Transcript K&N`s - Operations and Quality Management

Hazards to Human through Food Chain
•
Bacterial
•
Viral
•
Toxins
•
Drug Residues
Possible Sources
Bacteria
• Breeder Farms
• Hatchery
• Broiler Growing Farms
• Processing Plant
Toxins
• Feed
• Farms
Drug Residues:
• Broiler Growing Farms
Poultry Breeding
• A team of qualified and experienced Veterinarians to manage
entire operations
• Controlled Environment Housing
• All in All out flock placements
• Shower in and Shower out practice for all personnel
• Clean, Pure sanitized water served through automatic drinkers
• Immunization against Viral Diseases
• Regular Serology and Bacteriological Examination at K&N’s
Poultry Research and Diagnostic Laboratory established in
collaboration with PARC
• Culling of Positive Flocks
• Frequent Histological Examination
Poultry Breeding
• Frequent Egg Collection, Grading and Sanitization
• Integrated Pest Control
• Complete disinfection for a Zero Bacterial Count of houses before
each flock replacement
Hatchery Operations
• Controlled Environment for temperature, humidity and air exchange
• Dedicated Incubators for each Breeding farm/flock
• All in All out setting in Hatchers
• Regular Disinfection of entire Hatchery Environment through
automatic foggers
• Testing of Air, Floors and Fluffs for bacterial contamination
• Grading of Day Old Chicks
• Vaccination
• Transfer to Farms
Broiler Growing
• Same Practices as followed at Breeding Farms
• Complete Drug Withdrawal 10 days before Harvesting /
Slaughtering
Feed Milling
• Testing of each raw material for Bacteria and Toxins and other
contaminants
• Storage of Grains in Silos equipped with aeration to prevent buildup
of fungus and toxins
• Testing of finished feed for nutritional profile
• Palletization of feed at high temperatures to kill molds and bacteria,
if any
• Lab test for Nutritional Profile and Phyto-sanitary Testing before
dispatch to the farms
Processing
• Operations include Primary Poultry Processing, production of
Ready-to-Cook and Fully Cooked Value Added Chicken Products
• Air conditioned environment to prevent bacteria build up
• Thorough wash down of entire plant and machinery each day
followed by Lab tests for confirmation of bacteria free equipment
• Personnel Hygiene and Health monitoring – Salmonella and
Hepatitis
• In-house laundry for daily washing of uniforms
• In process chilling of carcass to prevent build up of bacteria
Processing
• Blast Freezing at -35°C to ensure food safety and maintain
freshness
• Value Added Products from fryer at 60°C to -18°C core
temperature, Individually Quick Frozen (IQF) in 30-40 minutes to
enhance food safety, product taste and appearance with better
retention of all essential nutrients
Quality Assurance
•
Periodic supplier audits and strict raw materials inspection and lab
testing
•
QC checks on all operational facilities, processes and finished
products
•
Open to International Customers quality audit for compliance
Microbiological Tests Conducted and their Frequency
Sample
Item Description
Test
Frequency
Name
Frequency
PRIMARY PROCESSING
TPC
Salmonella
On daily basis
E.Coli
Raw Meat
Daily
Coliform
Mold
Yeast
Once a week
Staph
Clostridium
In Process
Chilled
Carcass
TPC
Daily
E.Coli
Salmonella
On daily basis
Sample
Item Description
Test
Frequency
Name
Frequency
FURTHER PROCESSING
TPC (For Parfried)
TPC (For Cooked)
For each sample
Salmonella
E.Coli
Value-Added
Products (Readyto-Cook and Fully
Cooked)
Coliform
Daily
Alternate for each cooked
product
Staph
Listeria
Cooked products
(Once a week)
Clostridium
Once a month
Mold
For each parfried product
Yeast
For each parfried product
Sample
Item Description
Test
Frequency
Name
Frequency
FURTHER PROCESSING
TPC (For Parfried)
TPC (For Cooked)
Salmonella
E.Coli
Retail Outlets
Once a Month
Coliform
Staph
Clostridium
Mold
Yeast
For each sample
Quality Assurance
•
Monitoring and recording of temperature during various stages of
processing for compliance to HACCP guidelines
•
Constant update and conducting prerequisite internal QA audits to
gear up for bi-annual HACCP and ISO 9001:2000 audits
•
Implementation and reviewing the integrated pest control program
•
Waste water treatment before discharging out
•
Dedicated outdoor QA team
•
Regular team visits to retail market for verifying freezer temperatures
and evaluating product storage condition
Distribution
• Fleet of company owned refrigerated trucks and distribution centers
in major cities for complete control over distribution of products to
K&N’s Chicken Stores and other retailers and institutions for better
quality control
• Strict temperature monitoring and control through computerized
data loggers in delivery trucks to ensure proper cold-chain
management