meet diamond pet foods - wordpress.com...2005 –aflatoxin recall 2007 –melamine 3600 pet deaths...
TRANSCRIPT
3/5/2018
1
Recall to
Supplier of the Year in 18 months?
The Diamond Pet Food Story
Told from the perspective of:
Michele M. Sayles Ph.D.
• A family-owned company
– Founded in 1970
– Driven by the philosophy that super-
premium pet food should be
affordable and available to all pets
– 1000 employees in five locations
– Committed to caring for our
employees
– Diamond Pet Foods’ brands used in
50 states and in more than 70
countries
– Our business has grown from word-
of-mouth; retailers are our partners2
Meet Diamond Pet Foods
Where We Make Our Products Presentation Overview
• Set the Stage
• What happened?
• How did Diamond react:
– Commitment
– Immediate changes
– Control Programs
– New Technology / Innovation
– Culture Change
2005 – Aflatoxin Recall
2007 – Melamine
3600 pet deaths over 5300 products recalled
2007 – Mars Pet Care
Salmonella Schwartzengrund
62 people in 18 states
2012 – Diamond Pet Foods
Salmonella Infantis
49 people in 20 states
2012 – Hatchery in Ohio
Salmonella Infantis, Newport,
and Lille infections linked to live chicks &
ducklings 195 people, 27 states and 2 deaths
Interesting to Note:
Pet Food Recall Mail Order Poultry Recall
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What Happened?
• What happened?
– April 2012 Michigan Dept. Ag found Salmonellain an unopened bag during routine inspection
– This isolate was put into Pulse Net• This yielded a match of 28 illnesses
– 22 of 28 had contact with a dog 1 week prior to becoming ill
– 17 of 28 had purchased dog food;
– 11 people had purchased Diamond
• During additional state surveillance S. infantis strain with a different pattern was found, put into Pulse Net and an additional 16 illnesses linked
• Canada also reported 2 illnesses from non-outbreak strain
How Did Diamond React
• How did Diamond react:
– Immediately shut plant down
– Plant was down for 40 days
– FDA was in the plant for 7 days conducting
investigation
– Outbreak strain was never found
– No single source identified
• Immediate Reaction:
Company Commitment!
Some Immediate Reactions
• Tore every thing apart!
• Installed strict area segregation
• Installed Air Handling Units per production area
• Eliminated potential harborage
• Made equipment more accessible to clean
• Implement Test and Hold and a micro program
• Became DATA DRIVEN!
DATA DRIVEN
Strict Plant Separation
Control Programs
• Multi Hurdle Approach:
– Microbiological monitoring
– Cleaning and sanitation
– Effective pre-requisite programs
– Innovation technologies
Pre-Requisite Programs
• Specifications• HACCP Program• Food Defense• Vendor Approval• Equipment Sanitary
Design Standards
Pre-Production
• Training• Documentation• Mycotoxin Control• Water Quality• Air Quality• Cleaning and Sanitization• GMPs• Foreign Material Control• Glass and Brittle Plastic• Chemical Control• Pest Control• Raw Material Receiving• Micro
• Environmental• Finished Product
Production
• Recall / Withdrawal• Product Retrieval • Warehouse and
Distribution Center• Customer Complaints
Post Production
Taking these programs to new levels:
Example: Air Quality, Water Quality
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Microbiological Monitoring
• Within 2 weeks – onsite modular micro labs
• Implemented:
– Finished product testing
– Environmental monitoring program
– Ingredient testing / COA verification
Microbiological Monitoring
DATA DRIVEN
Major Challenges
• Legacy equipment
• Equipment Design– Sanitary design standards – originally non existent
• Cleaning and Sanitation– SSOP’s – how do we clean?
– Establishing frequencies
– C&S verification, validation
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Dryer room
OLD NEW
Extruder Room
OLD NEW
Cleaning and Sanitization
Strategies
• Cleaning and Sanitization: How and When??– Wet clean vs. dry clean
– New technology • Dry fog
• Ozone / Chlorine dioxide
• Probiotics
– New chemicals vs. old chemicals• Peracetic acid
• Acidified Calcium Sulfate
• Lactic Acid
– New Monitoring Technology – 16 s?
Innovation technologies• Cleaning and Sanitization
– New technology, improved chemicals
• Sampling and Monitoring
– Improved testing 16 S metagemnomics
• Ingredients
– Probiotics
• Processing Technology
– Radio frequency, UV light
WGS vs 16s Metagenomics
• WGS • 16s Metagenomics
WGS
Traditional (PFGE) Traditional
16s metagenomics
Investigations with 16s
Overview
• Sample multiple sites
• Sample multiple raw materials
• Compare spoiled vs. normal
• Understand facility microbiota
• Root cause analysis
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Data set # 1
Vials
What Are Probiotics?
• Commonly Used Strains
– Lactobacillus
– Bifidobacterium
– Enterococcus
What Do Probiotics Do?
• Aid in digestive health
– Competitive inhibition
– Competitive exclusion
– Receptor binding
– Antagonistic behavior
• Secondary benefits
– Antimicrobial
characteristics in product
Key Benefits of Probiotics
• Improve pet GI heath
• Food Safety Effect
– Competitive Inhibition of Pathogens (i.e.Salmonella)
– Competitive Exclusion of Pathogens
• Probiotics are effective against pathogens:
– In the laboratory
– In the human or animal
– In the environment
• Diamond’s cutting edge Environmental Application research
project
Culture Change
• Company - internal
• Customers
• Suppliers/vendors
• Trade Organization
• Professional Affiliations
• Regulatory Agencies
• No Really…HOW???
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The Diamond Pet Food Story
How did the story end?• Customers:
– Recall to Supplier of the Year in 18 months
• Regulators:
– Invite us to teach and present our story
• Industry Peers:
– Ask for advice and input