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D

4.1

EN

GMP+ D4.1

Safety of processing aids in feed

Version: 15 November 2013

GMP+ International B.V.

All rights reserved. The information in this publicati-on may be consulted on the screen, downloadedand printed as long as this is done for your own,non-commercial use. For other desired uses, priorwritten permission should be obtained from theGMP+ International B.V.

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GMP+ D4.1 Safety of processing aids in feed 2/48Version: 15 November 2013 GMP+ International

INDEX

1 INTRODUCTION .................................................................................... 4

1.1 G ENERAL ................................................................................................... 41.2 S TRUCTURE OF THE GMP+ FEED CERTIFICATION SCHEME ........................... 4

2 FOREWORD .......................................................................................... 6

2.1 U SE OF PROCESSING AIDS DURING THE PRODUCTION OF FOODSTUFFS .......... 6

2.2 L EGAL REQUIREMENTS FOR PROCESSING AIDS ............................................. 6

2.3 R ISK TO FOODSTUFFS INDUSTRY BY -PRODUCTS ........................................... 6

2.4 P RELIMINARY RESEARCH ............................................................................ 7

2.5 R ESULTS ................................................................................................... 7

INVENTORY OF PROCESSING AIDS IN THE FOODSTUFFS INDUSTRYWITH RESPECT TO THE SAFETY OF FEED FLOWS ............................... 8

1 SUMMARY ........................................................................................... 10

2 INTRODUCTION .................................................................................. 12

3 BRANCHES STUDIED ........................................................................ 13

4 STRUCTURE OF THE STUDY ............................................................ 14

5 USE OF PROCESSING AIDS PER BRANCH ..................................... 16

5.1 P OTATO INDUSTRY ................................................................................... 16

5.2 P OTATO STARCH ...................................................................................... 18

5.3 G RAIN AND STARCH INDUSTRY .................................................................. 195.3.1 Flour preparation......... ......... ......... .......... ......... .......... ......... ......... ....... 20 5.3.2 Starch preparation ......... ......... .......... ......... ......... .......... ......... ......... .... 21

5.4 S UGAR INDUSTRY ..................................................................................... 24

5.5 B REWERIES ............................................................................................. 25

5.6 D AIRY INDUSTRY ...................................................................................... 275.7 O IL (FROM SOY BEANS ) ............................................................................. 30

5.8 R ENDERING COMPANIES ........................................................................... 31

6 CONCLUSIONS AND RECOMMENDATIONS .................................... 34

6.1 G ENERAL DOCUMENTS ............................................................................. 34

6.2 C ONCLUSIONS PER BRANCH ...................................................................... 35

6.3 R ECOMMENDATIONS ................................................................................ 38

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APPENDIX 1 : LIST OF PROCESSING AIDS IN THE BRANCHESEXAMINED ................................................................................................. 39

APPENDIX 2: FEED PRODUCTS PROCESSING AIDS ANDPROCESSING AIDS QUESTIONNAIRE .................................................... 43

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1 INTRODUCTION

1.1 General

The GMP+ Feed Certification scheme was initiated and developed in 1992 by theDutch feed industry in response to various more or less serious incidents involvingcontamination in feed materials. Although it started as a national scheme, it hasdeveloped to become an international scheme that is managed by GMP+International in collaboration with various international stakeholders.

Even though the GMP+ Feed Certification scheme originated from a feed safetyperspective, in 2013 the first feed responsibility standard has been published. For

this purpose, two modules are created: GMP+ Feed Safety Assurance (focussedon feed safety) and GMP+ Feed Responsibility Assurance (focussed onresponsible feed).

GMP+ Feed Safety Assurance is a complete module for the assurance of feedsafety in all the links of the feed chain. Demonstrable assurance of feed safety is a'license to sell in many countries and markets and participation in the GMP+ FSAmodule can facilitate this excellently. Based on needs in practice, multiplecomponents have been integrated into the GMP+ FSA module, such asrequirements for the quality management system (ISO 9001), HACCP, productstandards, traceability, monitoring, prerequisites programmes, chain approach andthe Early Warning System.

With the development of the GMP+ Feed Responsibility Assurance module, GMP+International is responding to requests by GMP+ participants. The animal feed sec-tor is confronted with requests on working responsibly. This includes, for example,the use of soy (including soy derivatives and soy products) and fishmeal which areproduced and traded with respect for humans, animals and the environment. Inorder to demonstrate responsible production and trade, a company can get certifiedfor the GMP+ Feed Responsibility Assurance.

Together with the GMP+ partners, GMP+ International transparently sets clear re-quirements to guarantee feed safety & responsibility. Certification bodies are ableto carry out GMP+ certification independently.

GMP+ International supports the GMP+ participants with useful and practical infor-mation by way of a number of guidance documents, databases, newsletters, Q&Alists and seminars.

1.2 Structure of the GMP+ Feed Certification scheme

The documents within the GMP+ Feed Certification scheme are subdivided into anumber of series. The next page shows a schematic representation of the contentof the GMP+ Feed Certification scheme:

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B documentsNormative documents, appendices and country notes

A documentsGeneral requirements for participation in the GMP+ FC scheme

GMP+ Feed Certification scheme

Feed Safety Assurance Feed Responsibility Assurance

C

documentsCertification requirements of the GMP+ FC scheme

D documentsGuidelines to help companies with the implementation

of the GMP+ requirements

All these documents are available through the website of GMP+ International(www.gmpplus.org) .

This document is designated as GMP+ D4.1 Safety of processing aids in feed . It isnot a norm document but research at that time carried out in collaboration with theProduct Board Animal Feed.

Use is made in this document of the original text of the report. The information inthis research can be used to give a better implementation of the GMP+ FSA re-quirements.
http://www.gmpplus.org/http://www.gmpplus.org/

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2 Foreword

Safety of processing aids in feed

2.1 Use of processing aids during the production of foodstuffs

Companies use all kinds of processing aids during the production of (raw materialsfor) foodstuffs. Companies use these processing aids at certain moments in theproduction process to assist the production process, to make it easier or to bringabout a particular feature of the product. There are also other reasons for usingprocessing aids.Examples of such substances are:- anti-foaming agent- flocculants.- acids and salts to regulate the pH value- preservatives- extraction agents such as hexane

We can subdivide all these processing aids into three main groups:- processing aids such as a anti-foaming agent or a flocculant- utilities such as coolants, fuels and cleaning agents- additives such as a preservative for storage life.

2.2 Legal requirements for processing aids

The Directive 70/524/EEC, the so-called Additives Directive, also addresses theuse of processing aids. In article 1, section 2, this directive states that it does notapply to processing aids:

This Directive shall not apply to processing aids used deliberately as su b-stances in the processing of feed materials or of feedingstuffs in order toachieve a certain technological objective during treatment or processingwhich may result in the unintentional but technically unavoidable presenceof residues of the substances or their derivatives in the final product, provid-ed that these residues do not present any health risk and do not have anytechnological effect on the finished product.

Processing aids are therefore not designated as additives. There are no other regu-

lations for these products. This does not of course mean that companies do nothave to set requirements for these products and their use.

2.3 Risk to foodstuffs industry by-products

It is known that many feed raw materials are created as a by-product of foodstuffsproduction. The processing aids used by foodstuff manufacturers in the productionprocess for foodstuffs may get wholly or in part into the by-product, the feed rawmaterial.

Within the framework of the safety and risk control of feeds, it is therefore important

to pay attention to the safety and quality of the processing aids used.

