Control of microbial contamination in a feed plant Taiex workshop, Sofia, Bulgaria September 15-16 Kjell Larsson

Feed from Lantmännen Two cooperative companies Lantmännen and Kalmar Lantmän 9 feed plants on 8 locations ~ 1,4 mio ton compound feed ~ 65 % of the Swedish market Taiex workshop Sofia, 15-16 September 2010 Kjell Larsson

Possible problems caused by microbial contamination of feed Human health problems Sick animals Reduced animal productivity Deterioration of feed materials Taiex workshop Sofia, 15-16 September 2010 Kjell Larsson

Chemical versus microbial contamination Chemical contamination is more predictable - What comes in goes out Microbial contamination can be generated at feed plant and farm level How far does the responsibility of the feed supplier go? Taiex workshop Sofia, 15-16 September 2010 Kjell Larsson

General conditions for microbial growth Access to nutrients Suitable temperature Access to water Suitable pH Taiex workshop Sofia, 15-16 September 2010 Kjell Larsson

Feed and food born diseases and intoxications Microbial contamination Occupational health Mycotoxin production Temperature increase Moulds Fusarium Aspergillus Penicillium Bacteria Feed and food born diseases and intoxications Salmonella Bacillus Clostridium Taiex workshop Sofia, 15-16 September 2010 Kjell Larsson

Salmonella Control strategies in operation designed to meet Customer demands National legislation Voluntary feed safety standards Taiex workshop Sofia, 15-16 September 2010 Kjell Larsson

Relevant EU legislation Reg. 178/2002 General Food Law Art 15. Feed shall not be placed on the market or fed to any food-producing animal if it is unsafe. Dir 2003/99 on monitoring of zoonoses and zoonotic agents Reg. 2160/2003 on control of salmonella and other zoonotic agents Reg. 183/2003 Hygiene regulation Art 5.3 Feed business operators shall a) comply with specific microbiological criteria; (b) take measures or adopt procedures necessary to meet specific targets. Taiex workshop Sofia, 15-16 September 2010 Kjell Larsson

Relevant EU legislation con’t No harmonised legislation on salmonella in feed EFSA opinion July 2008 Salmonella is the major microbiological hazard in feed Oil seed meals are the major risk feed materials Some Salmonella serotypes found in feed are also found in humans Establishment of microbiological criteria along the feed chain is appropriate Taiex workshop Sofia, 15-16 September 2010 Kjell Larsson

EFSA report March 2010 Different reduction strategies proposed dependent on prevalence level in pig production. Calculated reduction levels (%) from different measures due to prevalence level Measure High Low Salmonella free breeding 70 - 80 10 - 20 Salmonella free feeds 60 - 70 Control of external sources (mice and birds) Taiex workshop Sofia, 15-16 September 2010 Kjell Larsson

The Swedish Salmonella strategy Control at slaughterhouse level Control of animals at farm level Extensive control in feed production Zero tolerance at all levels Zero prevalence in animal food produced in the country Almost zero prevalence in compound feed Taiex workshop Sofia, 15-16 September 2010 Kjell Larsson

Not zero prevalence at farm level in SE ! Taiex workshop Sofia, 15-16 September 2010 Kjell Larsson

How to provide Salmonella free feeds? The basic strategy includes 1. preventing salmonella from getting into the production lines 2. preventing what gets in from growing/multiplying 3. sampling program at critical points in order to find salmonella 4. cleaning and disinfection when salmonella is detected Production and deliveries are stopped if salmonella is found in finished feed or at defined sampling points Taiex workshop Sofia, 15-16 September 2010 Kjell Larsson

Preventing Salmonella from getting in The Swedish model Mandatory control program for risk feed materials - all meal from the vegetable oil industry - fish meal 100 subsamples to 10 analytical samples from each shipment (max 2000 tons) on loading PCR analysis during shipping All results have to be negative before use Treatment with acid on discharge if positive Taiex workshop Sofia, 15-16 September 2010 Kjell Larsson

Treatment with organic acids Mixture of propionic and formic acid Dose (1-2 %) dependent on material temperature Increased sampling frequency Analysis after >48 hrs pH dependence of Salmonella 1 ≈4,5 6,5 7,5 ≈9 14 No growth but survival No growth but survival Growth Taiex workshop Sofia, 15-16 September 2010 Kjell Larsson

Preventing Salmonella from getting in The Lantmännen model Defining zones with different hygienic status Pellet/mash coolers in closed rooms with excess pressure of filtered air Cooperation with and selection of feed material suppliers Taiex workshop Sofia, 15-16 September 2010 Kjell Larsson

Taiex workshop Sofia, 15-16 September 2010 Kjell Larsson

Preventing what gets in from growing Mandatory heat treatment of poultry feed (SE, DK) Voluntary heat treatment of all other feeds (Lantmännen) Taiex workshop Sofia, 15-16 September 2010 Kjell Larsson

Preventing what gets in from growing Water activity - aw 0,94 1 No growth but survival Growth Temperature, C 6 35 45 65 -25 No growth but survival Growth Optimum Growth Gradually dying off Taiex workshop Sofia, 15-16 September 2010 Kjell Larsson

Sampling programs Risk based with 5–30 samples per week samples/week or 5700 in 2009 Reduction to 78 samples/week or 4050 this year Sampling at: feed material inlet – filters in coolers filters on conveyors for finished feed bins for finished feed Extra sampling when salmonella is found Taiex workshop Sofia, 15-16 September 2010 Kjell Larsson

Taiex workshop Sofia, 15-16 September 2010 Kjell Larsson

Cleaning and disinfection Careful cleaning necessary before chemical treatment Clean equipment is free from visible feed residues Handling of disinfecting chemicals is left to subcontractors The effect of the measures is always confirmed by sampling Taiex workshop Sofia, 15-16 September 2010 Kjell Larsson

Applicability in other MS The present status in SE is the result of voluntary work starting around 1960! Mandatory chain approach partly financed by the government Feed approach not realistic when handling large shipments of feed materials Good experiences of the approach in production of meals and cakes The basic principles are recognised by chain partners Taiex workshop Sofia, 15-16 September 2010 Kjell Larsson

The way forward? Approach proposed by COCERAL, Copa-Cogeca, FEDIOL and FEFAC Development of a common set of principles including the following elements: Risk management Prevention Monitoring / Control of processes Corrective actions Verification Sectorial guidelines for proper implementation Taiex workshop Sofia, 15-16 September 2010 Kjell Larsson

Thank you for your attention! Taiex workshop Sofia, 15-16 September 2010 Kjell Larsson