03n 0312-ts00002-vol1-1
- 1. A Comprehensive Feed Safety Approach for Rendered Products FDA Public Meeting Discussion of Animal Feed Safety System September 23, 2003 David Harlan Taylor Packing Co., Inc An Excel Food Solutions Company
- 2. Animal Feed Manufacture Pet Foods Food Animal Production Rendered Co-Products Feed Ingredients Meat Processing Consumer Foods Rendering Cycle Plays a Critical Role
- 3. Beef Processing Typical Fed-Cattle Plant USDA Ante mortem Blood Drying Dressing Floor Inedible Rendering Fabrication Further Process Edible Beef Products Edible Rendering Feed & Technical
- 4. Beef Processing Taylor Packing USDA Ante mortem Dressing Floor Fabrication Blood Drying Inedible Rendering Further Process Edible Beef Products Feed & Technical
- 5. Taylor Rendering Process Dressing Offal MIX & GRIND FILTER TANK Liquid LOADOUT/ BLENDING C O O K E R BEEF TALLOW TANKS CENTRIFUGE Fab Bone & Fat STORAGE SCREEN GRIND/SCREEN COOLER Solid PRESS (3)
- 6. Comprehensive Program Philosophy & Commitment Raw Material Source, Specifications & Assurances Hazard Analysis & Critical Control Point program Good Manufacturing Practices Employee Training Programs Transportation Policy Third Party Audits
- 7. Philosophy & Commitment Preventative Mindset Proactive vs. Reactive Continuous Improvement Commitment from Entire Team – – – Leadership Management Production
- 8. Raw Material Specifications In-House Packer Source – 100% Bovine with mixed supply from 70% mature cows and 30% fed-cattle 100% from Cattle Passing Ante Mortem Inspection Conducted by USDA:FSIS Veterinarian Packinghouse Training & Awareness Relative to Potential Physical & Chemical Contaminants CNS Tissue Removed in Packinghouse
- 9. Hazard Analysis and Critical Control Point (HACCP) 7 Principles 1. 2. 3. 4. 5. 6. 7. Assess Hazards Determine Critical Control Points – CCP Establish Critical Limits for CCP’s – CCPCL Procedures to Monitor CCP’s Develop Corrective Action Plans Recordkeeping Verification
- 10. Potential Hazards 3 Classes Biological – Microbiological – Insect Infestation – TSE’s Chemical – Pesticides & PCB’s – Lubricants, oils, etc. Physical – Metal – Plastic
- 11. HACCP Example Microbiological - Pasteurization Assess Hazard 1. • 1. Raw material contains potential pathogens Determine Critical Control Points – CCP a. Cooker discharge temperature - TEMP b. Raw material grind - GRIND c. Processing rate - RATE 2. Establish Critical Limits for CCP’s – CCPCL a. TEMP - Minimum 270o F based on validation study b. GRIND - Maximum 30 mm anvil gap on pre-breaker c. RATE - Maximum 36,000 pounds/hour feed rate
- 12. HACCP – Microbiological Continued 4. Procedures to Monitor CCP’s a. TEMP - Continuous monitoring by certified thermocouple b. GRIND - Inspection, Weekly measurement of anvil gap c. RATE - Computer tracking of cooker feed auger 5. Develop Corrective Action Plans a. TEMP - Alarm notification, automated discharge shutoff b. GRIND - Repair, Rebuild when gap reaches 30 mm c. RATE - Reduce feed rate if over 36,000 pounds/hour
- 13. HACCP – Microbiological Continued Recordkeeping 6. a. TEMP - Computer tracking of CCP and alarm log b. GRIND - Operations & maintenance logs c. RATE - Computer tracking of CCP and alarm log Verification 6. • • • Clostridium perfringens testing – indicator organism 15 day intervals Rotate shift and time within shift
- 16. Good Manufacturing Practices (GMP) Housekeeping Issues Recordkeeping Pest Control Program Facility Design & Repair Sanitation Program Startup & Shutdown Procedures
- 17. GMP Example Prevent Salmonella Recontamination APPI model adopted by +99% of industry Process zones in facility Work habits & policies Startup procedures Reprocessing of product spills Dry cleaning of finished product areas Sanitation practices that target “hot spots” Facility design & equipment maintenance Effectiveness verified by finished product testing No CCP available except formaldehyde addition
- 18. Employee Training Specific Modules on HACCP, GMP’s and SOP’s New Hires – Entry at Trainee position – Individualized training over several months Career Advancement – Training program for each position – Certified by written & verbal testing All Employee’s – Quarterly quality training – Immediate team review of feed safety issues
- 19. Transportation Policy Certification of regulatory compliance by carriers Trucks are only to haul agricultural commodities Trucks are to be clean prior to arrival Visual inspection of empty trucks upon arrival – No visible carryover regardless of past ingredient hauled – Will the integrity of our product be maintained? Assurance of cleanout after delivery – – Included in policy signed by carriers & drivers Prominent reminder to driver attached to Bill of Lading Clean Conveyances and Inspection Prior to Loading Is the Responsibility of Every Ingredient Supplier!!
- 20. Third Party Audits 21 CFR 589.2000 APPI Certification via Cook & Thurber – – – Found high compliance in Rendering Industry Confirmed by FDA Inspections Discontinued because of high compliance Facility Certification Institute - FCI – – – – Requirements are based upon FDA rule Must prove compliance with FCI program Ingredient supplier and transport certifications Must demonstrate adequacy of flushing when co-mingling restricted use products – Annual audits to maintain status in program
- 21. Thank You Special Thanks To: Debby Capela, Taylor Packing The Taylor & Excel Rendering Team
Editor's Notes
- #2: Thank Dr. Erdtmann and the Institute of Medicine for the invitation. My background is primarily from the rendering side of the beef packing industry. Presentation will cover both the edible beef processing and rendering sides of the business.
- #4: Fed cattle are typically processed in the following manner. A large beef processing facility will process 4 to 6,000 head of cattle each day. Prior to entering the dressing floor, the USDA conducts ante mortem inspection on the live animal. The animal is stunned, bled and then dressed during which the USDA conducts post mortem inspection on the carcass and organs. Once complete the sides of beef are chilled for several days. Then they are fabricated into wholesale beef cuts. These cuts and meat trimmings can be further processed on site into case ready or ground beef products or shipped to specialized meat processing facilities. Inedible portions of the carcass generated during dressing are sent to an inedible rendering plant for the production of MBM and tallow. However, bones and fat trimmings from fabrication go to a separate edible rendering process where fat is melted to produce edible tallow and dried bone is sold for gelatin manufacture. In addition blood is processed to produce a dried blood meal.
- #5: While very similar to fed-cattle plants, cow plants are typically smaller in scale and generally do not contain an edible rendering process. This schematic is typical of Taylor Packing where we processes around 1900 head of cattle a day the majority being cull dairy cows. Materials generated from both the dressing and fabrication steps are mixed together and then rendered.