Quality Assurence Program in Feed Manufacturing
Quality Assurence Program in Feed Manufacturing
Quality Assurence Program in Feed Manufacturing
EED manufacturers are often forced by circumstances to focus on short-term concerns such as: How many tons were produced this week? How many customers do I have, or how much down time did I have this week? While important, short-term problems can cause manufacturers to focus on solving problems rather than pursuing the companys mission. Manufacturers who regularly examine their companys mission tend to have a sense of who they are and where they are going. How many feed manufacturers know and regularly examine the organizations mission? The immediate response of some manufacturers might be: Our mission is to make a prot. Although making a prot is certainly necessary for company survival, prot as a sole objective is short sighted. What are we trying to accomplish when feeds are formulated and manufactured? Although there can be numerous mission statements, an overall mission of feed formulation and manufacturing might be: To provide customers with efciently manufactured, safe, high-quality feeds that are correctly delivered to their facilities and consistently contain the available nutrients required by animals for body maintenance, growth and reproduction. A comprehensive feed quality assurance (QA) program should manage the materials (ingredients and supplies), equipment, personnel and procedures to efciently deliver a safe feeds that consistently contain the formulated nutrients to optimize the production of meat, milk and eggs. QA is a comprehensive program of controls directed at ensuring the production of feeds that meet a predened set of standards (Rydell, 2005; Boyd, 1993). QA refers to the policies, procedures and process controls that yield a consistent product, where as quality controls are the in-plant process measurements that insure quality parameters are met during receiving, manufacturing and delivery.
(1) Purchasing and receiving; (2) Feed manufacturing and process control; (3) Finished feed sampling, inspection and labeling; (4) Feed shipment and delivery; (5) Sanitation and pest/rodent control, and (6) Feed product investigations/recalls. Since the development of an actual QA program, control policies and procedures must be adapted to the needs of each facility, this article will focus on the basics of a feed QA program and quality control measures rather than on specics in the hope that the discussion will stimulate thinking and innovation in the eld of feed-quality assurance and controls.
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Process control
The process by which high-quality ingredients are made into high-quality feeds involves three components within the feed mill: personnel, equipment and procedures. If quality is lacking in any of these three components, the consistent production of high-quality, safe feed is unlikely. However, it is equally important to ensure that personnel, equipment and procedures are blended together toward the goal of efcient production of high-quality safe feed. Personnel. Three general characteristics should be sought in new mill employees: productivity, interest or alertness and the ability to work as a team member. Once hired, employees should complete a formal training process that outlines their responsibilities in manufacturing a safe, quality feed (Stark, 2009). This training should include not only what job to do, but why the job is necessary. Employees should be informed initially and reminded periodically through the performance review process how important their job is to the total quality effort and how their performance compares to that of their job description. Training documentation is also required by government agencies and is a component of thirdparty certication programs. Once trained, the company saves money if employees are encouraged to stay with the company. This means employees must be motivated, either by the work or by the manager to remain on the job. Company commitment to quality must be supported by everyone from top management down. Employees who do not follow the company policy on quality will tend to undermine the program. Managers who accept ingredients that do not meet company specications send a message to their employees that quality standards are not important. Equipment. Equipment selection, operation, repair and troubleshooting can become a very complicated matter, which can not be covered adequately in a short space. However, applying the following general points to each specic piece of equipment will help reduce equipment problems: Application: Was the equipment designed to do the job it is doing? Installation: Was the equipment installed according to the manufacturers recommendations? Adjustment: Are the critical adjustment points within the machine set correctly? Operation: Is the machine being operated according to the manufacturers recommendations? Capacity: Is the equipment being run within the rated capacity? Lubrication: Is the correct amount and type of lubricant used within the time frame suggested by the manufacturer? Maintenance: Does your company have a written preventive maintenance program? Can you predict when maintenance and possible repairs will be needed on each piece of equipment? Do you have spare parts and tools to perform maintenance and repairs? Procedures. Procedural difculties are common problems in feed mill operations. Feed mills either dont have written standard operating procedures (SOPs), havent trained their 64 Feedstuffs, September 15, 2010
Finished feed
In many situations, feeds are used rapidly after they are manufactured and animals consume the feeds before any assays can be performed. However, nished-feed assays are necessary and important because they provide the mill with a nal report card on how well quality was controlled. How much nished-feed sampling and analysis should be done? While the answer to that question will depend on numerous factors, a general rule of thumb is to collect two samples of each formula per week or one per batch run. Integrated operations should develop a sampling program that obtains one or two feed samples on each shift in order to monitor the manufacturing process throughout the week. Commercial operations should collect a sample of each batch run in the event that there is a customer complaint. Labeling feed correctly and the nal review of the feed labels is typically the responsibility of the QA group. AAFCO has established labeling guidelines as part of its model feed bill, which has been adopted by a number of the states. Labeling requirements may vary from state to state; therefore, it is important to be familiar with the requirements of the state(s) in which you manufacture and sell feed. The AAFCO label format can be found at its web site at www.aafco.org.
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