New Jersey Slaughterhouses

NOTICE of SUSPENSION HELD in ABEYANCE:

On January 24,2014, your establishment received official notification from the Food Safety and Inspection Service (FSIS) Raleigh District, of the suspension ofthe assignment of FSIS inspectors for slaughter operations at Catelli Brothers, Est. 01809A–M. The decision to suspend inspection at your establishment was based on the determination, by FSIS that your establishment failed to slaughter and handle animals humanely.

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NOTICE of SUSPENSION REVISED:

This is the revised Notice of Suspension that incorporates additional information as basis for the suspension as noted in the previous letter you were given on January 24, 2014. This letter confirms the verbal notification you were given on January 24, 2014 by the Food Safety and Inspection Service (FSIS) of the suspension of the assignment of inspectors for slaughter operations at Catelli Brothers, Inc., Est. 01809A–M, herein after referred to as “your establishment”. This action was initiated, in accordance with Title 9 of the Code of Federal Regulations (CFR), part 500.3 (b), after FSIS determined that your establishment failed to handle animals humanely.

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Code: 06D01
Violation: 416.2(b)(2)

Citation: While performing a 06D01 I observe the entrance area of the slaughter floor had a broken side panel and screws were loose. I notify Plant management. The plant was not in compliance with CRF9 416.1 General rules. Each official establishment must be operated and maintained in a manner sufficient to prevent the creation of insanitary conditions and to ensure that product is not adulterated. 416.2(b)(1) Establishment buildings, including their structures, rooms, and compartments must be of sound construction, be kept in good repair, and be of sufficient size to allow processing, handling, and storage of product in a manner that does not result in product adulteration or the creation of insanitary conditions. 

Regulation: (b) Construction. (2) Walls, floors, and ceilings within establishments must be built of durable materials impervious to moisture and be cleaned and sanitized as necessary to prevent adulteration of product or the creation of insanitary conditions.

Code: 04C02
Violation of: 313.1

Citation: At approximately 0915 hrs while performing unscheduled task 04C02. I observed the establishment putting animals in to holding pen. Where they separate the federal inspected animals, and close off the pen with a gate. At 0930 hrs while performing ante mortem I observed that the establishment, had turn 1 pen into 2 pens by separating the animals with a f14 Sepence. I then observed the animals in pen no.2 had no water. I then notified Robert Seugling the production manager, about the situation. Robert Seugling immediately put water in the pen. 04C02 Water and Feed availability, that livestock must have access to water at all times. Also during ante mortem I observed the loading dock of the livestock. I observed the fence inside the loading area to the left, that where 3 pieces of wire sticking out that could cause injury to the livestock. I also observed on the inside of the fence were 2 more pieces of wire sticking out. I observed the livestock being unloaded this morning, at 0745 hrs, and the livestock did not come in contact with the fence. The establishment took immediately corrective action on the fence by bending the hooks down. Mr. Robert Seugling told me that he would have it replace next week. There was no regulatory control action taken.

Regulation: Livestock pens, driveways and ramps. (a) Livestock pens, driveways and ramps shall be maintained in good repair. They shall be free from sharp or protruding objects which may, in the opinion of the inspector, cause injury or pain to the animals. Loose boards, splintered or broken planking, and unnecessary openings where the head, feet, or legs of an animal may be injured shall be repaired. (b) Floors of livestock pens, ramps, and driveways shall be constructed and maintained so as to provide good footing for livestock. Slip resistant or waffled floor surfaces, cleated ramps and the use of sand, as appropriate, during winter months are examples of acceptable conctruction and maintenance. (c) U.S. Suspects (as defined in § 301.2(xxx)) and dying, diseased, and disabled livestock (as defined in § 301.2(y)) shall be provided with a covered pen sufficient, in the opinion of the inspector, to protect them from the adverse climatic conditions of the locale while awaiting disposition by the inspector. (d) Livestock pens and driveways shall be so arranged that sharp corners and direction reversal of driven animals are minimized. [44 FR 68813, Nov. 30, 1979, as amended at 53 FR 49848, Dec. 12, 1988]

Code: 01B02
Violation: 416.4(a)

