Standard Operation Procedure for Quality Control in Feed Production Process

Responsible Department
1. Nutritionist
2. QC (QC in Process)
3. Production
Critical point
1. Feed formulation.
2. Formulas apply
3. RM intake
4. Grinding
5. Batching & Mixing
6. Pelleting process
7. Bagging off (Packing)
8. Storage monitoring
Procedure
Feed Formulation
Formulation Apply
1. The new formulas must be sending to Accounting Dept. for cost calculation before
apply to the production.
2. Account will make the costing and margin comparison to the current using formulas
by using the current RM stocking prices. Then the costing will send to Nutritionist
(formulator).
3. Nutritionist (formulator) have right to apply any new formulas that the costing are
not higher than current using formulas. In case that nutritionist wants to apply any
formulas that more expensive than current using formulas, nutritionist must make
the suggestion with the explanations “Why we need to use these formulas?” The
suggestion will send to Head of Unit, Head of nutrition and Accounting Dept.
4. The formulas will send to Head of QC for apply in the production. Head of QC will
prepare the formulas into 2 parts, Base ingredient and Hand added ingredient.
5. Base ingredients part will send to Control panel room to install the new formulas into
the computer and delete the old formulas.
6. After install the new formulas QC in process must be check the formulas in computer,
then print out one copy for reference. The hard copy of any formulas will not allow
having in the control panel room.
7. The part of hand added ingredients will send to premixes unit base on the requesting
for production.
 Intake RM in to the production line
1. QC must supervise ware house keeper and production staff (Intake supervisor) about
the RM using.
2. The using of RM in the warehouse will follow the FIFO. Any case that the RM intakes
do not follow the FIFO, the production staff must get the agreement from Head of
QC.
3. In the intake process, QC has the responsibility to monitoring the quality of intake
RM. Any RM that not met the STD must be rejected. The sample of RM at the intake
must be sampling and check the physical (color, smell, caking …) and analysis the
moisture level.
4. RM Intake Monitoring Report must be record by QC.

RM Intake report file

Intake control

Moistu Quali Intak

RM Quan Target bin
Dat Kav re ty e Chec Remar
Nam tity
e No ker k
e (ton) B. A.grindin
A B
(%) grinding g
Grinding RM
1. Bin man is the key person in grinding process. From control panel room inform to bin
man, kind of RM, hammer mill screen size and target bin.
2. Bin man must check the condition of target bin. The target bin must empty to avoid
contamination of RM.
3. Hammer mill operator make sure the screen size is correct.
4. The control room starts grinding process. At the beginning of grinding, Bin man
checks the grinded RM, right kind and right bin.
5. Bin man must take the 250g (min) sample (each 10MT) of grinded RM and send to QC
ASAP.
6. QC will check the quality of grinded RM, physical check, moisture, particle size
analysis. The result must be report to control room with in 15 minutes after got the
sample from bin man. QC Grinded RM Report.
7. The results that not meet QC STD must be stopping the process to find out the
problems.

Grinded RM Quality Control

Raw material name: _________________ Date:_______

Screen size: _________________ Shift: _______

Grinding time: from ___:___ to ___:___ Target bin: ____

Grinded quantity(MT): ________

Result Particle

Moisture (%) % on # 2.0mm

Physical (ok/no) % on # 1.0mm.

Contamination (Y/N) % on # 0.5mm.

Grinded quality Pass Not Pass

QC Comment: __________________________________________

______________________________________________________

QC Staff Control room

Particle size analysis:
 Equipment
1. Weight balance (0.01g min)
2. Sieve set, 3 mm, 2 mm, 1 mm and 0.5 mm.
Procedure
1. Weight 200g of sample.
2. Sieve set from biggest to smallest and with the pan.
3. Put the sample on the top sieve then sieve about 1 minute.
4. Take the remaining on each sieve, then weight and calculated in to
percentage.
5. Compare the result to the STD of Grinded RM Sieve Profile.

