How to Evaluate Feasibility, Update your HACCP, and Meet Human Food Safety Requirements without Guesswork

Pet food manufacturers are increasingly being required to meet human food safety standards—a shift that brings new hazards to manage, new controls to implement, and additional documentation to maintain. Peg Dorn, WMEP Consultant and food safety expert, says the key is to address these changes proactively, not reactively. “The best thing manufacturers can do is start with a thorough assessment of their facility and processes,” Peg explains. “It’s always easier—and cheaper—to plan right than to fix it later.”

First: Can Your Plant Meet the Standard?

Before changing a single SOP, Peg emphasizes the importance of understanding the full effort required to meet human-grade standards. “Start by determining whether your facility and equipment can truly meet human food requirements,” Peg advises. “Some feed facilities have open areas or structural issues that make it impractical. For some companies, the cost would mean essentially rebuilding.”

A good first step is to evaluate your physical environment for compliance readiness, for example:

• Enclosed, maintainable structure: no open walls or doors; no ceiling leaks
• Hygienic design: cleanable walls, sealed floors, smooth, non-porous surfaces
• Suitable equipment: stainless steel or food-grade materials where required

Update the HACCP: New Hazards Require New Controls

Pet food manufacturers must update their HACCP plans to address hazards traditionally reserved for human food. “Pet food plants didn’t always consider microbial hazards like Salmonella or Listeria, or allergens,” Peg explains. “Now they must. Go line by line through the HACCP plan to identify where those hazards apply and build preventive controls.” This step ensures the plan reflects real risks to both pets and humans—and satisfies the higher expectations of regulators and customers alike.

New Standards Demand Proof

As pet food companies move toward human-grade expectations, verification and validation become non-negotiable parts of their food safety program. Peg emphasizes two essentials that bring rigor and reliability to every system:

• Verification: Supervisors or designated staff regularly confirm that records and procedures are being followed correctly.
• Validation: Prove that procedures actually work—sanitation that truly cleans, pasteurization that truly delivers, and controls that consistently perform as designed.

Just as important, documentation such as temperature logs, metal detector checks, and sanitation records all demonstrate that safety processes are working. “If it isn’t documented, it didn’t happen,” Peg cautions. “Make sure your paperwork shows control at all times. That’s how you pass consistently—not just once.”

Safe Practice Before the Registrar — No Risk, No Danger

Peg recommends that manufacturers put their systems to the test before the registrar ever steps on-site. “Run a full audit in a safe environment—no risk, no danger—so you know exactly where you stand before the real thing,” she says. This internal audit mirrors the rigor of an official certification audit, but without the pressure or consequences. It allows manufacturers to experience the full process, uncover weaknesses, and correct them before they become findings. Peg emphasizes that this isn’t about passing for one day—it’s about building confidence, consistency, and control.

Plan Carefully, Proceed Confidently

Some pet food companies can meet the new human-grade requirements with small adjustments, while others face larger gaps in facilities, processes, or documentation. Either way, success depends on careful planning, diligence, and follow-through. Taking time to assess, document, and verify before you act prevents costly missteps later. For added confidence, consider bringing in expertise for either a fresh perspective or for mentoring and training. “Outside experts bring a fresh set of eyes,” Peg says. “Sometimes just a few adjustments can make the difference between hoping you’ll pass and knowing you will.”

WMEP is a nonprofit consulting organization with a simple mission: help Wisconsin manufacturers succeed. Our advisors bring real-world industry experience and deliver practical solutions across three key focus areas: Growth, Operations, and People. Contact us to assess your facility, update your HACCP plan, and meet human-grade requirements—without costly surprises or delays.