official controls in processing plants: check

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official controls in processing plants: check
Approval and registration
Regulation (EC) No 1069/2009 and Commission
Regulation (EU) No 142/2011
Examples
Marko Mahne, dr.vet.med.
Beograd, 27. 3. 2012
1
Example: Processing plant
Rendering
•
Rendering is a process that converts ABPs
into stable, value-added material
•
One of the oldest recycling industries
– Making of soap or candles
– Essential for modern food industry
•
Products:
– MBM / PAP (proteins): fertiliser, petfood
– Fat: grease, animal feed, biodiesel
– Water
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Example: Processing plant
Hygiene requirements
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•
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Article 25 of Reg. 1069/2009
Additional requirements in Annex IV of Reg. 142/2011
Not located at the same site as slaughterhouse (or any other food
establishment), except:
– Total physical separation
– Conveyer system
– Separate entrances, reception bays, equipment and exits
•
•
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Adequate facilities for cleaning and disinfecting the containers or
receptacles and the means of transport
Waste-water disposal system
Laboratory : own or external
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Example: Processing plant
Wastewater treatment
•
Pre-treatment process for the retention and collection of animal
material
– drain traps or screens with apertures with a filter pore or a mesh size of
no more than 6 mm
– No grinding, maceration or any other processing or application of
pressure
•
•
Retained material shall be collected and transported as Category 1
or Category 2 material and disposed of in accordance with Reg
1069/2009
Wastewater, having passed the pre-treatment process:
– treated in accordance with Union legislation, and
– without restrictions in accordance with this Regulation.
•
Disposal of ABPs, including blood and milk, or derived products
through the wastewater stream shall be prohibited
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Example: Processing plant
Cat 3 Processing
plant
Biogas plant
Cat 3 plant - handling &
storage of hides
Combustion of
fat
Cat 1 Processing
plant
Cat 1 Intermediate plant
post-mortem
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Example: Processing plant
MBM
Cat 1 fat
combustion
Cleaning and disinfection
of vehicles
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Example: Processing plant
Cat 3 Processing
plant
Slaughterhouse
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Example: Processing plant
Closed conveyer
system
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Example: Processing plant
Processing requirements
•
•
•
Calibrated gauges/recorders must be used
Records shall be maintained for at least two years
Recirculation of material that did not receive suficient treatment
•
Critical control points (Cat 3):
(a) raw material particle size;
(b) temperature achieved in the heat treatment process;
(c) pressure, if applied to the raw material;
(d) duration of the heat treatment process
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Example: Processing plant
Processing standards
•
Pressure sterilisation (Method 1)
– 133°C, 3 bar, 20 min, max. particle size 50mm
•
Methods 2 – 6
– Description :
• Reduction – size of particles
• Time, temperature and pressure
• Batch or continuous systems
•
Method 7 - Any processing method authorised by CA
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Example: Processing plant
Processing standards
•
˝Alternative˝ processing methods
– Starting materials
– Processing method
•
Alternative methods – Art 20 Reg. 1069/2009
– use or disposal of ABPs or DP
– EFSA opinion
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Example: Processing plant
Disposal and use of derived products –
alternative processing methods
•
Cat. 1 derived products
– Disposal (incineration / co-incineration, landfill)
– Biogas*
– Processed into fat derivatives for uses other than feeding
•
•
Cat. 2 & Cat. 3 derived products:
Disposal (incineration / co-incineration, landfill)
– Biogas and compost
– Organic fertiliser / soil improver
– Processed into fat derivatives for uses other than feeding
•
Disposal of waste from the processing of ABPs (sludge, filter
contents, ash and digestion residues)
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Example: Processing plant
Marking with GTH
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•
•
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Cat. 1 & Cat. 2 derived products
Avoid re-contamination
homogenously throughout the substance a minimum concentration
of at least 250 mg GTH per kg of fat
Operators must demonstrate to CA that concentration is achieved
– system of monitoring and recording
•
Marking is not required for:
–
–
–
–
Liquid DP destined for biogas/composting
DP for feeding of fur animals
Biodiesel and renewable fuels
DP, moved by closed conveyer system for
• Incineration/co-incineration
• Use with alternative processing method
• Use for research or other specific purposes
•
Determination: gas chromatography
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Example: Processing plant
Approval
• Approval - Article 24(1)(a) of Reg. 1069/2009
• Category must be specified
Documents:
• Site map of the establishment with clean and unclean sectors
• Layout plan for installations, equipment and devices
• Process flow chart
• Proof of sufficient capacity for steam and hot water
• Calibrated instruments for measuring temperature, pressure and
time on CCP
– Data recording
•
•
•
Monitoring of reduction of particles
Safety system against unsuficient heating
Marking with GTH
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Example: Processing plant
Approval
•
•
•
On-site visit
Decision
OFFICIAL CONTROLS IN PROCESSING PLANTS:
CHECK:
– general conditions of hygiene of the premises, equipment and
staff
– efficacy of the own checks
– effective implementation of HACCP
– products after processing – testing
– storage conditions
TAKE samples required for laboratory tests
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Example: Processing plant
Validation procedure
•
•
Prior to approval, carried out by operator
Procedure:
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Example: Pet food plant
Pet food in Europe
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Example: Pet food plant
Annex I of Reg. 142/2011: Definitions
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Example: Pet food plant
•
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Approval - Article 24(1)(e) of Reg. 1069/2009
Regulation (EC) No. 183/2005
– Art. 9 – Registration
– Art. 10 - Approval
•
Regulation (EC) No. 767/2009
– Placing on the market in EU
– Labelling
•
•
HACCP
Placing on the market (Art. 35 of Reg. 1069/2009)
– Starting material:
• Cat. 3 – except Art. 10 (n)(o)(p)
• Cat. 1 – imported pet food or of pet food produced from imported materials
• Cat. 3 – for raw pet food, only Article 10(a) and (b)(i) and (ii)
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Example: Pet food plant
General requirements – Reg. 142/2011
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Example: Pet food plant
Specific requirements – Reg. 142/2011
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Example: Pet food plant
Specific requirements – Reg. 142/2011
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Example: Pet food plant
Specific requirements – Reg. 142/2011
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Example: Pet food plant
Specific requirements – Reg. 142/2011
Sampling of dogchews/processed petfood and raw petfood
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Example: Pet food plant
Registry of plants / establishments
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Example: Handling
•
•
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Ex ˝Tehnical˝ and ˝intermediate˝ plants
Approved in accordance with Art. 24(1)(h) of Reg. 1069/2009
Activities:
– Article 19 of Reg 142/2011
– Annex IX, Chapter II
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Example: Handling
General requirements
•
•
Art. 25 of Reg 1069/2009
Annex IX Chapter II Section 1 of Reg 142/2011
–
–
–
–
–
–
–
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Separated from major roads and other premises (E.g. slaughterhouses)
Total separation of categories
Covered space to receive and dispatch ABPs
Easy to clean and disinfect, drainage of liquids
Facilities for staff
Arrangements against pests
If necessary, temperature contolled storage facility
Adequate facilities for cleaning and disinfecting the containers and
receptacles / vehicles
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Example: Handling
Hygiene requirements
•
Annex IX Chapter II Section 2 of Reg 142/2011
– Avoid risk of propagating animal diseases at sorting
– Separation of other goods
– Properly stored before re-dispatch
•
Annex IX Chapter II Section 3 of Reg 142/2011
– hygienisation/pasteurisation
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Example: Handling
•
Storage of hides and skins, intended for the production of gelatine
and collagen for human consumption, in plant or establishment,
approved in accordance with Reg 1069/2009
Authorisation in line with Reg. 853/2004
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