Particle size STD of Grinded RM

Hammer mill On Sieve (%)
RM Name
Screen Size (mm) # 2.0mm # 1.0mm. # 0.5mm
Broken rice 2.0 0 7 - 15 35 - 40
Cassava 2.0 0 2 - 12 10 - 20
2.0 0 12 - 25 35 - 40
Corn
8.0 14 - 20 25 - 30 25 - 30
2.0 0 10 - 20 40 - 50
SBM
8.0 10 - 35 30 - 35 20 - 35
WB 2.0 0 8 - 16 30 - 50

Batching
1. QC must be checking the formulas in control panel, in every time of updated
formulas. Print out copy of each feed, need to check and keep by QC for reference.
2. Each batch of mixing must be store the report. At the end of each production (feed),
the batching report must print.
3. QC must check the summary of batching report compare with the formula. If find any
error, all of individual batching report must be printed out for checking.
Mixing
1. QC must re-check the mixing detail as time of mixing, liquid application, mix feed
quality.
2. The hand added was check and control by QC following the SOP of Hand Added
Premixes and Additives.
3. QC must take samples of feed after mixer. The sample of mixer must be 500g min.
and take 1 sample in every 10 MT of each production.
 4. The mixer sample must be checking the physical, Moisture and particle size profile
(as method in grinded RM).
5. The result of particle size analysis must be compare to the Mixer Particle size STD.

Pelleting
1. QC must control the moisture and temperature of each stage of pelleting.
a. Pelleting temperature: The temperature of following point must be control
and record.
i. After Conditioner
ii. Die shoot
iii. After cooler
iv. Room temperature
b. Pelleting moisture: The temperature of following point must be control and
record.
i. After Conditioner
ii. Die shoot
iii. After cooler: feed temperature must higher room temperature not
more than 4 degree C.
2. The temperature of pelleting process must following the STD of QC to avoid over
heating and get good pellet quality.
3. The moisture of pelleting process must following the STD of QC to avoid too high
moisture or too dry pellet.
4. Pellet and Crumble quality must be check by QC. The sample must be check in every
10MT of production.
a. After pelleting process the feed was screen out the powder, the finish feed
will send to product bin. At the top of product bin, bin man must collect the
sample of finish product, 1,000g/sample in every 10MT of production. The
samples must send to QC ASAP.
b. QC will check the quality of pellet and/or crumble. Then send back the result
to control room with in 15 min after get the sample.
c. In case of the pellet not meet the STD. QC has right to stop the production to
solve the problem.
STD Particle Size of Feed from Mixer

Feed Mash particle on sieve

(After mixer) Remark
name
3mm 2mm 1mm 0.5 mm
Concentrate feed
251 0 8÷16 35÷45
252 0 6÷14 35÷45
253 0 7÷15 34÷42
256 0 9÷18 35÷45
257 0 6÷12 34÷40
Pig Mash feed
433 2÷10 20÷30 28÷45 23÷30 Grinding Corn and SBM with sieve 8mm
452 0 8÷15 34÷42
453 0 13÷20 30÷40
454 0 7÷14 25÷31
456 0 8÷16 28÷36
457 0 8÷16 33÷40
Quail feed
461 0 10÷16 34÷44
462 0 12÷22 33÷43
Broiler feed
610 0 10÷20 34÷44
611 0 8÷22 34÷44
612 0 8÷25 33÷44
Garden chicken
621 0 9÷15 32÷42
622 0 9÷21 32÷42
Duck feed
644 0 2÷18 30÷42 Double grinding to get higher hardness
645 0 3÷10 37÷47
Pig feed
650 0 2÷8 25÷36 Double grinding
651 0 3÷16 30÷44 Double grinding
652S 0 7÷20 32÷40
652 0 7÷20 30÷43
652L 0 6÷17 30÷40
653 0 5÷20 31÷42
653L 0 6÷17 24÷40
654 0 5÷15 26÷38
656 0 8÷20 31÷41
657 0 8÷20 31÷41
Pellet Quality Test
 The quality of pellet will be considering in the detail of fine percentage, pellet diameter,
pellet length, PDI and hardness.
Fine percentage in Pellet
1. Sample, 1 kg, from bin man was mix and divided in to 2 parts, 500g each.
First part use for check fine percentage and the other part for PDI test.
2. Sieve 500g of sample with # 2 mm. sieve.
3. Weight the fine that pass through the sieve, and then calculated the fine
percentage.

