On-farm Processing Adds Another Dimension to Biosecurity Plans
On-farm processors use signs to guide customers. (Image credit: Ginger Fenton, Penn State Extension)
The detection of Highly Pathogenic Avian Influenza (HPAI) in dairy cattle has added new urgency to the discussion of biosecurity plans for dairy farms. For most dairy farms, the pathway to the finished product after milking involves the milk leaving the farm for further processing. Producers generally reconnect with their product only once it reaches their breakfast tables or dinner glasses. However, additional steps are added between the bulk tank and the table for an on-farm processor. With these additional handling steps comes the potential for lapses in biosecurity as traffic to the farm increases and the purpose for more people on the farm changes.
In short, biosecurity includes a series of management steps and practices that have been implemented to keep from introducing infectious agents to the farm, prevent the spread of infectious agents within the farm, and avert infectious agents from spreading to other farms or herds. Also, remember there are many routes by which infectious agents can spread, including oral transmission, direct contact, airborne transmission, and via inanimate objects like tires, boots, or tools. Some biosecurity practices should always be in place regardless of outbreak status and are referred to as "everyday biosecurity." This article focuses on those everyday practices versus the enhanced level of biosecurity that would be required in the event of an outbreak.
A value-added or on-farm dairy processor has additional biosecurity considerations when creating their biosecurity plan. While each plan is unique to a facility, many templates are available to assist with developing a plan. The plan should include written protocols as well as an aerial map of the farm and processing facility. In addition to the plan for the farm operation, on-farm processors may include contact information for key personnel, businesses, or agencies related to the processing operation. The map should denote the processing facility and, if applicable, the retail facility location when determining the line of separation. Employees who may work in the retail or processing facility should be trained to adhere to biosecurity policies, including where the line of separation is and what that means for them.
Shipping and Receiving
An on-farm processor will likely have additional deliveries or increased traffic to the farm as packaging materials or containers, raw materials for manufacturing products, including items such as cultures, vitamins, flavors for milk, and, possibly even milk from other farms may be delivered. If milk is received from another farm for co-packing or mixed species milk products, what is being done to minimize the potential spread of pathogens during transport to the receiving facility and when returning from the facility to the shipper's farm? Do cooperating farms also have a biosecurity plan in place? Additionally, finished products may need to be transported to markets or retail outlets, necessitating travel off the farm and back to the processing facility. Are those products packed and transported in disposable containers, or will crates, bins, bottles, and other fomites, which are inanimate objects that can spread disease, need to be cleaned and disinfected before re-entering the on-farm processing facility?
Waste Streams
Does the wash water or discarded milk create a waste stream that could potentially spread pathogens? Consider the surroundings of the processing facility. Are there nearby homes and businesses, or is the processing facility surrounded by the farm? The disposal of waste milk is a consideration for a biosecurity plan for a farm and a processing facility. If waste milk or by-products are generated by the processing facility, heat treatment is an option to reduce the potential movement of pathogens.
Visitors
Increased biosecurity can serve as an opportunity to educate customers and others who visit the farm. Directions for visitors should include clearly outlined instructions such as where to park and denotation of areas that are off-limits to visitors. Processing facilities are likely to have increased traffic compared to farms without value-added businesses, although many dairies can be a hub of activity in a rural area. An on-farm store or agritourism venture is dependent on this increased traffic. Policies for limiting visitor access to the facilities are a must for safety and biosecurity. If visitors can access animal facilities, signage for clean footwear or expectations for wearing disposable booties should be obvious while also supplying the booties. If booties are provided, there should be a conveniently located waste receptacle can be placed near the parking area. Handwashing is extremely important for everyone on the farm, including visitors, processing employees, and farm employees.
One element of a biosecurity plan for a farm is a visitor log. Processing facilities should maintain a visitor log for biosecurity and food safety purposes. However, an on-farm processor may struggle to do this if retail sales are conducted at the farm, as these sales may be conducted in a variety of ways, from a full-service store to a self-serve kiosk. An on-farm retailer can ask visitors to sign in on a log sheet. In the case of self-serve, some ask customers to sign a log and list their purchases. This practice can be beneficial for food safety in the event of a recall while providing insight into your customers and their purchasing habits. Templates for these logs can be found in resource materials. Retail customers may be more willing to complete a log if an explanation is provided about the importance of these logs. Keep in mind that customers are seeking transparency and the backstory associated with products. The biosecurity plan for an on-farm process should demonstrate an assessment of the risks posed by visitors to the facility.
Food Safety
Biosecurity and food safety practices are intertwined. Good manufacturing practices (GMPs) related to personal hygiene should be followed in all dairy processing facilities regardless of the size or location. These practices include attention to clothing and footwear to prevent them from being a source of contamination, excluding personal items from food processing areas, and the use of personal protective equipment or PPE such as gloves. Additionally, good biosecurity encompasses pest control for the processing facility, cleaning and sanitizing, and sanitary facilities. Implementing and executing GMPs and sanitation standard operating procedures will set the stage for good biosecurity by building a food safety culture and mindset. As a dairy processor re-evaluates their food safety plan, it may be necessary to consider HPAI as a biological hazard and address it accordingly.
Communication
Strong and frequent communication between the processing operation and the farm is a good management practice for any on-farm value-added dairy business. Practicing good biosecurity emphasizes the importance of communication. For some on-farm processors, it may be a matter of talking with other family members at the dinner table, while for others, a weekly status meeting or text chain may be more appropriate. Items for communication can include training for all, changes in animal health status, cleaning and disinfection practices, and employee feedback about biosecurity concerns for the farm and the processing facility.
Another tier of necessary communication is with the customers of an on-farm processing business. As a processor, it is important to convey the safety of dairy products and provide an overview of the measures that are in place for consumers. Prepare the message to convey to customers. Make sure employees understand the message and are prepared to interact with the public if a retail outlet is part of the on-farm processing operation.
Stay current on information regarding emerging pathogens, keep the food safety plan up to date, and have a biosecurity program for your farm, including the processing facility. Utilize the resources that are available to develop plans, then implement them.
