Importance of HACCP for Feed Safety and Quality

1. Importance of HACCP for Feed Safety and Quality Prof Dr Abdul RazakAlimon Adjunct Professor UGM (Formerly University Putra Malaysia) razalimon@yahoo.co.uk

2. Animal feed must: • Contain all the necessary nutrients required by the animal • Clean, hygienic, free from contamination • Palatable and acceptable to the animal • Sufficient texture for animal to take, chew and swallow • Able to be stored for a certain period of time • Does not change in quality after a period of time • Easy to handle, transport and deliver to animals

3. Reasons for poor quality feed • Source of ingredients • Poor storage of ingredients • Processing of feedstuffs and compound feeds • Formulation of feeds • Packaging and Storage of feeds • Transport and Distribution of feeds

4. Sources of ingredients • Sources tend to vary in composition from different areas due to: • Variety • Soil type • Atmosphere, climate • Harvesting techniques • Drying, processing, storage • contamination

5. Poor storage • Feed after mixing, packaging, • Storage need to be not conducive to growth of molds, bacteria • Right temperature, humidity • Air circulation

6. Processing of feeds • To improve digestibility, hence intake • To improve handling, e.g. pelleting • To remove and destroy toxins, microbials • To increase shelf life • To increase palatability

7. Physical processing Soaking Chopping Grinding Rolling Flaking Hot processing Boiling Steaming Steam pelleting Extrusion Popping autoclaving

8. Processing • Feedmill • Feed quality control very important • GMP • HACCP • Inspection for compliance

10. Feed Formulations • Incorrect info on feed, DM, CP, etc • Incorrect calculations, use of units • Materials used not consistent • Different batches using different sources • Requirements of animals • Age group, production status

11. Packaging and Storage? • Transportation costs • Handling of feeding • Future use • Feed availability • Economic considerations

12. Distribution of feed • Delivery methods • Practice of distribution

13. Good Manufacturing Practice • 1. Quality assurance • 2. Good manufacturing practices for feed and feed ingredients (GMP) • 3. Sanitation and hygiene • 4. Qualification and validation • 5. Complaints • 6. Product recalls • 7. Contract production and analysis • 8. Self-inspection and quality audits

14. Good Manufacturing Practice • 9. Personnel • 10. Training • 11. Personal hygiene • 12. Premises • 13. Equipment • 14. Materials • 15. Documentation • 16. Good practices in production • 17. Good practices in quality control

15. HACCP in Feed Quality Control Hazard Analysis Critical Control Point

16. Intake and cleaning The cleaning of raw materials ensures a problem-free total process and a high-quality semi-finished or end product • Dosing and Weighing The perfect end product and the most economical production method are dependent on the right dosage. Precise harmonization of the components demands a high level of dosing and weighing accuracy. • Grinding Grinding or particle-size reduction is a major function of feed manufacturing. • Mixing In the mixers a wide range of raw materials, additives and liquids are mixed into a homogeneous animal feed mixture.

17. Conditioning The meal is heat treated by the addition of steam in the conditioner before entering the pellet mill • Pelleting In the pellet mill the hot meal is transformed into feed pellets. Animal feed pellets can be produced in several diameters and hardness’s. • Cooling The pellets will be cooled in a counter flow cooler. • Crumbling During crumbling pellets are reduced to crumbs. The size of the crumbs is adapted to the need of the animal and the feeding system.

18. Sieving Sieving may take place at the beginning of the process and after pelleting and crumbling: • Sieving of raw materials is intended to separate sizes. Smaller sizes do not need to be ground. • By sieving the raw materials first the grinding process is optimized and energy can be saved. By sieving pellets and crumbles fines are sorted out, improving the quality of the end product. • Coating - depends on the product, post pellet liquid addition can be applied. • Loading -products are prepared for shipment whether this is in bulk or bags

19. Transport Low-contamination, horizontal or vertical transportation of semi-finished or finished products within the factory. • Storage For an optimal capacity batches are stored in bins and bunkers before and after the main machines • Process Automation To achieve maximum performance of your feed mill, feed mill automation helps you to control and optimise the complete production process.

21. Components of feedmill: Hammermill

22. Horizontal mixer, pellet mill

23. Crusher, rotary shifter

25. What is HACCP • HACCP is a management system in which food safety is addressed through the analysis and control of biological, chemical, and physical hazards from raw material production, procurement and handling, to manufacturing, distribution and consumption of the finished product.

26. Why HACCP • Hazard Analysis Critical Control Points (HACCP) is an internationally recognized method of identifying and managing food safety related risk and, when central to an active food safety program, can provide your customers, the public, and regulatory agencies assurance that a food safety program is well managed.

27. Steps in establishing HACCP • Identify hazards that must be prevented, eliminated or reduced • Identify the critical control points at the step or steps at which control is essential • Establish critical limits at critical control points • Establish and implement effective monitoring procedures at critical control points

28. Steps in establishing HACCP • Establish corrective action when a critical control point is not under control • Establish procedures to verify that the measures outlines in points (a) to (e) are complete and working effectively. • Establish documents and records the effective application of the measures set out in points (a) to (f).

