There are four areas crucial to the success of a biosecurity plan: identification of hazards, assessment of risk, communication among all involved parties, and verification that the plan is based in sound practice and is actually working.
By Adam Fahrenholz, Charles Stark and Wilmer Pacheco
Biosecurity has always been a concern for animal agriculture, probably even before it was known by that particular term. The emphasis on biosecurity has taken on a new meaning as the feed industry emerges from the COVID-19 pandemic while also keeping an eye on emergent and recurring animal diseases. In the past, biosecurity was focused on animal impacts, but as the animal feed industry moves forward human diseases must also be added to biosecurity plans. The design of workspaces, decontamination of the interior of vehicles, and air movement within control rooms and offices are now being reconsidered along with other longstanding practices.
We have always strived to do those things considered important and necessary to prevent animal disease from impacting the animals under our care and management. This is of course both an economic decision as well as our responsibility as animal caretakers and the very basis of the meat, milk, and egg food chain. However, the importance of biosecurity at feed mills has become exceedingly important in recent years. Some of this is due to the emergence of particular human (COVID-19) and animal diseases (most recently porcine epidemic diarrhea virus (PEDv), African swine fever (ASF), and highly pathogenic avian influenza (HPAI)), and some is because of the technology available and the management strategies we’ve learned to implement.
In January 2019, AFIA released its “Guidance for Developing Biosecurity Practices for Feed and Ingredient Manufacturing.” As is the case with a number of AFIA’s guidance resources, this document can be freely downloaded on AFIA’s web site. The guidance was put together with input from various sources, including both feed and ingredient companies as well as groups such as NGFA, NPPC, and NRA. In addition to this document, trade organizations, universities, and government agencies release updates based on emerging risks such as COVID-19, ASF, and HPAI. Another good resource is the K-State Feed Safety Resources website in the Department of Animal Sciences and Industry. Using these resources as a base, let’s discuss some of the strategies you can implement in your facilities to address biosecurity.
First off, it is important to understand that the feed mill’s biosecurity policy should address any factors that could contribute to a disease transfer among employees and visitors and/or due to feed consumption. This includes control of incoming raw materials, process evaluations, and maintaining a clean facility. However, it is also important to keep in mind that in many cases the feed mill can be an activity hub, either within your company or among your customers. So, in addition to protecting the finished product from contamination, feed mills should conduct a hazard assessment of their facility, feed ingredient transporters, finished feed trucks, and suppliers. For example, are there locations in the feed mill that are open to the public or common areas for truck drivers and employees? These areas may be potential transfer sites for disease. Consider such questions as: Are plans in place to restrict movement of personnel and/or equipment that have potentially come in contact with animal diseases? On the farm is it common to verify a visitor’s most recent contact with animals. How about at your facility?
There are four areas crucial to the success of a biosecurity plan: identification of hazards, assessment of risk, communication among all involved parties, and verification that the plan is based in sound practice and is actually working. In the feed mill we need to consider pre-manufacturing, manufacturing, and post-manufacturing steps, as well as the transport in between.
In pre-manufacturing, our biggest concern is going to be incoming raw materials. The easiest, and best, way to limit risk at this step is supplier verification. This includes knowing how ingredients are sourced, processed, and transported. Different ingredients may carry different levels of risk, and this needs to be understood not only when developing a plan, but when determining what is required of any individual supplier. You will need to have some idea of your suppliers’ biosecurity practices. Is there a plan in place? Is it effectively practiced? Have you verified this through visits, periodic testing, or by receiving third-party certifications? It is understandable? If thinking about these things gives you pause, as you don’t want to create a tense relationship with your suppliers, remember that you are the one answering for the feed going to the animals.
In pre-manufacturing, our biggest concern is going to be incoming raw materials. The easiest, and best, way to limit risk at this step is supplier verification. This includes knowing how ingredients are sourced, processed, and transported.
In addition to verifying supplier information, steps need to be taken when ingredients arrive on site. If loads are expected to be sealed, procedures need to be in place to remove seals and verify they are correct. It is important to verify that the transport vessel won’t be a potential source of contamination from road grime, leaking fluids, etc. Also, consider whether you are able to limit access to receiving pits when not in use; e.g., they are behind locked doors and/or have locking covers. And we cannot forget about proper sample collection procedures, which should already be in place according to your QA plan.
For the primary processing areas, most biosecurity concerns can be addressed by conforming to CGMPs and having adequate housekeeping practices in place. This includes having documented storage and inventory procedures, having a pest control plan in place, and maintaining a clean facility, both indoors and outdoors. Strategically placing and monitoring foot baths at entrances may be a strategy to reduce the risk of disease transfer by drivers and employees.
Biosecurity at the feed mill is everyone’s responsibility, starting with the commitment of management to provide the necessary resources to minimize the transfer of human and animal diseases.
For all areas (pre-, post-, and during manufacturing) consider staffing and facility layout in regards to limiting potential access to the site. Finally, what is your disposal program for any contaminated ingredients/feeds and disposable coveralls and boots?
Post-facility factors are some of the most difficult to address, as these may or may not be under the feed mill’s control (condition of farms, traffic between farms, wind, etc.). First and foremost, delivery drivers should know the disease status of any delivery locations; plan deliveries and subsequent activities accordingly. In reality, any time we can limit a driver from putting boots on the ground at the farm, the lower the risk. However, if drivers must get out of the truck, disposable boots and coveralls may be required. Keep in mind that such boots/covers may create a slip hazard. Drivers should receive training on how to safely use the equipment and dispose of their boots and coveralls prior to leaving the site.
Biosecurity at the feed mill is everyone’s responsibility, starting with the commitment of management to provide the necessary resources to minimize the transfer of human and animal diseases. Employee training and awareness is critical for any biosecurity program, especially because in many instances the risks are associated with unseen pathogens that affect human and animal health. Lastly, realize that the risks change and evolve over time, and the biosecurity plan should be routinely evaluated and updated as necessary.