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The idea that these processing aids cannot represent a hazard because they areused during the production of foodstuffs intended for human consumption is notwholly correct. At the beginning of 2000, for example, there was the beet pulp af-fair. It was established that because of contamination of the processing aids usedin sugar recovery, undesirable substances got into the by-product, beet pulp.

2.4 Preliminary research

The Product Board decided to have a study carried out in order to find out what therisks are to by-products in which processing aids might possibly be found andwhich control measures could be taken. This research was carried out within theframework of the Quality Assurance Improvement Plan for the Feed Sector in whichresearch was carried out in many sub-areas of the feed sector with respect to thesafety of feeds.

You will find the results of this research in this report. The report provides an over-view of the production processes in a number of foodstuff sectors and the pro-cessing aids which are used. The report also provides an answer to the question ofwhether, and how, foodstuff companies control the quality and safety of the pro-cessing aids used.

2.5 Results

The major findings are:- The companies studied were so-called A companies, leading companies in their

sector. The results and findings cannot be applied generally as they are to allcompanies.

- The level of quality assurance in the companies studied is high. The processingaids used also fall within the quality assurance of the companies although theycould expand this quality assurance further in this respect.

- This research shows that there are almost no risks to waste flows due to theuse of processing aids.

- The companies studied have no overview of the risks which may occur in thesubsequent links. This is, however, not their responsibility but that of their cus-tomer.

Feed companies or traders which obtain products (waste flows) of foodstuff prod-ucts can, for example, use the results and conclusions in the carrying out of theHACCP analysis. The way in which Tebodin carried out the research among food-stuff manufacturers can serve as an example to customers of waste flows for usewith other foodstuff manufacturers.

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Inventory of processing aids

in the foodstuffs industry with

respect to the safety of feed flows

client Product Board Animal Feed

project Preliminary study of processing aids in feed productsorder number 27142report number 3212000revision 1date 22 September 2000authors A.J. Rottier, M.E. Heijbrock, E.A. Maarseveen

Tebodin B.V.

Laan van Nieuw Oost-Indi 252593 BJ The HagueP.O. Box 160292500 BA The Hague

telephone 070 - 3480 294fax 070 - 3480 591E-mail [email protected]
mailto:[email protected]:[email protected]

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authorisation

author: release approval: A.J. Rottier, M.E. Heijbrock,E.A. Maarseveen

F. van Woerden

Senior Consultant /Consultants

Head of the Department of Environmentand Safety

The Hague, 22 September 2000

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1 Summary

Research is currently being carried out within the framework of the Quality Assur-

ance Improvement Plan for the Feed Sector in many sub-areas of the feed sectorwith respect to the safety of feeds. One of the studies is focused on the safety andquality of processing aids and processing aids which are used in production pro-cesses in the foodstuffs industry.

In this regard a study was carried out among 13 foodstuff companies in varioussectors into the use and risks of processing aids, additives and utilities with respectto feed flows. A questionnaire was used during the visit to the company. Use wasmade of the same questionnaire during each company visit. Table 1 shows a sum-mary of the results.

Table 1 Branches studied and their products and hazardsBranch Feed flows / products possible risksPotato Peel, parings and pro-

duction waste, starch- grey starch- internal transport containers- processing at clients

PotatoStarch

Fibres, concentrated juice and protein.

- forming of nitroso-amines (via NOx) dur-ing the drying of protein and Protapec.

Flour Wheat feed meal pellets,wheat feed flour pellets,maize feed meal

- contamination of raw material with my-cotoxins (moulds)

Starch from

wheat

Wet wheat feed

Wheat gluten feedVital gluten

- contamination in auxiliary agent wood

flour- conversion process in wet wheat feedStarch frommaize

Maize gluten feedMaize proteinCrushed maizeMaize solubles

- no identifiable risks

Sugar Press pulpPulp blocks

- contamination of the auxiliary agentgypsum with fluorine and heavy metals

- use oil as fuel during direct drying- further processing in chain

Beer Brewers grains YeastMalt substanceReturn beer

- further processing of brewersgrains(mixing in beet / citrus pulp)

Dairy Mix of products / waterflow

- in the event of contamination of oneflow, everything is contaminated

- error during cleaning procedure- use sludge of physical chemical purifica-

tionSoya oil Soya extract - hexane in feed

- Salmonella- other undesirable substances

DIGES-

TION

Meat meal

Feather meal Animal fatBlood meal

- Salmonella

- chemical contamination in corpses

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The quality awareness among the companies studied appeared to be high. The useof processing aids is limited. No processing aids at all are used in some branches.In the companies studied there were generally no complicated further processingsteps carried out on the co-products for the feed.

The released feed flows are mixed by the feed manufacturers into compound feedsand also fall within the responsibility of these clients. The responsibility of the food-stuffs companies usually ends at the storage in the silos on their own terrain.

The foodstuffs industry has good quality assurance as far as its own processes areconcerned. The processing aids supply sector has not yet got full control of thefoodstuffs companies. Product control lies in many cases exclusively with thesesuppliers.

It is recommended that the feed companies (as waste flow clients) regularly auditthe released feed flows in the foodstuffs industry. In turn, the foodstuffs companiescould regularly audit the suppliers of processing aids. The foodstuffs companiescould expand their HACCP quality systems to include the processing aids and feedflows.

It is recom mended that the compound feed companies experience of foodstuffscompanies should be examined and used to visit a number of foodstuffs compa-nies. Some divisions of the companies visited have been left out of considerationwithin the framework of this study. It is advisable also to carry out research here.

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2 Introduction

The Product Board Animal Feed is a semi-governmental body which is tasked with,

among other things, the quality of feed products. Research is currently being car-ried out within the framework of the Quality Assurance Improvement Plan for theFeed Sector in many sub-areas of the feed sector with respect to the safety offeeds. One of the studies is focused on the safety and quality of processing aidsused in production processes in the foodstuffs industry. These processing aids arematerials which are used directly or indirectly in the production process and whichcan get into the waste flows which are destined for feed without the intention ofadding them to the final products or by-products. Examples are product drying withcombustion gases or dosage with gypsum to improve the press quality (dry mattercontent) of beet pulp.

A number of recent incidents have shown that contaminants in processing aids andprocessing aids can lead to quality problems in the (waste) product, the feed.

The Product Board decided to have a study carried out in order to find out what therisks are which are associated with the use of processing aids in food materialsproduction where feeds or feed raw materials are created as a waste flow andwhich control measures can be taken. The Product Board Animal Feed engagedTebodin to carry out the study.

The first phase of the study was a global inventory of the processes in a number ofbranches. On the basis of the results an assessment can be made of whether it isnecessary to take technical and organisational measures in the feed production

chain in question. The follow-up studies are not part of the first phase of the study.

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3 Branches studied

The inventory was drawn up among a number of companies in the feed materials

industry which may be considered to be model companies in a branch. The food-stuff branches and companies were selected in consultation with the ProductBoard.

Table 2 Branches selected for the study

BranchPotato industryPotato starchGrain and starch industrySugar industryBreweriesMilk-processingSoya oil industryRendering industry

A total of 13 companies were visited. The foodstuffs processes in the Netherlandswere examined per company. In most cases this involved a number of sites withdifferent processes per site.

These companies were examined to see which additives are used in particular pro-duction steps and whether these may possibly lead to contamination of the feedproduct.

