# Presentation: 549177

## Animal Feed Safety System

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- Timothy E. Costigan
- Manager of Quality and Analytical Services
- Prince Agri Products, Inc.

## Mineral Premix System

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**Controlled Formulations**
**Computer Controlled Ingredient Addition**
**Manual Double Checks**
**Electronic Scale Records**

## Production System Checks

**Raw Materials**
**Ingredient specifications based on:**
**Supplier process**
**End use**
**Known hazards **
**Inbound ingredients sampled / retained for 1 year**
**Scheduled chemical and physical analyses**
**By lot, by shipment, by month**
**Complete analysis (annual)**

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## Ingredient Evaluation

**Analysis Requirement for Zinc Oxide**
**Zn (formulated value)**
**Pb, Cd, As (process issue / known hazards)**
**Annual Review**
**Analyses listed above **
**Zn Metal (process issue)**
**Dioxin (known hazard)**
**Scan for 70 trace elements, densities, particle size, and moisture**

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## Production Process
Appearance check 
Batch yields
Periodic analysis
Batch samples are retained for 1 year
Magnet inspection
Inventory reconciliation

**Appearance check **
**Batch yields**
**Periodic analysis**
**Batch samples are retained for 1 year**
**Magnet inspection**
**Inventory reconciliation**

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**Production System Checks**

## Custom formulas
Tags/preprinted bags
Mix records
Scale records
Receiving records

**Tags/preprinted bags**
**Mix records**
**Scale records**
**Receiving records**

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**Records**

**Shipping records**
**Load sheets**
**Sales records**
**Analytical records**
**Audit records**

**Controlled Distribution**
**Traceable through item number / lot number**

## Ingredients:
Resale ingredients by supplier’s lot number
Consumed macro and trace ingredients by shipment (applied lot number)
Consumed micro ingredients by supplier’s lot number
Finished Product:
By applied lot number

**Resale ingredients by supplier’s lot number**
**Consumed macro and trace ingredients by shipment (applied lot number)**
**Consumed micro ingredients by supplier’s lot number**
**Finished Product:**
**By applied lot number**

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**Traceability**

## Visitors
Must sign in and out, visitor’s tag issued
Must be accompanied by an employee
Employees
Background checks before hiring
Training of employees on procedure
Materials
Seals on inbound and outbound loads (sans LTL)
Inspection of trailers, review of paperwork

**Must sign in and out, visitor’s tag issued**
**Must be accompanied by an employee**
**Employees**
**Background checks before hiring**
**Training of employees on procedure**
**Materials**
**Seals on inbound and outbound loads (sans LTL)**
**Inspection of trailers, review of paperwork**

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**Biosecurity**

## Contamination Concerns

**Chemical**
**Toxic elements (Pb, Cd, As, Hg)**
**Cross contamination / incomplete blending**
**Organic (pesticides, lubricants)**
**Microbial and biological**
**Limited concern (insects, rodents)**
**Physical**
**Metal and glass**

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## Document and Data Control (3)
Purchasing (5)
Product Identification and Traceability  (2)
Process Control (18)
Inspection and Testing (17)
Control of Inspections, Measuring and Test Equipment (5)

**Purchasing**** (5)**
**Product Identification and Traceability****  (2)**
**Process Control**** (18)**
**Inspection and Testing**** (17)**
**Control of Inspections, Measuring and Test Equipment**** (5)**

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**Controlled Documents**

## Controlled Documents

**Controlled Documents**

**Inspection and Test Status**** (3)**
**Control of Nonconforming Product**** (1)**
**Corrective and Preventive Action**** (2)**
**Handling, Storage, Packaging, Preservation and Delivery**** (3)**
**Control of Quality Records**** (1)**
**Training**** (1)**

## Production Personnel:
Monthly safety audits
Weekly sanitation audits 
Periodic procedural audits
Periodic dock audits
Quality Unit:
Annual comprehensive audits
Annual formulations audit

**Monthly safety audits**
**Weekly sanitation audits **
**Periodic procedural audits**
**Periodic dock audits**
**Quality Unit:**
**Annual comprehensive audits**
**Annual formulations audit**

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**Audits**

## Statistical Techniques

**Yearly Mix Plant Error Assessments**
**Raw Material Variation**
**Ingredient Addition Error**
**Mixing and Segregation Error**
**Sampling and Analytical Error**
**Semiannual Mixing System Evaluations**
**Quarterly Bag Weight Studies**

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## Ingredients
Scheduled sample submission is based on:
Supplier history and the amount of shared data
Ingredient variation / previous concerns
Complete analysis yearly
Premixes
Every batch - safety or quality concern
Single batch - process check
Production issue

**Scheduled sample submission is based on:**
**Supplier history and the amount of shared data**
**Ingredient variation / previous concerns**
**Complete analysis yearly**
**Premixes**
**Every batch - safety or quality concern**
**Single batch - process check**
**Production issue**

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**Analytical Work**

## Overall Quality Program

**Overall Quality Program**

**Apply portions of existing programs that apply**
**HACCP for risk assessment**
**ISO for document control, procedures**
**GMP for hygiene, traceability, contamination issues **
**Focus on preventative measures**
**Ingredient quality**
**Process evaluation**
**Confirmatory testing**