Citation: At approximately 0915 hrs on main production floor. After plant management had told inspection personnel that they had conducted pre-operational inspection and found everything acceptable. Inside main holding cooler were (7 meat hooks were hanging in the cooler upon further inspection I notice that 2 of the meat hooks, had meat and blood from previous day production). I immediately notified Robert Seugling production supervisor about the non-compliance. Which is a direct contact surfaces. 9 CFR 416.4(a) States that food contact surfaces. All food contact surfaces, including food contact surfaces of utensils and equipment, must be clean and sanitized as frequently as necessary to prevent the creation of insanitary conditions and the adulterated of product. Robert Seugling remove meat hooks immediately. No product was involved, sanitary conditions were restore no tag was used. 9CFR 416.4(a) was not met. Past Similar NRs – Previous Ineffective Plant Actions: visecra is clean every week and sill be clean every week to prevent contamination NR: 5-2009 dated 7/7/209

Regulation: All food-contact surfaces, including food-contact surfaces of utensils and equipment, must be cleaned and sanitized as frequently as necessary to prevent the creation of insanitary conditions and the adulteration of product.

Code: 06D01
Violation of: 416.2(a)

Citation: At approximately 0925 hrs after performing pre-operations. I did an unscheduled 06D01, In the storage room beside the bath room and the holding pen. On main production floor the storage room has spiders and cobwebs and spider eggs in the storage room. I then notified Robert Seugling about this situation. On (6-16-09) I wrote Mr. Seugling in a plant meeting with Dr. Wilson and also Dr. Samy about these issue. I then tagged room with tag No. B 20 521355. 9 CFR 416.2(a) States that the Establishment must have in place a pest management program to prevent the harborage and breeding of pest on the grounds and within the establishment facilities. Pest control substances must be safe and effective . 9 CFR 416.2(a) Was not met. Tag is still applied.

Regulation: Grounds and pest control. The grounds about an establishment must be maintained to prevent conditions that could lead to insanitary conditions, adulteration of product, or interfere with inspection by FSIS program employees. Establishments must have in place a pest management program to prevent the harborage and breeding of pests on the grounds and within establishment facilities. Pest control substances used must be safe and effective under the conditions of use and not be applied or stored in a manner that will result in the adulteration of product or the creation of insanitary conditions.

Code: 01B02
Violation of: 416.4(a)

Citation: At 0900 hrs on main production floor, after management, had told inspection personnel that they had conducted their pre-operational inspection and found everything acceptable. I observed (feces inside of the viscera pan in the corner). I tagged the pan with tag No B 20 521352  I then notified Robert Seugling production supervisor. The pan was clean immediately. 9 CFR 416.4(a) States that all food contact surfaces, including food-contact surfaces of utensils and equipment, must be cleaned and sanitize as frequently as necessary to prevent the creation of insanitary conditions and the adulteration of product. 9 CFR 416.4(a) was not met. Sanitary conditions were restore.

Regulation: All food-contact surfaces, including food-contact surfaces of utensils and equipment, must be cleaned and sanitized as frequently as necessary to prevent the creation of insanitary conditions and the adulteration of product.

Code: 01B02
Violation of: 416.13(a), 416.15(a), 416.15(b)

Citation: At 0915 hrs the following was observe, after management told inspection personnel that they had finish their pre-operations inspection. Inside main holding cooler, was blood and unknown substances on walls I rub the unknown substances it came off when I rub it. The shackles inside holding cooler had blood and meat from previous day production The racks inside the holding cooler had hair on them The main production floor had blood and unknown substances on walls. The rooms were tag with NO B 20 521336. Robert Seugling plant Production Manager was notified immediately about non-compliance. 9CFR 416.13 (a) States that each official establishment shall conduct pre-operations procedures in the Sanitation SOP before the start of operations. 9 CFR 416.15 (a) (b) States that each official establishment, shall take appropriate corrective action(s) when either the Establishment or FSIS determines that the establishment Sanitation SOP or the procedures specified therein, or the implementation or maintenance of the SSOP may have failed to prevent direct contamination or adulteration of product(s). (b) Corrective actions include procedures to ensure appropriate disposition of product(s) that may be contaminated, restore sanitary conditions, and to prevent the recurrence of direct contamination adulteration of product(s), including appropriate reevaluation and modification, of the SSOP’s and the procedures specified therein. 9 CFR 416.13 (a). Was not met. Sanitary conditions were restore.

Regulation:

416.13(a): Each official establishment shall conduct the pre-operational procedures in the Sanitation SOP’s before the start of operations.

416.15(a): Each official establishment shall take appropriate corrective action(s) when either the establishment or FSIS determines that the establishment’s Sanitation SOP’s or the procedures specified therein, or the implementation or maintenance of the Sanitation SOP’s, may have failed to prevent direct contamination or adulteration of product(s).