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4 Structure of the study

The following method was used in the study:

Tebodin created a questionnaire for use during the interview with the compa-nies. The questionnaire was discussed with the Product Board Animal Feed,the comments were incorporated and a final questionnaire was drawn up. Thesame questionnaire was used for all the companies.

Tebodin contacted the companies to establish the correct contact person for theinterview. The contact person can be roughly classified into three groups: pro-duction managers, quality managers and environment managers. The ProductBoard presented the existing contact persons for feed for a number of compa-nies and in other companies Tebodin found a contact person.

The Product Board sent a letter to all the contact persons in which the Tebodinstudy was officially announced.

Tebodin contacted the contact persons to make an appointment. The questionnaire was sent in advance to the contact persons so that they

could prepare properly for the meeting. The questionnaire was handled during the meeting. In most cases one of the

production sites at which the feed flow was released was also visited. The finished survey was fed back to the company for comments. The report was drawn up on the basis of the details provided by the company

with an overview and an evaluation of the results in which there was an investi-gation of in which branches risks were present when using processing aids.

The report may be considered to be a quick scan of the use of processing aidsand utilities in the foodstuffs industry with respect to feeds.

The foodstuffs processes in the Netherlands were examined per company. In mostcases this involved a number of sites with different processes per site. During thecompany visits, the following were examined (see the survey questions in appendix2):

1. Main and by-products of the processes.2. Use of substances in the processes:

a) use of raw materialsb) use of processing aidsc) use of utilities such as coolants, combustion gases, fuels, steam, lubricants,

inert rendering gases and cleaning agentsd) additives (for example preservative for the storage life of the feed).

3. Sub-stages of the foodstuffs process with attention to the point where the pro-cessing aids are used and where the feed flows are released.

4. Quality Assurance.5. Transport and responsibilities for the feed product.

Use is made of a single survey with the same questions for each company. Theanswers were provided in confidence by the companies to the Product Board Ani-mal Feed.

All the companies cooperated with the study. In most cases there was an extensive

prior discussion with Tebodin about whether to participate. An extra visit was some-times necessary to get the company to decide to participate.

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The companies cooperated on the basis of the confidentiality of the study and onthe data being known only internally at the Product Board. One company wished tocooperate with the survey only on the basis of anonymity. No company visit wascarried out in this case. The company provided its answers in writing.

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5 Use of processing aids per branch

A section follows for each branch with an evaluation of the findings. If various dif-

ferent companies were examined within the branch then the companies are speci-fied separately. Appendix 1 contains a summary diagram with an overview of theresults of the inventory at the companies in question.

5.1 Potato industry

Two companies were visited in the potato industry. The raw material is of coursethe potatoes which are obtained from contracted suppliers and through purchasingon the European potato market. The business processes are particularly focusedon products for the consumer: deep-frozen fries and potato specialities. Feed flows

are a co-product in which there is no further handling of these flows. The size of thefeed flows is considerable and, depending on the season, amounts to 25% to 40%of the ingoing potato flow.

Washing ofpotatoes Peeling Grading cutting Blanching Drying Frying Freezing

Dirct steam Anti-foam

Indirect steamdextrose acid soium

pyrophosphateFrying vat

herbs

Steam peelingscuttings

Production wast

Frying fat

Packaging

Fine grinding Sieving

Storage of feed product

Indirect steam

Process water fromproduction Concentration

stachHeat treatment Feed storage

Figure 1 Potato products flow chart.

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The co-products which are released during the production processes (see Figure 1)and are processed as feed, are: Steam peelings which are sold after fine grinding (14-16% dry matter).

Potato cuttings where excess moisture is first separated using curved screens(20% dry matter). Grey starch which is obtained through the evaporation of released process wa-

ter from the various process stages and then heated using indirect steam. Production waste and potato products which are not eligible for consumer sale

due to quality requirements. Production waste refers especially to deviations incolour, length, taste and an excess of eyes' in the potato products.

White starch which is obtained from the water after the cutting of the potatoes.

Steam peelings, wet parings and grey starch are the major flows and amount tocirca 80% of the released feed flows.

The processing aids used in the processing are an anti-foaming agent and salt. Theanti-foaming agent is used during the grading and cutting of the potatoes. Salt isused to be able to separate the potatoes on the basis of their specific gravity.

Sodium pyrophosphate and dextrose are used as product additives during theblanching of the potatoes. The purpose of sodium pyrophosphate is to prevent thegrey colouring after the deep-freeze process. Dextrose is for colouring so that theproduct has the same colour throughout the year.

There is a selection procedure for all processing aids and additives in which thesupplier and the product are subjected to a check of their specifications and prod-

uct characteristics. Once the supplier/product combination has been chosen thenthis product is then used in production. Purchasing is done centrally with a contractbeing entered into for a number of years with a leading trading company in theNetherlands. Deliveries are made in portions within the framework of the estab-lished rules and quality requirements (delivery certificate).

The utilities used are primarily steam (steam peelings), freon and ammonia (deep-freeze end products) and thermal oil (heating of ovens and driers). Only steamcomes into direct contact with the product.

The storage of additives, processing aids and other agents is done in strict separa-tion where the various product groups cannot come into contact with one another.No internal checks are done on the delivery of these substances after the certifica-tion of a supplier or a product.

All wet' feed flows are pump through a closed circuit and stored whereas the dry'products are stored in containers.The responsibility for the feed flows is transferred to the processor at the manufac-turers site. In general a company will work with a single client or carrier. The meth-od of working of this processor was not examined within the framework of this as-signment.

At one of the companies questioned they worked in accordance with the ISO 9000

standards for the consumer product. Procedures and working methods have beenlaid down in an own quality system for the handling of the feed containers.

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At another company the production process for the consumer products was qualityassured under HACCP. The feed product was quality assured under GMP becauseof the carrier / client selected.

The frying fat was specified as another additive or auxiliary agent (and waste flow).The same rules apply to the disposal of this fat as described above. The finishedfrying fat is picked up by a fat processing company.

5.2 Potato starch

In the production of potato starch, the feed flows amount to about 30% of the totaloutput.

The following products are produced as feed: Potato pulp Concentrated juice Protein.

Figure 2 Potato starch flowchart.

The feed raw materials are extracted during the starch production and further pro-cessed separately into feed products.

washing fibreextractio

Vegetablewaterextraction

Further processing into starch

grinding

fibre dewatering

De- foaming

Water SO2 Anti-foam

fibres Coagulatio

protein seperation

Filtrate concentra tion

Mixing

Protein

protei drying

Drying

Protapec

Water

Naturalgas

Soya beanhulls

SO2, Steam

Anti-foam

Potatoes

Naturalgas

Specific for feed

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The potato pulp is dewatered and then stored in containers. The extracted vegeta-ble water is further processed after coagulation for protein production. The potato

juices which are released during protein separation are mixed with soya bean hulls,dried and stored.

The following processing aids are used during the production of starch and feeds: SO 2 Anti-foaming agent Natural gas Water

SO 2 and anti-foaming agent are obtained from suppliers in the market. Suppliersare selected in advance and guarantee the best quality with a delivery certificatesupplied.

Low-NO x burners are used during the drying process. The burners work on naturalgas which is obtained via the national natural gas network. The water used duringthe processes is purified surface water. The water is of drinking quality, free of mi-crobiological and organic substances. Soya bean hulls are added as an additiveduring the processing of the concentrated juice and the soya bean hulls arechecked per consignment for moisture and protein content.