Crumble size analysis

1. The crumble feed will be checking the particle size by using difference sieve
size.
2. The 500g of sample was sieve with 3mm, 2mm and 1mm.
3. Weight and calculation the percentage on each sieve.
4. Compare with the Crumble Size STD of each kind of feed.

Pellet diameter and length

1. The remaining on the #2mm. sieve from fine percentage test was using for
this test.
2. Measure the pellet diameter and length by Vernier.
3. The measure must randomize take from 20 pellets. Calculation the average
from 20 data.
4. Compare the diameter and length with the STD.

Pellet Hardness
1. The hardness will be test by the hard ness scale or hardness tester. The
hardness is the press in kg unit that broken the pellet.
2. Randomize 10 pellets, and then test with tester.
3. The data will calculate for the average hardness.
4. Compare the hardness result with STD

STD of Pelleting Temperature Table

 Pelleting
Feed Code Feed Name Type of feed Temperature (oC)
Min Max
Broiler Feed
610 Pre-Starter (1-14 day) Small Crumble 80.0 85.0
611 Starter (15 - 28 day) Crumble 80.0 85.0
612 Grower (29 - 42 day) Pellet 80.0 85.0
613 Finisher (42 day - sale) Pellet 80.0 85.0
K20, GT 51 Concentrate Mash
Color Chicken
621 Starter Mid Crumble 80.0 85.0
622 Grower - Finisher Pellet 80.0 85.0
Layer Commercial
F30 Starter-Grower Crumble 80.0 85.0
F31 Developer Crumble 80.0 85.0
F32M, GD 32 Layer Big Crumble 80.0 85.0
433 Layer II Big Crumble 80.0 85.0
K32, GD 51 Concentrate Mash
Broiler Breeder (LIR)
F40a Pre-Starter Small Crumble 80.0 85.0
F40 Starter Big Crumble 80.0 85.0
F41 Grower Pellet 80.0 85.0
F42 Pre-Breeder Pellet 80.0 85.0
F43 Breeding Pellet 80.0 85.0
F45 (F41a) Male Pellet 80.0 85.0
Duck
F60, VT13 Duck Broiler Starter Pellet 80.0 90.0
F61, VT23 Duck Broiler Grower - Finisher Pellet 80.0 90.0
644; 645 Duck Layer Pellet 80.0 90.0
Swine Feed
650 Pre Starter (5 day - 8 Kg) Pellet 65.0 75.0
651 Pre Starter (7 day - 15 Kg) Pellet 65.0 75.0
652S Starter ( 15 - 30 Kg) Pellet 80.0 85.0
652 Starter ( 15 - 30 Kg) Pellet 80.0 85.0
653 Grower (30 - 60 Kg) Pellet 80.0 85.0
654 Finisher (60 Kg - Sale) Pellet 80.0 85.0
656 Gestation Pellet 80.0 85.0
657 Lactation Sow Pellet 80.0 85.0
652L Starter - Grower Pellet 80.0 85.0
653L Grower - Finisher Pellet 80.0 85.0

Pellet Durability Index (PDI)

1. The PDI will test by using Thimble can.
2. The second part of sample, 500g was take out the fine by using 2mm sieve,
was put in to the Thimble can.
3. Rotate the Thimble can with the speed of 50 rpm for 10 min.
4. Take out the containing then sieve with 2mm screen. Take the part on sieve
and weight.
 5. The PDI calculated by;

