The purpose of quality control is determining and applying a method with regular professional plan which would provide the products according to essential standards.
Quality control is an important part in all industries, especially food and animal feed industry and poultry that has duty from the beginning of raw materials and even started to buy raw materials and ultimately continues to export the product from the factory to the farms. And without a strong part of quality control, high quality products is practically impossible.
Our stringent quality control lead to increase quality and reduce pathogens and animal feed and consequently caused to increase the quality of our human food.
GMP principles in livestock and poultry food manufactures:
By trend of economic globalization and the establishment of integrated economic chain in all areas of production such as livestock and poultry feed, acquiring the necessity general principles for the comprehensive production has become an important issue in the global arena. In recent years, the quality of livestock and poultry feed is considered seriously. The aim of the discussions was the standardization of the quality of livestock and poultry feed which is essential for human food safety.
Good manufacturing practices (GMP)
are the practices required in order to conform to the guidelines recommended by agencies that control authorization and licensing for manufacture and sale of food, drug products, and active pharmaceutical products. These guidelines provide minimum requirements that a pharmaceutical or a food product manufacturer must meet to assure that the products are of high quality and do not pose any risk to the consumer or public.
Now a days, GMP is the opening door to joining the international and regional markets and rival in national and international business.
GMP rules or proper operation for production the animal feed developed and collected in different fields such as storage, handling, transportation, sales of prepared food, feed raw material, additives and supplements.
All guidelines follow a few basic principles:
• Manufacturing facilities must maintain a clean and hygienic manufacturing area.
• Controlled environmental conditions in order to prevent cross contamination of food or drug product from adulterants that may render the product unsafe for human consumption.
• Manufacturing processes are clearly defined and controlled. All critical processes are validated to ensure consistency and compliance with specifications.
• Manufacturing processes are controlled, and any changes to the process are evaluated. Changes that have an impact on the quality of the drug are validated as necessary.
• Cross contamination with unlabeled major allergens is prevented.
• Records are made, manually or by instruments, during manufacture that demonstrate that all the steps required by the defined procedures and instructions were in fact taken and that the quantity and quality of the food or drug was as expected. Deviations are investigated and documented.
• Records of manufacture (including distribution) that enable the complete history of a batch to be traced are retained in a comprehensible and accessible form.
• The distribution of the food or drugs minimizes any risk to their quality.
• A system is available for recalling any batch from sale or supply.
• Complaints about marketed products are examined, the causes of quality defects are investigated, and appropriate measures are taken with respect to the defective products and to prevent recurrence.
Based on the rules for access to basic quality GMP in the animal feed sector shall be considered following options:
– Consuming the animal drugs and supplements
– Level of foreigner materials
– Hygienic methods (bacteriologic control conditions)
GMP regulations of the attitude of the HACCP (Hazard Analysis and Critical Control Point) will follow.
HACCP is interpreted all communication in the production process and the identification and documentation of product quality and the health risks it assumes. All potential hazards on the quality of products and their health must be properly controlled by prescribed methods and procedures.
Livestock and poultry food GMP in target groups:
Including the producing units, preparing feed, concentrates and supplements is expressed to a third party for marketing, production, storage, handling or transportation offer. The aim of the GMP regulations is ensured that the process of storage, production, handling and transport to how to comply with regulations and standards for product supply which have been determined by the target groups.
GMP requirements in livestock and poultry feed factories:
GMP covers all stages of production and defines GMP principles within the whole process of production. In general GMP requirements is considered as follows:
Buildings and facilities:
Animal feed manufactory should be designed as:
1- Preventing the entry any pollution and carriers to the production complex
2- Facilitating the process manufacturing operations, maintenance and purging the feed to minimize feed pollution.
3- Tanks, pipes, and equipment should be manufactured suitable materials that can be produced with less pollution and more clean.
4- Water supplied from health and quality standards sources for producing the animal feed.
