Introduction

Biosecurity is a strategic approach encompassing policies and regulatory frameworks to manage risks in food safety, animal and plant health, and environmental safety (FAO 2007). Effective biosecurity in the animal supply chain requires all stakeholders to prevent the introduction or spread of pathogenic agents. Governments in many countries mandate individual responsibility for biosecurity, including restricting movements of animals, plants, soil, and equipment that may carry pathogens.

Feed mill managers must allocate resources to ensure employees follow biosecurity protocols. This guidance helps feed mills implement biosecurity practices into operational procedures, reducing the risk of pathogen spread through feed manufacturing and delivery.

Importance of Feed Mill Hygiene

Feed mill biosecurity protects animals from pathogens introduced via feed and limits their spread among animals and humans. Pathogens, whether causing visible or hidden diseases, reduce productivity and financial viability in animal production.

Steps to Maximize Biosecurity in Feed Mills (Stewart et al., 2019):

Assess Biological Hazard Risks: Identify hazards specific to the feed mill’s operations and customers (species-specific risks).

Minimize Hazard Entry: Implement protocols to reduce hazard entry, such as screening suppliers, restricting access, and securing entry points.

Mitigate Risks: Use effective mitigation strategies, including dust collection and chemical treatments, while complying with legal requirements.

Decontaminate the Feed Mill: Develop a decontamination strategy involving physical and chemical cleaning, disinfection, and high-heat treatments, adhering to national regulations.

Transmission of pathogenic agents

Pathogenic agents can spread through various routes, including:

1. Animals:

1. Wild birds
2. Rodents (e.g., rats, mice)
3. Feral animals (e.g., predators)
4. Domestic animals (e.g., livestock, poultry, pets)
5. Insects
6. Products with animal-origin ingredients (e.g., processed meats, meat and bone meal)

2. People:

1. Feed mill and farm personnel
2. On-site family members
3. Customers (producers collecting, transporting, and using feed)
4. Truck drivers
5. Contractors, maintenance, and service personnel
6. Visitors and neighbours

3. Vehicles and Equipment:

1. Utilities, front-end loaders, trucks
2. Veterinary equipment
3. Spray packs and tools

4. Air:

1. Aerosols (e.g., dust, bacteria, viruses, moulds)

5. Feed and Water Supply:

1. Faeces from birds or pest animals
2. Raw materials (e.g., prohibited or contaminated materials)
3. Post-production contamination during transport or storage
4. Poor-quality ingredients or damaged feed (bacteria, mold)
5. Pollutants and infectious microorganisms

Good Manufacturing Practices (GMP) and Feed Safety

The practices outlined in this manual align with the FAO/IFIF Good Practices for the Feed Sector (2020) and may already be part of existing feed safety programs. However, management practices vary by site, making a site-specific risk assessment crucial to identify and address biosecurity risks effectively.

Key Factors to Consider in Risk Assessment:

Operation Size: Scale and complexity of the feed mill.

Location and Layout: Property and mill setup, including proximity to animal production sites and wildlife presence.

Cleaning Tools: Availability and usage of cleaning implements.

Water Supply: Sources and quality of water used.

Feed Ingredients: Origin of feed components and additives (domestic and international).

Intended Species: The animals for which the compound feed is produced.

Regional Pathogen Status: Pathogenic agent prevalence in the feed mill’s region and sourcing areas.

Customer and Supplier Interactions: Activities such as pickups, deliveries, and contractor visits.

Customer Requirements: Specific biosecurity needs of customers.

Operational Considerations: Other site-specific management factors.

Figure 1 Points of exposure for a feed mil (AFIA, 2019)

Levels of biosecurity

Routine biosecurity procedures

Implementing and adhering to daily biosecurity procedures is essential to:

1. Prevent the introduction of pathogenic agents and pests into the feed mill.
2. Minimize the risk of pathogen transmission between production runs.

These procedures represent the minimum industry standards and provide a high level of assurance for maintaining feed mill biosecurity.

Action plan for suspected or detected pathogens

Each feed mill owner/manager should establish a documented Action Plan to address suspected or detected pathogenic agents. The plan should include:

1. Clear Reporting Guidelines: Define when to report unusual products, contaminants, or pathogenic agents (e.g., Salmonella in feed inputs) and clinical signs of disease in target animals.
2. Notification Protocol: Specify who to inform, including relevant authorities, in case of a suspected emergency animal disease event.
3. Movement Restrictions: Cease movements on and off the feed mill and property where feasible.
4. Special Precautions: Implement additional biosecurity measures to contain the risk.