416.15(b): Corrective actions include procedures to ensure appropriate disposition of product(s) that may be contaminated, restore sanitary conditions, and prevent the recurrence of direct contamination or adulteration of product( s), including appropriate reevaluation and modification of the Sanitation SOP’s and the procedures specified herein or appropriate improvements in the execution of the Sanitation SOP’s or the procedures specified therein. [61 FR 38868, July 25, 1996, as amended at 62 FR 26219, May 13, 1997]

Code: 01B02
Violation of: 416.13(a)

Citation: On 0900 hours the following was observed. After plant management told USDA inspection that they had conducted pre-operational sanitation. On the slaughter floor, the pan that holds the viscera had residue from previous day production, the wall had meat on it from previous day production. I then informed Robert Seugling Jr. production supervisor about my findings. No tag was used the pans and walls, were clean immediately, Regulations 416.13 (a), states that each official establishment, shall conduct the pre-operational procedure in the SSOP before the start of operations. Regulation 9 CFR 416.13 (a) was not met.

Regulation: Each official establishment shall conduct the pre-operational procedures in the Sanitation SOP’s before the start of operations.

Code: 01B02
Violation of: 416.4(a)

Citation: At 0930 after establishment finish sanitation pre-op. Prior to plant operations, I notice blood and meat from previous day operation in holding pan for meat parts. Also notices meat and blood on meat hooks, from previous day operation. Their SSOP states (b)(4)[Redacted by USDA] Regulation 416.4 (a) states that all food contact surfaces, including non food contact surfaces, utensils and equipment must be clean and sanitize as frequently as necessary to prevent the creation of insanitary conditions, and the adulteration of product. Plant management Robert Seugling was notified about the non compliance, Past Similar NRs – Previous ineffective Plant Actions: Knives and scabbleboard were sanitize in the presence of the Inspector, before start of kill. Knives will be clean on daily basic to prevent rust build up. NR: 1-2009 dated 4/14/2009

Regulation: All food-contact surfaces, including food-contact surfaces of utensils and equipment, must be cleaned and sanitized as frequently as necessary to prevent the creation of insanitary conditions and the adulteration of product.

Code: 01B02
Violation of: 416.13(c)

Citation: At 0195 hours the following was observed in the main kill floor area. Employee knives and scabbard were found unclean with a accumulation of dried blood, animal hair and even rust in some areas of the blade especially by the knifes blade and handle junction. Management was immediately shown the non-compliance. Establishments SSOP Program last signed and dated 5/6/08 on page (b)(4) [Redacted by USDA]it Clearly states:(b)(4)[Redacted by USDA](b)(4)[Redacted by USDA] This fail to meet the requirements of 9 CFR 416.13(c) which states: “Each official establishment shall monitor daily the implementation of the procedures in the Sanitation SOP’s.” The knives was immediately rewashed and sanitized in the presence of inspection personal before operation were aloud to commence.

Regulation: Each official establishment shall monitor daily the implementation of the procedures in the Sanitation SOP’s.

Code: 03J01
Violation of: 310.25(a)

Citation:
On 09/23/2008 approximately 0920 hours while performing an 03J01 procedure, I observed in the establishment’s HACCP records that there were no results available for the recent E.coli 0157:H7 testings from the goats slaughtered. This establishment slaughters goats once per week under USDA inspection. I immediately notified the owner, Mr. Robert Seugling. Regulation 310.25(a)(4) was not met in this area today.

Regulation: Criteria for verifying process control; E. coli testing. (1) Each official establishment that slaughters livestock must test for Escherichia coli Biotype 1 (E.coli) Establishments that slaughter more than one type of livestock or both livestock and poultry, shall test the type of livestock or poultry slaughtered in the greatest number. The establishment shall: (i) Collect samples in accordance with the sampling techniques, methodology, and frequency requirements in paragraph (a)(2) of this section; (ii) Obtain analytic results in accordance with paragraph (a)(3) of this section; and (iii) Maintain records of such analytic results in accordance with paragraph (a)(4) of this section.

Code: 03J02
Violation of: 417.2(c)(7)

Citation: On 07082008 at approximately 0915 hours while reviewing the establishment’s HACCP records, I discovered that no tests had started for the sampling collection for the E.Coli testing of goats that was to be performed at a frequency of the first full week after June 1 of the year according to regulation. Mr. Seugling of plant management was informed. Regulations 417.2(c)(7) and 310.25(a)(2)(v)(A) was not met in this area today.

