPC - PFSSDPC - PFSS

DPC – PFSSDPC – PFSSRisk – Based Preventative SystemRisk – Based Preventative System Detailed analysis of pet food processing Detailed analysis of pet food processing

systemssystems

Identification of potential food safety hazards and Identification of potential food safety hazards and assessment of process & product risksassessment of process & product risks

Implementation of adequate process control measures Implementation of adequate process control measures including employee trainingincluding employee training

Verification & documentation that control measures are Verification & documentation that control measures are rigorously followedrigorously followed

Validation that prevention systems are effectiveValidation that prevention systems are effective

DPC – PFSSDPC – PFSSRisk – Based Preventative SystemRisk – Based Preventative System Detailed Analysis of every pet food processing Detailed Analysis of every pet food processing

system at each plantsystem at each plant Identification of potential food safety hazards and Identification of potential food safety hazards and

assessment of process & product risksassessment of process & product risks Implementation of adequate process control Implementation of adequate process control

measures including employee trainingmeasures including employee training Verification & documentation that control Verification & documentation that control

measures are rigorously followedmeasures are rigorously followed Validate that prevention systems are effectiveValidate that prevention systems are effective

DPC – PFSSDPC – PFSSPet Food Safety by DesignPet Food Safety by Design Buildings (Pest-Proof, clean & secure)Buildings (Pest-Proof, clean & secure)

Grounds (Harborage-free & secured)Grounds (Harborage-free & secured)

Processing Equipment ( Safe & Sanitary )Processing Equipment ( Safe & Sanitary )

Packaging ( Tamper Resistant )Packaging ( Tamper Resistant )

People ( Trained & Engaged in PFSS )People ( Trained & Engaged in PFSS )

DPC – PFSSDPC – PFSSKey System ComponentsKey System Components

– Ingredient IntegrityIngredient Integrity– Quality ManualQuality Manual– Sanitation & Microbiological ControlSanitation & Microbiological Control– Integrated Pest ManagementIntegrated Pest Management– Control of Foreign MaterialControl of Foreign Material– TraceabilityTraceability– Validation by AuditValidation by Audit– Continuous ImprovementContinuous Improvement

DPC - PFSS DPC - PFSS Quality ManualQuality Manual

Uniform policies, standards & procedures Uniform policies, standards & procedures ISO - 9000 BasedISO - 9000 Based

Updated by a plant & corporate teamUpdated by a plant & corporate team

Controlled and audited documentControlled and audited document

DPC - PFSS DPC - PFSS Ingredient IntegrityIngredient Integrity Vendor Q. A. Program CertificationVendor Q. A. Program Certification Joint Program – Quality & PurchasingJoint Program – Quality & Purchasing

– Ingredient Quality ManagerIngredient Quality Manager– On-site inspections On-site inspections – Sampling & analysis of shipmentsSampling & analysis of shipments– Plant mycotoxin testing & rejection capabilityPlant mycotoxin testing & rejection capability– Vehicle InspectionVehicle Inspection

Documentation Documentation Physical Inspection & Bottom SamplingPhysical Inspection & Bottom Sampling

DPC - PFSSDPC - PFSS

DPC - PFSS DPC - PFSS Ingredient IntegrityIngredient Integrity Vendor Q. A. Program CertificationVendor Q. A. Program Certification Joint Program – Quality & PurchasingJoint Program – Quality & Purchasing

– Ingredient Quality ManagerIngredient Quality Manager– On-Site inspections On-Site inspections – Analysis of Ingredient ShipmentsAnalysis of Ingredient Shipments– Plant mycotoxin testing & rejection capabilityPlant mycotoxin testing & rejection capability

– Vehicle InspectionVehicle Inspection Documentation Documentation Physical Inspection & Bottom SamplingPhysical Inspection & Bottom Sampling

DPC - PFSS DPC - PFSS

DPC – PFSSDPC – PFSSSanitation & Microbiological ControlSanitation & Microbiological Control Plant-Specific Sanitation Schedule & SSOP’sPlant-Specific Sanitation Schedule & SSOP’s Conducted at plant by Quality Assurance Conducted at plant by Quality Assurance