High risk biosecurity procedures

Biosecurity procedures are typically implemented under the guidance of relevant government authorities. To enhance biosecurity, the following measures should be adopted:

1. Deliver to Infected Farms Last: Schedule deliveries strategically to reduce cross-contamination risks.
2. Vehicle Wash Facilities: Use wash-down facilities before and after entering farms, if available.
3. Additional PPE: Wear appropriate biosecurity personal protective equipment (PPE) for added protection.

In case of an emergency, promptly communicate the nature and extent of the situation to the relevant authority to minimize risks and potential public health impacts.

Routine biosecurity procedures

Manage Inputs

The most effective component of a feed mill biosecurity plan is the prevention of entry of hazards

Potable water

Objective: Maintain water quality to minimize feed and equipment contamination.

1. Use potable water – Ensure water meets WHO standards, free from physical, chemical, and biological contaminants.
2. Consult experts – Seek expert advice if water testing shows poor quality.
3. Regular monitoring – Test and monitor water treatment systems for effectiveness.
4. Closed system – Maintain a closed system for treated water from treatment to use.

Purchase of feed inputs

Objective: Manage the introduction and movement of feed ingredients to minimize the risk of pathogenic agents and pests.

1. Supplier Approval Program:
   1. Set specific requirements for purchased ingredients.
   1. Verify supplier protocols and conduct facility reviews if necessary.
   1. Communicate safety expectations to suppliers.
2. Preferred Suppliers:
   1. Purchase from approved suppliers with quality assurance and biosecurity programs.
3. Ingredient Sourcing:
   1. Ensure suppliers meet the feed mill’s biosecurity and feed safety standards.
4. Compliance with Legislation:
   1. Verify feed commodities comply with national regulations on chemical residues and contaminants.
5. Risk Assessment for Products:
   1. Consider the following:
      1. Origin of the product.
      1. Presence of pests or pathogens in the source region.
      1. Production methods used (e.g., mechanical vs. household).
      1. Type of packaging (clean/new vs. recycled).
      1. Previous truck loads for bulk products.
      1. Biosecurity protocols of third-party transporters.
      1. Time since product manufacture.

Receival of feed ingredients

Objective: Minimize the risk of feed contamination during the receival of ingredients.

1. Vehicle Cleanliness Declaration
   1. Require signed declarations regarding cleanliness and previous load identity.
   1. Avoid vehicles that previously carried contaminants like chicken litter or animal-based fertilizers.
2. Vehicle Cleaning
   1. Ensure vehicles are free from mud, dust, dirt, and manure before entry.
   1. Deny entry to vehicles posing contamination risks.
3. Visual Checks
   1. Conduct on-site visual checks based on company risk ratings.
4. Feed Spill Management
   1. Clean up spills promptly to avoid pest attraction.
5. Unloading Procedures
   1. Use methods like funnels and socks to minimize contamination during unloading.
6. Ingredient Inspection
   1. Inspect all feed ingredients upon receival for contaminants.
7. Risk-Based Monitoring
   1. Establish a monitoring program for high-risk feed ingredients, particularly for pathogens like Salmonella.
8. Packaging Standards
   1. Reject products in reused bags from high-risk regions.
9. Traceability
   1. Maintain receival records (e.g., date, lot number) for traceability and response in case of contamination or product recall.

Manage the movement of personnel

Objective: Minimize the risk of contamination due to personnel actions and hygiene practices.

1. Clean Clothing
   1. Personnel should wear clean, laundered clothes each day, free from animal contact.
   1. Change clothes after decontaminating machinery and equipment.
2. Protective Clothing
   1. Do not take protective clothing and footwear outside the feed mill unless they are cleaned first.
   1. Wear protective clothing only within the feed mill to prevent contamination.
3. Work Area Awareness
   1. Personnel should avoid areas with high contamination risk.
   1. Employees handling raw materials should not handle finished products to prevent cross-contamination.
4. Hand Hygiene
   1. Wash and disinfect hands upon entering and leaving the feed mill to reduce the spread of pathogens.
5. Designated Eating Areas
   1. Eat only in designated areas to avoid contaminating feed and attracting pests.

