Ingredient verification, COAs
It is imperative for pet food makers to work with trusted and reliable ingredient suppliers, Tovey notes. As dog and cat food makers work with their ingredient suppliers, they may take additional steps to ensure ingredient safety and quality, including:
• Conducting regular ingredient supplier audits. Supplier audits are required under FSMA, but pet food makers may go a step further and increase frequency.
• Requiring that the ingredient supplier provide a Certificate of Analysis (COA) that confirms quality and safety checks.
• Testing incoming ingredients for safety and quality. This may mean sampling for safety hazards such as mycotoxins or confirming protein, fat, moisture and ash content.
Lombardo notes that the receiving company conducts the verification of ingredients. “As ingredients may be sourced either domestically or imported into the US, verification activities will vary,” he says. For domestically sourced ingredients, suppliers are often approved through questionnaires, review of food safety systems and facility audits. Ingredients are most commonly verified either through testing or by comparing the results listed on the COA to the specification requirements.
“For ingredients imported into the United States, another FDA regulation (Foreign Supplier Verification Program, or FSVP) details all of the regulatory requirements for ingredient verification. The entity identified as the importer of record must ensure compliance to FSVP. This make be a broker, distributor or the manufacturing company,” Lombardo adds.
A COA is a document that attests that certain laboratory tests were performed on the ingredient and includes the result of testing that was requested by the manufacturer. “It is often a requirement that a COA accompanies the ingredient during shipment so that it can be reviewed before the product ever exchanges hands,” Tovey says.
Lombardo adds that the COA affirms that the ingredient meets the quality and food safety requirements. “The required tests depend on the ingredient but often include both food safety (pathogens of concern, foreign material, water activity) and quality (color, odor) attributes. The required tests for each ingredient are included on the product specification, which should be mutually agreed upon by both the suppling and receiving companies,” he says.
Testing, instrumentation
There are several different types of testing and instruments used for managing pet food ingredients to ensure quality and safety. Pet food manufacturers will test in a variety of ways to help control against known and foreseeable hazards that may occur during the manufacturing process.
“For example,” Tovey says, “pet food makers will sample and test incoming loads of grain ingredients for mycotoxins upon arrival at the manufacturing facility. Prior to receipt, the pet food maker can pull a representative sample from throughout the load for testing to make sure the product is safe, and not allow entry into the facility if the ingredient does not meet safety standards. Using accept/reject criteria such as this would meet the preventive control requirements of FSMA, since the company is taking steps to mitigate that identified hazard.”
Pet food makers also take seriously the possible presence of pathogens throughout the production line, such as salmonella, listeria or E. coli. Facilities may take random samplings of the production environment to ensure no salmonella or other pathogens are found and that the environment is not conducive to growth of these bacteria, test incoming ingredients and sample the finished product, as well, Tovey adds.
“Pet food makers may even go so far as to use magnets, metal detectors or density detectors to keep food safe,” Tovey says. (See sidebar below.) As ingredients move between trains, trucks, production lines and packaging, it is possible that items such as small rocks or pieces of metal can somehow enter the product. Pet food makers are aware of this risk and work to keep food safe along the way by monitoring for any outside objects that do not belong.
Lombardo adds, “For safety, testing could include microbiological analysis for pathogens of concern. Chemical testing for mycotoxins and physical testing for foreign material may also be relevant. Specific to quality, microbiological testing could include spoilage organisms such as yeast and mold.”
Chemical testing could include moisture content. For physical testing, color, odor and flavor could all be important attributes.
Instruments for all of these tests range from very complex, sensitive machines to visual comparisons against a standard. Some tests are on the factory floor while others, such as pathogen testing, requires a certified laboratory and trained microbiologists to conduct.