aspects of the food safety systems at dmk group

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

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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CheeseDairy

productsIngredients

Baby food /

dieteticsIce cream

Health

products

Portfolio

International brands

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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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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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

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


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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•

Example of a flow chart

Analysis


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


Risk analysis

Part of the Excel-Tool

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Guidelines


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

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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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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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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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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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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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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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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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!

aspects of the food safety systems at dmk group

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