Manage the movement of visitors, contractors, suppliers and other service personnel

Objective: Prevent the introduction and transmission of contaminants by external personnel.

1. Visitor Compliance
   1. Ensure visitors follow biosecurity practices to minimize the risk of introducing pathogens.
2. Access Control
   1. Limit access to the feed mill area for visitors and suppliers. Use signage to clearly communicate biosecurity procedures and risks.
3. Designated Meeting Area
   1. Direct visitors to a meeting area away from production, receiving, and loading zones before entering the feed mill.
4. Visitor and Vehicle Register
   1. Maintain records for all visitors and vehicles, including:
      1. Date, time, name, company, contact number, vehicle registration, signature, biosecurity risk assessment, and last contact with farmed animals.
5. Risk Assessment
   1. Assess visitors, contractors, and auditors for biosecurity risks before granting access to the feed mill.
6. Hygiene Procedures
   1. Ensure visitors follow the same hygiene procedures as feed mill personnel before entry.

Manage the movement and use of equipment

Objective: Prevent contamination through the movement of equipment in and out of the feed mill.

1. Personal Equipment:
   Employees and contractors must ensure that personal tools and equipment (e.g., laptops, phones, cameras) are cleaned and free of organic matter before use in the feed mill.
2. Education on Equipment Risk:
   Educate employees about the risks of using borrowed, hired, or second-hand equipment, particularly the potential for introducing pathogenic agents.
3. Separation of Equipment Use:
   Ensure that the same equipment is not used for both feed handling and waste management. If it must be, clean and disinfect the equipment thoroughly between uses to prevent cross-contamination.
4. Equipment Risk Assessment:
   Any equipment entering production areas must be assessed for potential risks. It should be cleaned and disinfected as needed before and after use to ensure that it does not introduce contaminants.

Manage the movement and use of vehicles

Objective: Minimize the risk of site contamination due to the movement of vehicles.

1. Employee Education:
   Educate feed mill employees about the potential risks of pathogenic agents introduced by visiting vehicles and machinery.
2. Limit Vehicle Access:
   Limit the entry of non-feed mill vehicles, machinery, and equipment beyond designated delivery areas.
3. Designated Parking Area:
   Establish a designated parking area for vehicles not entering the production area.
4. Visitor Vehicle Parking:
   Visitors should park outside the production area unless it’s essential for the vehicle to enter (e.g., maintenance contractors). Vehicles and machinery entering the feed mill should be directed to specific locations.
5. Vehicle Risk Assessment:
   Any vehicle entering production areas should undergo a risk assessment, as determined by the production manager.
6. Prohibited Vehicles:
   Trucks carrying animals, animal products, or contaminated vehicles (e.g., those carrying organic waste) should not be allowed into the feed mill area.
7. Vehicle Wash Area:
   Consider establishing a designated wash area for disinfection or fumigation of vehicle wheels before entering the parking area.

Manage Production Practices

Storage of ingredients

Objective: Minimize contamination risks during storage.

1. Prevent contamination – Store ingredients away from pests, dust, moisture, and waste.
2. Clean spills quickly – Leftover feed attracts pests and can lead to hygiene issues.
3. Maintain integrity – Prevent cross-contamination and follow regulations for restricted products.
4. Label and organize – Store ingredients according to their intended use and manufacturer guidelines.
5. Keep dry and elevated – Use pallets to prevent mold and spoilage.
6. Follow FIFO & FEFO – Use a “first-in, first-out” or “first-expiry, first-out” system to maintain freshness.

Mange pests and vermin

Objective: Minimize the risk of introducing infectious and pathogenic agents through pests and vermin in production and storage areas.

1. Implement a control program – Use secure, tamper-proof bait stations with mapped locations.
2. Monitor regularly – Check bait stations as per the pest management plan and replace baits as needed.
3. Keep records – Track inspections, analyze trends, and adjust control measures accordingly.
4. Place baits safely – Keep them away from feed areas; avoid toxic or high-risk baits like grain or powder.
5. Use safe methods – If shooting is necessary, opt for non-toxic ammunition.
6. Secure entry points – Keep doors, windows, and screens well-fitted and in good repair.
7. Maintain buildings – Seal holes and drains or use barriers like wire mesh to block pest access.

Mange feral animals and wildlife

Objective: Reduce the risk of site and feed contamination by controlling feral animals and wildlife.

