HACCP-Food and Feed Additives

HACCP – Food and Feed Additives

SÜD-CHEMIE AGFood and Feed AdditivesOstenrieder Straße 1585368 MoosburgGermanyPhone: +49-8761-82-603Fax: +49-8761-82-670www.sud-chemie.com

Süd-Chemie De Mexico, S. A. de C. V.Apartado de Postal 828Puebla, Pue 72000Phone: +52-222881188Fax: +52-222881200

Sud-Chemie do Brasil Ltda.Rua Industrial;802 Bairro di Rio AbaixoSP CEP 12300-000Jacareí; BrazilPhone: +55-12-3953 22 88Fax: +55-12-3951 11 81

Sud-Chemie Peru S.A.Calle nueve no. 296Urb. Ind. OquendoCallao, Lima, PeruPhone: +51-1-5770034Fax: +51-1-5770167

Süd-Chemie U.K. Ltd. (SCUK)Suite 3, Richmond HouseGadbrook Business Centre • NorthwichCheshire CW9 7TNUnited KingdomPhone: +44-1606-813060Fax: +44-1606-813061

Süd-Chemie Spain S.L.Francisco Gervás, 12-1B28020 Madrid, SpainPhone: +34-91-42527-15Fax: +34-91-4250550

Süd-Chemie Turkey Madencilik Ve Tricaret A.S.Izmir Yolu 14, km .K. 195, 10034Balikesir, TurkeyPhone: +90-266-264 8757Fax: +90-266-264 8752

Sued-Chemie S.A. (Pty.) Ltd.Private Bag X 105Halfway House 16851 Horn Street, Chloorkop 1624Gauteng; RSAPhone: +27-11-9295800Fax: +27-11-3934194

P. T. Süd-Chemie Indonesia (SCINDO)Jln. Raya Narogong Pangkalan 10, km.14Desa Limusnunggal, Cileungsi16820 – Bogor, West JavaIndonesiaPhone: +62-21 8249 7445Fax: +62-21 8249 8585

Main Sites of Food and FeedAdditives

� �HACCP – Food and Feed Additives

Aerial photograph of our works in Moosburg, Upper Bavaria

HACCP – Food and Feed Additives

Süd-Chemie is a specialty chemicals enterprise holding leading positions on the world markets for adsorbents & addi-tives and catalysts.

For over a hundred years, the Industry Group for Food and Feed Additives has manufactured a wide range of bleaching-earth and bentonite products for both the edible oils and fats industry and the food and beverage industry. As the world's leading supplier in this sector, we have an extensive network of production, research and sales facilities across Europe, North and South America, Asia and Africa.

At Süd-Chemie, focus is on the customer. An inter-disciplinary team helps customers with product selection and ensures optimal use of our products. We advise customers on an ongoing basis, especially in the case of difficult applications or in their search for "new" solutions.

The same demands are made on our quality manage-ment system and implementation of the HACCP concept. With an interdisciplinary team and the involvement of all manufacturing sites, we seek the best and most pragmatic solution - to the benefit of our customers and of Süd-Chemie.

This highly-qualified interdisciplinary team monitors the entire supply chain, acting as an integrative partner for leading industrial enterprises in our markets.

Our Tonsil® bleaching earth and many other products have meanwhile become synonymous with entire product ranges. We continue to strengthen this position based on constant innovation and improvement.

Süd-Chemie – the world's leading supplier of bleaching earth for the edible oils and food industries

� �HACCP – Food and Feed Additives

Since 1906, we, Süd-Chemie, have been producing an extensive and highly-diversified range of bleaching-earth and bentonite products for a wide variety of customer applications.

Food and Feed Additives – Our Philosophy

Block Diagram

Tonsil®

Legal Requirements

MonitoringProgram

ProductCompliance

HACCP Plan

QM-SystemCertificates

HACCP – Food and Feed Additives

Meeting customer expectations was and is our unqualified goal. As a supplier to the food and feed industries, we are very much aware of our great responsibility to our customers. As well as producing top-quality products, this also includes consistent compliance with the provisions of food and feed-pro-cessing legislation.

The following measures guarantee a high level of lasting customer satisfaction.

s SteGreat care in the selection of raw materials, based on one hundred years' of clay-mining experience. We expect such care from all our suppliers and from our subsidiaries.

s SteCareful processing our high-quality raw materials, paying constant attention to hygiene and quality.

s SteRegular controls of both the raw materials and our finished products based on predefined parameters to ensure compliance with customer expectations.

s SteDocumentation of the entire process and of measures to control quality and processes, for both internal and external use.

s Ongoing development of our self-control system by a team of experienced staff based on the HACCP concept, and regular modification of this system in line with changing conditions and state-of-the-art technology.

