July 13, 2012 Charles Hurburgh, Professor, Agricultural and Biosystems Engineering. IGQI Advisory Committee Meeting. Agenda 9:30 AM Welcome and introductions College of Agriculture, Extension update plans : John Lawrence 10:00 AM Bioprocessing projects:
July 13, 2012 Charles Hurburgh, Professor, Agricultural and Biosystems Engineering IGQI Advisory Committee Meeting
Agenda 9:30 AM Welcome and introductions College of Agriculture, Extension update plans: John Lawrence 10:00 AM Bioprocessing projects: RFS, E15 and pathways for plants to expand Current projects – corn sourcing and frac Discussion of future direction and opportunity 11:00 AM QMS/Food Safety projects FSMA and grain handling – update FDA grant update, results 12:00Noon Lunch Break 12:30PM Storage and Grain Management projects Storage Team Potential mold toxin and other drought impacts 2:00 PM Update; International Center for Grain Operations and Processing 2:30 PM Next meeting plans then adjourn. Suggested date: Friday, January 4, 2013
Program Update Agriculture and Natural Resources Extension College of Agriculture and Life Sciences
GQI Projects 2013 Bioprocessing QMS/FSQMS Food Safety Grain Management Processing inventory FDA Food safety project Grain storage team Fractionation Training (FSMA)- industry component Update materials Feed balance QMS templates, etc. Current events Soybean marketing Traceability 30% 40% 30% Expectation: Each project will create at least 2-3x its allocation in proposals ~ $150,000 Extension Allocation FY2013
Corn Grind for Ethanol Source: DOE-EIA
Ethanol Stocks Source: DOE-EIA
U.S. Blended Gasoline Consumption 7.6 bil. gal. 7.4 bil. gal. Source: DOE-EIA, via USDA-ERS
Current Projects within the IGQI Bioprocessing GroupJuly 2012- Development of Iowa Grain Flow Survey 2013- Validation of Ethanol Yield Equation - Plant test with new corn genetics - United BioEnergy survey- Discussions with fractionation companies
Grain Storage and Handling Team • First issue team under new plan • Grain science well understood. Challenge is volume and value of grain • Delivery team of field specialists Shaun Shouse, Greg Brenneman: ABE Kelvin Leibold, Steve Johnson: Farm Mgt Mark Licht: Agronomy • Collect regional info; short multi media on key topics, annual technology review and updates, early warning.
Harvest conditions and projected needs • The first condition (heat at silk) for aflatoxin has been met. We will review and update our aflatoxin/mycotoxin materials • (Hurburgh, Robertson, Shepherd) • New concern- FSMA, the reportable food registry and crop insurance. • (Hurburgh, Laury) • If severe drought; nitrate levels in silage • (Loy et al.) • High alpha amylase corn. Bad in corn dry milling and alkaline cook. One plant plans to take all.
List of training topics that might be useful. Aeration management: Brenneman Dryeration: Shouse Ventilation – fan sizes and performance: Brenneman Energy bulletins: Hanna –format to use for all the handouts. Mycotoxins: Robertson, Hurburgh and Licht Food safety act and grain farms: Laury and Hardy Bin drying: Drying systems - how should I spend my money: Economics of drying and storage: Leibold and Johnson Grain testing – grading: Hurburgh
FDA - Food Safety Modernization Act Update registration every two years A written food safety plan is required Carrier certification and examination (BSE)!!!!! Surveillance inspection every 5-7 years Accuracy guidelines for enhanced traceability FDA now can force a recall Self reporting website apply to mycotoxins??? Inspect records and audit without prior cause
First Actions • Train new inspectors, visit facilities • Emphasis on food safety plans – FEED! • Specific audits and checks in familiar areas; eg sanitation, BSE/meat products • Traceability/recall – ask state of the art • Wild card: Moldy grain and mycotoxins • Third party audits – fading reputation
Food Safety Training for Bulk Agricultural Product Handling and Processing Charles R. Hurburgh, Jr., Professor, Agricultural and Biosystems Engineering Principal Investigator
Project Team-ISU • Dr. Charles R. Hurburgh, PI • Dr. Jim Roth, DVM, CoPI; • Center for Food Security and Public HealthEducational Resources, College of Vet. Med. • Feed Safety and Animal Health tracking • Dr. Gretchen Mosher, Industrial Technology; • risk, mapping • Howard Shepherd, IGQI Coordinator • Connie Hardy, Extension; current practice survey
ISU Responsibilities: Process map of grains supply chain and food safety risk points Survey of current food safety regulatory practice, jurisdictions. Templates and procedure for creating a food safety plan/recordkeeping plan Course unit in animal production from the food safety viewpoint Course unit on traceability and recordkeeping Risk analysis of the grain supply chain ISO22000 coded to FSMA; PAS220, 222; AAFCO; FDA job analysis Scientific publications and list of publications in the FSQMS area. KSU Responsibilities: Feed short course taught at KSU (VM101) Process for ANSI accreditation of training materials Course uniton mycotoxins Addition of Food Safety Plan development to the GEAPS QMS course
Mycotoxins • Aflatoxin • Fumonisin • Vomitoxin • Zearalenone • Ochratoxin Mycotoxins are an example of a food safety issue that covers the entire supply chain.