Regulation: List the verification procedures, and the frequency with which those procedures will be performed, that the establishment will use in accordance with § 417.4 of this part.

Code: 03J01
Violation of: 310.25(a)

Citation: On 07012008 at approximately 0920 hours while performing a recordkeeping procedure, I observed that there were no records available for the E.Coli sampling of goat carcasses that should have started the first full week after June 1st of this year. Plant manager Mr. Seugling was immediately notified. Regulation 310.25(a)(4) was not met in this area today.

Regulations: E. coli testing. (1) Each official establishment that slaughters livestock must test for Escherichia coli Biotype 1 (E.coli) Establishments that slaughter more than one type of livestock or both livestock and poultry, shall test the type of livestock or poultry slaughtered in the greatest number. The establishment shall: (i) Collect samples in accordance with the sampling techniques, methodology, and frequency requirements in paragraph (a)(2) of this section; (ii) Obtain analytic results in accordance with paragraph (a)(3) of this section; and (iii) Maintain records of such analytic results in accordance with paragraph (a)(4) of this section.

For further details, visit Subchapter A – AGENCY ORGANIZATION AND TERMINOLOGY; MANDATORY MEAT AND POULTRY PRODUCTS INSPECTION AND VOLUNTARY… (Parts 300 – 381) 2004

Code: 03J02
Violation of: 417.5(a)(2)

Citation: On April 22, 2008 while reviewing the establishment’s HACCP Plan, I observed that the flow chart of the plan has hot water as an anti-microbial agent at CCP (Redacted by USDA) but in the Hazard analysis plan it has lactic acid as the CCP (Redacted by USDA). Immediately owner Mr. Robert Seugling was notified. This document serves as a written notification of the failure to meet the requirements of 417.5(a)(2).

Regulations:
417.5(a)(2) The written HACCP plan, including decisionmaking documents associated with the selection and development of CCP’s and critical limits, and documents supporting both the monitoring and verification procedures selected and the frequency of those procedures.

Code: 06001
Violation of: 416.2(a)

Citation:
On Tuesday, January 8, 2008, while performing unscheduled procedure, 06D01, the following non-compliances were observed: A 1 inch and a 3/4 inch brown roach were observed in the USDA office. A 1 inch brown roach was also observed in the large red hallway adjacent to the kill floor. Bobby Seugling was notified of the non-compliance. Product adulteration was not evident due to the non-compliance. This report serves as written notification of a failure to meet the requirements set forth in 9CFR 416.2(a).

Regulations:
Grounds and pest control. The grounds about an establishment must be maintained to prevent conditions that could lead to insanitary conditions, adulteration of product, or interfere with inspection by FSIS program employees. Establishments must have in place a pest management program to prevent the harborage and breeding of pests on the grounds and within establishment facilities. Pest control substances used must be safe and effective under the conditions of use and not be applied or stored in a manner that will result in the adulteration of product or the creation of insanitary conditions.

Code: 06D01
Violation of: 416.2(a), 416.2(h)(1), 416.2(h)(2)

Citation:
On Tuesday, October 2, 2007, while performing an unscheduled 06D01 procedure, the following non-compliance was observed: The plumbing fixtures in the lavatory connected to the USDA office  were observed in a filthy condition. There was also no paper towels available for use in this bathroom. In the hallway adjacent to the USDA office was observed two large freezers which had various household trash under and behind them. This unsanitary condition created a possibility of attracting and harboring various pests and insects. At the time of this observance, no evidence of pests was noticed. In the second floor storage area accessed from the stairs outside the USDA office  was observed a cluttered mess of tools and equipment. The messy condition hampered the ability to thoroughly inspect the grounds for any evidence of rodents. The areas which were accessible were inspected and no evidence of rodent or pests were observed. This report serves as written notification of failure to meet the requirements set forth in 9CFR 416.2(a), and 416.2(h)(1-2).

