Practices and procedure at different stages of feed plant operation (HACCPs) to prevent contamination and safe feed production

1. Good Manufacturing
Practices (GMPs) in
Feed Plant
Course Name: Advances in Feed Technology
Course No.: ANN 708 (1+0)
Course Teacher: Dr. Meenu Dubey
Student Name: Rakesh Sheel
Class: PhD II Semester
Session: 2022- 23
Department of Animal Nutrition
College of Veterinary Science and Animal Husbandry, Anjora (Durg), C.G.

2. Introduction
GMPs are the practices and procedures that ensure the safety of
feed so that to ensure safe meat, milk, and egg production.
GMPs are prerequisite programs to implement HACCPs and are
intended to prevent, control and detect potential contamination
during the process of feed manufacturing
These are the necessary precautions to prevent cross
contamination of feed, feed contact surfaces or feed packaging
materials with microorganisms or foreign substances.
These regulations are based on 11 principle

3. 01. Personnel
a) Disease Control
 Person should not suffering from any contagious disease, open wound,
boil or bruish
 Personnel must report such health conditions to their supervisors
b) Cleanliness:
 Personnel must wear protective garments during operations
 Must maintain adequate personal hygiene (washing and sanitizing
hands)
 Must remove all unsecured jewellery
c) Personnel hygiene facilities:
 Well separated toilets, wash basins with adequate changing facilities
 Provided with soap, paper towels or other suitable means for drying
hands
 Constant supply of potable water

4. 02. Buildings and facilities
A) Design and Layout
• Adequate space for all plant operations with careful
installation of different equipment
•Easy access for maintenance and cleaning
•Pest/ rodent proof building design
•Gardens, vegetation, trees and surface water bodies should
possibly avoided
•Contamination through vehicles must be avoided

5. 02. Buildings and facilities
B) Internal structure and fittings
• Walls, partitions and floors surface should be made of
impervious materials
• It should be smooth to allow easy cleaning and drainage
(standing water should be prevented)
•Ceilings and overhead fixtures should be constructed to
minimize dirt, dust and condensation
•Laboratories should be designed, located and operated to
prevent contamination

6. 02. Buildings and facilities
C) Water supply
• Adequate supply of potable water with appropriate
facilities for its storage and distribution
•Separate system for non potable water (steam
production /refrigeration etc.)
•Water treatment chemicals should be food compatible
D) Lightings
E) Air quality, temperature and ventilation

7. 02. Buildings and facilities
F) Cleaning facilities
• Use of corrosion – resistant materials
•Cleaning chemicals should be feed compatible
•Should be adequately separated from the working area
G) Location of feed establishment
• Free from smoke, dust and other contaminants
• Avoid areas prone to natural calamities (flood and earthquake)
•Avoid areas with the history of presence of wild animals
•Avoid areas where wastes (solid and liquid) cannot removed effectively
•Must follow strict measures to control the access of non- employee

8. 03. Equipment and utensils
• Must be so installed so as to facilitate the cleaning and
maintenance
•Food contact surface must be corrosion resistant
•Made of non- toxic materials and should not react with
cleaning and sanitization chemicals
•All the plant equipment and machines (automatic or
manual) should be tested regularly for accuracy
•Feed storage compartments must be installed with
thermometer and temperature recording device
•Compressed air used to clean food contact surface must
be free from contaminations

9. 04. Work areas
This section states that production area must be
separated physically from area that are used for
manufacturing fertilizers, herbicides, insecticides,
fungicides, or rodenticides that are not approved for
use in the production of animal feed

10. 05. Components
This area deals with the inventory records of drugs (medicines used
in feed manufacturing)
 Receipt, usage and storage record separately
Receipt record should be recorded in a form and accurately indicate
the lot number of each shipment
A daily inventory should be maintained at the beginning and end of
the work day
These records should be kept for at least 01 years after the
production of batch

11. 06. Laboratory Control
 Periodic assays for medicated feed for drug components
should be carried out
At least 03 samples of feed containing the medication should
be tested
Originals of test results should be kept for at least 1 years
after production
 If the result indicated that the medication is not in accord
with the labelled specifications, action should be implemented
and documented

12. 07. Equipment Clean out Procedure
Adequate cleanout procedures for all equipment
used in the manufacture and distribution of
medications are essential to maintain proper drug
potency and avoid unsafe contamination of feed
Procedures includes; vacuuming, sweeping,
flushing and washing.
 Flushing material should be identified properly
and used appropriately to prevent contamination

13. 08. Packaging and Labeling
 Appropriate labeling identifies the feed and provides the
consumer with proper direction to use product
Labels should be received, handled, and stored in a
manner that prevents mix- ups
Upon printing, labels should be proofread against a
master copy and kept in a master label file for 1 years
Label stock should be reviewed periodically and
discontinued labels should be discarded

14. 09. Records
A) Master Record
• Provide the complete procedure for manufacturing a product,
formulations, theoretical yields, assay requirements and labeling of
batches
•Should be prepared, checked, dated by a qualified person and retained
for 1 yr. after production of the batch. The file should consist:
Name of the medicated feed
Measure of the drug or drug combination and each non drug
ingredients
A copy of the label that accompanied the feed
Manufacturing instruction
Appropriate control direction (including the manner and frequency of
sample for specified lab test)

15. 09. Records
B) Production Record
Should be prepared by a qualified person and retained
for 1 yr. after production of the batch. The file should
consist:
Product identification, date of production, initials by a
responsible individual
The quantity and name of the drug components used
The actual quantity of medicated feed produced
In the case of custom formula feed made for the specific
customer, the master and production records should
consist all the records.

16. 09. Records
C) Batch Records
Should be checked by a responsible person at the
end of the working day to determine whether all the
production steps were noted.
Each batch should be identified with its own
number, code, or other suitable identification
applied to the label, package, invoice or shipping
documents.
These records helps in tracing the complete and
accurate manufacturing history

17. 09. Records
D) Distribution Records
The records should consist:
The date of shipment, name and address of the
purchaser, the quantity shipped and the name of the
medicated feed
Records should be retained on the premises for 1 yr.
This records permits the manufacturer to relate
complaints to specific batches in case a recall is
warranted

18. 10. Complaints
Consists of copy of the complaint and notes made
of an oral or written contact containing the date of
the problem, the name and address of the
complainant, the lot number of the feed, the date of
manufacture, and specific details of the complaint.
Timely and appropriate follow up action can serve
to correct a manufacturing problem and minimize
future problems

19. 11. Bovine Spongiform Encephalopathy
(BSE)
To protect dairy animals from BSE, in 1997, the FDA added a new
regulation in cattle feed section.
The regulation prohibits the use of certain protein derived from
mammalian tissue in feed for ruminants, e.g., meat and bone derived
from cattle.
 However, certain animal proteins are exempt from the regulation:
Blood and blood products
Milk products
Pure porcine or pure equine protein
Gelatin
Non mammalian protein products (poultry, marine, vegetable)
Special labeling guidelines apply to any product that contains the
prohibited materials. The label must contain the following statement
“Do not feed to cattle or other ruminants”.

20. Conclusions
Production of contaminant free material should be
the first priority of each individual associated with
feed manufacturing
GMPs are the critical control practices and
regulation must be followed by feed manufacturer
at various stages.
It provide a healthy, contamination free product
for overall improvement and disease free animal
production.