Delaware Slaughterhouses

Code: 01D01
Violation: 416.1, 416.2(a), 416.2(b)(3), 416.4(b)

Citation: This morning while performing pre-operational sanitation inspection prior to the start of operations and after the plants Sanitation SOP procedures I observed the following noncompliance: I observed evidence of rodent activity within the evisceration processing area in the areas between lines eviscerators and the heart pump with the visual observation of a rat, which was also observed by several of the sanitation associates.  Sanitation Superintendent was immediately notified at 0431 hours Based on this insanitary condition and potential for product adulteration, I immediately initiated a regulatory control action with the application of U.S. Reject tag #B34292562 to the evisceration area. I then requested the drain covers in these areas removed and observed poultry Viscera and intestines remained hanging inside the drain directly under the heart harvester and heart pump area. The drain covers and sides of the drains were also coated with fat and product debris. was present and observed the noncompliance.  I also observed flies in the area with one crawling on the floor and two in a drip pan, which was also observed by and 1st processing superintendent. Product was not affected by the above cited noncompliance. The rat disappeared in the vicinity of the heart pump, presumably into the floor drain, and the flies were immediately killed. After the area was thoroughly washed down and sanitized regulatory control was relinquished at 0500 hours.  Pest control issues of flies and the maintenance of drains have been discussed and documented in weekly meetings with establishment management on 5/30/12 and 6/06/12. Please see MOI’s YXA2712053030G and YXA3204062606G. Plant response included: Management response to MOI 6/06/12 has not been received at this time. Regulatory requirements 9 CFR 416.1, 416.2(a), 416.2(b)(3), and 416.4(b) were not met. Assistant Plant Manager is hereby notified in writing of the plant’s failure to comply with regulatory requirements and regulatory control actions were taken in accordance with 9 CFR 500.2(a)(1)(b) Effective measures must be implemented and documented to prevent recurrence. This document serves as written notification that your continued failure to comply with regulatory requirements could result in additional regulatory or administrative action as described in 9 CFR 500.4.

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.

416.2(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)(3) Walls, floors, ceilings, doors, windows, and other outside openings must be constructed and maintained to prevent the entrance of vermin, such as flies, rats, and mice.

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: 01D01
Violation: 416.4(b), 416.1, 416.3(a)

Citation: This morning while performing pre-operational sanitation inspection prior to the start of operations and after the plants Sanitation SOP procedures I observed the following noncompliance: While inspecting the gizzard rework table I requested the chain guard covers removed for inspection and found a gross buildup of product residues, including fat, a whole gizzard and a gizzard piece measuring approximately ¾ inch in size remained inside the covers and around the chains. These drive chains and guards attach to the sides of the gizzard skinner rollers and were not open for inspection. Based on this insanitary condition and the potential for direct product contamination, I initiated a regulatory control action, rejecting the unit for use with U.S. Reject tag #B34292565 at 0440 hours. Sanitation Supervisor was notified and observed the nonfood contact surfaces had not been cleaned at a frequency to preclude the buildup of product residues to prevent the creation of insanitary conditions and the adulteration of product. Equipment was not maintained to ensure all surfaces and parts are capable of being cleaned. Regulatory control was relinquished at 0455 hours after the unit was cleaned, sanitized, reinspected and found acceptable. Product was not affected by the above cited noncompliance. Then while inspecting the backup gizzard rework table near the chiller I found the same insanitary conditions with fat and a gross accumulation of product debris inside and around the chain cover and chain. Unit was rejected for use with U.S. Reject tag #B34292561. Sanitation Supervisor observed the insanitary condition and was notified of all regulatory actions that were taken as per 9 CFR 500.2(a)(1)(b). Regulatory control was relinquished at 0503 hours after the unit was cleaned, sanitized, reinspected and found acceptable. Product was not affected by the above cited noncompliance. Regulatory requirements 9 CFR 416.1, 416.3(a), 416.4(b) were not met. Assistant Plant Manager is hereby notified in writing of the plant’s failure to comply with regulatory requirements. Effective measures must be implemented and documented to prevent recurrence. This document serves as written notification that your continued failure to comply with regulatory requirements could result in additional regulatory or administrative action as described in 9 CFR 500.4.

Regulation:

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.

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.

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

Code: 03J04
Violation: 417.2(c)(4), 381.65(e)

Citation: While performing a zero tolerance fecal check on evisceration line at 0521 hours I observed visible fecal material on one carcass out of 10. Birds were randomly selected at CCP 3 pre-chill location. Fecal material measuring approximately 1/8 inch was located on the tip of the tail, light green in color, with a solid consistency. , Shift Manager was notified and observed this monitoring noncompliance as per 9 CFR 500.2(b) Ms notified maintenance to initiate corrective actions and had the back up washer turned on as per HACCP Plan procedures. I observed as HACCP performed a retest on this evisceration line at 0524 hours, as well as a subsequent hourly monitoring check at 0535 hours. No visible fecal material was observed. Product Disposition: The identified carcass was taken to the salvage station and reprocessed with chlorinated water in accordance with HACCP Plan procedures. Management determined the cause of the deviation as the nozzles were not positioned properly to wash the tail. Maintenance made equipment adjustments to the IOBW (Inside Outside Bird Washer) and proposed monitoring to prevent recurrence. I then verified all regulatory requirements were met, including pre-shipment review for the affected production lot and found regulatory requirements were met. There are no interventions between the pre chill location and the chiller. Poultry carcasses contaminated with visible fecal material must be prevented from entering the chill system in accordance with regulatory requirement 9 CFR 381.65(e). Regulatory requirements 9 CFR 417.2(c)(4) and 381.65(e) were not met. This is also a deviation from the critical limit of zero visible fecal contamination at CCP 3, found in CCP section, page 4 of the establishment’s HACCP Plan. , Assistant Plant Manager is hereby notified of this monitoring noncompliance and the need to implement and document effective measures to prevent recurrence. This document serves as written notification that your failure to comply with regulatory requirements could result in additional regulatory or administrative action in accordance with 9 CFR 500.4.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

Code: 01B02
Violation: 416.4(b), 416.1, 416.13(c), 416.4(a)

Citation: This morning while performing pre-operational sanitation inspection prior to the start of operations and after the plants Sanitation SOP procedures I observed the following noncompliance: While inspecting the overhead boneless breast product conveyors in Cone Deboning, I found dried yellow product residues remained on the direct product contact surfaces of the most of the flaps on conveyors 1 Area included the curved portions of the flaps that help convey product up the incline, measuring approximately 4 inches. I also found conveyors 3 4 had dried product residues across some of the flaps, as well as numerous (too numerous to count) meat and fat scraps scattered throughout the inside surfaces of the belt; especially near the incline portions. Based on this insanitary condition and potential for product contamination, I initiated a regulatory control action with the application of U.S. Reject tag #B34292544 at 0643 hours. Gwen Smack, Sanitation Supervisor and Sanitation Superintendent were immediately notified and observed the noncompliance at 0643 hours Regulatory control was relinquished at 0716 hours after conveyors were recleaned, reinspected and found acceptable. I reviewed the Pre-Operational SSOP Inspection Form and found Area 5, Unit 54 Overhead Belts were included in the random inspection and area was relased at 6:20. Product was not affected by the above cited noncompliance. Regulatory requirements 9 CFR 416.13(c), 416.4(a), 416.4(b), and 416.1 were not met as well as SSOP procedures found on page 1, section 1. , Assistant Plant Manager is hereby notified in writing of the plant’s failure to comply with regulatory requirements and that a regulatory control action was taken as per 9 CFR 500.2(a)(1)(b). Effective measures must be implemented and documented to prevent recurrence. This document serves as written notification that your failure to comply with regulatory requirements could result in additional regulatory and or administrative action as described in 9 CFR 500.4.