All Süd-Chemie production facilities have a quality management system that is regularly reviewed and therefore continually improved.

Our comprehensive HACCP concept forms an integral part of the quality management systems implemented at each site and is supplemented by several global guidelines.

This HACCP concept is continually modified and optimized in response to market demands. Our team ensures that Süd-Chemie's concept is integrated into the overall HACCP concept used by the customer.

On the following pages of this brochure, we would like to present the cluster of modules that accompa-nies our production, thereby guaranteeing a safe and above all, high-quality Tonsil® product.

6 HACCP – Food and Feed Additives �HACCP – Food and Feed Additives

Exploration

HumusClay

TopsoilFarming Biotope

Lenticular bed of bentonite, approx. � m

Layer of water

Approx.�0 m over-burden

Test

bor

e

Opening up Extraction Refilling/Recultivation Renaturalization/Restoration

ActivationRaw Clay Conditioning Filtering/ Washing Drying/ Milling

Raw Clay

Coarse Material Waste Water TreatmentHeating Energy

HeatWater Steam, Acid Water

Dustfilter

Raw

Cla

y M

inin

gC

lay

Con

diti

onin

g/P

rodu

ctio

nS

tora

ge/P

acka

gin

g/L

oadi

ng

Cus

tom

er

Bag Big Bag Silo Truck

Rail Transport Customer’sproduction site

Tonsil®

Silo

Tonsil®

Tonsil® is the worldwide brand name for our highly-activated bleaching earth made from natural bentonite and manufactured using acid activation.

Exploration measures (geological surveys and selective boreholes) are used to analyze the quality and quantity of clay deposits, these being excavated as required, depending on the quality of the clay. They are found at depths of up to 30 m.

The first step in the production process is to crush and grind the bentonite, reducing all the clay particles to a consistently fine range of grain sizes. With the addition of water, mud is created.

During the next step, namely activation, this mud is mixed with acid in accordance with the relevant formula and then heated. As a result, the calcium ions are firstly exchanged for protons and at a further stage in the activation process, the stacked bentonite layers are attacked, expanded and more ions released. This results in a considerable increase in the surface area of these crystalline lamellae and acid centers are created.

Following activation, the acid-activated clay is very carefully washed until it is free from acid and the material to be filtered out is separated using a filter press.

The grain size distribution is adjusted to the desired quality to comply with the customer's requirements. The Tonsil® we produce is therefore highly-activated, yet also offers excellent filtration properties.

The bleaching earth is subsequently stored in a silo. Depending on customer requirements, Tonsil® is packed either in sacks or big bags, or dispatched in bulk.

This entire process is depicted in form of a block diagram and analyzed by our HACCP team, serving as a basis for identifying and analyzing the critical control points and their parameters.

Tonsil® Productionat Süd-Chemie

BlockDiagram

Tonsil®

LegalRequire- ments

MonitoringProgram

ProductCompliance

HACCP Plan

QM-SystemCertificates

� HACCP – Food and Feed Additives 9HACCP – Food and Feed Additives

In order to comply with the requirements of FEDIOL (EC Seed Crushers' and Oil Processors' Federation) and the overall needs of the food industry, as reflected in the demands and requests from our customers worldwide, Süd-

Chemie has introduced a dedicated monitoring program. This includes a complete check of raw materials and additives used in the production of the bleaching earth, as well as the final product, Tonsil®. Consideration is given to the parameters specified by FEDIOL (e.g. dioxin, furan, polycyclic aromatic hydrocarbons). The critical control points have been defined by Süd-Chemie in such a way that full-scale screening is ensured and appropriate action can be taken if necessary. Having implemented this system, Süd-Chemie can guarantee the quality of its Tonsil® products and offer high flexibility in meeting customer needs.

Süd-Chemie's Monitoring Program

BlockDiagram

Tonsil®

Legal Require-ments

MonitoringProgram

ProductCompliance

HACCP Plan

QM-SystemCertificates

Exp

lora

tion

Ble

ach

ing

-ear

th p

rod

uct

ion

Exploitation of beds and deposits

Raw-clay analysis

Analysis ofprocess materials

and additives

Productanalysis

s impuritiess dioxin, furans radioactivity s LCHC

s impuritiess dioxin, furans PAHs PCBs microorganisms

Based on suspicion or previous experiences dioxins heavy metalss PAH, PCB

s impuritiess heavy metalss pesticidess dioxin, furans PAH, PCBs radioactivity

10 HACCP – Food and Feed Additives 11HACCP – Food and Feed Additives

Legal RequirementsBlockDiagram

Tonsil®

LegalRequire- ments

MonitoringProgram

ProductCompliance

HACCP Plan

QM-SystemCertificates

Product ComplianceBlockDiagram

Tonsil®

LegalRequire-ments

MonitoringProgram

ProductCompliance

HACCP Plan

QM-SystemCertificates

We not only take legal requirements seriously, but also help to actively define them.

