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Digital Re-print January | February 2013

Recycling surplus factory food into quality animal feeds

Grain & Feed Milling Technology is published six times a year by Perendale Publishers Ltd of the United Kingdom. All data is published in good faith, based on information received, and while every care is taken to prevent inaccuracies, the publishers accept no liability for any errors or omissions or for the consequences of action taken on the basis of information published. Copyright 2013 Perendale Publishers Ltd. All rights reserved. No part of this publication may be reproduced in any form or by any means without prior permission of the copyright owner. Printed by Perendale Publishers Ltd. ISSN: 1466-3872



Recycling surplus factory food into quality animal feeds

by Paul Featherstone, group director, SugaRich, United Kingdom
hen food is manufactured, a number of by-products are created and a proportion of the finished product cant be placed on the market for consumption by humans. This can be for a variety of reasons such as packaging defects, or for technological reasons such as the wrong size or weight biscuits, over-baking, trial runs or over ordering and out of date stock. Many of these former foodstuffs, including biscuits, bread, breakfast cereals, grain products, crisps and confectionery can have a very high nutritional value being a source of high quality fats, sugar and carbohydrates. After checking their safety and traceability and therefore suitability, SugaRich converts them into high quality ingredients for use in animal feed, avoiding waste from food that is not destined for human consumption. After processing, the foods are blended to the required feed formulation, then sieved and ground to create a free flowing meal. Finished feed is delivered direct to the compounder, blender or farm. With so many other issues to manage within busy food production sites or supermarket chains, getting the surplus food disposed of as waste may seem like the simplest choice, even if this results in a cost being levied to the business and the waste potentially ending up in landfill. However, by working in partnership with feed compounders, blenders and farms, we provide food businesses with an environmentally friendly alternative.
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According to a United Nations study, Global Food Losses and Food Waste , a third of the worlds food is wasted and we all have a part to play in solving this problem. Former foodstuffs should be regarded as a resource, not a waste product. Diversion of food waste from disposal is becoming an increasing priority for the UK government. Under current European Union waste regulations, the waste hierarchy gives the highest priority to waste prevention, followed by re use through the development of markets for valuable products, recycling and recovery. Disposal of waste products through landfill should be avoided wherever possible.

Business and environmental benefits

This closed-loop recycling, by which the waste from one product is used in the making of another product, brings measurable economic gains to businesses and long-term benefits to the environment. Food loss and waste are a major squandering of resources - water, land, energy and labour - and contribute to greenhouse gas emissions. Food sent to landfill biodegrades, releasing methane into the atmosphere that has damaging effects on the environment, while incineration may cause harmful greenhouse gas emissions. The recovery of former foodstuffs and by-products for use as animal feed is a sustainable and economically beneficial solution for all major food businesses, encouraging zero waste to landfill, cost savings and even revenue generation. Preventing food waste makes good business sense. Revenue is generated not just by the money saved from sending waste to landfill and the associated charges involved, but from the waste itself. Using materials

more efficiently, and managing waste better enables manufacturers to reduce costs, make money and decrease the environmental impact. From our work with the largest European food manufacturers, supermarkets and distributors, over 350,000 tonnes of surplus food per annum has been diverted from traditional waste disposal routes. Many businesses are unaware of how significantly waste impacts on their bottom line. We replace the term waste with resource, working with organisations to help them ensure compliance in respect of the waste hierarchy, encouraging them to reduce, reuse and recycle. Organisations need to think differently about waste to move beyond waste reduction to actively eliminating waste from the supply chain.

Legislative compliance
Anything designated for feed use will ultimately be re-entering the food chain, so strict adherence to regulations are essential. When former foodstuffs are used to produce animal feed, certain legal obligations are placed on the factory of production. By law, the factory is deemed a Feed Business Operator and has to be compliant under the Feed Hygiene Regulations EU 183/2005, which applies to all businesses that make, use or market animal feed. Feed businesses in this context include manufacturers selling by-products of food production into the feed chain, livestock farmers and arable farms growing crops for feed use. The regulation applies at all points in the supply and use of feed, and requires feed businesses to comply with standards in respect of facilities, storage, personnel and record-keeping. Hygiene standards are very important in the disposal of the surplus foodstuffs.

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ent challenges. Our expert team audit the whole location and production processes to identify the areas where there are issues to be addressed and highlight possible hidden revenue sources. Tailor-made surplus food handling installations are designed and built to suit each individual food factory site, with on-going maintenance, reporting and review. Critical control points for food safety are implemented through our HACCP systems which prevent the mixture of any nonfood waste and ensure feed materials are free from any chemical or microbiological impurities. Where inedible products or products prohibited from inclusion in feed (such as meat or fish) are stored or handled on the same site as surplus foods intended for feed use, there must be physical separation between these products and the feed products. This will ideally be full physical segregation of buildings and equipment. Detailed records of disposal of non-feed products must be maintained. To make the process of segregating the waste as straightforward as possible, the
14 | January - february 2013

total waste management side of our business, SugaRecycle, can help with the streaming and managing of all waste products from plastics and oils through to card, packaging, metal and more. Sealed containers with surplus food are collected and returned using specialist vehicles. All containers are clearly marked to avoid any chance of confusion between surplus food materials and waste. The surplus food is then transported to our purpose built reprocessing centres where computer generated formulations manufacture a feed material to exact customer specifications. SugaRich produce a range of bakery, biscuit and confectionery meals to suit feed compounders, blenders and home mixers. This includes SugaRich Premier Biscuit, a high oil biscuit meal suitable for inclusion in both broiler and high intensity pig feeds.

Quality feed within the food chain

Remember to take the advice of a nutritionist on feed mixtures and ensure

they are used as part of a balanced diet paying particular attention to an adequate supply of long fibre. Animal feed plays an important part in the food chain and has implications for the composition and quality of the livestock products (milk, meat and eggs) that people consume. Our high-quality feed is delivered direct to the compounder, blender or farm. This highenergy livestock feed helps to improve livestock productivity. The Food Standards Agency is responsible for drawing up the rules on the composition and marketing of animal feed. The Agency's main aims in this area are to help protect consumer and animal health. Another aim is to ensure that those buying the feed are provided with sufficient information to allow them to make informed choices. In summary, by recognising that former foodstuff is a resource and not a waste product, the feed industry and food businesses can work together to reduce the amount of waste sent to landfill every year, save costs, turn waste into revenue and lessen environmental damage.

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Products no longer intended for human consumption, which may be destined for farm animal feeding, must be kept separate during transport, storage and dispatch to and from a supermarket returns depot or food manufacturing plant. Our services are fully accredited to the

Feed Materials Assurance Scheme (FEMAS) standard ensuring that all feeds are fully traceable from source to supply giving both quality controlled service and products. The scheme is based on Hazard Analysis Critical Control Point (HACCP) principles, an internationally recognised system of hazard analy-

sis. Over recent years HACCP has become a central requirement of food and feed safety legislation.

The logistics from food production to the feed industry

Each food production site has differ-

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This digital Re-print is part of the January | February 2013 edition of Grain & Feed Milling Technology magazine. Content from the magazine is available to view free-of-charge, both as a full online magazine on our website, and as an archive of individual features on the docstoc website. Please click here to view our other publications on www.docstoc.com.
January - February 2013

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In this issue:
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Recycling surplus factory food

into quality animal feeds

Use of computer programming in animal diet formulation

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