SO 2 is stored in liquid form in tanks, the anti-foaming agent is stored in closedtanks, the soya bean hulls are stored in silos on the terrain.

Continuous process checks are carried out during the production of the main and

by-products. Work is done in accordance with the ISO 9000 standard for the pro-duction of protein, concentrated juice and soya bean hulls. Additional GMP rulesapply for the processing of potato pulp. Quality rules apply to both the processingaids and the end product and checks are carried out to prevent any harmful conse-quences.

There are possible risks in the drying process. Nitroso-amines can be formed in thelow-NO x burners (from NO x). The safety of the feed is guaranteed by sampling.

5.3 Grain and starch industry

Two companies were visited from the grain-processing industry. Flour preparationtook place at one of the companies. The other company makes starch from wheatand maize.

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5.3.1 Flour preparation

Figure 3 shows the general production process for flour preparation.

pelleting

conditioningsupply cleaning griding sievingflour/ meal

steam,vinasse

pellets

water

Figure 3 Grain-processing industry flow chart

The most important raw material is wheat (95% of turnover). In addition, maize, rye,barley and rice are processed. The by-products come from the wheat and themaize. The husks are separated from the flour during sieving. To simplify thetransport of the by-product, it is pelleted using (direct) steam and vinasse. The vi-nasse comes from the sugar industry and contains a minimum dosage of the endproduct.

The feed products released are: wheat feed middlings pellets wheat feed flour pellets maize feed meal.

The requirements of GMP, HAZOP and GMP+ apply for the lubrication of movingequipment parts which can come in contact with the product.

The cleaning of equipment is usually done dry mechanically because moisture canlead to contamination. If contamination is observed then spot cleaning is applied.There are other reasons apart from mould for rejection such as the product being

too wet or there being too much flour. If the product is too wet then the pellets aredried again. If there is too much flour then the starch and protein levels are higherthan described in the specifications. This has no consequences for health but itdoes for the compound feed industry which bases its production and specificationson the lower starch and protein levels.

The feed product is transported by truck or vessel to the clients. Vehicles are usedonly for the transport of feed and are checked for contamination on a random sam-ple basis. Vessels are always checked either when loading or when unloading.

The risks consist of contamination with mycotoxins which are checked for beforethe cargo is unloaded. If there is contamination then the load is destroyed. As noharmful processing aids are used and the transport is checked, there are no identi-fiable risks..

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5.3.2 Starch preparation

Starch is obtained from two raw materials: wheat or maize. These are separateprocesses with many processing steps in which a whole range of feed flows are

released. Roughly 30% of the raw material is sold as feed. Two types of feed flowsare created during production: specific feed product (regular feed flow) incidental feed flow (during the starting and stopping of production, product de-

viations, etc.).

A simplified flow chart for the production of starch from wheat is shown in figure 4.

dry grinding Wheat

Vital glutens food + feed

Mixen

delite dough

Vital gluten screen

wet separation

washing

Dewater

Drying

mixing

centrifuging

Inculation

evaporation

Filtration

starch rafinery

Drying

Washing Mexing

Drying

pelletising

cooling

Cellulose Water

Condensate

Water Condensate 25% NaOH

Hot air

woodmeal

Glucose (food)

HCl 33%

Wheat starch

Concentrate

Solubles

flour

Bran

Mud

-amylase

Liquid feed ( Wet wheat feed )

Wheat gluten feed

Figure 4 Flowchart for the starch industry using wheat as raw material

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After the flour preparation the first step is dough preparation. Vital glutens are re-covered from the dough. This product is used for both human consumption and forfeed. It is the same product in both cases.The remaining dough flow is used for the production of starch and glucose. Duringwet separation a separate flow is further processed into feed products, wet wheatfeed and wheat gluten feed.

In the process various flows are mixed for the production of the released feed flows(see figure 4) wet wheat feed: solubles which are released during the centrifuging and wheat

starch wheat gluten feed: bran which is released during dry grinding, the auxiliary

agent wood flour mud released during the filtration of glucose and concentratereleased during centrifuging.

vital glutens: no internal mixing of process flows.The mixing of the flows does not involve specific risks. The flows come from thesame wheat grains.

The processing aids used are: the enzymes cellulase and -amylase hydrochloric acid and sodium hydroxide solution wood flour during the filtration of glucose (absorbs proteins, minerals and glu-

cose) preservative propionic acid for wet wheat feed.

Drying takes place at various points in the process. The wheat gluten feed is indi-

rectly dried with steam. The vital glutens are directly dried, first with air heated bysteam and then using combustion air from a heat coupling plant where natural gasis used for combustion.

The lubricants used are mainly food grade. The process equipment is cleaned onceevery 2 months using cleaning-in-place with cleaning agents. The section for drygrinding is only mechanically cleaned.

The risks in this process lie in the wet wheat feed and in the auxiliary agent woodflour mud. Conversion processes could occur in the event of longer storage of wetwheat feed. The company will examine this in a study by an internal working group.

All the wood flour goes into the feed product wheat gluten feed. Fresh wood flour iscurrently used. Theoretically there is a risk of contaminated wood flour being usedon occasion.

The simplified flow chart for the recovery of starch from maize is shown in Figure 5.The food products released are starch and maize germ. Unlike the process forwheat, no glucose is produced in this process. The major feed flows released are: maize gluten feed maize protein crushed maize maize solubles.

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SievingMaiz

Soaking vats

Maize crushers

DSM-tank Centrifuging

Bran wash - steps

Dewater

Drying

Pelletising

germ drying

Soadingwater verdamper

Concentration

Sodiumbisulphite Processwater

Hot air

Maize germ (food)

flour

Mais gluten feed Mais protein

Crushed maize

Maize soluble

proteins Water, starch protein

Starch (food)

Modifiedstarch (food)

acids & bases

Gluten drier

Specifically for feed Specifically f or f eed

Figure 5 Flow chart for the starch industry using maize as raw material

Only one auxiliary agent is used in the process: sodium bisulphite solution duringthe soaking of the maize. Some of the sulphur gets into the products. Starch (forhuman consumption) may contain a maximum of 50 ppm SO 2.

During the modification of the starch use is made of processing aids such as sul-phuric acid and sodium hydroxide solution. The process for modified starch was notanalysed further because no regular feed flows are released as a co-product here.

The feed products are dried using direct drying: maize gluten feed using a natural gas fired drum drier maize protein (gluten drier) with a combination of combustion gases from a nat-

ural gas fired heat and power plant and a natural gas fired drum drier.

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The lubricants used are food grade where necessary. The process equipment iscleaned only with water and every two months. The germ drier and the feed drierare only dry cleaned.

As only one auxiliary agent which is approved for human consumption is used andas natural gas is used for drying, there are no identifiable risks. There may be risksin the further processing by clients.

The feed flows from the wheat and maize processes are collected for 70-80% bythe clients themselves. The clients themselves are responsible for this. The com-pany has a contract with a single company for the remaining flows. The feed flowsare removed in bins on trucks with a canvas over them. Wet flows are transportedusing tankers.

The company is ISO 9002 certified and is currently implementing GMP andHACCP. A working group has also been established for GMP / HACCP which isfocused on feed. This working group is currently working on maize and a start willbe made on wheat shortly.

5.4 Sugar industry

Two companies in the Netherlands were visited for the sugar industry. Both have anumber of production sites in the Netherlands with regional differences in the pro-cessing. Figure 6 is a global production scheme. The raw material is the sugar beetwhich is processed during a campaign of about 100 days. The main product is sug-ar (in all its variations). Press pulp and pulp blocks are released as feed product.