5- Sewage and waste materials should be disposed in hygienic methods.
Production, processing, storage, transportation and distribution of animal feed and raw materials.
A. All those involved in animal feed factories are responsible for the GMP principles.
B. Health hazards include GMP in all stages of production and production management elements responsible for controlling it.
1- Foreigner pollution in the production cycle
2- Increasing pollution due to undesirable storage or processing
3- Operation, maintenance and calibration of the equipment
A. All tools quantifiers (scales, thermometers and etc.) should have the calibration program.
B. All tools and machines should have particular manual.
4- Control and Inspection Methods
A. Includes all steps is the chain of production.
B. Should have a regular schedule and system documentation is archived.
C. Inspection systems should be based on an objective risk assessment appropriate to the conditions they are designed and implemented.
Obviously, these systems must conform to international standards for control and inspection.
5- Sampling, testing and control at all stages of production
A. Each factory shall have an individual feed quality control unit.
B. Sampling should be based on the standard principles and values carried by the quality control unit.
C. Control inspections during production and processing stages are responsible of the quality control unit.
D. Each laboratory analysis and microbial food should have a quality assurance unit.
Label and information signs must comply with all legal requirements or feed livestock and poultry.
7- Tracing and record keeping of feed and raw materials
8- Staff Training
9- All employees, who are related to production, storage and handling of animal feed, should be adequately trained and aware of the role and its responsibility in maintaining food safety.
Health risks associated with feed:
Animal feed and raw materials must be have safety standards.
The level of undesirable substances in animal feed should be minimal somewhat is lower than the detrimental amount in human food (for humans).
Note 1- Codex regulations regarding the maximum residues legible (MRL) and the maximum residual foreign substances in animal feed should be met.
Note 2- The maximum residue levels set for human food (such as Codex regulations) can be used for determine the minimum safety standards for animal feed.
Laboratory and quality control of Faraz Daneh Avand:
Quality control of Faraz Daneh Factory includes experts in quality control, laboratory, and nutrition and diet formulation. The laboratory of factory is equipped with advanced equipment for laboratory analysis of food include Kjeldahl, Soxhlet extractor, digital spectrophotometer, digital hydrometer, electric stoves and ovens which can help to analyze the test chemical, biological, Aflatoxin and heavy metals by experts and professional staffs.
Chemical tests are including measurement of moisture, crude protein, crude fat, crude fiber, ash, calcium, phosphorus, salt and Aflatoxin.
Description of Operation:
At first, the raw materials purchased by the initial visit with expert quality control and physically evaluated and after the necessary sampling, it would be sent to the lab for analysis. Raw material samples sent to laboratory for chemical, biological and Aflatoxin analysis and if approved, it will be delivered to nutritionist and ratio experts to be based for proper ratio.
Products are sampled on a daily basis and every batch production and after testing and confirming the quality control department offered to customers.
The entire process and quality control operations have been done in accordance with the instructions and rules of Veterinary Organization and the national standard of Iran.
Our products are including poultry grain and concentrated livestock feed which is in the form of pellets.
All products are produced according to GMP guidelines veterinary organizations and international standards ISO 9001, ISO 22000, HACCP Scheme and also Standards No. 605 and the 3774 Institute of Standards and Industrial of Iran.
All raw materials used in poultry feed manufacturing are provided by accredited distribution centers and then transferred to the factory to inspect by the quality control unit and samples sent to the laboratory for quality control. If the raw materials have seen the necessary quality, would be entered to production cycle.
This unit has a chemical analysis laboratory equipped with the most advanced devices and laboratory equipment and can be done all initial tests such as measuring humidity – crude protein – crude oil – raw fiber, ash, Calcium, Phosphorus, Sodium, Potassium, fluoride, salt and energy measurements and Aflatoxin. The Microbial and heavy metals testing have been done by the collaborator lab.
Periodic sampling and quality control is carried out by the National Veterinary and Standard Institute.