aspects of the food safety systems at dmk group
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The responsibility for a dairy company Aspects of the food safety systems at DMK Group
Burkhard Voss Head of QM-Systems and Suppliermanagement
Beijing, 6th November 2015
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DMK Group - Key figures (1)
DMK Group is a German dairy
68 companies worldwide
28 locations in Germany
No. 7 in Europe and No. 13 in the World (Source Rabobank 2014)
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DMK Group - Key figures (2)
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DMK Group - Key figures (3)
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CheeseDairy
productsIngredients
Baby food /
dieteticsIce cream
Health
products
Portfolio
International brands
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Definitions of Food safety (1)
Food safety is according to …
(the) assurance that food will not cause harm to the consumer when it is
prepared and/or eaten according to its intended use.
(Food hygiene - basic text 4th edition section 2.3)
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Definitions of Food safety (2)
Food safety is stated to …
Chapter 1 of the Food Safety Law of the People's Republic of China (Release Date: 2015/04/24)
Article 1 This Law is formulated to assure food safety and safeguard
people's health and life.
Article 3 Food safety work shall follow the principles of “putting prevention
first, risk management, whole-process control, and making efforts
by the whole society”, aiming to establish the science based and
strict oversight system.
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Definitions of Food safety (3)
Food safety is according to …
Article 2 (2) of the Regulation (EC) No 852/2004 of the Europaen Union:
food hygiene (…) the measures and conditions necessary to control
hazards and to ensure fitness for human consumption of a foodstuff taking
into account its intended use.
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Responsibility for a food business operator
Also in the Regulation (EC) No 852/2004 you find in Article 3 the
requirement for the responsibility of food safety:
Food business operators shall ensure that all stages of production,
processing and distribution of food under their control satisfy the relevant
hygiene requirements laid down in this Regulation.
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Food safety transferred to systems of DMK Group
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Requirements
Guidelines
• gggg
Analyses
Measures
European and German law Food law of export countries
International / trading standards Scientific information
Directives and standard operating procedures
implemented in an Integrated Management System (IMS)
Risk analyses
HACCP-Plan Sampling plans Monitoring plans
IT-solutions
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Risk-based Food safety system (1)
DMK Directive HACCP
• is progressive and very comprehensive.
• was composed over 1 year by a working group of specialists.
• was established for all companies of DMK Group.
• complies fully with the Regulation (EC) No 852/2004.
• meets the requirements of the Codex alimentarius and ISO 22000.
• expands existing standards and combines CCP’s, CP’s and PRP’s in
logical matters.
Since 2015 a group of university professors has supported the working
group in their further development of the food safety system.
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Guidelines
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Risk-based Food safety system (2)
Flow-charts
• were revised within the implementation of the HACCP directive.
• point out a very high level of details.
• were all harmonised by the central quality management (approx. 500).
• are published in web-based process-models with additional information.
and connection to the document libaries.
The flow-charts are validated yearly or, by the change of the process, in
every shift and every operating status.
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Guidelines
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Risk-based Food safety system (3)
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•
Example of a flow chart
Analysis
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Risk-based Food safety system (4)
Risk analysis
• The risk analysis was newly published as an Excel-Tool.
• The tool is very comprehensive and consists of logics not covered by the
Codex alimentarius so far.
• Identified risk are set as measures with a modified decision tree as
CCP‘s (Critical control points)
CP‘s (Control points)
PRP‘s (Prerequisite programs)
• There are more than 4000 identified points based on the flow-charts in
big plants, checked for hazards and risks with the Excel-Tool.
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Guidelines
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Risk-based Food safety system (5)
Risk analysis
Part of the Excel-Tool
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Guidelines
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Risk-based Food safety system (6)
Advanced directives
In addition to the HACCP directive, following directives were published at
DMK Group within the last 2 years, e.g.:
• Directive for Heat exchangers
• Directive for the prevention of foreign matters and detection systems
• Process for the residue monitoring of raw-milk
• Directives for the pathogen monitoring in dairy-, cheese- and powder
plants
• Process and directive for process validation
• Directive for pest control
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Guidelines
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Examples of practical implementation (1)
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Milk receipt (1)
• The cooperative farmers of DMK are contractually
bound. The have to fullfil strict rules regarding
animal keeping and the application of antibiotics.
• Beside the DMK regulation for milk supplies, DMK
established the new MILKMASTER-programme, the
contents of which go beyond legal requirements.
• In this regard DMK takes into account the
requirements of export countries like e.g. China and
Russia.
Measures
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Examples of practical implementation (2)
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Milk receipt (2)
• Upon receipt of the raw milk the truck
automatically collects and stores data (GPS,
time, quantity, temperature).
• At the same time, the truck system
proportionally takes single-samples of each
farmer and a mixed-sample.
• These samples are used for further testing and
also for traceability.
Measures
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Examples of practical implementation (3)
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Milk receipt (3)
• Before receipt of the milk in the plant, an antibiotic
testing (CCP) and an examination of the pH-content
is done out of the mixed truck sample for the
acceptance of the milk.
• Non-conforming raw milk is verifiable diposed of in
accordance with the Regulation (EC) No.
1069/2009.
• The mixed-sample is used for further examinations
while the single-samples are sent to an external lab
in accordance with the German MilchgueteVO.
Measures
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Examples of practical implementation (4)
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Milk receiption (4)
• In accordance with the risk-based plan (PRP) the
samples are taken for the residue monitoring and
sent to an external lab.
• Following resuidues are in scope (selection):
PCP‘s, pesticides (603), Aflatoxin M1, heavy metals,
veterinary drug residues, radionuclides, hormons
• Independently from DMK sampling, there are
samples taken by the veterinary authorities..
Measures
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Examples of practical implementation (5)
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Milk treatment (1)
• The specifications for the pasteurisation of raw milk
were harmonised in all plants of DMK Group with
the implementation of the directive for heat
exchangers.
• The new specifications describe technical
conditions that go further, comparable with state of
art technology.
• The relevant CCP-parameter (temperature,
pressure and flow) were also unified.
Measures
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Examples of practical implementation (6)
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Milk treatment (2)
• DMK Group has started the implementation of a web-
based platform to monitor all CCP‘s in the plants and
to store the information in accordance with legal
certainty.
Measures
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Examples of practical implementation (7)
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Measures
Drying (1)
• A standardized zoning concept, based on a risk
analysis, has been implemented in the powder
plants.
• The extensive environmental monitoring was
aligned to the zoning concept to prevent
contamination of pathogens.
• Additionally, the plants use a method called MTA
(microbiological trend analysis) to detect potential
contaminations in the productat an early stage.
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Examples of practical implementation (8)
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Measures
Drying (2)
• The examinations of end products are effected on
the basis of risk-based sampling plans (PRP).
• Requirements of export countries like China are
mentioned in the sampling plans.
• For the evidence of foreign matters, combinations of
detectors (CCP), like x-ray-systems or metal
detectors and magnets or sieves (CP) are mostly
used in the bagging of the powder.
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Thank you for the attention!