Sugar beetssupply washing sutting

Scalding trough +diffusion Juixe purification concetnration cooking

Anti-foaming agent Formalin, calciumsulphate, sulphate

Pulp pressing

Pulp drying

Pelleting

Molesses, sugar

Kalkwater gips

driers

Molasses, steam

Pressed pulp

Pulp lumps

Specifically for feed

Figure 6 Sugar industry flow chart

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An anti-foaming agent is added to the washing water during washing. The washingwater is partly condensate and partly purified, recirculated washing water. In somesites an anti-foaming agent is also added during the cutting of the beets.

In the extraction phase (scalding trough and diffusion towers) formalin shots areadded to keep infection under control. In addition, calcium sulphate and sulphuricacid (or sulphite) are used to regulate the pH level. Milk of lime or gypsum is addedduring pulp pressing to increase the dry matter level. Gypsum has a higher dry mat-ter level than milk of lime. The milk of lime is made by the companies themselvesfrom burnt lime. The pulp can be sold if the dry matter content is about 18%. Pulpblocks are created by then drying the pulp (in gas burners) and pelleting it (usingmolasses from its own process).

The agents which are used are FDA approved or comply with other requirementsset by the foodstuffs industry. The only entry requirements are for the limestonewhich forms the basis for the milk of lime (must contain at least 96% calcium car-bonate). Gypsum is checked for the level of heavy metals and fluorine. The endproducts are regularly sampled for any harmful substances.

The by-products are sold ex works . The clients hire a carrier whereby the sugarmanufacturers require that the carriers be GMP certified. Press pulp is sometimesremoved in the same trucks which supplied beet in which case the trucks must bebrush cleaned.

The risks lie in the use of gypsum which can be contaminated as was shown fromincidents in the past. Currently, apart from a single location, the gypsum (calcium

sulphate) is made from limestone and sulphuric acid by the company. Gypsum issampled per consignment for heavy metals and fluorine. The risk is therefore cov-ered.

The risks at manufacturers are covered in this branch by the HACCP and GMPwhich are in use. There is no insight into the further processing carried out at sub-sequent links in the chain. This could be a source of risks. The use of oil duringdrying can also be a risk. This could lead to contamination of the product.

5.5 Breweries

Two companies were visited for the beer brewing branch which both have variousproduction locations.

Beer is made from malt by brewing (mashing, clarification), after which the sugarsare converted by yeast into alcohol (see figure 7). The following feed flows are re-leased during the production of beer: Brewers grains (the insoluble part of the clarification), Yeast, Malt substance, Return beer.

The brewers grains are a particularly large flow.

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Malt flakes Maltsubstance

Water Beslaan50 - 75 C

Acid clarification Brewers grain 75 - 80 C

Boiling

100 C

cooling5 - 8 C

Deyeast yeast Beer yeast 0 10 C

Kiezelguhr FiklterTannin 0 CPVPP

Beer topping up0 - 2 C

Figure 7 Beer brewing flow chart

Processing aids used in production are:

Hydrochloric acid or lactic acid Calcium sulphate and calcium chloride for source water treatment); Kieselguhr (silica); Tannin (tannic acid); Polyvinyl polypyrolidon (absorbents for polyvinols).

Only the hydrochloric acid (or lactic acid) and the calcium salts can get into thefeed. As this acid gets into the beer primarily intended for human consumption,there is no risk. The other processing aids are used after the last feed flow hasbeen separated off.The calcium salts occur naturally in water and are only added because the waterused is treated by micro-filtration whereby the desired components are also re-moved.

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Precautionary measures are taken to prevent components of utilities getting intothe product. Steam is used indirectly and coolants are also used indirectly. An al-cohol and water mix is used indirectly as a coolant (common in the foodstuffs in-dustry) which is in turn indirectly cooled by ammonia. In the event of a leak onlyalcohol / water can get into the beer. Also, only foodgrade lubricants are used.Cleaning agents are primarily sodium hydroxide solution and sometimes acid. Inthe event of production errors cleaning agents will usually get into the beer and notso much the feed flows.

The processes in the breweries examined were generally comparable. The numberof feed flows is limited. Processing aids are bought in accordance with a specifica-tion.

The quality assurance for the feed at the companies examined is regulated viaGMP or ISO 9002. The responsibility for removal and further processing lies withthe clients. This is generally a limited number. There is no insight into the furtherprocessing carried out at subsequent links in the chain. For brewers grains beet orcitrus pulp is mixed in. This could be a source of risks.

5.6 Dairy industry

One company in the dairy industry was visited. This concern has 3 product groups: drinking milk and consumption products cheese refinery products from milk; feed is also produced here as a product: rearing

powders.

The company was examined for the product group drinking milk and consumptionproducts. Two more interviews would have been necessary for the other productgroups with the employees from the product groups in question. In view of thescope of the current scan the cheese and refinery product groups were not exam-ined. It is advisable to arrange these interviews. The company is prepared to coop-erate in this.

In the product group drinking milk and consumption products, it is the raw materialmilk which is pasteurised and possibly further processed into drinking milk productssuch as custard, yoghurt, buttermilk, etc. During product all the flows which are

suitable for feed are collected into a single tank and removed as one flow. The sizeof the feed flow is very small in comparison to the processed raw material milk be-ing about one promille.

The origins of the flows which are mixed are (see figure 8): Product remains: when switching from one product to another, production

faults, return products from clients Water mix with product: during cleaning the water/product mix is released Sludge from physical chemical purification (only at one location, see figure 9).

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water

Product remains in

object (tank,pasteuriser, cooler)

Product / water mix (from cleaning objects) (Products can be custartd, yoghurt,buttermilk, porridge)

2-3% d.s.

Production faults

Tapped product from filter machines Product / water mix (cleaning) product /product mix (changeover)

Return product from clients press Sieve

Feed tanksFeed

Figure 8 Dairy industry feed flows flow chart

No processing aids are used during the production of drinking milk or consumerproducts. Additives are, however, added including lactic acid bacteria, thickeningagents, aromas, fruit preparations and colouring agents These also get into thefeed product but they are all suitable for human consumption.

With respect to utilities, use is made of steam (generally indirect), cooling (indirectlywith water which is in turn indirectly cooled with ammonia) and foodgrade lubri-cants. These are in anticipation of the prevention of emergences.

Acids and bases are used as cleaning agents. The procedure for cleaning objects(once per 24 hours) is that first the product remains are removed from the objectand rinsed with water. This goes to the feed tanks. Cleaning is then done with asolution of sodium hydroxide / potassium hydroxide or nitric acid and then rinsedwith water. This flow goes to the sewers. The first product / water mix goes back tothe feed tanks. Cleaning agents could theoretically get into the feed flow if the pro-cedure was wrongly applied. The chance of this is however very small. The clean-ing and production processes are kept strictly separate from one another for thesake of product quality. In addition, various safeguards have also been incorpo-rated into the automatic process (such as reporting the equipment empty).

HACCP is applied to the feed flow except for the processing of returned products.

The feed product is removed by tanker as drink for pigs (4% dry matter) and theclient is responsible for this. One client is used per location.

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At one of the locations all the waste flows are processed in one physical chemicalpurification. Use is made during the purification process of the processing aids sul-phuric acid and a flocculant on a cellulose basis. The sludge which is formed is soldby the client as a separate flow.

