Arkansas Slaughterhouses

Code: 01802
Violation: 416.13(c)

Citation: At approximately 0633 hours, Friday, December 30, 2011, Preoperational Inspection-insanitary product contact surfaces: I performed Preoperational SSOP Review and Observation task after plant personnel  had inspected and released the East Packaging 1 area. I conducted lock-out tag-out and found the following noncompliance: 1) There were approximately 4 small pieces of meat tissue on the face of the bacon slicer that is next to the blade. Each piece was approximately 1/16″ in size.2) A white piece of meat tissue was found on the meat wash rack located in the meat wash sink. The piece was approximately 1/2″ in length.3) A residue was found on the inside of the bacon slicer blade. Brown residue came off on my fingers when I ran my fingers across the blade. 4) The bacon  scrap/catch pan had approximately 3 pieces of tissue inside it which were each approximately 1/16″ in size. 5) The white [redacted] board that is used to hold the bacon while the bacon  hooks are removed  had numerous pitted places on both sides of the board. The pitted spots, approximately 1/4 of the board, had brown  residue on it. [redacted] was verbally and visually notified of all the above noncompliance. I did not use any US Rejected tags because all units were cleaned in my presence and the [redacted] board  was removed from the area and replaced  with a different one. All units were reinspected and found to be acceptable.The area was released at approximately 0615 hours.

Regulation:

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

Code: 01C02
Violation: 416.l5(b), 416.16(a)

Citation: Wednesday, December 21, 2011, SSOP-corrective action and record keeping: On 11/17/2011:The plant found metal in RTE cracklings. The metal was found as the cracklings were being packaged. On 11/18/2011: When I reviewed the SSOP records, the records stated that an SSOP supplement would be attached for the metal found in the cracklings and that all cracklings were on hold . I was verbally informed that the corrective actions were: 1) Disposition of prod uct:The product would be condemned. 2) Restore sanitary conditions: The mesh screen used in the crackling dipper was thrown away. 3) Prevent the recurrence: Mesh screen would not be used again. On 12/20/2011: [redacted] and [redacted] informed me that the crackling’s HACCP Hold ribbon had been removed, and unknowingly by plant management, the cracklings had been shipped from 12/5/2011through 12/13/2011. [redacted] further explained that on 11/17/2011, when the first piece of metal was found at the beginning of the packaging process that the employees had reworked the product before they packaged it. The rework would have occurred before the cracklings were under HACCP Hold ribbon.On 12/20/2011, the establishment removed all cracklings from commerce until consultation with USDA personnel. On 12/21/2011: I notified [redacted], who reviewed all information related to the incident and it was determined that the metal was not a food safety hazard. [redacted] then consulted with the Springdale District Office and it was determined that the product was not adulterated as it had went through a rework process, but all parts of corrective action and record keeping had not been met. The following noncompliances were noted: 1) The establishment failed to maintain records docu menting corrective actions per 416.16(a).The SSOP records did not contain the SSOP supplement which [redacted], had stated that would be attached to the SSOP form, dated 11/17/2011. 2) The establishment failed to ensure appropriate disposition of product per 416.lS(b) . Corrective actionson the disposition of product were different than what I was told on 11/18/2011. On that date I was informed that the product would be cond emned. 3) The establishment failed to maintain records documenting corrective actions per 416.16(a).Corrective actions did not document the disposition of product.It was documented that the product was placed on hold, but it did not document the rework or shipping of the product. 4) The establishment failed to document on records corrective actions taken per 416.16(a).Corrective actions d id not document restoration of sanitary conditions until 12/20/2011. [redacted] documented that the metal found was from a wire mesh used on the crackling dipper and the mesh was th rown away. 5) The establishment failed to document corrective actions per 416.15(b). Corrective actions did not document measu res to prevent recurrence.

Regulation:

416.l5(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 therein or appropriate improvements in the execution of the Sanitation SOP’s or the procedures specified therein.

