hazards to human through food chain bacterial viral toxins drug residues
TRANSCRIPT
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Hazards to Human through Food Chain
• Bacterial
• Viral
• Toxins
• Drug Residues
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Possible Sources
Bacteria• Breeder Farms
• Hatchery
• Broiler Growing Farms
• Processing Plant
Toxins• Feed
• Farms
Drug Residues:• Broiler Growing Farms
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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
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Poultry Breeding
• Frequent Egg Collection, Grading and Sanitization
• Integrated Pest Control
• Complete disinfection for a Zero Bacterial Count of houses before each flock replacement
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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
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Broiler Growing
• Same Practices as followed at Breeding Farms
• Complete Drug Withdrawal 10 days before Harvesting / Slaughtering
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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
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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
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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
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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
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Sample Test
Item Description Frequency Name Frequency
PRIMARY PROCESSING
Raw Meat Daily
TPC
On daily basisSalmonella
E.Coli
Coliform
Once a week
Mold
Yeast
Staph
Clostridium
In Process Chilled Carcass
Daily
TPC
On daily basisE.Coli
Salmonella
Microbiological Tests Conducted and their Frequency
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Sample Test
Item Description Frequency Name Frequency
FURTHER PROCESSING
Value-Added Products (Ready-to-Cook and Fully
Cooked)
Daily
TPC (For Parfried)For each sample
TPC (For Cooked)
Salmonella
Alternate for each cooked product
E.Coli
Coliform
Staph
ListeriaCooked products
(Once a week)
Clostridium Once a month
Mold For each parfried product
Yeast For each parfried product
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Sample Test
Item Description Frequency Name Frequency
FURTHER PROCESSING
Retail Outlets Once a Month
TPC (For Parfried)
For each sample
TPC (For Cooked)
Salmonella
E.Coli
Coliform
Staph
Clostridium
Mold
Yeast
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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
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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
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