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 At Dawn quality is everyone's responsibility, we are totally committed to producing safe, quality product, every time. This can only be achieved through a total quality management approach, in partnership with our customers, in a continuous improvement culture.
Our primary objective is to ensure food safety across all facets of the Dawn Group. This is achieved by implementation of a vertically integrated, seamless supply chain using the Hazard Analysis Critical Control Point (HACCP) approach. Particular emphasis is naturally placed on livestock procurement and abattoir practices. A policy of zero tolerance with respect to carcase contamination is operated. Although the focus is naturally on meat, our expertise extends across the whole food spectrum, including packaging systems and distribution . This allows pro- active identification of food safety issues from raw materials through to presentation to the customer and beyond. HACCP
A generic approach has been used to generate a HACCP system which consists of employee training, pre-requisite training ( GMP ) and the HACCP plan for the various aspects of the Group business providing particular benefits for our customers with flexibility of movement between Group manufacturing sites without loss of integrity. Maintenance of the Group model is managed through a sophisticated software package (HACCP from QSA), ensuring continuous improvement Group wide. HACCP verification
Microbiological monitoring forms a key part of HACCP verification, to consistently confirm achievement of our own high performance standards, from carcass swabs at the abattoir, through raw material monitoring and finished product/ manufacturing standards. Non-microbiological critical safety limits are also applied as identified through our raw material quality assurance and product safety technical approval regimes. Testing of critical limits to make sure that people are following the right procedures are carried out on-site whilst the microbiological limits are independently verified at outside accredited laboratories. Monitoring of trends allows feedback into the control regime to allow performance measurement and continuous improvement.
Total Quality Management (TQM )
The systematic approach afforded by HACCP for food safety has been extended to accommodate other parameters in its scope. Inclusion of animal welfare, product quality, purchasing, health & safety, environmental issues in an integrated quality system forms the basis of TQM. Animal handlers and relevant slaughtermen are all trained by Animal Welfare Officers, who have successfully completed the recognized University of Bristol 'Animal Welfare' course.
Quality
Product quality standards are also implicit within the overall control regime. Meat quality standards are indirectly achieved through animal welfare standards and directly through process control. Techniques such as electrical stimulation, hip suspension, considerate chilling and primal maturation are widely applied according to customer specification.
Quality criteria for manufactured products are established through product development and integrated into the associated process control through HACCP management. Achievement of quality is subject to continuous review through organoleptic assessment.
Dawn employs competent personnel in order to ensure that the safety policy is adhered to. The safety policy is constantly being updated in order to ensure continuing safety. Great emphasis is placed on training our employees. In house accredited trainers, in addition to external trainers, are employed for the purpose of training our personnel to the group's high standards. Training covers areas such as -
· Food hygiene and product safety
· Health and Safety
· Ongoing skills training
· Manual handling
· Occupational first aid
· Forklift, etc
Environmental Management
Dawn Group is committed to conducting its activities with due care and regard for the environment and to continual improvement to achieve a high standard of environmental performance. Dawn Group has thus taken environmental considerations into the management structures at all sites. A programme of investment in Dawn Group facilities has significantly upgraded the plants to meet the increasingly high standards of environmental protection being demanded. This programme is ongoing.
In particular Dawn Group is committed to:
· Adhering to the National Environment Agencies pollution control licences and all relevant National and EU laws and regulations.
· Monitoring and assessment of all our emissions to prevent pollution to air, land and water.
· Waste Management through reduction, recycling and re-use whilst also ensuring the safe disposal of any wastes.
· Promotion of environmental awareness of our employees through appropriate environmental training and procedures.
· Conservation of natural resources through the responsible use of energy, water and materials.
These commitments will be met through a fully functioning Environmental Management System, which incorporates a publicly available Environmental Management Programme and Objectives and Targets. An Annual Environmental Report provides a performance review of these objectives and targets. Dawn Group is implementing the Environmental Management system at all its facilities. The EMS is based on the principles of the environmental management standard, ISO 14001. All environmental commitments and requirements have been integrated into the EMS, allowing continual environmental improvement in a controlled and organised manner.
