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Doane Pet Care Company

Doane Pet Care Company. Pet Food Safety System (PFSS) M.W. Merkel September 23, 2003 Animal Feed Safety System Public Meeting.

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Doane Pet Care Company

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  1. Doane Pet Care Company Pet Food Safety System (PFSS) M.W. Merkel September 23, 2003 Animal Feed Safety System Public Meeting

  2. Our Mission - ‘ the trusted partner of choice for our customers brands ’Our Primary Responsibility - assure all pet foods & treats we manufacture and distribute are safe & wholesome for petsOur Means of Assurance - DPC’s Pet Food Safety System (P.F.S.S.) DPC - PFSS

  3. DPC – PFSSRisk – Based Preventative System • Detailed analysis of pet food processing systems • Identification of potential food safety hazards and assessment of process & product risks • Implementation of adequate process control measures including employee training • Verification & documentation that control measures are rigorously followed • Validation that prevention systems are effective

  4. DPC – PFSSRisk – Based Preventative System • Detailed Analysis of every pet food processing system at each plant • Identification of potential food safety hazards and assessment of process & product risks • Implementation of adequate process control measures including employee training • Verification & documentation that control measures are rigorously followed • Validate that prevention systems are effective

  5. DPC – PFSSPet Food Safety by Design • Buildings (Pest-Proof, clean & secure) • Grounds (Harborage-free & secured) • Processing Equipment ( Safe & Sanitary ) • Packaging ( Tamper Resistant ) • People ( Trained & Engaged in PFSS )

  6. DPC – PFSSKey System Components • Ingredient Integrity • Quality Manual • Sanitation & Microbiological Control • Integrated Pest Management • Control of Foreign Material • Traceability • Validation by Audit • Continuous Improvement

  7. DPC - PFSS Quality Manual • Uniform policies, standards & procedures • ISO - 9000 Based • Updated by a plant & corporate team • Controlled and audited document

  8. DPC - PFSS Ingredient Integrity • Vendor Q. A. Program Certification • Joint Program – Quality & Purchasing • Ingredient Quality Manager • On-site inspections • Sampling & analysis of shipments • Plant mycotoxin testing & rejection capability • Vehicle Inspection • Documentation • Physical Inspection & Bottom Sampling

  9. DPC - PFSS

  10. DPC - PFSS Ingredient Integrity • Vendor Q. A. Program Certification • Joint Program – Quality & Purchasing • Ingredient Quality Manager • On-Site inspections • Analysis of Ingredient Shipments • Plant mycotoxin testing & rejection capability • Vehicle Inspection • Documentation • Physical Inspection & Bottom Sampling

  11. DPC - PFSS

  12. DPC – PFSSSanitation & Microbiological Control • Plant-Specific Sanitation Schedule & SSOP’s • Conducted at plant by Quality Assurance • Facilities design • Controlled movement of employees & materials • Sensitive Ingredient pre-delivery test and certification • Microbiological monitoring • Plant - Specific environmental micro mapping • In Process & Finished Product • Technical Services Laboratory • Full micro capabilities including pertinent pathogens • Training & On-Site facilities support

  13. DPC – PFSS

  14. DPC – PFSSIntegrated Pest Management • Plant - Specific Master Pest Control Schedule • Mechanical Exclusion • Non – pesticide controls • Pesticides • Nationally Contracted Pest Control Firms • Training • Electronic pest activity / service tracking • Fumigation

  15. DPC – PFSSForeign Material Prevention • Ingredient level • Vendor audits + transport vehicles & trailers • Magnets at unloading and key transfers • Audit of carriers and warehouses • Inspection of building and equipment • Magnets at key transfers • Metal detection at packaging

  16. DPC – PFSS

  17. DPC – PFSSForeign Material Prevention • Ingredient level • Vendor audits including transport vehicles and trailers • Magnets at unloading and key transfers • Audit of carriers and warehouses • Inspection of building and equipment • Magnets at key transfers • Metal detection at packaging • Preventive maintenance and repair • Evaluation of customer complaints • HOLD system to identify nonconforming materials and prevent use and distribution

  18. DPC – PFSST r a c e a b i l i t y • Ingredient level • Lot number on bagged ingredients • Bin designation on bulk receiving paperwork • Origin information on receiving paperwork • Finished product level • Printed code date checks • Mock trace & retrieval • Graded by Quality Systems Manager • Score counts toward plant performance objectives • Ingredient receipt and production archive documentation included in audits

  19. DPC – PFSSFood Safety Audits & Continuous Improvement • Internal GMP / FS audit at all plants • Auditors originally plant Quality Assurance Coordinators • External GMP / FS audit at all plants • Nationally recognized independent food safety experts • Scores count toward plant performance objectives • Customer quality audits • Customer representatives or consultants • Continuing education • Restricted use protein products control procedures; public health, security & bio-terrorism preparedness act • PFSS must be flexible, cost effective and appropriate for each specific application

  20. DPC’s PFSS Beneficiaries

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