Regulations:
416.2(a) Grounds and pest control. The grounds about an establishment must be maintained to prevent conditions that could lead to insanitary conditions, adulteration of product, or interfere with inspection by FSIS program employees. Establishments must have in place a pest management program to prevent the harborage and breeding of pests on the grounds and within establishment facilities. Pest control substances used must be safe and effective under the conditions of use and not be applied or stored in a manner that will result in the adulteration of product or the creation of insanitary conditions.
416.2(h)(1) Dressing rooms, toilet rooms, and urinals must be sufficient in number, ample in size, conveniently located, and maintained in a sanitary condition and in good repair at all times to ensure cleanliness of all persons handling any product. They must be separate from the rooms and compartments in which products are processed, stored, or handled.
416.2(h)(2) Lavatories with running hot and cold water, soap, and towels, must be placed in or near toilet and urinal rooms and at such other places in the establishment as necessary to ensure cleanliness of all persons handling any product.

Code: 05AOl
Violation of: 310.25(a)

Citation:
05AOl E. coli Testing and Criteria An Enforcement, Investigation and Analysis Officer EIAO from Food Inspection and Inspection Service (FSIS) Field Operations (FO) performed a comprehensive assessment of the plant HACCP food safety system between 05-02 -18-07. The following noncompliance was observed by the EIAD within the HACCP system and was discussed with plant management at the exit meeting held with on 05-18-07. The generic E. coli test result chart for 2006 was not filled out as required by 9 CFR 310.25 (a) v B (4). This regulation states in part: Results shall be recorded onto a process control chart or table showing at least the most recent 13 test results, by type of livestock slaughtered. Records shall be retained at the plant for a period of 12 months and shall be available to FSIS on request. Continued noncompliance with the regulatory requirements could lead to further regulatory or administrative actions.

Regulations:
310.25(a) Criteria for verifying process control; E. coli testing. (1) Each official establishment that slaughters livestock must test for Escherichia coli Biotype 1 (E.coli) Establishments that slaughter more than one type of livestock or both livestock and poultry, shall test the type of livestock or poultry slaughtered in the greatest number. The establishment shall:
(i) Collect samples in accordance with the sampling techniques, methodology, and frequency requirements in paragraph (a)(2) of this section;
(ii) Obtain analytic results in accordance with paragraph (a)(3) of this section; and
(iii) Maintain records of such analytic results in accordance with paragraph (a)(4) of this section.
For More Information See: Subchapter A – AGENCY ORGANIZATION AND TERMINOLOGY; MANDATORY MEAT AND POULTRY PRODUCTS INSPECTION AND VOLUNTARY… (Parts 300 – 381) 2004

Code:  03J02
Violation of: 417.2(a)(1), 417.2(e), 417.5(a)(2), 417.5(a)(3)

Citation:
03J02 Recordkeeping An Enforcement, Investigation and Analysis Officer (EIAO) from Food Inspection and Inspection Service (FSIS) Field Operations (FO) performed a comprehensive assessment of the plant’s (HACCP) food safety system between 05-02 -18-07. The following noncompliances were observed by the EIAD within the HACCP system and were discussed with plant management at the exit meeting held with on 05-18-07: 
[Section Redacted by USDA]
16…Q7. The verification procedure for the calibration of thermometers indicates that thermometers will be calibrated once a week or as necessary. These noncompliances do not meet the regulatory requirements of the following regulations: 9 CFR 417.2(a) (1) which states in part: Each plant shall conduct or have conducted for it a hazard analysis to determine the food safety hazards reasonably likely to occur in the production process and identify the preventive measures the plant can apply to control those hazards. 9 CFR 417.2 (c) (4) which states in part: List the procedures and the frequencies with which the monitoring procedures will be performed. 9 CFR 417.5 (a) (2), which states in part: The written HACCP plan, including decision making documents associated with the selection and development of CCP’s and the critical limits and documentation supporting both the monitoring and verification procedures and their frequency. 9 CFR 417.5 (a) (3), which states in part: Records documenting the calibration of processing monitoring instruments. Continued non-compliances with the regulatory requirements could lead to further regulatory or administrative actions.

Regulations:
417.2(a)(1) Every official establishment shall conduct, or have conducted for it, a hazard analysis to determine the food safety hazards reasonably likely to occur in the production process and identify the preventive measures the establishment can apply to control those hazards. The hazard analysis shall include food safety hazards that can occur before, during, and after entry into the establishment. A food safety hazard that is reasonably likely to occur is one for which a prudent establishment would establish controls because it historically has occurred, or because there is a reasonable possibility that it will occur in the particular type of product being processed, in the absence of those controls.
417.2(e) Pursuant to 21 U.S.C. 456, 463, 608, and 621, the failure of an establishment to develop and implement a HACCP plan that complies with this section, or to operate in accordance with the requirements of this part, may render the products produced under those conditions adulterated.
417.5(a)(2) The written HACCP plan, including decisionmaking documents associated with the selection and development of CCP’s and critical limits, and documents supporting both the monitoring and verification procedures selected and the frequency of those procedures.
417.5(a)(3) Records documenting the monitoring of CCP’s and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment’s HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter production lot. Each of these records shall include the date the record was made.