1. Employee awareness – Train staff on the risks of pests and disease transmission.
2. Control measures – Use deterrents like bird spikes and physical barriers to prevent access.

Site standards

Objective: Minimize contamination risks from people, pests, raw materials, vehicles, and equipment.

1. Control access – Secure entry points to reduce exposure to pests and wildlife.
2. Maintain roadways – Prevent puddles, mud, and dust buildup.
3. Keep areas clean – Regularly clean receiving and load-out zones to avoid contamination.
4. Manage traffic flow – Separate incoming and outgoing vehicle routes.
5. Schedule maintenance wisely – Conduct between production runs and remove all hardware after.
6. Ensure hygiene – Follow cleaning schedules, conduct line surveys, and flush equipment regularly.
7. Control vegetation – Keep grass short to deter rodents and pathogens.
8. Reduce waste risks – Remove old pallets, cover bins, and clear standing water to prevent pest attraction.

Feed manufacturing process

Objective: Minimize the risk of contamination throughout the feed production process.

1. Optimize feed flow – Ensure a one-way movement to reduce contamination risk; apply mitigation if necessary.
2. Prevent cross-contamination – Use sequencing, cleaning, dedicated lines, and flushing schedules, with records maintained.
3. Follow cleaning protocols – Establish schedules for equipment cleaning based on risk, monitoring effectiveness.
4. Apply safety controls – Follow site protocols for pathogen control, including temperature, contamination-reducing agents, and air quality measures.
5. Adhere to regulations – Prevent prohibited materials from entering feed and meet labeling requirements.
6. Control dust – Reduce airborne dust to limit pathogen and pest transmission.
7. Manage grain dust reuse – Assess and handle screened particles to prevent contamination.
8. Regular equipment cleaning – Maintain cleanliness inside and out.
9. Monitor safety – Conduct pathogen and bacteria testing on ingredients, feed, and facility environments.

Training, planning and recording

Training

Objective: Ensure all feed mill employees are trained in biosecurity protocols.

1. Comprehensive training – Train staff annually, during onboarding, and after biosecurity breaches.
2. Early detection – Educate employees on identifying and responding to contamination risks.
3. Safe chemical handling – Ensure proper training for disinfectant and herbicide use, with safety data sheets maintained.
4. Inclusive training – Train all staff, including delivery drivers, and keep records of completed training.
5. Ongoing evaluation – Regularly assess training effectiveness through supervision and periodic reviews.

Planning, documenting and record keeping

Objective: Facilitate early detection of feed contamination and ensure a prompt response to biosecurity breaches.

1. Maintain site maps – Keep an updated layout of production areas, sheds, and access points.
2. Keep records – Follow documentation requirements, meeting regional retention laws.
3. Emergency readiness – Have a documented Pathogenic Agent Control Action Plan accessible to all staff.
4. Verify product receipts – Ensure proper documentation before unloading any product.
5. Track processing – Maintain batch records confirming compliance with treatment procedures.
6. Implement sampling – Follow specified testing procedures for received products and retain results.
7. Ensure traceability – Use systems to track ingredients (one step back) and feed movement (one step forward).

Manage Outgoing Products

Scheduling deliveries

Objective: Reduce the spread of pests and pathogenic agents through feed deliveries.

1. Plan delivery schedules – Prioritize deliveries based on breeder status, livestock age, and risk profiles (low to high risk).
2. Maintain a disease log – Keep track of disease status at livestock production sites to inform delivery decisions.
3. Ensure communication – Coordinate with feed mills, contractors, and clients about known outbreaks to adjust delivery routes.
4. Adjust routes during outbreaks – Avoid high-risk areas and change routes to prevent contamination spread, especially when delivering to known infected sites.
5. Follow movement restrictions – Ensure deliveries comply with government regulations during outbreaks and require approval if necessary.

Feed delivery

Objective: Reduce the spread of pests and pathogenic agents through feed deliveries.

1. Clean attire – Drivers must wear clean, animal-free work clothing at the start of each day.
2. Follow on-farm biosecurity – Drivers should adhere to farm protocols, including closing gates and sticking to designated roadways.
3. Avoid production areas – Drivers should not enter animal production zones like sheds or ranges.
4. Clean up feed spills – Promptly clean and dispose of feed spills on-site, using farm equipment, and notify the feed mill.
5. Use wash facilities – Utilize available wheel wash or vehicle wash down systems before entering the farm.
6. Follow farm personnel instructions – Drivers must use required biosecurity PPE, follow washing/disinfection protocols, and comply with on-site restrictions.
7. Quarantine returned feed – Assess and quarantine any returned feed for potential contamination risks before re-entering the mill.

