In recent years, sweeping food safety reform has led to monumental changes in the food system, including how livestock feeds are manufactured. In 2011, the Food Safety Modernization Act (FMSA) was put into law. This mandated science-based preventative controls across the food supply chain for all food and feed facilities by the Food and Drug Administration. The biggest reform in the last 70 years, the changes aim to ensure the U.S. food supply is safe by shifting the focus from responding to food-related contamination to preventing it.
Since 2011, a host of rules have been implemented by the Food and Drug Administration to meet the law’s requirements. The independent Hazard Analysis Critical Control Point (HACCP) certification is federally recommended and is one requirement for feed manufacturing facilities. Additional mandates came in 2013 and those in the industry say they are just the first stages. By as early as 2017/2018, all feed manufacturing will be required to have the certification in place.
“It’s a systematic, preventative approach to food safety,” notes Farmers Co-op Elevator Safety Director/Compliance Officer Rich Fravel of the globally recognized program. “It will help us meet the requirements of the FSMA.”
“Farmers Co-op Elevator had the opportunity to make some improvements and it rolled right into the certification process. We were able to really evaluate how to make the process or steps better,” adds Fravel. “It was really an eye opener.” The process, from start to certificate in hand, took more than 18 months. “We needed to target where we wanted to invest.”
Due to age of the Rushford feed manufacturing facility and requirements of the certification, it was found more effective and economical to invest in the certification of the Houston site. Farmers Co-op Elevator proceeded with the consolidation of the two feed manufacturing sites and upgrades in Houston. The co-op reached its certification milestone this past August and manufacturing was moved to Houston in September.
The process included sizeable facility upgrades to the Houston site including a 100-ton load out tower, eight load bins, a heated liquid molasses tank, a texturizing feed mixing tower, and ten 10-ton charge bins for finished feed. A new scale system and a feed program software upgrade assist in better tracking inventory and qualities. Rushford feed employees are now working out of the Houston site, enabling the site to operate two production shifts.
Production at Houston has increased substantially, accounting for both increased business and the combining of the Rushford and Houston feed production.
“The entire feed team at Houston and Safety Director Rich Fravel worked long and hard to complete this intensive certification process,” said Feed Department Manager Rod Torgerson. “The certification means customers can be assured that Farmers Co-op Elevator has the procedures and processes in place to manufacture safe feed. Consumers continue to show more interest in what they eat, specifically where their food comes from and what is in it.”
The traceability system involved with the certification allows the co-op to document operations involved in the manufacture, processing, distribution, and handling of feed used to produce food. Additionally, it can facilitate the identification of the cause for a product issue and the ability to withdraw or recall lots of feed if necessary.
“It’s a continual process that will require the co-op to reanalyze and update the food safety/feed safety plan annually in our commitment to producing safe, quality, feed products for our producers,” said Torgerson. “In the end, it comes down to Farmers Co-op Elevator providing safe, quality feed. It provides reassurance that we have procedures and processes in place to manufacture safe feed for your animals, and keep the food system safe.”
“Farmers who buy feed from Farmers Co-op Elevator know they are getting feed that meets quality standards not visible to the naked eye and the knowledge that records and tracking are available if ever needed.”
More information regarding the new certification can be found on the Farmers Co-op Elevator website and Facebook page.