Regulation:

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.

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.

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

416.4(a) 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: 03J04
Violation: 381.65(e), 417.2(c)(4)

Citation: While performing a zero tolerance fecal check on evisceration line at 10:51 hours, I observed visible fecal material on the outside of one of  the ten birds carcass , randomly selected at the pre chill location. Fecal material was dark brown in color with a semi solid consistency, approximately1/4 inch in size ( circled ) located outside of the carcass on the right drumstick. Shift Manager Ms was immediately notified of this monitoring noncompliance. The back up wash cabinets on this evisceration line was turned on to initiate corrective actions in accordance with HACCP Plan procedures. I observed as HACCP Tech Mrs did a retest at 10:56 hours and no visible fecal material was observed.  The contaminated bird was taken to the reprocessing area and washed in chlorinated water. I reviewed Pre-Chill Fecal Contamination Log for CCP 3 and found the last acceptable check was performed at 10:39 hours, authenticated with initials I verified all records and procedure on the affected production lot and found all regulatory requirements were met, including pre-shipment review. Since there are no interventions between the pre chill location and the chiller it is a probability that the contaminated carcass would have entered into the chill system. Poultry carcasses contaminated with visible fecal material must be prevented from entering the chill system in accordance with 9 CFR 381.65(e). Regulatory requirements 9 CFR 381.65(e), and 417.2(C)(4) were not met. This is also a deviation from the critical limit of zero visible fecal material at CCP 3. Slaughter hazard analysis states: HACCP monitoring is to verify effectiveness of zero tolerance criteria. See FSIS Regulation 381.65(e). Assistant Plant Manager Mr. is hereby notified of this monitoring noncompliance and the need to implement and document effective measures to prevent recurrence.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

Code: 01B02
Violation: 416.13(c), 416.4(b), 416.1, 416.2(b)(1), 416.4(a)

Citation: This morning while performing pre-operational sanitation inspection prior to the start of operations and after the plants Sanitation SOP procedures I observed the following noncompliance: While inspecting Inside Outside Bird Washer #2 on evisceration line I found the nonfood contact surfaces of the overhead drive wheel had a crusty buildup consisting of feathers, fat and grease around the entire top and bottom surfaces. I also observed the water supply pipes directly over the unit also had black grease and spattered product residues. Based on this insanity condition and potential for product contamination, I initiated a regulatory control action with the application of U.S. Reject tag #B34292521 at 0432 hours. Debroah Richards, Sanitation Supervisor was immediately notified and observed the noncompliance at 0432 hours. Regulatory control was relinquished at 0450 hours after unit was recleaned, reinspected and found acceptable. Then while inspecting the back up washer on evisceration line I observed an overhead box fan cage and supporting chains that were extremely rusty. Based on this insanitary condition unit was rejected for use with U.S. Reject tag #B34292541 at 0440 hours. Sanitation Supervisor and Maintenance Supervisor were immediately notified and observed the noncompliance at 0440 hours. Maintenance covered the rusty overhead structures with plastic as a temporary measure and regulatory control was relinquished at 0453 hours. Then while inspecting the marination incline product conveyor in the marination room, I found numerous, (too numerous to count), paint flakes measuring from pinpoint to 1/4 inch in size on the direct product surfaces of the product conveyor as well as the inside and outside stainless side walls. This conveyor is in close proximity to an adjacent wall that had flaking paint. I also observed a whole wing flat remained in the drip pan directly under the conveyor. Based on this insanitary condition and potential for product contamination I initiated a regulatory control action with the application of U.S. Reject tag #B34292542 at 0700 hours. Sanitation Supervisor was immediately notified and observed the noncompliance at 0700 hours. Regulatory control was relinquished at 0726 hours after maintenance hung plastic along the wall as a temporary measure; unit was recleaned, reinspected, and found acceptable. Product was not affected by the above cited noncompliance. Regulatory requirements 9 CFR 416.13(c), 416.2(b)(1), 416.4(a), 416.4(b), and 416.1 as well as SSOP procedures found in section 1 were not met. Assistant Plant Manager is hereby notified in writing of the plant’s failure to comply with regulatory requirements and that a regulatory control action was taken as per 9 CFR 500.2(a)(1)(b). Effective measures must be implemented and documented to prevent recurrence. This document serves as written notification that your failure to comply with regulatory requirements could result in additional regulatory and or administrative action as described in 9 CFR 500.4.

Regulation:

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

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.

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.

416.2(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.

416.4(a) 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: 01C02
Violation: 416.13(c), 416.4(d)

Citation: While performing operational sanitation in the salvage reprocessing area at 07:45 hours I observed piles of product including breasts, wings, legs, and thighs in the floor. The salvage totes were overflowing and the product was falling directly onto the floor and onto a drain cover. I also observed in this area that the cones for cutting up the chickens were full causing several whole chickens to fall onto the drain cover. I initiated regulatory control as per Title 9 CFR Section 500.2(a)(1) by retaining the affected product with US Retain tag # B34292918. I notified Ms. Shift Manager who was present and did observe the establishments failure to comply with the regulatory requirements of Title 9 CFR Section 416.13(c), 416.4(d), and 416.1. This is also a deviation from # 5 parts A and B of the establishments own Sanitation SOP’s which deals with the handling of product at the salvage station. I observed as the affected product was condemned by the establishment and I relinquished regulatory control at 07:53 hours after sanitary conditions had been restored. This document serves as written notification to Mr. Plant Manager that failure to comply with regulatory requirements could result in additional regulatory or administrative actions.

