Putting Glass Walls on Pennsylvania Slaughterhouses So We Can See Behind Closed Doors from FAUN Friends Of Animals United
Tyson Foods

Address: 403 South Custer Ave, New Holland, PA 17557
Establishment No.: p01325

USDA Inspection Report: 7 Dec 2011

Code: 03J01
Violation: 417.2(b)

Citation: At 1323 hours I entered the Gizzard Department and observed an employee operating the valve for the fresh water intake for the gizzard chilling tank. I then looked inside for myself and observed that the water level was approximately 25% of what it normally is during production with very little ice present. I then observed that product was both entering and exiting the chilling tank at this time. I immediately retrieved [redacted], General Production Manager from across the hall and requested the use of one of the establishment's temperature monitoring devices. I then retrieved 3 pieces of gizzard from the gizzard exit conveyor. None of the temperatures for these 3 pieces were below 56 degrees F. Knowing that the establishment has identified this point of the process as a critical control point in the HACCP plan, I immediately applied U.S. Retain Tag #B36279399 to a cart of 17 boxes of packed gizzards. The gizzards remaining unpacked both inside and outside of the chiller were condemned and the equipment was washed down. Later I reviewed the HACCP plan and confirmed that the critical control point is the chilling tank exit, and that the critical limit is 40 degrees F or below. The establishment was also able to produce records that demonstrate 9 of the 17 boxes as being produced between 1200 hours and 1300 hours. The previous acceptable monitoring of this CCP was conducted at 1303 hours, so these 9 boxes were packed prior to this check and are therefore represented by that monitoring. However, this same documentation also shows that the remaining 8 boxes were packed between 1300 hours and the time when I tagged the cart at 1330 hours. This disparity was explained in the establishment's documentation of the root cause that water was flowing into the chilling tank and pushing gizzards to the exit faster than they should have. The product was placed on hold by both the establishment and the USDA pending an evaluation of the corrective actions.


417.2(b) The HACCP plan. (1) Every establishment shall develop and implement a written HACCP plan covering each product produced by that establishment whenever a hazard analysis reveals one or more food safety hazards that are reasonably likely to occur, based on the hazard analysis conducted in accordance with paragraph (a) of this section, including products in the following processing categories: (i) Slaughter—all species. (ii) Raw product—ground. (iii) Raw product—not ground. (iv) Thermally processed—commercially sterile. (v) Not heat treated—shelf stable. (vi) Heat treated—shelf stable. (vii) Fully cooked—not shelf stable. (viii) Heat treated but not fully cooked—not shelf stable. (ix) Product with secondary inhibitors— not shelf stable.


Next Report: USDA Inspection Report: 12 Dec 2011
Previous Report: USDA Inspection Report: 2 Dec 2011

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