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: 03G02
Violation: 417.5(a)(3)

Citation: Friday, December 9, 2011, at approximately 1245 hours, Stabilization-record keeping errors: I performed a Fully Cooked-Not Shelf Stable task and reviewed the HACCP records for link sausages which had the preshipment review dated 12/9/11. The l ink sausages were fully cooked on December 8, 2011. The HACCP records indicated that the sausages were at [redacted] at 9:50am which was at the end of the cook cycle.CCP 1B for [redacted] was met per Appendix A. The sausages have a CCP for stabilization (CCP 68).The stabilization CCP’s critical limits state that [redacted] The HACCP records indicated that during the stabilization the temperatures and times of the sausages were as follows: [redacted] The following stabilization (CCP 68) record keeping noncompliance were noted : 1) The monitor “WS” wrote down 9:10am instead of 10:10am. 2) The monitor [redacted]” wrote down 9:35am instead of 10:35am.3) The person who conducted a direct observation [redacted]” wrote down 9:35am instead of 10:35am.4) On 12-8-2011, at 11:33am, [redacted] conducted a records review and did not note the record keeping errors. 5) On 12-9-2011, [redacted] conducted a preshipment review and did not note the record keeping errors. A review of all records associated with the lot of product revealed that all critical limits were met, but the times were not documented correctly. No product was affected. [redacted], was notified of the record keeping errors.

Regulation:

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: 04804
Violation: 317.2(f)

Citation: Approximately 0800 hours, Friday, November 11, 2011, General Label-missing ingredient on product label: I performed a directed Fully Cooked-Not Shelf Stable task in regards to FSIS Notice 54-11,dated 9/28/2011, Verification Activities For The Use And Labeling Of Ingredients Of Public Health Concern . I went into the RTE room and observed that the plant was going to be runn ing Arkansas Style Sausage and the labels were near the packaging area. I reviewed the label and found that sodium phosphates was not listed as an ingredient on the label. The sausage contains sodium phosphates.I notified and after he investigated it was determined that the newest batch of labels had omitted sodium phosphates. I used US Retain No.827906022 to retain five boxes of misprinted labels. I then went into the finished product cooler/shipping department noted that the Arkansas Style Sausage was correctly labeled; therefore, no product was retained.

Regulation:

317.2(f)(1) The list of ingredients shall show the common or usual names of the ingredients arranged in the descending order of predominance, except as otherwise provided in this paragraph.

Code: 01802
Violation: 416.13(c)

Citation: At approxima tely 0630 hou rs, Tuesday, November 1,2011-preoperational  inspection-insanitary product contact surface:I performed Preoperational SSOP Review and Observation task after plant personnel had inspected and released all areas for USDA inspection . I found the following noncompliance in the pump room: 1) A piece of meat tissue on the feed ing plate of the injector machine.The tissue was approximately 1/2inch in diameter.This is a product contact surface.I placed a US Reject No. 831493533 tag on the piece of equipment. 2) A yellow electrical cord attached to the ingredient scale had a black residue on it. The residue was in various places through  out the length of the cord.This is a not a product contact surface. [redacted] was verbally and visually notified of the noncompliance [redacted]  had the feeding plate and the electrical cord cleaned in my presence and upon inspection I found both of them to be acceptable and I removed the US Reject tag. The plant’s SSOP state that [redacted]

Regulation:

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

Code: 03G02
Violation: 417.5(a)(3)

Citation: At approxima tely 1300 hours, October 28, 2011-Fully Cooked-Not Shelf Stable record keeping error: I reviewed the HACCP records asssociated with the Cedar Falls Ham Loaves which were cooked on October 27, 2011, in Vat 2. The mon itoring of CCP 1b [redacted] was conducted at 11:18am and the records ind icated that a records review was con ducted at 11:18am . When I asked of [redacted], if he had performed a direct observation he informed me that it was a direct observation that he had conducted at 11:18am.The lot of product had a records review and a preshipment conducted on it and the record keeping error was not noted .I informed [redacted] that I would issue a noncompliance record for record keeping. [redacted] corrected the record keeping error.