Process water with processremains

Ph = 4

H2SO4

Flotaion

Flocculant

Aereate

Scrape off sludgelayer

Feed tank


Figure 9 Flow chart for the physical chemical purification in the dairy indus-try feed flow

As no processing aids are used the risks in the dairy industry do not lie in the pro-cessing aids. There is a risk in the fact that all the flows are mixed into a singleflow. If a risk substance gets into the feed then the whole flow is contaminated.There is however a high dilution effect. Risk substances can theoretically get intothe sludge such as in the case of power failure or an interruption to the automaticprocess programmes. There is always however an error message. Precautionarymeasures can be taken for this to have the sludge taken away separately.

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The mixing of the sludge takes place at the clients beyond the responsibility of thecompany.

The product groups cheese and milk refinery products were not examined. Therisks here may be different.

5.7 Oil (from soy beans)

One company was visited for this branch and another company cooperated anon-ymously. The anonymous company makes oil from soya beans and from oil seeds.The following relates specifically to the process in which soya oil is recovered fromsoya beans.

A large quantity of waste products is released during the production of soya oil.These waste products are processed into soya bean meal and are supplied to feedcompanies. The production of feed raw material is thus part of the primary process.The sales relationship in kilos between the consumer product (oil) and the feed(soya meal) is 1 : 4. The extract' is further processed into feed raw material.In addition, very small quantities of oil intended for the consumer market are sup-plied to compound feed companies.

Figure 10 Soya oil and soya bean meal flow chart.

Sieve Cool Extract oil Process inot

Oil and lecithin Break and

cruch

EvaporateHexane

Steam air air

Drying

Grinding

Soja bean meal

Add Anti-dust

agent

Hexane

Soya bean hulls

Soya bean

Velasse Lime


Steam

Steam air

Extraced

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The following processing aids and utilities are used in the pre-treatment of soyabeans: steam

air hexane

During the further processing into soya bean meal, steam and air are used in add i-tion to anti-dust agents as an auxiliary agent or product additive for better producthandling.These are: lime molasses.

The water for steam generation is treated with lye (NaOH) and phosphate to bindthe remaining hardness of the water in the steam boilers. These substances com-ply with the requirements set in the food processing industry. The air is extracted tothe outside via filters. Hexane is supplied in accordance with the specifications indedicated tankers and internal regeneration takes place. Lime and molasses aresupplied via a broker with a quality guarantee from the supplier. The lime mustcomply with a CaCO3 content of 97%, the molasses is checked by an external la-boratory against the specification provided.Extra soya bean hulls are also added to the soya bean meal. Deliveries of thesesoya bean hulls are checked per consignment against the specifications provided.

All the processes in the feed production comply with the requirements set by GMPas established by the Product Board Animal Feed. A quality manual is complied

with internally and operator manuals have been drawn up. These describe, amongother things, the process checks to be carried out, the taking of samples of the endproduct and a check on the cleanliness of the means of transport.

5.8 Rendering companies

One rendering company was visited. Rendering companies process slaughter-house waste, bodies, blood and feathers into meat meal, animal fat, blood mealand feather meal. Feather meal is the only one of these that may be supplied to thecattle industry. The incoming material comprises 70% water. After cleaning in abiological purification plant this is discharged into the surface water. Another flow is

SRM (specified risk material such as BSE material). This is collected via renderingcompanies, processed into dry material and then incinerated.

Figure 11 shows the process description for the production of meat meal. The anti-oxidant BHT is dosaged in the raw waste just before the crusher. This gives thebest mix of fat and the antioxidant. Before crushing a return flow fat is added tomake the product liquid so that crushing is made easier. The blood meal which isadded in the standardisation step to correct the protein content comes from theirown production. Pelleting is done using steam and serves primarily to improve therunning characteristics of the product.

It is obligatory to process all HR (high risk) materials into feed ingredients. Thequality of the slaughterhouse waste is guaranteed by the slaughterhouses viaHACCP. The hazards are of a microbiological nature so in practice this is not ahazard due to the pasteurisation and sterilisation steps.

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Raw MaterialsSupply

crush

Pasteuiseand sterilise

Grinding

Evaporation and

decanting

Fat pressing

Standardise

Grinding

Pelleting

mixing Grinding

Pellet meat meal Animal fat

Cleaning

Water

Blood meal

BHT

Figure 11 Rendering companies flow chart

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Blood and feathers are also processed in addition to the slaughterhouse waste.Blood is delivered separately by the slaughterhouses. It is coagulated (heated), theproteins are decanted and the serum protein goes to the water purification. Theblood cake goes to the drier and is sterilised. Feathers are hydrolysed due to iner-tia. The drying takes place in disc driers using indirect steam.

There is strict zoning on the site to prevent cross-contamination. This zoning is inaccordance with the type of material (feathers / other) and process steps (raw /sterilised). People and vehicles are cleaned and disinfected.

The risks do not lie in the use of processing aids but in the raw materials used. Ifthere are chemical contaminants in the bodies then these also get into the feedproduct.

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6 Conclusions and recommendations

6.1 General documents

The following general conclusions may be drawn for the foodstuffs industry sectoras a whole:

1. Quality awareness is high within the first links in the chain, the foodstuffs com-panies visited. The companies visited have a good name in the market, theytreat the feed flows during the greatest part of the process in the same way asthe main flow. This is also because of the position in the process where thefeed flow is separated from the primary process flows. During a great part of theprocesses, the feed product goes the same as for the primary food products forhuman consumption. At some companies the feed flows belong to their mainproducts which are sold in the market. The feed flows are also sizeable as co-products for which a (small) financial payment is received. As a waste flow theywould be a major expense item.

2. The use of processing aids is limited. In some sectors no processing aids seemto be used at all such as the dairy companies during the preparation of drinkingmilk and consumption products and rendering companies. At other companiesthe use of processing aids is limited to a small number which are often the fa-miliar acids or bases or small quantities of permitted processing aids for foodproducts intended for human consumption.

3. The companies visited can be divided into 3 groups with respect to the feedflows produced: companies with one feed flow where all the flows are mixed (dairy industry) limited number of feed flows (for example breweries, potato industry) large number of feed flows (starch industry on the basis of wheat and

maize).

4. In the companies visited there were generally no complicated further pro-cessing steps carried out on the by-products intended for feed. This makes itrelatively easy to use or extend the HACCP and GMP system used for thefoodstuffs to include the feed flows. The clients for the feed flows at the compa-nies visited are generally limited to a number of brokers and feed manufactur-ers. There is often just one and not more than three clients who are contracted.Occasionally there are deliveries direct to farmers.

5. The feed manufacturers mix together the various feed flows which are releasedby the foodstuff companies into compound feeds. The responsibility of thefoodstuffs companies usually ends at the storage in the silos on their own te r-rain. During further processing there may be possible risks due to the risk ofcross-contamination.

6. In general the foodstuffs companies use processing aids with care. This is alsobecause of the strong interaction with the process flows for human food prod-ucts.

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The processing aids are supplied by a limited number of well-known supplierswith whom long contracts have usually been entered into varying from one tothree years (sometimes purchasing is arranged centrally by one company for allthe branches in the Netherlands). The processing aids are usually used directlyin the process without any further processing.

7. The foodstuffs industry has good quality assurance as far as its own processesare concerned (and where sampling takes place). The suppliers of processingaids are not yet fully controlled. Product control lies in many cases exclusivelywith the suppliers.