Code:  01802
Violation of: 416.13(c)

Citation:
At 0900, I went to Mr. Robert Seugling Jr. to see if he was ready for me to conduct Pre-Operational inspection. He replied that the kill floor was ready so I entered the area and found the following deviations. First, I observed the knives, scabbards and the chains of the scabbards and found dried blood, meat and fat on all items. I further looked over the hooks and found more dried blood, fat, and hair on two hooks. I then went to Mr. Seugling and told him that a Non-Compliance report would be issued for my findings.

Regulations:
416.13(c) Each official establishment shall monitor daily the implementation of the procedures in the Sanitation SOP’s.

Code: 01802
Violation of: 416.13(c)

Citation:
01802 Pre-operational Inspection. At approximately 09:30 and after plant management informed me the kill floor was acceptable on their pre operational inspection the following non-compliance were observed: All knife blades, that are used by the employees throughout the slaughter operations had rust, fat, and ? or dried blood from the previous days’ production on them. The product contact surfaces of the hooks had dried blood and fat from the previous day’s production on them. I informed Mr. Robert Seugling of these non-compliances. All equipment was recleaned, reinspected, and found acceptable. No tag issued. These non-compliance don’t meet the regulatory requirements of 9 CFR 416.13 (cl, which states in part: Each plant shall monitor daily the implementation of the procedures in the SSOP. NR-0012-2006, dated 10-24-06 preventive measure: was either not properly implemented or not sufficient to prevent the recurrence of this non-compliance. Continued non-compliances could lead to further regulatory or administrative actions.

Regulations:
416.13(c) Each official establishment shall monitor daily the implementation of the procedures in the Sanitation SOP’s.

Code: 01B02
Violation of: 416.13(c)
 
Citation: At 091S, while performing task 01B02, I entered the kill floor. I started checking the hooks and found dried meat, fat, and dried blood on (3) three out of 10 hooks. I then completed my inspection not finding any other deviations. I went to Mr. Robert Suegling Jr. and asked to see his Pre-Op paperwork. I reviewed it and did not find my deviations recorded, only his. I brought him to the kill floor and showed him my findings and stated that a Non-Compliance Report would be issued for what I had found. This is a monitoring deviation due to the Pre Operational procedures were performed but not all deviations were found and recorded. 9CFR 416.13(c) states that each official establishment shall monitor daily the implementation of the procedures in the Sanitation SOP. This requirement has not been met.
 
Regulation: 416.13(c): (c) Each official establishment shall monitor daily the implementation of the procedures in the Sanitation SOP’s.

Code: 06D01
Violation of: 416.2(b)(1)

Citation: At approx.: 09:00 Hours, I observed in the Kill Floor area on the right side middle a hole in the floor approx.: 4 inches square\ by 2 inches deep. A Mr. Robert Seugling, HACCP Manager, VP, was informed of this noncompliance. The requirements of regulation 416.2(b)(I), were not met. This document serves as written notification that your failure to comply with regulatory requirements could result in additional regulatory or administrative action.

Regulation: 416.2(b)(1): (b) Construction. (1) Establishment buildings, including their structures, rooms, and compartments must be of sound construction, be kept in good repair, and be of sufficient size to allow for processing, handling, and storage of product in a manner that does not result in product adulteration or the creation of insanitary conditions.

Date: 23-May-06
Code: 04C02
Violation of: 313.1

Citation:
At approx. 09:15 Hours, while performing Ante mortem Inspection I found the following:
1) In the holding Pen next to the kill floor area, I found screws protruding from boards on the top of the feeder bin in three places. I also found a broken board on the feeder. Also found was some wire mesh with pointed wire to the side of the feeder. All were located on the right and left side near the entrance to the pen. In the small Holding area by the kill floor, I found a metal separation Panel that was rusty and broken and with a sharp edge on the bottom of the metal panel. The requirements of regulation 313.1(03) were not met. A Mr. Robert Seugling, Vice president, was informed of these noncompliances. No animals found to be injured by these noncompliances.

