Quality Control in Poultry Feed

Manufacturing

Prepared By
Dr. Mayur M. Vispute,
Roll No: M-5631,
Division of PSC
INDIAN VETERINARY RESEARCH INSTITUTE, IZATNAGAR.
CENTRAL AVIAN RESEARCH INSTITUTE, IZATNAGAR.
What is Quality and Quality Control?

• Quality: Quality of a product

is a combination of assurance
of safety and wholesomeness
which is comforting to standards

• Quality assurance : Deals with the policies, procedures

and process controls that yield a consistent product.

• Quality control: Deals with the in-plant process

measurements that insure quality parameters are met
during receiving, manufacturing and delivery.
 Scenario In India
• Bureau of Indian standards (BIS) Regulates the quality of
poultry feeds in India.

• BIS has a subcommittee “Animal Feed Sectional Committee” for

animal feeds standardization. It includes Nutritionists from

1) ICAR institutes
2) SAUs
3) Feed industry
4) Government departments having specialization in
nutrition.
5) Feed technologists concerned with animal husbandry
activities.
(BIS Act, 1986).
 NGFA Model of Quality Control In Feed
Manufacturing

Purchasing
and
receiving
Feed Feed product
manufacturing investigation/
and process recalls.
control
Quality
control in feed
manufacturing
Finished feed Sanitation and
sampling, pest/rodent
inspection and control
labeling
Feed
shipment
and delivery
(NGFA, 2002)
 Purchase and Reception
of Ingredients
• Ingredients have variation in terms of their physical
appearance and nutrient quality.

• Suppliers plant history is important.

• Show commitment to quality in your behavior.

• End the practice of awarding the business on the basis of

price alone.

• Always work with single supplier to minimize the cost.

 Cont…
• Regular analysis of feed samples received from the
supplier is important.

• Development and maintenance of meaningful

laboratory reports and their use in decision making
about feed purchasing.

• There should be Regular communication with the

supplier about feed quality.

• File every deficiency claim possible, to ensure

more safety.
 Process Control
.Process control

Personnel Equipments Procedures (SOPs)

Productivity Application Communication

Installation Identification
Interest
Adjustment Traceability
Alertness
Operation Verification

Capacity Records

Lubrication Safety

Maintenance
 Finished Feed
• An assay must be done of a finished feed
prior to offering it for dispatch or to birds.

• Collect at least 2 samples/ formula/week or 1

sample/batch.

• It gives ‘final report card’ of feed quality and milling

operations.

• Ensure correct labeling of feed.

• Make final review of feed labels.

 Feed Shipment and Delivery
• It is a last step in feed manufacturing.

• Routine inspection of delivery trucks for, broken

gates, cracks in compartments, etc.

• Make adequate documentation to trace the

product from feed mill to delivery location.

• It is required in the event of product recall.

Sanitation and Pest/Rodent Control

• It maintains safe and clean working environment.

• Cleanliness is a result of commitment of

management, operators and maintenance group.

• It makes good impression on customers and

inspectors.

• Check for proper working of dust control

equipments and seal all the conveyors.
 Feed Product Investigations and Recall

• Necessity of a written program for customer complaints,

investigations and recalls.

• Immediate and effective investigation of customer

complaints is very important.

• Development of a process in place, which identifies the

recall team members and their responsibilities, if
investigation resulted in recall.

• Mock recalls can be conducted to evaluate the

effectiveness of the recall plan.
 Critical Control Points (CCPs)
• CCPs are the points in the manufacturing
chain of any good from which the hazard of
any type can enter into a final product.

• HACCP i.e. Hazard Analysis & Critical Control

Points is a system to check the entry of such
hazards into production chain.
 CCPs and Checking of Hazard in Feed Mill

• 1) Ingredient Inventory:

A) Allows to check whether correct amount of

ingredients are added or not in a given time period.

B) Allow to catch mistakes before they get out of hand.

C) Useful in reconciliation of theoretical and actual use

of ingredients
-McEllhiney (1981)
 Cont…
• 2) Bin Cleaning: To check the mold growth and
to ensure the safety of employees.

• 3) Inspection of equipment cleanliness and

condition:
Periodical examination of positions and wears
and cleanliness of equipments.

• 4) Grinding: Checking and cleaning of hammers,

magnets, screen condition and wear.
 Cont…
-Check for particle size of grains-
a) Pelleted feed : Less than 600 microns.
b) Mash feed : 700-900 microns.

-Allow the cooling of grains below 400 micron

size to avoid moisture migration and mold growth.

5) Batch System Validation:

Should be done on monthly basis. Batch weights
and truck weight must not have difference more
than 1%.
• 6) Mixers:
a) Batch mixers should be examined
routinely along with mixer shafts,
ribbon paddles or screws for build
up. Check for mixing time twice a year.

b) Coefficient of variation must be less than 10%.

• 7) Pelleting and Cooling:

Particle size, mash moisture, steam quality and
air temperature and humidity will affect the
quality of the finished feed.
 Cont…
a) Conditioning Temperature: As hot as possible, i.e.
180-190°F. for destruction of pathogens.
-(Blankenship et al., 1984).

b) Cool pellet temperature: Within 5°F of ambient temp.

c) Moisture gain: Should be 0 to 0.5%.

d) Crumble texture: Should be closely controlled as abnormal

size can create palatability problems.

e) Pellete durability: Have positive effect on growth & FCR. It

can be tested by the Kansas State University tumbling box
and Holmen tester.
-(McKinney and Teeter, 2004; Stark, 1994).
 Cont…

• 8) Meters and Scales:

Check for all the calibrations of meters and scales for
more accuracy. They can be checked and served
quarterly each year.

• (9) Truck inspection and cleaning:

Trucks may serve as a source contamination.
Companies should have flushing and sequencing
procedures in place. Check for the soundness and
cleanliness of trucks (both inside and outside).
Resolved the problems as soon as possible, if any.
 Conclusion
• Commitment to quality is important and for
that quality control measures are must.

• One should ensure the safety of product and

personnel engaged in manufacturing process.

• Quality assurance can help in building trust-

worthy business relations & ultimately in
growth of a business.