Regulation:

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

416.4(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

Code: 03J04
Violation: 417.2(c)(4), 381.65(e)

Citation: At 1042, I randomly selected ten carcasses after the final washer from evisceration line to perform a fecal check. I observed a smear of visible fecal material on the leg area of the 7th bird I checked of ten. The fecal material was less that 1/8th of an inch in diameter, greenish in color and of a semi-solid consistency. (Shift Manager) was notified and observed this monitoring noncompliance. Ms. had the back up washer turned on to initiate corrective action as per the HACCP plan procedure for CCP #3. I observed as HACCP Tech performed a retest on evisceration line and no visible fecal material was observed. The fecal contaminated carcass was taken to the salvage station for reprocessing with chlorinated water as per the HACCP procedure at this CCP. I reviewed HACCP records on the pre-chill/fecal contaminant log for CCP #3 and found the last acceptable check was performed at 0910, authenticated with initials . Management determined the cause of the deviation to be the carcasses being crossed on the line while going through the final washer cabinet plastic curtains. Ms. informed me that the curtains were trimmed and employees at the final trim location would be trained to prevent carcasses from going to the wash cabinet crossed. Ms. also informed me that a Management meeting would be held after work to discuss recent fecal failures. I then verified all regulatory requirements were met including pre-shipment review for the affected production lot and found all regulatory requirements were met. There is no intervention between the pre-chill location and the chill system. Poultry carcasses contaminated with visible fecal material must be prevented from entering the chill system. The requirements of Meat and Poultry Regulation 417.2(c) (4) and 381.65(e) were not met. This is also a deviation from the critical limit for zero tolerance for visible fecal contamination at CCP #3, found in the CCP section of the plants HACCP plan on page #4. Mr. (Assistant Plant Manager) is hereby notified of this monitoring noncompliance and the need to implement and document effective preventive measures. This document serves as written notification that your failure to comply with regulatory requirements could result in additional regulatory or administrative action.

Regulation:

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

Code: 03J04
Violation: 381.65(e), 417.2(c)(4)

Citation: While performing a Finished Product Standards check on evisceration line at 0532 hours, I observed visible fecal material on one carcass out of 10. Birds were randomly selected at CCP 3 pre-chill location. Fecal material was located on the uropygial gland (oil gland) area on the back side of the tail and on the front of the right leg. Fecal material was dark green in color, solid consistency with a distinct fecal odor, measuring approximately 1/4 x 1/2 inch glob on the tail, and a 1 1/2 inch smear on the leg. Shift Manager was notified and observed this monitoring noncompliance at 0532 hours as per 9 CFR 500.2(b). Ms. notified maintenance to initiate corrective actions and had the back up washer turned on as per HACCP Plan procedures. I observed as HACCP performed a retest on this evisceration line and no visible fecal material was observed. Product Disposition: The identified carcass was taken to the salvage station and reprocessed with chlorinated water in accordance with HACCP Plan procedures. I reviewed the CCP 3 HACCP record, Pre-Chill Fecal Contamination Log, and found the last acceptable check was performed at 5:27, authenticated with initials Management determined the cause of the deviation as birds misfeeding into equipment. Maintenance made equipment adjustments and Ms added an employee to monitor the birds on this evisceration line as a temporary preventive measure. I then verified all regulatory requirements were met, including pre-shipment review for the affected production lot and found regulatory requirements were met. There are no interventions between the pre chill location and the chiller. Poultry carcasses contaminated with visible fecal material must be prevented from entering the chill system in accordance with regulatory requirement 9 CFR 381.65(e). Regulatory requirements 9 CFR 417.2(c)(4) and 381.65(e) were not met. This is also a deviation from the critical limit of zero visible fecal contamination at CCP 3, found in CCP section, page 4 of the establishment’s HACCP Plan. Assistant Plant Manager is hereby notified of this monitoring noncompliance and the need to implement and document effective measures to prevent recurrence. This document serves as written notification that your failure to comply with regulatory requirements could result in additional regulatory or administrative action in accordance with 9 CFR 500.4.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

Code: 03J04
Violation: 381.65(e), 417.2(c)(4)

Citation: While performing a zero tolerance fecal check on evisceration line #1 at 10:40 hours, I observed visible fecal material inside one of the ten birds carcass , randomly selected at the pre chill location. Fecal material was dark brown in color with a semi solid consistency, approximately 1 inch in size ( circled ) located inside the left side of the keel bone of the carcass. Shift Manager Ms was immediately notified of this monitoring noncompliance. The back up wash cabinets on this evisceration line was turned on to initiate corrective actions in accordance with HACCP Plan procedures. I observed as HACCP Tech Mrs. performed a retest at 10:43 hours and no visible fecal material was observed. The contaminated bird was taken to the reprocessing area and washed in chlorinated water. I reviewed Pre-Chill Fecal Contamination Log for CCP 3 and found the last acceptable check was performed at 09:32 hours, authenticated with initials (TD). I verified all records and procedure on the affected production lot and found all regulatory requirements were met, including pre-shipment review. Since there are no interventions between the pre chill location and the chiller it is probable that the contaminated carcass would have entered into the chill system. Poultry carcasses contaminated with visible fecal material must be prevented from entering the chill system in accordance with 9 CFR 381.65(e). Regulatory requirements 9 CFR 381.65(e), and 417.2(C)(4) were not met. This is also a deviation from the critical limit of zero visible fecal material at CCP 3. Slaughter hazard analysis states: ” HACCP monitoring is to verify effectiveness of zero tolerance criteria. See FSIS Regulation 381.65(e). Assistant Plant Manager Mr. is hereby notified of this monitoring noncompliance and the need to implement and document effective measures to prevent recurrence.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

Code: 01D01
Violation: 416.2(h)(3), 416.3(a), 416.1, 416.4(b)

Citation: This morning while performing pre-operational sanitation inspection prior to the start of operations and after the plants Sanitation SOP procedures I observed the following noncompliance: While inspecting the USDA condemn barrels in Evisceration I found 5 barrels had cracks and or holes in the bottom. These barrels were set in place at the 7 inspection stations in preparation for USDA condemned carcasses from post mortem inspection. Barrels were not maintained in a good state of repair to avoid creating insanitary conditions. Sanitation Supervisor was immediately notified and observed the noncompliance at 0420 hours. Upon notification, Ms. had the barrels removed from the area. This issue was discussed and documented at the weekly meeting with plant management on 2/23/12. Management was reminded that condemn barrels must be leak proof. Plant response: “Sanitation and evisceration management will remove the damaged USDA barrels.” Then while inspecting the Hopper Incline belts in Cut Up at 0636 hours, I found product residues all along the underneath framework and guide bars of both product conveyors. There was a gross accumulation of meat, skin, and fat measuring at least one inch packed under and between hard to reach areas at the ends of the conveyors. Based on these insanitary conditions and potential for product contamination, I initiated a regulatory control action with the application of U.S. Reject tag #B34292522 at 0636 hours. , Sanitation Supervisor was immediately notified and observed the noncompliance. Sanitation Superintendent was also notified and observed the nonfood contact surfaces had not been cleaned at a frequency to preclude the buildup of product residues to prevent the creation of insanitary conditions and the adulteration of product. Equipment was not maintained to ensure all surfaces and parts are capable of being cleaned. Regulatory control was relinquished at 0713 hours after unit was cleaned, sanitized, reinspected and found acceptable. Product was not affected by the above cited noncompliance. Regulatory requirements 9 CFR 416.2(h)(3), 416.3(a), 416.4(b), and 416.1 were not met. Assistant Plant Manager is hereby notified in writing of the plant’s failure to comply with regulatory requirements and that a regulatory control action was taken as per 9 CFR 500.2(a)(1)(b). Effective measures must be implemented and documented to prevent recurrence. This document serves as written notification that your failure to comply with regulatory requirements could result in additional regulatory and or administrative action as described in 9 CFR 500.4.