Regulation:

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: 04804
Violation: 317.5

Citation: At approximately 1330 hou rs, September 20, 2011,General Labeling-generic label approvals not on file: I reviewed 18 different ham label approvals and found that two of the generic label approvals were not accurate.The following noncompliance were noted:  1) The Picnic Ham had a generic approval, dated 7/5/2000, with the pump listed at 18%. The Picnic Ham is actually pumped with a 25% brine. A calculation of the 25% brine revealed that it met all regulatory requirements; therefore, product was not retained. 2) The Ham Steak had a generic approval, dated 6/15/98, with the pump l isted at 25%. The Ham Steak is actually pumped with an 18% brine. A calculation of the 18% brine revealed that it met all regulatory requirements; therefore, product was not retained. [redacted], was visually and verbally notified of the labeling noncompliance. linkage:A similar noncompliance was documented on N R OLE1809082018N/1, dated 8/17/11.

Regulation:

317.5(a)(1) An official establishment or an establishment certified under a foreign inspection system, in accordance with part 327 of this subchapter, is authorized to use generically approved labeling, as defined in paragraph (b) of this section, without such labeling being submitted for approval to the Food Safety and Inspection Service in Washington or the field, provided the labeling is in accordance with this section and shows all mandatory features in a prominent manner as required in § 317.2, and is not otherwise false or misleading in any particular.

Code: 04804
Violation: 317.5

Citation: Tuesday, August 17, 2011, Spiral Sliced Ham’s generic label approval not on file: I performed a General Label task and reviewed the Spiral Sliced Ham label which was being placed on 1/2, hams in the Ready-To-Eat (RTE) department. The hams were pumped with [redacted] brine, but the label approval on file was for [redacted] brine. The establishment did not have a generic label approval for the [redacted] brine on spiral sliced hams. I reviewed the brine formulation sheet and calculated the restricted ingredients and determined that they met all regulatory requirements. [redacted] was verbally notified that a generic label approval had not been completed for a [redacted] brine and that it was a noncompliance. Upon notification of the noncompliance, completed a generic label approval. I reviewed the generic label approva l and found that it met all regulatory requirements. No product was retained.

Regulation:

317.5(a)(1) An official establishment or an establishment certified under a foreign inspection system, in accordance with part 327 of this subchapter, is authorized to use generically approved labeling, as defined in paragraph (b) of this section, without such labeling being submitted for approval to the Food Safety and Inspection Service in Washington or the field, provided the labeling is in accordance with this section and shows all mandatory features in a prominent manner as required in § 317.2, and is not otherwise false or misleading in any particular.

Code: 04804
Violation: 317.308

Citation: At approximately 1415 hours, on July 20, 2011, label has inaccurate number of servings on Nutrition Facts. I performed a general labeling task on hickory smoked bacon, 3 pound packages, and observed that the label’s Nutrition Facts listed the servings as 8 per package. A 3 pound package contains 24 servings and not the stated 8 servings. It is a regulatory requirement that the number of servings stated on a package be accurate. I used U.S.Retain No.827906031, No.827906445, No. 827906444, and No. 830372523 to retain approximately 16, 920 pounds of bacon.There was 10 full pallets and 2 partia l pallets of finished product. [redacted] was notified of the labeling noncompliance and had all of the product moved to the South Freezer where it is u nder U.S. Retain tags.

Regulation:

317.308 The label of any package of a meat or meat food product that bears a representation as to the number of servings contained in such package shall meet the requirements of § 317.2(h)(10).

Code: 03G02
Violation: 417.S(a)(3)

Citation: On Tuesday, July 12, 2011, at approximately 0610 hours, CCP [redacted]), inaccurate temperature recorded and failure of d irect observation to detect the monitor’s record keeping error. I performed a Fully Cooked-Not Shelf Stable HACCP Implementation Procedure (HIP) and used Book 1of 8, Fully Cooked Whole Muscle HACCP plan.The plant identified a microbiological food safety hazard (pathogens) as likely to occur, at the step of cooking, and has im plemented a critica l control point (CCP 1B) [redacted] The critical limit is [redacted] degree F. with a hold ing time a [redacted] seconds.