Regulations:
313.1 Livestock pens, driveways and ramps.
(a) Livestock pens, driveways and ramps shall be maintained in good repair. They shall be free from sharp or protruding objects which may, in the opinion of the inspector, cause injury or pain to the animals. Loose boards, splintered or broken planking, and unnecessary openings where the head, feet, or legs of an animal may be injured shall be repaired.
(b) Floors of livestock pens, ramps, and driveways shall be constructed and maintained so as to provide good footing for livestock. Slip resistant or waffled floor surfaces, cleated ramps and the use of sand, as appropriate, during winter months are examples of acceptable conctruction and maintenance.
(c) U.S. Suspects (as defined in § 301.2(xxx)) and dying, diseased, and disabled livestock (as defined in § 301.2(y)) shall be provided with a covered pen sufficient, in the opinion of the inspector, to protect them from the adverse climatic conditions of the locale while awaiting disposition by the inspector.
(d) Livestock pens and driveways shall be so arranged that sharp corners and direction reversal of driven animals are minimized.
[44 FR 68813, Nov. 30, 1979, as amended at 53 FR 49848, Dec. 12, 1988]

Code: 01802
Violation of: 416.13(c)

Citation:
At approx. 09:00 Hours, I observed the following:
1) In the kill floor area, I found the head rack with fat particles from the previous days operations.
2) I also found the hooks used for hanging the animals with grease and rust. A Mr. Robert Seugling, Vice President / HACCP Manager, was informed of these noncompliances. The requirements of regulation 416.13 (cl were not met. The hooks and head rack were rejected B 20521395. See NR 8-2006, dated 5/2/06, for similar noncompliance.

Regulations:
416.13(c) Each official establishment shall monitor daily the implementation of the procedures in the Sanitation SOP’s.

Code: 01802
Violation of: 416.13(c)

Citation:
At approx. 09:00 Hours, I observed in kill floor area, the viscera table was found with fat residues from the previous days operations, the table was rejected B 20521396. A Mr. R. Seugling was informed of this noncompliance. The requirements of regulation 416.13 (c) was not met. See Nr-6-2006, dated 3/21/06, for similar noncompliance. This document serves as written notification that your failure to comply with regulatory requirements could result in additional regulatory or administrative action.

Regulations:
416.13(c) Each official establishment shall monitor daily the implementation of the procedures in the Sanitation SOP’s.

Code: 06DOI
Violation of: 416.4 (b)

Citation:
At approx. 09:15 Hours, I observed in the hallway area two small box freezers with rust on the top and sides of the freezers. I also noticed in the kill floor area there was a 4 by 4 white cutting board on the floor area. A Mr. Robert 5eugling was informed of this noncompliance. The requirements of regulation 416.4(b) was not met. See Nr 3-2006, dated 2./7/06, for similar noncompliance. This document serves as written notification that your failure to comply with regulatory requirements could result in additional regulatory or administrative action.

Regulations:
416.4 (b) Non-food-contact surfaces of facilities, equipment, and utensils used in the operation of the establishment must be cleaned and sanitized as frequently as necessary to prevent the creation of insanitary conditions and the adulteration of product.

Code: 01B02
Violation of: 416.13 (c)

Citation:
At approx. 08:45 Hours, I observed in the kill floor area, the cervical station where the head rack was found with fat particles from the previous days operations. The head rack was rejected B 20521406. The requirements of regulations 416.13(c) was not met. A Mr. R. Seugling, Vice President, was informed of this noncompliance. See Nr 2- 2006, dated 2/7/2006, for similar noncompliance. This document serves as written notification that your failure to comply with regulatory requirements could result in additional regulatory or administrative action.

Regulations:
416.13 (c) Each official establishment shall monitor daily the implementation of the procedures in the Sanitation SOP’s.

Code: 01(02
Violation of: 416.16(a)

Citation:
At approx. 0915 Hours, I checked the plant’s operational sanitation records and I found that on 3/07/2006, the record for operational sanitation was not done. A Mr. R. Seugling, Vice President, was informed of this noncompliance. The requirements of regulation 416.16 (a) were not met. This document serves as written notification that your failure to comply with regulatory requirements could result in additional regulatory or administrative action.

Regulations:
416.16(a) Each official establishment shall maintain daily records sufficient to document the implementation and monitoring of the Sanitation SOP’s and any corrective actions taken. The establishment employee(s) specified in the Sanitation SOP’s as being responsible for the implementation and monitoring of the procedure(s) specified in the Sanitation SOP’s shall authenticate these records with his or her initials and the date.

