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03n 0312-ts00002-vol1-1
 

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  • Thank Dr. Erdtmann and the Institute of Medicine for the invitation. <br /> My background is primarily from the rendering side of the beef packing industry. <br /> Presentation will cover both the edible beef processing and rendering sides of the business. <br />
  • Fed cattle are typically processed in the following manner. <br /> A large beef processing facility will process 4 to 6,000 head of cattle each day. <br /> Prior to entering the dressing floor, the USDA conducts ante mortem inspection on the live animal. <br /> The animal is stunned, bled and then dressed during which the USDA conducts post mortem inspection on the carcass and organs. <br /> Once complete the sides of beef are chilled for several days. Then they are fabricated into wholesale beef cuts. <br /> 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. <br /> Inedible portions of the carcass generated during dressing are sent to an inedible rendering plant for the production of MBM and tallow. <br /> 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. <br /> In addition blood is processed to produce a dried blood meal. <br />
  • While very similar to fed-cattle plants, cow plants are typically smaller in scale and generally do not contain an edible rendering process. <br /> This schematic is typical of Taylor Packing where we processes around 1900 head of cattle a day the majority being cull dairy cows. <br /> Materials generated from both the dressing and fabrication steps are mixed together and then rendered. <br />

03n 0312-ts00002-vol1-1 03n 0312-ts00002-vol1-1 Presentation Transcript

  • 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
  • Animal Feed Manufacture Pet Foods Food Animal Production Rendered Co-Products Feed Ingredients Meat Processing Consumer Foods Rendering Cycle Plays a Critical Role
  • 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
  • Beef Processing Taylor Packing USDA Ante mortem Dressing Floor Fabrication Blood Drying Inedible Rendering Further Process Edible Beef Products Feed & Technical
  • 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)
  • 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
  • Philosophy & Commitment Preventative Mindset  Proactive vs. Reactive  Continuous Improvement  Commitment from Entire Team  – – – Leadership Management Production
  • 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
  • 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
  • Potential Hazards 3 Classes  Biological – Microbiological – Insect Infestation – TSE’s  Chemical – Pesticides & PCB’s – Lubricants, oils, etc.  Physical – Metal – Plastic
  • 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
  • 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
  • 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
  • Plant Operator Screen
  • Recordkeeping Cooker Temperature Trending and Statistical Analysis
  • Good Manufacturing Practices (GMP) Housekeeping Issues  Recordkeeping  Pest Control Program  Facility Design & Repair  Sanitation Program  Startup & Shutdown Procedures 
  • 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
  • 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
  • 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!!
  • 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
  • Thank You Special Thanks To: Debby Capela, Taylor Packing The Taylor & Excel Rendering Team