This document summarizes David Harlan's presentation on Taylor Packing Co.'s comprehensive animal feed safety approach for rendered products. Some key points:
1) Rendering plays a critical role in recycling animal co-products and waste into useful feed and technical ingredients.
2) Taylor has a preventative and proactive philosophy ensuring raw material quality and compliance with HACCP, GMPs, training programs, and third-party audits.
3) Potential hazards include biological, chemical and physical contaminants which are controlled through critical control points and limits during rendering and transportation.
The Document will help you up to create a HACCP plan for cooked meat " not shelf stable" that includes all related documents with instructions to assist food safety specialist to create and establish and implement HACCP plan food catering and food products in general.
Have a look, when ever you need any assistance please contact me via:
Skype: Karam2013
Email: Eng.karam@outlook.com OR VIA
Mobile: +962780777241
The Document will help you up to create a HACCP plan for cooked meat " not shelf stable" that includes all related documents with instructions to assist food safety specialist to create and establish and implement HACCP plan food catering and food products in general.
Have a look, when ever you need any assistance please contact me via:
Skype: Karam2013
Email: Eng.karam@outlook.com OR VIA
Mobile: +962780777241
How is Haccp used in the food industry?
What is Haccp in food service?
What are the seven principles of Haccp?
What is Haccp and why is it used in food production?What is HACCP? What are its 7 Principles?
Food Businesses and Food Safety in INDIA
Seven Principles of Hazard Analysis Critical Control Point for food safety management system based on the principles of will enable hazards to be identified and controlled
Hazard Analysis and Critical Control Point (HACCP)
Program
PLAN - D Raw, Ground Meat and Poultry
Principle 2 - CCP Determination
Product: A critical control point is defined as a point, step or procedure at which control can be applied and
a food safety hazard can be prevented, eliminated or reduced to acceptable levels.
The Safety measures of Pineapple Jam can be improved, maintained and sustained by implementing HACCP Plan, as it covers all aspects during raw pineapple conversion to Pineapple Jam
Control of temperature and time duration in boiling unit and Quantity of Pectin and Temperature during Gelatinization are CCPs.
To obtained good hygienic Pineapple Jam these CCPs must be controlled and HACCP Plan must revised every year.
HACCP allows manufacturers to identify hazards as they could occur through the stages of production so that adequate measures can be implemented so they can be prevent
Drainage in Commercial Kitchens is a Pre-Requisite of HACCP Food Safety Manag...Work Safe Scotland Ltd
Grease Management and Hazard Control
Food preparation and production in commercial kitchens or food processing factories naturally generate fats, oils and grease (FOG) in the waste water which can quickly lead to a build-up of solid residues in the drainage system restricting efficient flow of waste water and ultimately create blockages that can result in flooding of the food preparation area.
Unless adequate steps are taken to effectively manage FOG at source, local health and hygiene management is under extreme risk from the effects of odour, contaminated water and vermin. There area number of methods available to the specifier and user to manage FOG and an appreciation of the merits and disadvantages of each
system will be provided along with performance indicators.
Hygiene management is essential and Regulation (EC) 852/2004 applies to all food businesses and food operators. Article 5 (1) requires that permanent HACCP procedures are applied and importantly, drainage forms a pre-requisite to the supporting structure of HACCP.
What is HACCP? (Hazards Analysis Critical Control Point). This presentation provides a basic understanding of HACCP plus a history of its beginnings and how it became adopted by the food international food industry.
Is your fleet prepared to meet the new food safety requirements under FSMA? Learn about the regulations and how to keep food safe in the supply chain from end to end.
Safe feed and food starts with secure risk management. For this, GMP+ International offers knowledge and information through the Feed Support Products (FSP). The Feed Support Products are intended to support all (future) GMP+ certified companies when setting up their company-specific HACCP system
Aquatic feed production has undergone tremendous changes as the industry has advanced towards efficiency and sustainability of the aquaculture industry.
How is Haccp used in the food industry?
What is Haccp in food service?
What are the seven principles of Haccp?
What is Haccp and why is it used in food production?What is HACCP? What are its 7 Principles?
Food Businesses and Food Safety in INDIA
Seven Principles of Hazard Analysis Critical Control Point for food safety management system based on the principles of will enable hazards to be identified and controlled
Hazard Analysis and Critical Control Point (HACCP)
Program
PLAN - D Raw, Ground Meat and Poultry
Principle 2 - CCP Determination
Product: A critical control point is defined as a point, step or procedure at which control can be applied and
a food safety hazard can be prevented, eliminated or reduced to acceptable levels.
The Safety measures of Pineapple Jam can be improved, maintained and sustained by implementing HACCP Plan, as it covers all aspects during raw pineapple conversion to Pineapple Jam
Control of temperature and time duration in boiling unit and Quantity of Pectin and Temperature during Gelatinization are CCPs.
To obtained good hygienic Pineapple Jam these CCPs must be controlled and HACCP Plan must revised every year.
HACCP allows manufacturers to identify hazards as they could occur through the stages of production so that adequate measures can be implemented so they can be prevent
Drainage in Commercial Kitchens is a Pre-Requisite of HACCP Food Safety Manag...Work Safe Scotland Ltd
Grease Management and Hazard Control
Food preparation and production in commercial kitchens or food processing factories naturally generate fats, oils and grease (FOG) in the waste water which can quickly lead to a build-up of solid residues in the drainage system restricting efficient flow of waste water and ultimately create blockages that can result in flooding of the food preparation area.
Unless adequate steps are taken to effectively manage FOG at source, local health and hygiene management is under extreme risk from the effects of odour, contaminated water and vermin. There area number of methods available to the specifier and user to manage FOG and an appreciation of the merits and disadvantages of each
system will be provided along with performance indicators.
Hygiene management is essential and Regulation (EC) 852/2004 applies to all food businesses and food operators. Article 5 (1) requires that permanent HACCP procedures are applied and importantly, drainage forms a pre-requisite to the supporting structure of HACCP.
What is HACCP? (Hazards Analysis Critical Control Point). This presentation provides a basic understanding of HACCP plus a history of its beginnings and how it became adopted by the food international food industry.
Is your fleet prepared to meet the new food safety requirements under FSMA? Learn about the regulations and how to keep food safe in the supply chain from end to end.
Safe feed and food starts with secure risk management. For this, GMP+ International offers knowledge and information through the Feed Support Products (FSP). The Feed Support Products are intended to support all (future) GMP+ certified companies when setting up their company-specific HACCP system
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In beverage processing, Quality Control (QC) is vital for ensuring product safety and consistency. Critical Control Points (CCPs) are meticulously identified and monitored to mitigate risks throughout the production process. Through stringent QC protocols and CCP implementation, we uphold the highest standards of quality, guaranteeing that every sip of our beverage delights consumers with unmatched taste and safety assurance.
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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
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
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
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.
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.
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.