8. Incorrect operations during the cleaning or maintenance of the machines re-mains risky. (Approved) cleaning agents or lubricants could get into the feedflow. This risk applies to the same extent as for human food and much proce-dural attention is paid to this.

9. Most of the feed flows fall under GMP with respect to quality assurance. One ortwo work only with ISO 9002. Some are advanced in that the feed flows also fallunder HACCP.

10. The risks for the manufacturers examined lie not so much in the processes butmore in the subsequent links at the clients for the feed products and/or wasteflows.

6.2 Conclusions per branch

The table shows, for the individual branches in the foodstuffs industry, a summaryof the released feed flows and the possible risks with respect to the use of pro-cessing aids in the processes.

Table 3 Branches studied and their products and risks

Branch Feed flows / products possible risksPotato Peel, parings and produc-

tion waste, starch- grey starch- internal transport containers- processing at clients

PotatoStarch

Fibres, concentrated juiceand protein.

- forming of nitroso-amines (via NOx)during the drying of protein andProtapec.

Flour Wheat feed meal pellets,wheat feed flour pellets,maize feed meal

- contamination of raw material withmycotoxins (moulds)

Starch fromwheat

Wet wheat feedWheat gluten feedVital gluten

- contamination in auxiliary agent woodflour

- conversion process in wet wheat feedStarch frommaize

Maize gluten feedMaize proteinCrushed maizeMaize solubles

- no identifiable risks

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Sugar Press pulpPulp blocks

- contamination of the auxiliary agentgypsum with fluorine and heavy met-als

- use oil as fuel during direct drying- further processing in chain

Beer Brewers grains YeastMalt substanceReturn beer

- further processing of brewers grains(mixing in beet pulp)

Dairy Mix of products / water flow - in the event of contamination of oneflow, everything is contaminated

- error during cleaning procedure- use sludge of physical chemical puri-

ficationOil Soya extract - contamination from hexane in feed

product- Salmonella- other undesirable substances

DIGESTION Meat mealFeather meal

Animal fatBlood meal

- Salmonella- chemical contamination in corpses

The specified risks in the table can be explained as follows per branch:

1. Potato industry.The possible risks in this branch do not lie in the use of processing aids. Possi-ble risks are however acknowledged in the grey starch flow which is recoveredfrom a mix of various waste water flows from the production factory. The wastewater flows come from various locations in the factory and unwanted compo-nents may get into them. There are also risks in the internal processes of thecustomers for the feed products as well as the internal transport of productionwaste in containers.

2. Potato starch.There are possible risks in the drying process. Nitroso-amines can be formed inthe low-NO x burners (from NO x). The safety of the feed is guaranteed by sam-pling.

3. Flour.The risks consist of contamination with mycotoxins which are checked for be-fore the cargo is unloaded. If there is contamination then the load is destroyed.

As no harmful processing aids are used and the transport is checked, there areno identifiable risks..

4. Starch.Starch can be prepared using two processes and, depending on the raw mate-rial, these are the wheat [process or the maize process

The risks in the wheat process lie with respect to the released feeds in thewet wheat feed and in the auxiliary agent wood flour mud. All the wood flour

goes into the feed product wheat gluten feed. Fresh wood flour is currentlyused. Theoretically there is a risk of contaminated wood flour being used.

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Also in the released flow of wet flour there may be conversion processes inthe event of longer storage. This is currently being examined in the sector.

There are no identifiable risks in the maize process. There is one auxiliaryagent used which is approved for human consumption and natural gas isused for drying. There may be risks in the further processing by clients.

5. Sugar.The risks lie in the use of gypsum which can be contaminated as was shownfrom incidents in the past. Currently, apart from a single location, the gypsum(calcium sulphate) is made from limestone and sulphuric acid by the company.Gypsum is sampled per consignment for heavy metals and fluorine. The risk istherefore covered.

The risks at manufacturers are covered in this branch by the HACCP and GMP

which are in use. There is no insight into the further processing carried out atsubsequent links in the chain. This could be a source of risks. The use of oilduring drying can also be a risk. This could lead to contamination of the prod-uct.

6. Beer.Only the hydrochloric acid (or lactic acid) and the calcium salts added duringclarification can get into the feed. As this acid gets into the beer primarily in-tended for human consumption, there is no risk for the by-products.There is no insight into the further processing in the feed flows carried out atsubsequent links in the chain. For brewers grains beet or citrus pulp is mixedin. This could be a source of risks.

7. Milk. As no processing aids are used the risks in the dairy industry do not lie in theprocessing aids. There is a risk of contamination of the feed product in the factthat all the flows are mixed into a single flow. If a risk substance gets into thefeed then the whole flow is contaminated. There is however a high dilution ef-fect.

Risk substances can theoretically get into the sludge as a result of a fault.The mixing of the sludge takes place at the clients beyond the responsibilityof the company.

In the dairy industry in particular, there is a risk due to the method of operationwith various products in sequence and interrupted by cleaning operations, thatcleaning agents could get into the feed flow if the procedure is applied wrongly.The chance of this is however very small.

8. Soya oil.Hexane is used as an extraction agent in soya oil preparation. There is a risk ofhexane being contaminated by other components (such as benzene). Afterevaporation of the hexane these components could be compounded in the feedproduct.

9. Rendering.No use is made of processing aids in this branch. There could be a risk ofchemical contaminants in the bodies which then get into the feed product.

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6.3 Recommendations

1. There are generally sufficient control measures by the manufacturers of feed toguarantee the quality of the feed. The next step could be to follow the chain up

to the user in order to inventory all the hazards in each link and on this basis toset extra requirements if necessary for the control measures.

2. It is advisable for feed clients regularly to audit the previous link where the rawmaterials are released (the foodstuffs industry). This is already usual in somecompanies. In turn, the foodstuffs industry can audit its prior links including themanufacturers of processing aids. This is already being done by a number offoodstuffs companies.

3. Depending on their size, control measures and procedures are also applied tothe feed flows and in general the same rules are applied as for the foodstuffsprocesses for human consumption. If the feed products are only' a waste flowthen there is little checking. Checking at the client is then of extra importanceand should be improved.

4. With respect to processing aids the foodstuffs industry should not just trust thechecks by the suppliers but also take on its own responsibility and demonstra-bly include this in its own quality assurance.

5. A limited number of foodstuffs manufacturers have currently been examined.The question is in how far they are representative. The companies visited havea good name in the market. It is advisable also to visit other companies. Aspreparation for the selection the experiences with compound feeds and food-stuffs companies could be checked.

6. Only the drinking milk division was visited in the dairy industry. Other divisionssuch as cheese preparation and milk refinery could be examined.

7. It is advisable to extend the quality systems of the foodstuffs companies(HACCP) for the foodstuff products to include the processing aids and the feedflows.

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APPENDIX 1 : List of processing aids in the branches examined

Branch Rawmaterials

Products Feed flows Processingaids

Ownprocessingaids

Entry checkprocessingaids

Feedqualityassurance

Utilities Additives

Potatoindustry

Table pota-toes, herbs,fat and starch

Deep-freezefries andquick-frozenpotatospecialities

Peel waste, wetparings, rejectpotatoes, friedwaste, starch(white), crumbs,waste fat, pure,combination offat and pure,starch (grey)

Anti-foamingagent and salt

Specifica-tions andcertification

Check anumber oftimes peryear

GMP Broxo,ammoniaand freon,oxytreat,food-gradelubricants,thermal oil

Sodiumpyrophos-phate,dextrose

Table pota-toes, frying fat

Deep-freezefries, quick-frozen potatospecialitiesand potatoflakes

Peel, parings andproduction waste,starch

Anti-foamingagent

AVIKOqualityrequirements

No None Cleaningagents

Herbs,sodiumpyrophos-phate anddextrose

Potatostarch

Starchpotatoes

Potato starch Fibres, concen-trated juice(Protapec) andprotein.