Sample on 2mm sieve

PDI = X 100
Total weight of sample

6. Compare the PDI result with STD.

Packing
1. QC must check the following item at packing process;
a. Feed contamination: At the beginning of packing, feed always contaminated
with other kind. QC must reject until no more contaminated.
b. Feed Moisture: At the packing the feed moisture should not higher than 12%.
In case that the moisture of sample higher than 11%, the sampling and test
must be done more often (take 10 sample), and need to check the CV of
moisture.
c. Feed Temperature: The temperature of feed at packing must not higher than
room temp+5 degree C. The water will condensate and make moldy in the
bag, if the feed temp. was higher than room temp+5 degree C.
d. Fine percentage: The fine percentage is the parts that pass through 2mm
sieve. The acceptable fine percentage is 5% max for pellet feed.
e. Packing quality: QC monitoring the quality of packing as bag quality (printing,
and PE quality), sawing quality.
f. Date of production and expire date: Production and expire date must show
on the bag clearly. Also the feed code in the internal feed.
STD of Pellet and Crumble Quality Table
Type Pellet Quality Crumble Profile
Feed Code Feed Name of Pellet Size Hardness* % on % on %under
PDI Long
Feed (Фmm) Max 3mm 2mm 1mm
Broiler Feed
610 Pre-Starter (1-14 day) Small Crumble 3.5 90 - 96 2.5-4 2÷6 56-66 <15
611 Starter (15 - 28 day) Crumble 3.0 or 3.5 90 - 96 2.5-4 42÷48 36-42 <10
612 Grower (29 - 42 day) Pellet 3.0 or 3.5 88-95 3.5 4÷6 <2
613 Finisher (42 day - sale) Pellet 3.5 88-95 3.5 4÷6 <2
K20, GT 51 Concentrate Mash
Color Chicken
621 Starter Mid Crumble 3.0 90 - 97 6÷9 62-72 <13
622 Grower - Finisher Pellet 2.5 90 - 97 <2
Layer Commercial
F30 Starter-Grower Crumble 3.0 90 - 97 40-50 40-45 <15
F31 Developer Crumble 3.0 90 - 97 80-90 <15 <10
F32M, GD 32 Layer Big Crumble 3.5 90 - 97 3-4.0 85-95 <15 <10
433 Layer II Big Crumble 3.5 90 - 97 3-4.0 22-28 52-62 <10
K32, GD 51 Concentrate Mash
Broiler Breeder
(LIR)
F40a Pre-Starter Small Crumble 3.5 90 - 97 2-6. 56-66 <15
F40 Starter Big Crumble 3.0 or 3.5 90 - 97 42-48 36-42 <10
F41 Grower Pellet 3.5 90 - 97 4.5 4÷6
F42 Pre-Breeder Pellet 3.5 90 - 97 4.5 4÷6
F43 Breeding Pellet 3.5 90 - 97 4.5 4÷6
F45 (F41a) Male Pellet 3.5 90 - 97 4.5 4÷6
STD of Pellet and Crumble Quality Table (Continue)
Type Pellet Quality Crumble Profile
Feed Code Feed Name of Pellet Size Hardness* % on % on %under
PDI Long
Feed (Фmm) Max 3mm 2mm 1mm
Duck
F60, VT13 Duck Broiler Starter Pellet 2.5 90 up 3 up 8÷12
F61, VT23 Duck Broiler Grower - Finisher Pellet 3.0 92 up 3.5 up 8÷12
644; 645 Duck Layer Pellet 3.5 95 up 6.0 up 6÷10
Swine Feed
650 Pre Starter (5 day - 8 Kg) Pellet 2.5 95-99% 2.2-3.0 8÷12
651 Pre Starter (7 day - 15 Kg) Pellet 2.5 95-99% 2.3-3.3 8÷12
652S Starter ( 15 - 30 Kg) Pellet 2.5 93-98% 2.5-3.5 8÷12
652 Starter ( 15 - 30 Kg) Pellet 3.5 92-97% 2.5-4.0 8÷12
653 Grower (30 - 60 Kg) Pellet 3.5 90-96% 3.0-4.5 10÷15
654 Finisher (60 Kg - Sale) Pellet 3.5 90-96% 3.5-5.0 10÷15
656 Gestation Pellet 3.5 90-96% 3.5-5.0 10÷15
657 Lactation Sow Pellet 3.5 90-96% 3.5-5.0 10÷15
652L Starter - Grower Pellet 3.5 90-96% 3.0-5.0 10÷15
653L Grower - Finisher Pellet 3.5 90-96% 3.0-5.0 10÷15

Remark: STD of Mash and concentrate feed was follow the STD of Mixer Particle size analysis.
QC in Process Routine Job

Liquid dosing test and calibration

By weekly basis, QC must work with feed mill’s maintenances staff for checking all
liquid dosing system. The checking was doing the system leaning and calibration.

Mixer check and cleaning

By weekly basis, the mixer must be check and cleaning by maintenance staff with the
monitoring of QC.