Regulation:

416.2(h)(3) Refuse receptacles must be constructed and maintained in a manner that protects against the creation of insanitary conditions and the adulteration of product.

416.3(a) Equipment and utensils used for processing or otherwise handling edible product or ingredients must be of such material and construction to facilitate thorough cleaning and to ensure that their use will not cause the adulteration of product during processing, handling, or storage. Equipment and utensils must be maintained in sanitary condition so as not to adulterate product.

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.

Code: 03J04
Violation: 381.65(e), 417.2(c)(4)

Citation: While performing a zero tolerance fecal check on evisceration line at 1050 hours I observed visible fecal material on one carcass out of 10. Birds were randomly selected at CCP 3 pre-chill location. Fecal material measuring approximately1/4 inch was located on the inside of the right leg, light green in color, consisting of a semi solid glob . Supervisor was immediately notified and observed this monitoring noncompliance as per 9 CFR 500.2(b). Mr. notified maintenance to initiate corrective actions and had the back up washer turned on as per HACCP Plan procedures. I observed as HACCP performed a retest on this evisceration line and no visible fecal material was observed. Product Disposition: The identified carcass was taken to the salvage station and reprocessed with chlorinated water in accordance with HACCP Plan procedures. I reviewed the CCP 3 HACCP record, Pre-Chill Fecal Contamination Log, and found the last acceptable check was performed at 10:43, authenticated with initials I then verified all regulatory requirements were met, including pre-shipment review for the affected production lot and found regulatory requirements were met. There are no interventions between the pre chill location and the chiller. Poultry carcasses contaminated with visible fecal material must be prevented from entering the chill system in accordance with regulatory requirement 9 CFR 381.65(e). Regulatory requirements 9 CFR 417.2(c)(4) and 381.65(e) were not met. This is also a deviation from the critical limit of zero visible fecal contamination at CCP 3, found in CCP section, page 4 of the establishment’s HACCP Plan. Assistant Plant Manager is hereby notified of this monitoring noncompliance and the need to implement and document effective measures to prevent recurrence. This document serves as written notification that your failure to comply with regulatory requirements could result in additional regulatory or administrative action in accordance with 9 CFR 500.4.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits; 

Code: 03J04
Violation: 381.65(e), 417.2(c)(4)

Citation: While performing a finished product standards check on evisceration line at 0515 hours I observed visible fecal material on one carcass out of 10. Birds were randomly selected at CCP 3 pre-chill location. Fecal material was located on the kidneys at the end of an attached intestine, measuring approximately 1/8 inch, green in color with a semi- solid consistency. Evisceration Supervisor was immediately notified and observed this monitoring noncompliance at 0515 hours as per 9 CFR 500.2(b). Corrective actions were initiated according to the HACCP Plan with the activation of the back up washer. Product Disposition: The identified carcass was taken to the salvage station and reprocessed with chlorinated water in accordance with HACCP Plan procedures. I reviewed the CCP 3 HACCP record, Pre-Chill Fecal Contamination Log, and found the first hourly monitoring check had not been performed yet. I observed HACCP Tech perform a retest on this evisceration line at 0518 hours, as well as the first monitoring check at 0549 hours, and no visible fecal material was observed. The cause of the deviation was identified as poor job performance by the back up vent cutters and Mr. proposed retraining and monitoring the back up vent cutters as a preventive measure. I then verified all regulatory requirements were met; including pre-shipment review for the affected production lot, and found regulatory requirements were met. There are no interventions between the pre chill location and the chiller. Poultry carcasses contaminated with visible fecal material must be prevented from entering the chill system in accordance with regulatory requirement 9 CFR 381.65(e). Regulatory requirements 9 CFR 417.2(c)(4) and 381.65(e) were not met. This is also a deviation from the critical limit of zero visible fecal contamination at CCP 3, found in CCP section, page 4 of the establishment’s HACCP Plan. Assistant Plant Manager is hereby notified of this monitoring noncompliance and the need to implement and document effective measures to prevent recurrence. This document serves as written notification that your failure to comply with regulatory requirements could result in additional regulatory or administrative action in accordance with 9 CFR 500.4.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits; 

Code: 01C02
Violation: 416.4(d), 416.13(c)

Citation: At 0743, I observed operational sanitation noncompliance in the thigh debone department. I observed as an employee returned from her break and picked up a yellow 14X24, square inch foot grate from the soiled floor and carried the foot grate to her work station at the thigh debone trim table. She had white cloth gloves in her other hand. She stood on the grate and put on her cloth gloves on each hand. Casually she reached into her left boot and pulled out plastic gloves and put them over her cloth gloves. She then grabbed thigh meat from the trim table and commenced trimming thigh product. Ms. (Shift Manager) was walking by, so I notified her of the operational sanitation noncompliance. Thigh debone operations were stopped and US reject tag # B 292520 was applied to the trim table. Ms. (Thigh Debone Supervisor) was notified. Ms. instructed designated employees to remove the thigh product(s) from the trim table and transport the product to the wash station. Three totes of thigh product were retained with US retain tag # B 292516. The requirements of Meat and Poultry Regulations 416.1, 416.13 (c) and 416.4 (d) were not met as well as requirements in the Plant’s SSOP for Operation Sanitation in 2nd Processing on page 6, sec. (b). It states Mr. (Evisceration Supervisor) informed me at 0753 that the trim table had been cleaned, sanitized and ready for inspection. Mr. (1st Processing Superintendent) informed me that only floor men will be allowed to handle foot grates and that all employees in thigh debone would be retrained on sanitizing gloves prior to returning from breaks. He also ensured me that employee responsible would be disciplined and reminded not to keep gloves in her work boots. At 0759, after inspection was completed, thigh debone was acceptable and regulatory control on the trim table was released. At 0840, I was informed by Ms that thigh product(s) in all (3) totes had been reconditioned and ready for inspection. I randomly inspected thighs from all (3) totes and product(s) were released as acceptable at 0847. Mr. (Assistant Plant Manager) in hereby notified in writing with this NR for operational sanitation noncompliance in thigh debone department. Effective preventive measure must be implemented and documented to prevent recurrence. This document serves as written notification that your failure to comply with regulatory requirements could result in additional regulatory and/or administrative action.