– Facilities designFacilities design– Controlled movement of employees & materials Controlled movement of employees & materials – Sensitive Ingredient pre-delivery test and certificationSensitive Ingredient pre-delivery test and certification– Microbiological monitoringMicrobiological monitoring

Plant - Specific environmental micro mappingPlant - Specific environmental micro mapping In Process & Finished ProductIn Process & Finished Product

– Technical Services LaboratoryTechnical Services Laboratory Full micro capabilities including pertinent pathogens Full micro capabilities including pertinent pathogens Training & On-Site facilities supportTraining & On-Site facilities support

DPC – PFSSDPC – PFSS

DPC – PFSSDPC – PFSSIntegrated Pest ManagementIntegrated Pest Management Plant - Specific Master Pest Control SchedulePlant - Specific Master Pest Control Schedule

– Mechanical ExclusionMechanical Exclusion– Non – pesticide controlsNon – pesticide controls– PesticidesPesticides

Nationally Contracted Pest Control FirmsNationally Contracted Pest Control Firms– TrainingTraining– Electronic pest activity / service trackingElectronic pest activity / service tracking– FumigationFumigation

DPC – PFSSDPC – PFSSForeign Material PreventionForeign Material Prevention Ingredient levelIngredient level

– Vendor audits + transport vehicles & trailersVendor audits + transport vehicles & trailers– Magnets at unloading and key transfersMagnets at unloading and key transfers

Audit of carriers and warehousesAudit of carriers and warehouses Inspection of building and equipmentInspection of building and equipment

– Magnets at key transfersMagnets at key transfers– Metal detection at packagingMetal detection at packaging

DPC – PFSSDPC – PFSS

DPC – PFSSDPC – PFSSForeign Material PreventionForeign Material Prevention Ingredient levelIngredient level

– Vendor audits including transport vehicles and trailersVendor audits including transport vehicles and trailers– Magnets at unloading and key transfersMagnets at unloading and key transfers

Audit of carriers and warehouses Audit of carriers and warehouses Inspection of building and equipmentInspection of building and equipment

– Magnets at key transfersMagnets at key transfers– Metal detection at packagingMetal detection at packaging

Preventive maintenance and repairPreventive maintenance and repair Evaluation of customer complaintsEvaluation of customer complaints HOLD system to identify nonconforming HOLD system to identify nonconforming

materials and prevent use and distributionmaterials and prevent use and distribution

DPC – PFSSDPC – PFSST r a c e a b i l i t yT r a c e a b i l i t y Ingredient levelIngredient level

– Lot number on bagged ingredientsLot number on bagged ingredients– Bin designation on bulk receiving paperworkBin designation on bulk receiving paperwork– Origin information on receiving paperworkOrigin information on receiving paperwork

Finished product levelFinished product level– Printed code date checksPrinted code date checks– Mock trace & retrievalMock trace & retrieval

Graded by Quality Systems ManagerGraded by Quality Systems Manager Score counts toward plant performance objectivesScore counts toward plant performance objectives

Ingredient receipt and production archive Ingredient receipt and production archive documentation included in auditsdocumentation included in audits

DPC – PFSSDPC – PFSSFood Safety Audits & Continuous Food Safety Audits & Continuous ImprovementImprovement Internal GMP / FS audit at all plantsInternal GMP / FS audit at all plants

– Auditors originally plant Quality Assurance CoordinatorsAuditors originally plant Quality Assurance Coordinators External GMP / FS audit at all plantsExternal GMP / FS audit at all plants

– Nationally recognized independent food safety experts Nationally recognized independent food safety experts – Scores count toward plant performance objectivesScores count toward plant performance objectives

Customer quality auditsCustomer quality audits– Customer representatives or consultants Customer representatives or consultants

Continuing educationContinuing education– Restricted use protein products control procedures; public Restricted use protein products control procedures; public

health, security & bio-terrorism preparedness acthealth, security & bio-terrorism preparedness act PFSS must be flexible, cost effective and PFSS must be flexible, cost effective and

appropriate for each specific applicationappropriate for each specific application

DPC’s DPC’s PFSSPFSS Beneficiaries Beneficiaries