Development and implementation of hazard analysis and critical control point plans by several U.S. feed manufacturers

The commitment to consumer food safety, global trade, and proposed new regulations by the U.S. Food and Drug Administration Center for Veterinary Medicine has led to increased adoption of hazard analysis and critical control point (HACCP) by the U.S. feed industry. A project supported by the U.S. Department of Agriculture Integrated Food Safety Initiate titled "Development and Implementation of a Voluntary HACCP Program for the US Feed Industry" enabled faculty from three land grant universities to assist individuals from 14 feed companies that collectively manufacture 15 million metric tons of feed in 100 facilities to develop HACCP plans. The process flow in these plans averaged 20 steps, and the most detailed plan included 60 process steps. Chemical hazards were more commonly identified in HACCP plans (average of four hazards per plan) than were biological hazards (average of one per plan). The most prevalent chemical hazards were cross-contamination of type A medicated articles and type B medicated feeds, aflatoxin, and wrong ingredient inclusion in feed. The most common biological hazard was mammalian protein contamination of feed ingredients and finished feed for cattle. An assessment of time and costs associated with developing HACCP plans revealed that approximately 29% of the companies needed additional personnel or additional equipment to implement a HACCP plan, and on average 268 additional person hours were needed to develop and implement a HACCP plan. Plan design, compliance monitoring, and record keeping were the three most time-consuming activities needed for developing and implementing a HACCP plan. The average cost of additional equipment needed to implement a HACCP plan was $250.