Regulation:

416.4(d)  Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

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

Code: 03J04
Violation: 381.65(e)

Citation: While performing a zero tolerance fecal check on evisceration line at 0626 hours, I observed non compliance of visible fecal material on one carcass out of 10, randomly selected at the pre chill location. This check is performed after the final washer. Fecal material was dark brown in color pasty consistency and approximately 1/2 inch in size located on the right leg hock covering it. Supervisor Mr. was immediately notified of this monitoring noncompliance. Mr. had the back up wash cabinet on this evisceration line turned on to initiate corrective actions in accordance with HACCP Plan procedures. The affected carcass was taken to the reprocessing area to be washed in chlorinated water. I observed as QA Tech performed a retest at 06:35 hours and no visible fecal material was observed. I reviewed Pre-Chill Fecal Contamination Log for CCP 3 and found the last acceptable check was performed at 0601 hours authenticated with initials ( . All regulatory requirements including pre-shipment review were verified and found to be acceptable. Since there are no interventions between the pre chill location and the chiller it is probable that the contaminated carcass would have entered into the chill system. Poultry carcasses contaminated with visible fecal material must be prevented from entering the chill system in accordance with 9 CFR 381.65(e). Regulatory requirements 9 CFR 381.65(e), and 417.2(c) (4) were not met. This is also a deviation from the critical limit of zero visible fecal material at CCP 3, found in CCP section, page 4 of the establishment’s HACCP Plan. Slaughter hazard analysis states Mr. Assistant Plant Manager is hereby notified of this monitoring noncompliance and the need to implement and document effective measures to prevent recurrence. This document serves as written notification that your failure to comply with regulatory requirements could result in additional regulatory or administrative action.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

Code: 03J04
Violation: 381.65(e), 417.2(c)(4)

Citation: While performing a zero tolerance fecal check on reprocessed whole birds at 0923 hours, I observed visible fecal material on one carcass out of 10. Birds were randomly selected from a bin of birds that had been released by HACCP at 9:15. Fecal material was located on the pelvic muscle just inside the tail on the left side of the spine, measured approximately 1/4 inch by 1/4 inch, had a semi-solid consistency, and was light green in color. Supervisor was notified at 0923 hours of the monitoring noncompliance and observed the fecal material as per 9 CFR 500.2(b). I observed as corrective actions were initiated by the HACCCP Technician, including retaining the bin in which the fecal material was found. Product Disposition: The identified carcass was reprocessed with chlorinated water in accordance with the HACCP Plan procedures. I reviewed the CCP 1(a) HACCP record, Whole Bird Reprocessing Fecal Contamination Log, and found the bin had been checked, found acceptable and released, authenticated with initials I then verified all regulatory requirements were met, including pre-shipment review for the affected production lot and found regulatory requirements were met. In response to the deviation, Mr. proposed retraining to address the cause of employee error, as well as performing a 100% monitoring recheck of any product bin the employee checks in the salvage process.There are no interventions between salvage reprocessing and the chiller. Reprocessed whole birds are transported to the chiller in stainless bins and conveyed into the chill system after being released by production and HACCP. Poultry carcasses contaminated with visible fecal material must be prevented from entering the chill system in accordance with regulatory requirements 9 CFR 381.65(e). Regulatory requirements 417.2(C)(4) and 381.65(e) were not met. This is also a deviation from the critical limit of zero visible fecal contamination at the . Similar noncompliance is documented with NR YXA071211720N / 1. Cause of deviation:” .” Establishment proposed preventive measures included: Employee was disciplined according to company policy. Employee was retrained for whole bird reprocessing. In addition, employees have been reminded to not fill the bin completely to allow for more thorough monitoring. (1/23/12 to 1/27/12) Findings of monitoring will be recorded on Preventive measures were implemented but ineffective in preventing recurrence. Assistant Plant Manager is hereby notified in writing of this monitoring noncompliance and the need to implement and document effective measures to prevent recurrence, as was discussed with management in the weekly meeting today. This document serves as written notification that your continued failure to comply with regulatory requirements could result in additional regulatory and or administrative action in accordance with 9 CFR 500.4.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

Code: 03J04
Violation: 417.2(c)(4), 381.65(e)

Citation: While performing a zero tolerance fecal check on reprocessed whole birds at 1127 hours, I observed visible fecal material on one carcass out of 10. Birds were randomly selected from a bin of birds that had been released by HACCP at 11:14 and were in the process of being placed on the whole bird conveyor and conveyed into the chill system. I requested the tank to be rolled back to the salvage area and found fecal material measuring approximately 1 inch by ½ inch was located inside the breast, had a semi-solid consistency, light green color. Supervisor and 1st Shift Manager were immediately notified at 1127 hours of the monitoring noncompliance and observed the fecal material as per 9 CFR 500.2(b). I observed as corrective actions were initiated by the HACCCP Technician, including retaining the bin in which the fecal material was found. Product Disposition: The identified carcass was reprocessed with chlorinated water in accordance with the HACCP Plan procedures. I reviewed the CCP 1(a) HACCP record, Whole Bird Reprocessing Fecal Contamination Log, and found the bin had been checked, found acceptable and released, authenticated with initials I then verified all regulatory requirements were met, including pre-shipment review for the affected production lot and found regulatory requirements were met. There are no interventions between salvage reprocessing and the chiller. Poultry carcasses contaminated with visible fecal material must be prevented from entering the chill system in accordance with regulatory requirements 9 CFR 381.65(e). Regulatory requirements 417.2(C)(4) and 381.65(e) were not met. This is also a deviation from the critical limit of zero visible fecal contamination at the in the establishment’s HACCP Plan found in the CCP section, page 1. In response to the deviation, Ms. proposed retraining to address the cause of employees not performing job duties as previously trained, as well as adjustments in the management hold monitoring process. Similar noncompliance is documented with NR YXA2413011304N /1. Cause of deviation: Poor job performance-Line Leader did not perform job duties as perviously trained. Establishment proposed preventive measures included: Findings of monitoring will be recorded on Preventive measures were implemented but ineffective in preventing recurrence. Assistant Plant Manager is hereby notified of this monitoring noncompliance and the need to implement and document effective measures to prevent recurrence. This document serves as written notification that your continued failure to comply with regulatory requirements could result in additional regulatory and or administrative action.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

Code: 03J04
Violation: 417.2(c)(4), 381.65(e)