The second year project will continue the sector specific training approach • Make the basic feed course (FFM) will be made more accessible in an on-demand format as well as in a physical classroom format. This will be done by condensing individual course units into 20-30 minute webinars, each with a 5-10 question self test at the end. • The FFM course repeated at North Carolina State, but in a shorter format assuming that participants have seen selected key elements by webinar, in advance. Classroom time can be redirected to problem solving exercises. • The structure and materials for the Advanced Feed Manufacturing will be created. • The wheat supply chain training( always connecting feed components to the feed course) –production, milling, flour distribution to the baker, feed by products – will be done. Kansas • The corn and soybean supply chain training- wet milling, ethanol, dry milling, soy crush, soy expeller plus production and product distribution to second stage will be done in the webinar followed by shorter on-site training format. owa. • The basic animal husbandry and nutrition will be expanded to other species beyond cattle and swine, for inclusion in the AFM training. • The identification of risk points and priority with industry will be published.
Food Safety Plan Dr. Angela Laury Department of Food Science and Human Nutrition Extension and Outreach
Food Safety Plan • All companies must have plan by June 2012 • More detailed than a traditional HACCP Plan • New concept of proof of compliance • More than prevention • Companies must evaluate known and reasonably foreseeable hazards • Science (validation) and Risk-based (traditional contamination) prevention strategies (interventions), monitoring (written), and record keeping (traceability) • Each program requires a separate hazard analysis
Aflatoxin Years • 1983 • 1988 About the same as 1983 • 2005 SE IA 5-10 counties
Summary from 2005 1. Accurate testing 2. Accurate sampling 3. Need for flexibility in testing and sampling 4. Costs incurred by producers for the aflatoxin testing 5. Role of elevator in the sampling and testing process 6. Insurance coverage in bins. 7. Why can't corn go in the bin and still be covered in Iowa? 8. Timely visit by adjuster 9. Consistency among insurance companies10. Inconsistency in information11. Consistency in the field testing process 12. Extreme variability within fields13. International implications for grain < 20 ppb aflatoxin 14. Use of grain > 20 ppb aflatoxin in livestock feed 15. What to do with truck loads of rejected corn 16. Marketing high testing grain 17. Variance for > 300 ppb grain by FDA 18. Co-mingling grain 19. Regulations after grain is at the elevator 20. How to measure the yield for APHif the field is zeroed out because of aflatoxin 21. Can corn be destroyed by leaving it in the field? 22. Can processing destroy aflatoxin? 23. This is beyond the control of producers 24. Worker safety issues in working with this corn
The primary education and applied research partner to the global grain handling and commodity utilization industry. International Center for Grain Operations and Processing International Center for Grain Industry Operations and Processing
ICGOP Organization – Current Draft $500K over 5 years = Board In kind counts. Companies by themselves or Organizations pool funds Scientific Societies ex Officio Incorporators: ISU, KSU, AAI, KGFA, GEAPS KSU: Lead, Distance Ed. ISU: Issue solving, Ed. February 3, 2012: Kansas City
ICGOP Organization – Status • Articles of Incorporation: • Filed in KS • KGFA Official Agent • Tax Exempt Application: • Information under review • Submit to Legal Counsel by Aug 1, 2012 • GEAPS has offered to pay attorney fees • KEY!!: Affiliation Agreements:AKA who does what
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