I was at smoke house 4 when I observed [redacted] take a monitoring temperature of bone-in smoked hams.I observed the dial thermometer had a reading of 158 degrees F. on the hams. I observed as [redacted] documented. [redacted] degrees F. on the CCP Record for Cooked Products.I then observed as [redacted] performed a direct observation, initialed the form to ind icate acceptable results. I informed [redacted] that the temperature was not degrees F. He looked at the thermometer again, agreed with me, and made a correction on the CCP Record for Cooked Products to reflect the actual temperature of 158 degree F.

I verbally notified [redacted], of the record keeping errors.I informed [redacted] that I would be issuing a noncompliance record.

I completed the HIP and did not find any other errors. All products met the critical limits.

Regulation:

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: 03G02
Violation: 417.2(b)

Citation: Wednesday, May 25, 2011, products not listed in HACCP plan: I performed a Fully Cooked-Not Shelf Stable HACCP Implementation Procedure and observed that two sausages, Venison and Pork with Jalapeno and Cheese Sausage and the Beef and Pork with Bacon and Cheese Sausage, were not listed in the Fully Cooked-Emu lsified HACCP Plan Book 3 of 8.It is a regulatory requ irement that the HACCP plan cover each product produced by the establishment. A review of formulation records, production records, packaging records, and SSOP records revealed that the Allergen SSOP program was implemented when the sausage products were formulated, stuffed, packaged, and labeled. [redacted] was verbally notified of the noncompliance.

Regulation:

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.

Code: 03G02
Violation: 417.2(a)(1), 417.2(a)(2), 417.4(a)(3)

Citation: Wednesday, May 4, 2011-failure to reassess for new process step and step not in flow chart: A review of the Fully Cooked-Not Shelf Stable Emulsified, Book 3 of 8, HACCP plan revealed that it did not include the step of spraying Antimicrobia l Intervention XG-940 on product casings prior to the remova l of the casing.Themit] is a blend of stabilized sodium chlorite and is approved for use under 21 CFR 173.325. The establishment has supporting documents that the [redacted] can be effectively used at [redacted] ppm.The Technical Data Sheet lists an effective pH range o [redacted]. The [redacted]. A review of the plant ‘s test results from April 4 to May 4, 2011, revealed that all tests met the ppm and pH parameters of the supporting documents. The following noncompliance were noted: 1) The plant failed to reassess the Fully Cooked Emulsified Book, 3 of 8, HACCP plan when they implemented the process.2) A review of the flow chart revealed that it did not describe the [redacted] process step. 3) The establishment did not address the [redacted] as a chemical in the hazard analysis. [redacted] was notified of the record keeping noncompliance.

Regulation:

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(a)(2) A flow chart describing the steps of each process and product flow in the establishment shall be prepared, and the intended use or consumers of the finished product shall be identified.

417.4(a)(3) Food safety hazards might be expected to arise from the following:
(i) Natural toxins;
(ii) Microbiological contamination;
(iii) Chemical contamination;
(iv) Pesticides;
(v) Drug residues;
(vi) Zoonotic diseases;
(vii) Decomposition;
(viii) Parasites;
(ix) Unapproved use of direct or indirect
food or color additives; and
(x) Physical hazards.

Code: 01001
Violation: 416.1, 416.4(b)

Citation: At approximately 0530 hours, I performed task Pre-Op SSOPWednesday, April 27, 2011, non-food contact surface-insanitary multivac 855 (bacon packaging machine): At approximately 0530 hours, I performed task Pre-Op SSOP Review and Observation after the plant completed their preoperational inspection and released the bacon area for USDA preoperational inspection. I observed on the multivac 855 that there was residue, black pepper, small pieces of bacon tissue, and strings of clear film next to the forming die. I used a white paper towel to remove some of the accumulated particles and visually and verbally notified [redacted] There was no product or food contact surface adulterated.

Regulation:

416.1 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.

416.4(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.