CJ Feed and Care Tianjin Branch Quality Control
Feed, as an animal food, its safety and quality are directly related to the healthy growth of livestock, poultry and fish, the production efficiency of the animal husbandry industry, and ultimately affect human food safety and public health. Therefore, quality control (QC) management in feed mills is not merely an ordinary internal task of enterprises, but a systematic project concerning the safety of the industrial chain and shouldering significant social responsibilities. An outstanding QC system is the lifeline of a feed enterprise and the fundamental manifestation of its core competitiveness. Here, we will provide a detailed explanation of the QC management of our company.
Core Guiding Ideology of Quality Control Management
Modern feed quality control management adheres to the principles of "prevention first, comprehensive control, strong traceability, and continuous improvement." Its goal is to nip quality risks in the bud, rather than relying on post-mortem testing.
This means that from raw material intake to finished product shipment, clear quality control points are established at every stage of the process. A comprehensive record-keeping system ensures accurate forward and reverse traceability for every batch of product.
Let's discuss the specific quality control steps and how to effectively manage quality.
The specific quality control steps and how to effectively manage quality
Phase 1: Raw Material Quality Control (Incoming Quality Control - IQC)
This is the first and most important step in quality management. It is impossible to produce high-quality products with inferior raw materials.
1. Supplier Management:
Evaluation and Selection
Potential suppliers are comprehensively audited and evaluated for their production base, quality management system, and reputation. Qualified suppliers are included in the "Qualified Supplier List."
Certificate and Invoice Request
Each batch of raw materials must be accompanied by the supplier's factory inspection report and certificate of conformity.
Regular Review:
Suppliers are regularly re-evaluated, and the list is dynamically adjusted based on supply quality, eliminating unqualified suppliers.
2. Arrival Inspection:
The Purchasing Department notifies the arrival date in advance. The raw material arrival notification must clearly indicate the raw material name, arrival date, quantity, supplier, and vehicle number for confirmation.
Vehicle Inspection
Check the transport vehicle for cleanliness, odor, cross-contamination, and rain damage.
Sensory Inspection
Conduct a preliminary assessment of each batch of raw materials using a "look, smell, and touch" approach.
Observe
Check for color, luster, shape, uniformity, and presence of mold, lumps, insect damage, or foreign matter.
Smell
Check for the expected odor of raw materials, including any abnormal odors such as rancidity, mildew, mold, or burnt materials.
Touch
Check for hand feel, moisture content (rough assessment), and particle size.
Sampling
After weighing, notify the Quality Control Department to collect samples. Strictly following sampling standards (GB/T 14699.1), using tools such as a "probe sampler," representative samples are collected from multiple locations, including the top, center, bottom, left, and right sides. After mixing thoroughly, the samples are then separated and sent for inspection to ensure they are representative of the entire batch. The quality of the 50% intermediate material at unloading also requires verification.
3. Laboratory Testing:
Rapid Testing: For raw materials urgently needed for delivery, we conduct rapid on-site testing according to raw material acceptance standards, such as:
Moisture:Rapid moisture meter.
Bulk density: Determines the fullness of grains such as corn.
Freshness: For example, rapid testing of volatile basic nitrogen (VBN) in fish meal.
Mycotoxins:Rapid mycotoxin test strips (ELISA).
Physical and Chemical Testing: Accurately analyze samples in the laboratory. Common indicators include:
Nutritional indicators:Crude protein, crude fat, crude fiber, crude ash, calcium, phosphorus, etc.
Hygiene indicators: Mycotoxins (aflatoxin B1, vomitoxin, etc.), microorganisms such as Salmonella, and heavy metals (lead, arsenic, cadmium, mercury).
Microscopic Examination:Microscopically observe the structure of raw materials to identify authenticity and adulteration (e.g., feather meal or leather powder etc added to fish meal).
4. Determination and Action
Test results are compared with raw material procurement standards and national standards.
Qualified: The warehouse keeper organizes temporary unloading, samples are sent to the quality control department, and the laboratory technician conducts chemical testing. Once qualified, the raw materials are stored, labeled, and issued a "Raw Material Acceptance Report." This allows storage and records batch information for traceability. Unqualified materials are returned to the unqualified area.
Unqualified: A "Raw Material Rejection Report" is issued, clearly stating the reasons for non-conformity, and immediately notify the purchasing department and the supplier. Unqualified raw materials must not be stored.
Phase 2: In-Process Quality Control (IPQC)
Ensure that the formula is implemented according to production standards and that the production process strictly complies with regulations.
Input Verification:
Verify that the type and quantity of raw materials fed into the feed are consistent with the production formula to prevent incorrect, excessive, or insufficient feeding.