Citation: While performing a zero tolerance fecal check on reprocessed whole birds I observed visible fecal material on one carcass out of 10. Birds were randomly selected from a bin of birds that had been released by HACCP and were in the process of being placed on the whole bird conveyor and conveyed into the chill system. Fecal material was located in several places, including a light brown smear inside the breast measuring approximately 2 inches by 2 inches, and a semi-solid dark brown glob along the spine measuring approximately 1/8 inch x ½ inch in length. Supervisor and 1st Shift Manager were immediately notified at 1039 hours of the monitoring noncompliance and observed the fecal material as per 9 CFR 500.2(b). I observed as corrective actions were initiated by the HACCCP Technician, including retaining the bin in which the fecal material was found. Product Disposition: The identified carcass was taken to the salvage station and reprocessed with chlorinated water in accordance with the HACCP Plan procedures. I reviewed the CCP 1(a) HACCP record, Whole Bird Reprocessing Fecal Contamination Log, and found the last acceptable check was performed at 10:25, 10:26, and 10:27 with 3 bins released, authenticated with initials I then verified all regulatory requirements were met, including pre-shipment review for the affected production lot and found regulatory requirements were met. There are no interventions between salvage reprocessing and the chiller. Poultry carcasses contaminated with visible fecal material must be prevented from entering the chill system in accordance with regulatory requirements 9 CFR 381.65(e). Regulatory requirements 417.2(C)(4) and 381.65(e) were not met. This is also a deviation from the critical limit of zero visible fecal contamination at the in the establishment’s HACCP Plan found in the CCP section, page 1. Assistant Plant Manager is hereby notified of this monitoring noncompliance and the need to implement and document effective measures to prevent recurrence. This document serves as written notification that your failure to comply with regulatory requirements could result in additional regulatory and or administrative action.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

Code: 03J04
Violation: 381.65(e)

Citation: While performing a zero tolerance fecal check on evisceration line at 11:11 hours, I observed visible fecal material on one carcass out of 10, randomly selected at the pre chill location. Fecal material was dark brown in color with a semi solid consistency, approximately ½ inch in size located in three spots spread over the vent area down into the back of the bird, there was a portion of intestine approximately 4 in long curl in the area. Supervisor Ms was immediately notified of this monitoring noncompliance. The back up wash cabinet on this evisceration line was turned on to initiate corrective actions in accordance with HACCP Plan procedures. I observed as HACCP Tech Mrs. performed a retest at 11: 19 hours and no visible fecal material was observed. I reviewed Pre-Chill Fecal Contamination Log for CCP 3 and found the last acceptable check was performed at 10:36 hours, authenticated with initials . I verified all recordsand procedure on the affected production lot and found all regulatory requirements were met, including pre-shipment review. Since there are no interventions between the pre chill location and the chiller it is probable that the contaminated carcass would have entered into the chill system. Poultry carcasses contaminated with visible fecal material must be prevented from entering the chill system in accordance with 9 CFR 381.65(e). Regulatory requirements 9 CFR 381.65(e), and 417.2(C)(4) were not met. This is also a deviation from the critical limit of zero visible fecal material at CCP 3, found in CCP section, page 4 of the establishment’s HACCP Plan. Slaughter hazard analysis states: HACCP monitoring to verify effectiveness of zero tolerance criteria. See FSIS regulation 381.65(e). Assistant Plant Manager Mr. is hereby notified of this monitoring noncompliance and the need to implement and document effective measures to prevent recurrence.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

Code: 01B02
Violation: 416.1, 416.3(a), 416.13(c), 416.4(d)

Citation: This morning I performed pre-operational sanitation inspection (review and observation component) after completion of the pre-operational inspection by the plant associate and after performing lock-out. At 0442 hours, I observed 4 pairs of white boots on a rack in the foyer to the ice house. I inspected the boots and all 8 were visibly soiled with blackened unidentified foreign material. I observed UFM in cracks and cervices on all boots. I rubbed the blackened material with my hands and the substance smeared from the boots onto my hands. My observation was made after plant’s pre-operational sanitation associate inspected the area and released the area. Employees assigned to work in the ice house uses the white boots from the rack in the foyer to maneuver around in the ice house. During operations, employees stands directly in the ice wearing the white boots. Ice is readily used from the ice house to chill raw carcasses. The plant’s SSOP states, Based on the probability of cross contamination from the soiled boots, (Sanitation Supervisor) was notified and regulatory control action was taken by tagging all 4 pairs of boots with US reject tag # B292518. (Shift Manager) arrived in the area and elected to dispose of all the white boots into the trash dumpster. Regulatory control was released. No product was involved. Ms. said that she would document preventive measures on the response sheet generated from this noncompliance. The requirements of Meat and Poultry Regulations 416.13 (c), 416.1, 416.3(a) and 416.4(d) were not met. (Plant Manager) is hereby notified of this failure to comply with regulatory requirements and the need to implement and document effective measures to prevent recurrence.

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.

416.3(a) Equipment and utensils used for processing or otherwise handling edible product or ingredients must be of such material and construction to facilitate thorough cleaning and to ensure that their use will not cause the adulteration of product during processing, handling, or storage. Equipment and utensils must be maintained in sanitary condition so as not to adulterate product.

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

416.4(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

Code: 04A06
Violation: 381.84, 381.79

Citation: This morning at the salvage reprocessing station I watched as an employee was in the process of salvaging a poultry carcass with a longitudinal cut down the back, identifying the USDA inspector determined during post mortem inspection that the carcass was to be destined for Air Sac Salvage. I watched as both whole wings were salvaged, instead of removal from the radius wing joint as described in the establishment’s airsacculitis salvage procedure. These wings were then tossed into the wholesome product salvage totes. Plant procedure states: I immediately initiated a regulatory control action rejecting salvage operations with U.S.Reject tag #B34292631. One tote of salvage wings was retained with U.S.Retain tag #B34292632 at 0532 hours. Shift Manager and Supervisor was notified and observed the noncompliance. Management opted to condemn the affected product. Regulatory control was relinquished after Ms. had employees retrained and proposed keeping Supervision in the salvage area to monitor salvage operation procedures for the rest of the day. Regulatory requirements 9 CFR 381.79 and 381.84 were not met as well as the establishments salvage procedure. , Acting Plant Manager is hereby notified of the establishment’s failure to comply with regulatory requirements and that the official control action was initiated as per Rules of Practice 9 CFR 500.2(a)(1)(2)(b). This document serves as written notification that your failure to comply with regulatory requirements could result in additional regulatory and or administrative action in accordance with 9 CFR 500.4.

Regulation:

381.84 Carcasses of poultry with evidence of extensive involvement of the air sacs with airsacculitis or those showing airsacculitis along with systemic changes shall be condemned. Less affected carcasses may be passed for food after complete removal and condemnation of all affected tissues including the exudate.

381.79 Each carcass and all organs and other parts of carcasses which are found to be not adulterated shall be passed for human food.