Delivery truck

Objective: Minimize the spread of pests and pathogens due to feed deliveries.

1. Coordinate with contractors – Ensure freight contractors are aware of and follow biosecurity requirements for feed deliveries.
2. Regular cleaning – Delivery vehicles must be cleaned or disinfected as per a defined schedule, with records maintained.
3. Truck cabin hygiene – Keep cabins clean, free from waste, and disinfect high-contact surfaces like steering wheels and pedals.
4. Use approved wash facilities – Trucks should use designated wash down facilities before returning to the feed mill, where applicable.

Storage of finished products

Objective: Minimize the risk of contamination of finished feed products during storage before delivery.

1. Proper storage – Store feed in ways that prevent contamination by animals, pests, and other feed types.
2. Clean feed spills – Clean up spills immediately to avoid attracting pests and vermin.
3. Maintain product integrity – Implement procedures to avoid cross-contamination and follow regulations for restricted products.
4. Clear labeling – Label feed correctly by type, species, and storage instructions.
5. Store off the ground – Keep feed raised to prevent mold growth and contact with the ground.
6. Use FIFO – Apply a first-in-first-out system to ensure feed is used within its designated time frame.

Waste management

Objective: Minimize the spread of pests and pathogens due to improper waste disposal.

1. Proper waste disposal – Ensure waste is disposed of in ways that prevent contamination of feed, ingredients, or equipment.
2. Regular waste collection – Collect waste regularly to prevent accumulation in processing and handling areas.
3. Segregate and label waste – Store waste in clearly identified, closed bins to prevent accidental use, and differentiate waste by risk profile.
4. Designated containers – Use containers strictly for waste and never for feed or ingredients.

Premise design and facilities for new mills

Location

Objective: Choose a mill location that minimizes the risk of contamination.

1. Consider contamination risks – Evaluate potential environmental contamination sources and the effectiveness of protective measures when selecting a location.
2. Avoid high-risk areas – Feed mills should be located away from polluted environments, industrial activities, flood-prone areas, pest infestations, and places with poor waste management.

Design and layout

Objective: Design a feed mill that ensures discrete operations while maintaining high biosecurity levels.

1. Separate operations – Ensure physical separation of activities that could cause contamination.
2. Separate areas – Keep receiving, storage, and shipping areas separate from processing areas to reduce contamination risk.
3. Protect feed and ingredients – Ensure buildings and facilities protect feed from potential hazards.
4. Adequate space – Design the layout to allow for sufficient operational space and safe storage of materials and equipment.
5. Easy access for cleaning – Ensure buildings and equipment are designed for easy access and cleaning.
6. Pest deterrence – Build facilities to prevent pest access, with no unprotected openings, properly located air intakes, and sealed roofs, walls, and foundations.

Internal structures and fittings

Objective: Build a mill that facilitates easy cleaning.

1. Easy-to-clean materials – Use materials for internal structures (e.g., walls, doors, partitions) that are easy to clean and prevent buildup.
2. Proper floor design – Ensure floors are designed to allow adequate drainage following spills.

Equipment

Objective: Ensure all equipment is designed for easy cleaning.

1. Easy-to-clean materials – Use materials for equipment that can be easily disassembled, cleaned, and maintained to prevent feed contamination, cross-contamination, and carryover.

Hygiene facilities

Objective: Ensure there are adequate facilities to maintain hygienic operations for the people running the mill.

1. Hygiene Facilities:
   1. Provide adequate hygiene facilities, including means for washing and drying hands, to maintain personal hygiene and avoid feed contamination.
2. Potable Water and Soap Availability:
   1. Ensure a constant supply of potable water and availability of soap at designated delivery points for handwashing.

Conclusion

In conclusion, effective biosecurity procedures in feed mill operations are crucial for minimizing contamination risks and ensuring product safety. By implementing strict protocols for inputs, personnel, visitors, equipment, and waste management, alongside regular training and compliance with regulations, the risk of pathogens and contaminants is reduced. This proactive approach safeguards the integrity of the feed production process, ensuring hygiene and contamination prevention throughout.