Doane Pet Care Company

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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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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 -
DPCs Pet Food Safety System (P.F.S.S.)
DPC - PFSS
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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

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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

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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 )

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DPC PFSSKey System Components

• Ingredient Integrity
• Quality Manual
• Sanitation Microbiological Control
• Integrated Pest Management
• Control of Foreign Material
• Traceability
• Validation by Audit
• Continuous Improvement

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DPC - PFSS Quality Manual

• Uniform policies, standards procedures
• ISO - 9000 Based
• Updated by a plant corporate team
• Controlled and audited document

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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

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DPC - PFSS
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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

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DPC - PFSS
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DPC PFSSSanitation Microbiological Control

• Plant-Specific Sanitation Schedule SSOPs
• 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

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DPC PFSS
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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

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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

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DPC PFSS
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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

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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

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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

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DPCs PFSS Beneficiaries