Code: 03J04
Violation: 417.2(c)(4), 381.65(e)

Citation: While performing a zero tolerance fecal check on evisceration line 1 at 1048 hours I observed visible fecal material on one carcass out of 10. Birds were randomly selected at CCP 3 pre-chill location. Fecal material was located inside the back along the spine, measuring approximately 1/2 inch in length by 1/4 inch, brownish green, solid consistency. Shift Manager was notified and observed this monitoring noncompliance as per 9 CFR 500.2(b). notified maintenance to initiate corrective actions and had the back up washer turned on as per HACCP Plan procedures. I observed as HACCP performed a retest on this evisceration line and no visible fecal material was observed. Product Disposition: The identified carcass was taken to the salvage station and reprocessed with chlorinated water in accordance with HACCP Plan procedures. I reviewed the CCP 3 HACCP record, Pre-Chill Fecal Contamination Log, and found the last acceptable check was performed at 10:41, authenticated with initials . I then verified all regulatory requirements were met, including pre-shipment review for the affected production lot and found regulatory requirements were met. There are no interventions between the pre chill location and the chiller. Poultry carcasses contaminated with visible fecal material must be prevented from entering the chill system in accordance with regulatory requirement 9 CFR 381.65(e). Regulatory requirements 9 CFR 417.2(c)(4) and 381.65(e) were not met. This is also a deviation from the critical limit of zero visible fecal contamination at CCP 3, found in CCP section, page 4 of the establishment’s HACCP Plan. Assistant Plant Manager is hereby notified of this monitoring noncompliance and the need to implement and document effective measures to prevent recurrence. This document serves as written notification that your failure to comply with regulatory requirements could result in additional regulatory or administrative action in accordance with 9 CFR 500.4.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

Code: 01D01
Violation: 416.4(d), 416.4(a), 416.1

Citation: This morning at start-up, I observed sanitation performance standard noncompliance for sanitary operations. At 0506, I observed small particles of dried up blood (<1/8 in), remnants of poultry meat particles(<1/8 in) and a greasy residual from previous day operation inside and outside the gray parks buckets used for evisceration salvage parts on evisceration line including the final trimmer’s bucket. The buckets were set up at trimmer’s stations ready for use. Ms. (Shift Manager) was notified immediately and all parks buckets on the line ere collected. I proceeded to check evisceration parts buckets on line and they were soiled as well with the same above mentioned substances. All 9 parts buckets were rejected with US reject tag number B 292507. (1st Processing Superintendent) and Mr. (Evisceration Supervisor) were notified as well. No products were affected at this point but birds were on the lines. Evisceration parts are salvaged from carcasses on the lines, and then placed in the icelayered parts buckets during evisceration operations. Once filled the buckets are taken to the salvage station and parts saved. Mr. informed me that employee responsible for cleaning parts buckets at the end of the shift would be disciplined and that he would make sure from now on, parts buckets are cleaned and sanitized before start-up. At 0528, Mr. informed me that all parts buckets were cleaned and sanitized and ready for inspection. I inspected all bucket and they were acceptable. At 0530, evisceration parts buckets were released as well as regulatory control. The requirements of Meat and Poultry Regulation 416.4(a) and 416.4(d) were not met. Mr. Plant Manager in hereby notified in writing with the NR for SPS noncompliance for sanitary operations and advised of the need to implement and document effective preventive measures to prevent recurrence. Continued failure to comply with regulatory requirements could result in additional regulatory or administrative actions as described in 9 CFR Part 500.

Regulation:

416.4(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

416.4(a) 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.

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.

Code: 01D01
Violation: 416.3(a), 416.1, 416.4(b)

Citation: This morning while performing pre-operational sanitation inspection prior to the start of operations and after the plants Sanitation SOP procedures I observed the following noncompliance: After the QA Tech had inspected and released Area 4 at 0635 hours, including the sizer belts, I noticed an odor in the vicinity of the associated chain guards that may indicate accumulations of product residues within the equipment that has not had a regular cleaning. These drive chains and guards attach to the sides of the product conveyors and were not removed for inspection. I requested the covers at the top of the belts removed and found a gross buildup of product residues packed at least 2 inches thick inside and around the chains and covers. I then requested all of the chain guards removed and found the same insanitary conditions. Based on this insanitary condition and the potential for direct product contamination, I initiated a regulatory control action, rejecting the unit for use with U.S. Reject tag #B34292505 at 0638 hours. Sanitation Superintendent was notified and observed the nonfood contact surfaces had not been cleaned at a frequency to preclude the buildup of product residues to prevent the creation of insanitary conditions and the adulteration of product. Equipment was not maintained to ensure all surfaces and parts are capable of being cleaned. Regulatory control was relinquished at 0711 hours after the unit was cleaned, sanitized, reinspected and found acceptable. Product was not affected by the above cited noncompliance. Regulatory requirements 9 CFR 416.1, 416.3(a), 416.4(b) were not met. Assistant Plant Manager is hereby notified in writing of the plant’s failure to comply with regulatory requirements and that a regulatory control action was taken as per 9 CFR 500.2(a)(1)(b). Effective measures must be implemented and documented to prevent recurrence. This document serves as written notification that your continued failure to comply with regulatory requirements could result in additional regulatory or administrative action as described in 9 CFR 500.4.

Regulation:

416.3(a) Equipment and utensils used for processing or otherwise handling edible product or ingredients must be of such material and construction to facilitate thorough cleaning and to ensure that their use will not cause the adulteration of product during processing, handling, or storage. Equipment and utensils must be maintained in sanitary condition so as not to adulterate product.

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.

Code: 01B02
Violation: 416.4(b)

Citation: During a pre-op inspection of Est. 8892 at 7:15 am on the slaughter floor I observed two sanitizers that had not been cleaned and sanitized from the previous days operations. Plant owner Jeff Haass was notified of these findings. These sanitizers were not noted on the plants pre-op form

Regulation:

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: 04B04
Violation: 317.2(c)

Citation: While performing a General Labeling task the label for Haass Country Scrapple it was observed that the label was not in compliance with 317.4 of the federal code of regulations. The label was discussed with plant owner Jeff Haass and was made aware that the label was not in compliance and that two carts of scrapple will be retained until an&nbsp;approved label can be obtained. At 3:55 pm&nbsp; on 4-25-2012 the scrapple was tagged with US Retained tags # B20 465067 and Retain Tag # B20 465067.

Regulation:

317.2(c) Labels of all products shall show the following information on the principal display panel (except as otherwise permitted in this part), in accordance with the requirements of this part or, if applicable, part 319 of this subchapter:

(1) The name of the product, which in the case of a product which purports to be or is represented as a product for which a definition and standard of identity or composition is prescribed in part 319 of this subchapter, shall be the name of the food specified in the standard, and in the case of any other product shall be the common or usual name of the food, if any there be, and if there is none, a truthful descriptive designation, as prescribed in paragraph (e) of this section;

(2) If the product is fabricated from two or more ingredients, the word ‘‘ingredients’’ followed by a list of the ingredients as prescribed in paragraph (f) of this section;

(3) The name and place of business of the manufacturer, packer, or distributor for whom the product is prepared, as prescribed in paragraph (g) of this section;

(4) An accurate statement of the net quantity of contents, as prescribed in paragraph (h) of this section;

(5) An official inspection legend and, except as otherwise provided in paragraph (i) of this section, the number of the official establishment, in the form required by part 312 of this subchapter;

(6) Any other information required by the regulations in this part or part 319 of this subchapter.