Check the cleanliness of the feed port to prevent cross-contamination.
Grinding Process Control:
Regularly check the sieve aperture of the grinder to ensure that the particle size meets process requirements (different animals have different particle size requirements).
Process control for ingredient mixing (the core of the core):
Addition of ingredients: A dedicated person is responsible for the pre-mixing and addition of trace components (vitamins, trace elements, drug additives, etc.), and double-checking and recording are conducted to ensure 100% accuracy.
Calibration of the batching scale: The electronic batching scale is calibrated regularly to ensure measurement accuracy.
Mixing time: The mixing time is strictly set and controlled to ensure uniformity (CV value ≤ 7%). Insufficient time leads to uneven mixing, while too long a time may result in classification.
Cleaning inspection: After each batch of ingredients is produced, check the residual situation in the mixer. Especially when changing the formula, it is necessary to thoroughly clean to prevent cross-contamination.
Granulation and Cooling Control:
Quality control temperature and time: Control the steam pressure and temperature to ensure complete starch gelatinization and improve digestibility.
Ring die aperture and compression ratio: Select the appropriate ring die according to product requirements.
Amount and time: Reduce the moisture and temperature of the granule material rapidly to a safe standard (moisture ≤ 12.5%, temperature close to room temperature) to prevent mold .
Finished Product Packaging and Palletizing:
Inspect the packaging bag quality and ensure that label information (product name, specifications, production date, batch number) is clear and correct.
Inspect the sewing quality to ensure there are no missed stitches or skipped threads.
Samples should be taken from each batch to test the moisture content of the finished product.
Phase 3: Final Quality Control (FQC)
This involves a comprehensive "physical inspection" of the final product to ensure it complies with company standards and legal and regulatory requirements.
Sampling
Representative samples are collected on the production line or in the finished product warehouse according to standard methods.
Comprehensive Laboratory Testing:
Routine Nutritional Indicators: Crude protein, moisture, ash, fat, fiber, vitamins, calcium, phosphorus, copper, iron, etc.
Physical Indicators: Particle hardness, powdering rate, and stability in water (for aquatic feed).
Hygiene Indicators: Mold, toxins, total microbial count, etc.
Mixing Uniformity: Regularly measured.
Sample Retention and Observation
Samples must be retained from each batch of finished product and kept for at least the expiration date. These samples are used for quality traceability and re-inspection.
Determination and Release
Once all indicators meet the requirements, the quality control department will issue a "Finished Product Certificate" and maintain the test report. Only then can the product be released for sale.
Phase 4: Warehousing and Logistics Quality Control
Prevent the deterioration of product quality during storage and transportation.
Warehousing Management:
Zone Storage: Raw materials, finished products, and premix additive storage areas are separated. Clear labels indicate the areas of qualified products, unqualified products, and items awaiting inspection.
"First-In-First-Out" principle: Goods are issued in accordance with the production date and batch number sequence to prevent product expiration.
Environmental Control: The warehouse should be kept clean, dry, and well-ventilated. It should have facilities for preventing rats, birds, and insects. Regular monitoring of temperature and humidity is conducted.
Logistics Management:
Check if the transportation vehicles are clean, non-toxic, harmless, and pollution-free. It is strictly prohibited to mix them with toxic or hazardous materials.
Phase 5: Quality Traceability and Continuous Improvement
Record Management:
All quality control activities (inspection records, reports, production records, etc.) must be clearly, accurately, and completely completed and archived, and retained for at least 2-3 years.
Traceability:
Batch number management enables full forward tracing from raw material supplier → raw material receipt → production batch → finished product → customer, as well as backward tracing from customer complaints to problematic raw materials and production.
Customer Complaint Handling:
Establish a standardized complaint handling process, promptly investigate the cause, implement corrective and preventive measures, and provide feedback to the customer.
Continuous Improvement:
Conduct regular quality analysis meetings.
Conduct root cause analysis of nonconformities and implement corrective actions (CAPA).
Continuously optimize process parameters and quality standards.
Perform regular employee training and assessments to strengthen quality awareness.
Summary
The quality control management of the feed factory is a rigorous, scientific, and interrelated organic whole. It is not merely a single inspection process, but a complete process that covers supplier management, raw material acceptance, production process, finished product inspection, storage and logistics, and is carried out by all personnel throughout the entire process. It is supported by clear standards, standardized operations (SOP), real records, and a professional team. Only by establishing such a modern quality control system that is "prevention-oriented, full-process control, traceable, and capable of continuous improvement" can feed enterprises fundamentally ensure product safety and stability, build an outstanding brand, and truly fulfill the glorious mission of safeguarding the livestock industry and protecting human food safety.