Code: 03J01
Violation of: 417.4(a)(3)  
Citation: At approx.: 09:30 Hours, I checked the plant’s HACCP Program! Found that there was no reassessment for the year 2005, the last reassessment was done in 2004. The requirements of regulation 417.4(a)(3), were not met. A Mr. R. Seugling, Vice President, was informed of this noncompliance. This document serves as written notification that your failure to comply with regulatory requirements could result in additional regulatory or administrative action.

Regulations:
417.4(a)(3) Reassessment of the HACCP plan. Every establishment shall reassess the adequacy of the HACCP plan at least annually and whenever any changes occur that could affect the hazard analysis or alter the HACCP plan. Such changes may include, but are not limited to, changes in: raw materials or source of raw materials; product formulation; slaughter or processing methods or systems; production volume; personnel; packaging; finished product distribution systems; or, the intended use or consumers of the finished product. The reassessment shall be performed by an individual trained in accordance with § 417.7 of this part. The HACCP plan shall be modified immediately whenever a reassessment reveals that the plan no longer meets the requirements of § 417.2(c) of this part. (b) Reassessment of the hazard analysis. Any establishment that does not have a HACCP plan because a hazard analysis has revealed no food safety hazards that are reasonably likely to occur shall reassess the adequacy of the hazard analysis whenever a change occurs that could reasonably affect whether a food safety hazard exists. Such changes may include, but are not limited to, changes in: raw materials or source of raw materials; product formulation; slaughter or processing methods or systems; production volume; packaging; finished product distribution systems; or, the intended use or consumers of the finished product.

Code: 06001
Violation of: 416.2(a),
416.2(b)(1),
416.2(b)(2),
416.2(b)(4),
416.3(c)

Citation: During performing the scheduled procedure 01B02, I noticed the following:
1- There is noticeable rust build up on the overhead rails in the kill floor and in the finished product holding cooler; this rust was unsuccessfully covered with whitish colored food grade grease which has turned into yellowish matter after becoming “mixed in” with the rust.
2- The “U.S. retained” cage inside the holding cooler is showing heavy signs of rust.
3- There are dark spots seen inside the covers of the overhead light fixtures in the kill floor and other areas in the plant. These dark spots could be dirt particles or probably dead flies that flew off the animals killed in the area.
4- There are three barrels on the kHl floor that are used for inedible product, but none of them is marked with such designation. Mr. Robert Seugling was notified verbally and is hereby notified in writing with this NR that regulation requirements are not met.

Regulations:
416.2(a) Grounds and pest control. The grounds about an establishment must be maintained to prevent conditions that could lead to insanitary conditions, adulteration of product, or interfere with inspection by FSIS program employees. Establishments must have in place a pest management program to prevent the harborage and breeding of pests on the grounds and within establishment facilities. Pest control substances used must be safe and effective under the conditions of use and not be applied or stored in a manner that will result in the adulteration of product or the creation of insanitary conditions.
416.2(b)(1) Establishment buildings, including their structures, rooms, and compartments must be of sound construction, be kept in good repair, and be of sufficient size to allow for processing, handling, and storage of product in a manner that does not result in product adulteration or the creation of insanitary conditions.
416.2(b)(2) Walls, floors, and ceilings within establishments must be built of durable materials impervious to moisture and be cleaned and sanitized as necessary to prevent adulteration of product or the creation of insanitary conditions.
416.2(b)(4) Rooms or compartments in which edible product is processed, handled, or stored must be separate and distinct from rooms or compartments in which inedible product is processed, handled, or stored, to the extent necessary to prevent product adulteration and the creation of insanitary conditions.
416.3(c) Receptacles used for storing inedible material must be of such material and construction that their use will not result in the adulteration of any edible product or in the creation of insanitary conditions. Such receptacles must not be used for storing any edible product and must bear conspicuous and distinctive marking to identify permitted uses. 

Code: 06D01
Violation: 416.2(b)(1)

Citation: Corrective action on non-compliance 0006-2005-7312 says doors will be painted as soon as possible. Inspector was told verbally by Mr. George Rude, Sr. on 11-29-05 that entrance door was going to be replaced but at this point no door repair, painting or priming or rust removal has taken place. Failure to comply may result in further regulatory or administrative action.

Regulation: Walls, floors, and ceilings within establishments must be built of durable materials impervious to moisture and be cleaned and sanitized as necessary to prevent adulteration of product or the creation of insanitary conditions.