Sulphur dioxide Specifica-tions andcertification

Yes,sampling orcontrol label

HACCP Natural gascombustiongases, sur-face waterfor cooling

Soya beanhulls

Grain andstarchindustry

Wheat, maize,rye and barley

Flour (300varieties)

Wheat feedmiddlings pellets,

wheat feed flourpellets and maizefeed meal.

Vinasse Specifica-tions andapprovedsuppliers

Vinasse forDS level,protein andpotassium

GMP, in theprocess ofHACCPcertificationwithin theframework ofGMP+

Lubricatingoil

Enzymes,emulsifiersand salt

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Branch Rawmaterials


Ownprocessingaids



Utilities Additives

Maize Starch,modifiedstarch, wheatproteins

Maize glutenfeed, maizeprotein, crushedmaize, maizesolubles

Sodiumbisulphite solu-tion

Specificationsheet

Visual in-spection

ISO 9002,engaged inGMP andHACCP

Steam,combustiongas fromnatural gas,lubricants,

cleaningagents

None

Wheat Glucose,starch,modifiedstarch, wheatproteins

Wheat glutenfeed, wet wheatfeed, vital gluten,partly hydrolysedwheat gluten,concentratedwheat solubles

Cellulase, sodi-umhydroxide solu-tion, wood flour,alpha-amylase,propionic acid,hydrochloricacid

Specificationsheet

LimitedControlaccording toschedule

ISO 9002,engaged inGMP andHACCP

Steam,combustiongas fromnatural gas,lubricants,cleaningagents

Ascorbicacid

Sugar Sugar beets Sugar andsugarspecialities

Beet tails, presspulp and pelletedpulp

Water,formalin,gypsum or milkof lime, sul-phuric acid andsulphite, molas-

ses, sodiumhydroxide solu-

tion

For ownproduction ofmilk of lime:FDA rawmaterials

Limestoneshouldcontain atleast 96%calciumcarbonate

GMP+ Steam andcombustiongases fromnatural gas,lubricants

None

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Branch Rawmaterials


Ownprocessingaids



Utilities Additives

Sugar beets Sugar andsugarspecialities

Press pulp andpulp blocks

Anti-foamingagent, water,gypsum, calci-um sulphate,limestone, for-

malin, molas-ses, possibly apressing auxilia-ry agent fromthe positive list

Delivery inaccordancewith specifi-cation

Gypsum isonly ana-lysed exter-nally perconsignment

for heavymetals andfluorine.

GMP andISO 9001 /9002.HACCP fromautumn

2000

Combustiongases fromoil and natu-ral gas, foodand feed

grade lubri-cants

None

Breweries Water, maltand hops

Beer Brewers' grains,yeast and maltsubstance

Hydrochloricacid, kieselguhr,tannin, polyvinylpolypirolidon

Specifica-tions andHACCPrequirements

By function-ality

ISO 9002 Coolants,steam, lubri-cants, clean-ing agents

Lactic acidand nitrogengases

Water, malt,maltose syrup,hops

Beer Brewers' grains,yeast, maltsubstance andreturned beer

Yeast, calciumsulphate, calci-um chloride,lactic acid bac-teria, kiesel-guhr, polyvinylpolypirolidon

Specificationand certifiedprocessingaids

Not forprocessingaids ingeneral

GMP Coolants,steam,lubricants,inert render-ing gases,cleaningagents

Herbs

Dairy Milk, sugar,starch, milkprotein pow-der

Drinking milkand consump-tion milkproducts(custard,yoghurt, etc.)

One animal feedflow of productionwaste + prod-uct/water mix+ (insome casessludge from phys-ical chemicalpurification)

None Notapplicable

Not applica-ble

HACCP Pasteurising,chilling,lubricants,cleaningagents

Lactic acidbacteria,thickeningagents,aromas, fruitpreparations

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Branch Rawmaterials


Ownprocessingaids



Utilities Additives

Oil Soya beans Soya oil andlecithins

Soya extract Hexane Delivery inaccordancewith specifi-cation

In accord-ance withGMP guide-line

HACCP Steam andcoolingwater

Soya beanhulls,molassesand lime

Soya beans Soya meal

and soyabean oil

Soya bean hulls Hexane and

steam

Delivery in

accordancewithspecification

Limited HACCP +

GMP from1 Oct 2000(is thiscombinationcorrect?)

Cooling

water,combustiongas, steam,lubricants,nitrogen andabsorptionoil

Talc, ligno

sulphonate,gums, clay &emulsion

Sunflowerseed andrapeseed

Sunflowerseed andrapeseed oil

Sunflower mealpellets and rape-seed meal pellets

Hexane andsteam

Specifica-tion, ifpossible withhold-cleanand vitocertificate

Limited HACCP +GMP from 1Oct 2000

Steam, out-side air,lubricants,absorptionoil, water

Water,emulsion /soap

DIGES-TION

Bodies,slaughter-house waste,

blood andfeathers

Only feedflows

Meat meal,feather meal,animal fat and

blood meal

None Notapplicable

Notapplicable

GMP Steam Anti-oxidantBHT

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APPENDIX 2: Feed products processing aids and processingaids questionnaire

Product Board Animal Feed

Tebodin ConsultantsP.O. Box 160292500 BA THE HAGUE

telephone 070 3480911

1. General details

1.1 Name of questioner

1.2 Date of interview

1.3 Location of interview

1.4 Existing Tebodin contact person (if applicable)

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2. Company details

2.1 Company name

2.2 Address

2.3 Place

2.4 TelephoneFaxE-mail address

2.5 Contact personFunction

2.6 Number of employees

2.7 Turnover per calendar year

2.8 Branch and SBI code

2.9 (Primary) productsNature of the production

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4. Process

4.1 Out of which sub-stages is the production process constructed? Are there PFDs/ block diagrams available which clearly show which process steps there are andwhich substances are included and where (raw materials, processing aids andadditives)?

4.2 Give for each sub-process the nature (chemical, thermal, physical, biological)and type (batch, continuous).

4.3 Primary process data such as temperatures and pressures

4.4 Where are utilities used (for example drying using combustion gases, chilling)?

4.5 Which cleaning methods are used and where?

4.6 Where and how is the feed product released?

4.7 Are there opportunities for cross-contamination?

4.8 Is there any further treatment of the feed flow?

4.9 What happens to off-spec or returned products?

4.10 Can undesired reactions or conversions take place in the process and can thishave an effect on the feed product?

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5. Quality Assurance

5.1 Is there a GMP/QM certificate or a quality management system for the feed pro-duction?

5.2 Do you (also) apply HACCP to the production of feed?

5.3 Which relevant requirements are specified in the permits?

5.4 Does the purchase or use of processing aids or processing aids and their moni-toring fall within any of your quality regimes?

5.5 Are there any other special physical, chemical or biological safety requirementsestablished? For example under the Commodities Act, hygiene codes or by theclient?

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6. Main and by-products

6.1 What are the main and by-products?

6.2 How is the feed product transported?

6.3 Who is responsible for this transport?

6.4 Is packaging used and, if so, which?

6.5 Control measures and procedures

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