Traceability test scheme

Customer Order No.

Lot No. and CoA

SAP

Process Monitoring System

Production Records

Clay Preparation Records

Clay Quality Records

Clay Deliveries

Invoice

SAP

EDP data

EDP data

EDP data

EDP data

Loading papers

Reference sample(analysis, contents, …)

Compliance with internal and external parameters is ensuredand documented on the basis of a predefined process.

Legal requirements are becoming increasingly more demanding and far-reaching. We are fully aware of our responsibility for the safety of our food-processing products. This all depends on us being familiar with the various requirements, checking their relevance to our products and taking appropriate action. Trade associations in which we are actively

involved (e.g. IMA) provide support in mastering this challenge by supplying advance information on new developments. As a result of the leading role we play in trade associations and interest groups, such as the German Society for Fat Science (DGF), we are able to influence future legal and organizational parameters, both for ourselves and our customers.

Additional analyses are carried out throughout the entire process which, coupled with reference samples of each final customized product, ensure the reliable high quality of the Tonsil® product portfolio expected by our customers.

High demands on our products are made by

s our customers, depending on the field of applications associations and industry federations, e.g. FEDIOL

Before agreeing specifications with a customer, requirements are discussed by an interdisciplinary team to assess their feasibility and/or practicability and determine the parameters. These then form the basis for the customized "product specifications". In addition to marketing and sales staff, members of the product-

management, production and quality-control teams are also extensively involved in this definition process. In this way, compliance with the given parameters is ensured at an early stage.

Compliance with all product requirements is finally checked by way of outgoing-goods and quality controls and, upon request, can also be confirmed in the form of a test certificate. Additional requirements resulting from legislation and standards are dealt with using a similar process.

1� HACCP – Food and Feed Additives 1�HACCP – Food and Feed Additives

Süd-Chemie has received a large number of national and international certificates which meet the highest standards.

Test Certificates and Approvals

BlockDiagram

Tonsil®

Legal Require-ments

MonitoringProgram

ProductCompliance

HACCP Plan

QM-SystemCertificates

Each plant is regularly inspected and approved by in-dependent auditors. Such reviews may also be carried out by the local authorities or religious communities, which then certify compliance with their require-ments.

This collection of certificates illustrates the extent to which Süd-Chemie has realized its aim of every production plant implementing a quality management

system and conducting at least regu-lar internal reviews of this system.

1� HACCP – Food and Feed Additives 1�HACCP – Food and Feed Additives

HACCP-Plan

The HACCP plan is the key working document used to implement and ensure adherence to HACCP during the Tonsil® production

The HACCP plan provides a detailed summary of all measures and control stages from raw materials and production to outgoing-goods control, makes reference to the relevant documentation and stipulates the parameters to be complied with. This plan represents the framework for the entire Tonsil® production process and is used by the Food and Feed Additives Group as a controlling and monitoring instrument.

The chart shows the structure of the HACCP plan in a simplified form. In practice, this consists of a large number of individual control points and parameters.

The staff members responsible for customer contact will be pleased to present this plan in detail. We look forward to talking to you.

Our interdisciplinary HACCP team adapts this plan to coincide with the measures and characteristics agreed with each customer. Based on this instrument, we are able to integrate the HACCP concept into the supply-chain concepts applied by both Süd-Chemie and the customer.

BlockDiagram

Tonsil®

LegalRequire-ments

MonitoringProgram

ProductCompliance

HACCP Plan

QM-SystemCertificates

Schematic HACCP-Plan (Simplified)

ImpuritiesDioxinValues

ExplorationAnalysis

Industrial TrainingPlan and Controls

QualityControls

andDocumenta-

tion

Internal and External Product and Process Parametersaccording to FEDIOL, EU Guidelines etc.

RegularAnalysis

of Each Lot

EDP AlarmSystem and

Process Controls

VisualChecks

BatchControl

andDocumenta-

tion

RawMaterial

Production MaintenanceFinal

Products

ControlPoint

PreventiveMeasures

Parameters

Supervision

Processstep

Actions