29. Customer requirements The compound feed company needs to: • Identify the important feed safety and economic requirements of different customer groups • Assess whether and how these requirements might be addressed by the company

30. Customer needs: • Productive feeds to ensure efficient and economic animal production • Safe feeds to minimise the risk to animal production from contaminants e.g. Salmonella, dioxin, etc. • These safe feeds are required to give confidence not only to livestock producers but also to • Meat processing industry • Dairies • Egg packers and ultimately the retail trade and consumer

31. What is HACCP?

32. APPLY HACCP • Work on facts • If no facts are available - measure and run trials • If necessary, develop a method • Apply to the mill process

33. Steps & Principles of the HACCP System

34. Terms of Reference of the HACCP • The manufacture of safe animal feedingstuffs • Start at the selection of raw materials and end with delivery to farm • Consider hazards from microbial & chemical contaminants to both human and animal life and health

35. Terms of Reference of the HACCP • Prevention of cross contamination between batches of feed • Ensure the intended feed is manufactured to the correct formulation • Prevention of the contamination of feeds with microbial or chemical contaminants that would: • Cause an animal safety or welfare problem • Result in the presence of residues in meat, milk or eggs above the maximum residue limit or other action limit

36. Team Member Chairman Buyer Product specialist Production operator Engineer Transport planner External assistance Skills Facilitator, HACCP Knowledge of sources of feed materials Animal production Plant operation Plant construction Vehicle operation Assemble the HACCP Team

37. Define the Process • Obtain and check an engineering flow diagram of the feed mill • Divide the process into steps and draw a flow chart – the team will check for hazards at each process step • Describe & understand the production, especially heat treatment and delivery process • List the products made & the feed materials and additives used • List any existing controls designed to prevent contamination

38. Feed mill

39. Feed Mill Equipment for Grinding Feed Ingredients Hammermill Roller Mill

40. Typical Post Grind Feed Mill (computerised process control)

41. Collect information : to identify hazards • Medicine/zootechnical residue analysis of feed • Problem of validation of levels of cross contamination • Microtracers can be used to mimic action of medicines or other additives • If additive used @ 100 mg/kg, microtracer added @ 100 mg/kg • Gives 2,500,000 particles/tonne = 1250 particles in each 0.5 kg of feed

42. Collect Information to IdentifyCross ContaminationHazards • Check physical characteristics of individual additives, medicines & zootechnical substances, e.g. are they electrostatic? Compare granular products & fine powders • Check contamination at hand tip points. Are residues left in hopper or in filter units?

43. RESULTS OF HACCP STUDIES C. The first 2 mixes after additive addition are likely to contain more than 1% of the added level of additive D.Traces of additive as shown by microtracers may be present up to 10 batches after the time of addition.

44. Analyse Information & ConsiderControl Measures • First….. • Modify plant & equipment to remove cross contamination hazards where possible. Engineering controls • Design any new equipment & vehicles to minimise cross contamination.

45. Analyse Information & ConsiderControl Measures • Then….. • Consider each process step in turn • Is a control needed at this step to remove contamination or reduce it to below the critical limits? • A control may be:- • A manual procedure • A computer control

46. CCP No Process Step Critical Control Monitoring 1 Feed material Supplement & Premix Purchase Approved & audited suppliers Supplier analysis data 2 Formulation Control level of any returned product Feed residue analysis 3 Intake Flush intake after intake of medicated returned product Feed residue analysis 4 Blending & weighing Do not add medicines & zootechnical premixes here Feed residue analysis Typical Critical Control Points

47. CCP No Process Step Critical Control Monitoring 5 Hand tip point for Premixes Premixes tipped or blown into mixer. Batch identification. Inspection of hand tip point and flushing if necessary. Filters shake down into same batch Batch records Auditing Cross Contamination trials Maintenance records 6 Mixer Mixer flushed with e.g. wheatfeed, if harmful cross contamination into following batch could occur. Computer controlled Batch records Cross Contamination trials Typical Critical Control Points

48. CCP No Process Step Critical Control Monitoring 7 Press bins Routine inspection & cleaning especially if bin is not self cleaning Hygiene audits 8 Press lines, coolers, sieves, fats coaters Batches scheduled through the plant to prevent harmful cross contamination from one blended batch to to the following batch. Computer controlled e.g. pig finisher feed does not follow pig feed containing sulphamethazine Manager checks press line schedules Feed residue analysis Production records. Typical Critical Control Points

49. CCP No Process Step Critical Control Monitoring 9 Route to & from finished product bins Self cleaning conveyors installed. Timers set correctly. Bins inspected before re-filling. Timers checked if plant changed Auditing 10 Loading vehicles Vehicles inspected before loading. Rules on feed that should not be in adjacent compartments Auditing 11 Delivery on farm Bins & bin labels checked before delivery Delivery records checked Typical Critical Control Points

50. Monitoring the Control Points Control Monitor Improve the controls Are the Controls Working? No Yes Keep records!!