Clean and check the magnet, RM screen, feeds screen.

By weekly basis, all of these items must be check and cleaning by maintenance staff
with the monitoring of QC.

Insect Monitoring in production line

By weekly, QC must check and monitoring the insect contamination in production line.
All of possible areas of insect habit, as bottom of bucket elevator, end of feed conveyer, under
the cooler …

Feed Reproduction
Feeds for reproduction were come from the production line, finish products ware house
and some of feed return from market. For economic reason these amount of feeds can be
considerable to reproduction back to the new feed. The procedure for feed reproduction must
be strongly control by QC.
Group of reproduction feeds
1. Normal rejected feed in production line: These feeds were rejected from
production line by production staff or QC. The reason and point of rejected
as following;
a. Beginning of pellet mill running. The beginning part of pellet
process the out put not yet stable and got some contamination with
previous production.
b. Beginning of bagging off. The first few bag of bagging of will able
to get contaminated.
c. Problem in pellet quality. Some part of feed, esp. in the beginning
of production may be not yet good and stable in pellet quality.
2. Lab rejected feeds. In case of Lab result of any kind feeds was abnormal,
QC will get informed and that feeds will blocked.
 3. QC rejected feeds. QC will reject some feed that not meet STD. Example
high moisture, contamination, bad pellet quality, abnormal physical ….
4. Miss Production Feeds. Any miss production feed will be rejected.
5. Market return. Market return can be come from 2 reason, products called
back and customer return. Both of market returns were come from under
STD feeds, mistake from company.
6. Sweeping feed. There are dust and feed falling from the production
process. The cleaner will sweep these amounts and screen out the
contamination.
7. Over stocking age. The finish products have the stock time limit. The feed
that our stocking time in warehouse will be send back to reproduction.

Feed Reproduction Procedure

1. All kind of reproduction feed will collect by RM warehouse, make the receiving,
input to the stock report.
2. Repro feeds must be check the quality at the receiving (to RM ware house) and
intake. All items must be clearly the sources (Where it comes from? Why it happen?
What is it condition, quality and safety to repro?)
3. QC will reject the feed that not safety for repro. Not safety are not clearly the
sources, moldy, bad physical, insect contaminate, highly contamination from non
feed material …
4. Warehouse keeper will make the proposal for sale out or destroy the rejected feed
as weekly basis.
5. The stock report of repro feeds will send to QC process.
6. In every 3 day, QC process, Head of QC and Nutritionist will discuss for feed repro.
7. The way to repro will depend on the situation or condition of the sources also
quality of repro feeds. The following is the basic procedure or regulation that QC
process can apply.
a. Repro feed in pellet form must be grinding before repro.
b. Seriously check the quality of repro feeds before use.
c. Moldy and abnormal physical (rancid, bad smell, insect, and change in
color) from market return feed can not be use for repro. All these items
must reject from warehouse ASAP.
d. Repro feeds from normal reject feed (beginning of pellet, packing and
problem in pellet quality) and our storage age can be direct repro in the
same feed with the rate of 5% maximum.
 e. Miss production feed must be sampling and send to check by Lab. Then the
repro procedure will setting by Nutritionist.
f. Not allow to production staff to do repro with out the informed or
supervise from QC.
8. The reproduction feeds must be show the name and amount of repro in the
production report.

Mixing performance of Mixer

The Mixer test will be done by monthly basis. In each test will do in 2 difference batch
of 2 difference kind of feed production. The CV of mixer will calculated from the chloride level
of the 10 samples.
Procedure
1. Select the batch of feed production one from compound (low Cl) feed and the
other one from concentrate feed (high Cl)
2. After completed the mixing time the 10 sample, 250g each, were took in difference
place of mixer. Label feed code, mixing time, sample number. Send feed to Lab to
analysis Cl level.
3. The 10 data of Cl level were calculated CV.
4. The CV has the meaning to the mixing performance as following table;

Percent Coefficient of Variation Rating Corrective Action

<10% Excellent None

10-15% Good Increase mixing time by 25–30%

Increase mixing time 50%, look for worn

15-20% Fair equipment, over filling, or sequence of
ingredient addition.

Possible combination of all the above. Consult

>20% Poor
feed equipment manufacturer