Group Quality System
The Group Quality System includes all existing and impending standards, either from customers or independent bodies and is a definitive all encompassing reference of Good Manufacturing Practice. Particular emphasis has been placed on internal auditing and continuous self - assessment to ensure standards are continuously met and improved. The greatest point of difference between Dawns own and any other existing standard is that it is customised to the nature of our business. This has the added benefit of facilitating approval against any other external standard that may become recognised in the future, whether it be generic or sector specific.
In addition this provides greater assurances to our customers of common standards being applied, by provision of an objective measuring tool and accelerating the integration of any further sites acquired to achieving a common standard, thereby providing an excellent foundation for further growth. These standards have also been instrumental in influencing the Legislators as well as contributing to Industry codes, maintaining Dawn at the forefront of new developments. Key attributes of the Group Quality System are outlined below: Raw material management
Purchase of all raw materials across the Group is carried out according to the Dawn Meats Technical Policy for the Quality Assurance of Raw Materials. Integration of the Group raw material management regime with supplier and specification management provides an integrated Group control mechanism for food safety and quality assurance. Site Management
The development of Dawn Group standards and associated scoring regimes, allows objective assessments to be made in order to facilitate site management , as a Group management tool and as a means of rewarding technical improvement. Verification of site self assessment carried out on a risk basis against the same criteria by a Group auditor provides exceptional assurances, in particular consistency of application. New Product Development(NPD)
In order to ensure new products are safe, legal and of consistent quality, procedures have been developed to control & verify the design of products and manufacturing processes as an integral part of NPD. The Dawn Group NPD critical path and associated guideline documents provide the customer with assurances of food safety and the ability to rapidly progress concept products to launch with confidence. Using a coordinated HACCP- based approach, we can offer safe products to quality specifications every time. Product safety technical approval
Prior to launch, all new products are technically approved, ensuring their inherent safety, quality and legality. Critical limits for raw materials and manufactured product are assigned using techniques such as mathematical microbiological modeling. Specification management
Our investment in a specification management software system allows us to optimise efficiencies for ourselves and for our customers; in terms of accuracy of information, flexibility, speed of response and as a product development tool.
Independent Accreditation
EFSIS (European Food Safety Inspection Service) EFSIS approval is currently the generally accepted food safety standard for the food industry. EFSIS approval against the British Retail Consortium (BRC) Standard has been awarded to all Irish and UK plants. Beef Quality Assurance Scheme (BQAS)
The Bord Bia (Irish Food Board) Beef Quality Assurance Scheme is in operation at all of Dawn's Irish plants. The BQAS is an integrated scheme involving the farmer, the beef plant and participating customers. We ensure that cattle are only purchased from approved farmers and have in place procedures covering hygiene, chilling, and product traceability. This food safety management plan is based on the principles of HACCP.
Control of the scheme is by audit carried out by independent auditors contracted by Bord Bia. The Dawn Group continues to meet all requirements of the scheme and is therefore entitled to use the quality assured logo on our produce. ABM (Assured British Meat)
These standards cover criteria specific to the British meat industry, over and above the general food manufacturing standards according to the BRC standard (see EFSIS). Particular emphasis is placed on animal welfare, traceability and GMP (Good Manufacturing Practices).
The approval of all Dawn's UK sites was successfully achieved at EFSIS inspection following the launch of the ABM standard. We are therefore able to offer the 'red tractor' British Farm Standard label for all UK customers. Highland Meats and Sandyford Foods are audited by the Guild of Scotch Quality Meat Suppliers (GSQMS) on a regular basis to ensure the strict standards and practices, which have been set, are met. These audits test all the plant systems including quality, HACCP, traceability systems, as for ABM. Adherence to all of the above allows Highland Meats and Sandyford Foods to market their Scotch Beef under the "Specially Selected Scotch Beef",(SSSB), brand.
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