Code: 04B01
Violation: 317.4

Citation: While performing a General Labeling task at EST 8892 the labels for Haass Country Scrapple were observed and found not to be in compliance. The labels do not have a generic approval or an approval from the Food Labeling Division as required in 317.4 of the Federal Code of Regulations.Jeff Haass owner of EST.8892 was notified at once of these findings. A Retained tag was applied to two carts of scrapple in the holding cooler untill a label approval can be obtained.

Regulation:

317.4 (a) No final labeling shall be used on any product unless the sketch labeling of such final labeling has been submitted for approval to the Food Labeling Division, Regulatory Programs, Food Safety and Inspection Service, and approved by such division, accom panied by FSIS form, Application for Approval of Labels, Marking, and Devices, except for generically approved labeling authorized for use in §317.5(b). The management of the official establishment or establishment certified under a foreign inspection system, in accordance with part 327 of this subchapter, must maintain a copy of all labeling used, along with the product formulation and processing procedure, in accordance with part 320 of this subchapter. Such records shall be made available to any duly authorized representative of the Secretary upon request.

Code: 01B02
Violation: 416.13(a)

Citation: During a pre-op inspection of EST.8892 I observed the processing room and equiptment. I observed the bacon slicing machine and found the conveyor belt to have black particles of mold adhered to the belt.The slicer was rejected and tagged # B20 465156. Plant management was notified at once of these findings. The slicer was not noted on the plants pre-operational form Dated 4-10-2012.

Regulation:

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

Code: 01C02
Violation: 416.2(b)(2)

Citation: During an operational inspection of EST. 8892 I observed the kill floor and found&nbsp;the hog stunning area with excessive manure and blood stains adhered to the walls and metal gates. Also the hand wash sink has excessive rust stains inside sink (b) (6) NR Listing Humane Handling Incidents Date Range: 06/24/2010 – 07/18/2012

Regulation:

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.

Code: 04C02
Violation: 313.2

Citation: Today at approxamately 8:05 A.M. I went into the livestock holding area to verify the Humane Handling regulatory requirements. The smaller of the two holding pens had three large beef in it, there was one empy bucket on the floor, and no other source of water available to these animals. This is a non compliance with CFR 313.2(e). I spoke with Mr. , Owner regarding the lack of water in the holding pen. Mr. told me that they had just come from the livestock holding pens, and they needed to put their boots on before providing the animals with water. I was accompanied by a plant employee who took immediate corrective action to provide all the animals with access to water.

Regulation:

313.2 (e) Animals shall have access to water in all holding pens and, if held longer than 24 hours, access to feed. There shall be sufficient room in the holding pen for animals held overnight to lie down.

Code: 06A01
Violation: 381.105(c), 381.105(a)

Citation: This non compliance is being generated in response to the establishment’s failure to complete and submit FSIS Form 9060-5, Meat and Poultry Export Certificate of Wholesomeness, for export of poultry products to Bermuda on July 4, 2012. It was brought to my attention on July 5th that an export shipment had been sent from the establishment without the issuance of FSIS Form 9060-5 from USDA. When I inquired on July 6th about the shipment and requested information regarding what type of product was shipped, how much product, and to what country to Mr. Export Manager, I was told that information would be given to me in a timely manner. However, I did not receive this information after requesting over a three day period. It was at this time that this issue was addressed in the weekly establishment meeting on July 10th. Even though documents were finally produced to show what product, the amount shipped and to what country on July 10th, it was learned that FSIS Form 9060-5 was not filled out and submitted which is a regulatory requirement for all meat and poultry products destined for export. Since there was failure to notify USDA for the issuance of FSIS Form 9060-5, this results in the issuance of a non compliance of 9 CFR 381.105. Additionally, there is the issue of requesting and receving records in a timely manner. It is the agency’s expectation that records be provided within a minimum of 24 hours of request unless held offsite. This issue of records not being made readily available was addressed in a Memorandum of Interview (MOI) dated June 22, 2012 from Dr. SPHV. This document serves as written notification to Mr. , Director of Operations, that continued failure to comply with regulatory requirements could result in additional regulatory or administrative actions as per 9 FCR 500.

Regulation:

381.105(c) Only one certificate shall be issued for each consignment, except in case of error in the certificate or loss of the certificate originally issued. A request for a new certificate, except in the case of a lost certificate, shall be accompanied by the original and all copies of the first certificate. The new certificate shall carry the following statement: ‘‘This certificate supersedes certificate No.___ Dated ___. The outside container of the poultry product covered by this certificate is stamped with United States Department of Agriculture Certificate No.___.’’

381.105(a) Upon request or application by any person intending to export any poultry product, any inspector is authorized to issue an official export certificate as prescribed in §381.107 with respect to the shipment to any foreign country of any inspected and passed poultry product, after adequate inspection of the product has been made by the inspector to determine its identity as inspected and passed and eligible for export: Provided, that the product is offered for inspection at an official establishment. Each shipping container covered by the export certificate, except ship stores, small quantities exclusively for the personal use of the consignee and not for sale or distribution, and shipments by and for the U.S. Armed Forces, shall be marked with an official export stamp as shown in §381.104 bearing the number of the export certificate. Official export certificates will be issued only upon condition that the products covered thereby shall be subject to reinspection at any place and at any time prior to exportation to determine the identity of the products and their eligibility for certification, and such certificates shall become invalid if such reinspection is refused or discloses that the products are not eligible for certification. If reinspection discloses that any poultry products covered by an export certificate are not eligible for such certification, a superseding certificate setting forth such findings shall be issued and copies shall be furnished to interested persons.

Code: 01C02
Violation: 416.13(c), 416.2(d), 416.4(d), 416.4(b)

Citation: At approximately 1953 hours while performing SSOP Review &amp; Observation Inspection procedure, the following non-compliances were observed: Condensation from overhead beams and rails was observed dripping onto product and product contact surfaces in the Second Processing DaPec area on saddle line Wings, front halves, and whole birds littered the floor in the area. Employees in the area were walking on and over the product that was littering the floor. The condemn barrels present in the area showed evidence of a black mold-like substance growing on both the inside and outside of the barrels. Product was lodged in the wing and leg processors.&nbsp;After observing the above mentioned insanitary conditions, I immediately stopped saddle lines and placed US Rejected Tag # B34336337 on the area. I spoke with the QA employee present in the area, Ms. as well as management present at the time the non-compliances were observed. Ms. provided me with the SSOP documents for Grading, Pinning, Cut Up-Dapec and Cut Up Stack off areas, stating that a check for dripping condensation was performed and found acceptable at 1936. An acceptable check for product flow was also performed at 1938.&nbsp;Employees in the area began wiping the condensation and picking up the product on the floor and elected to condemn all the product found littering the floor and/or caught in machinery. According to the establishments SSOP corrective actions the following should occur in the event condensation is observed in Second Processing: After corrective actions had began, Mr. arrived in the area. I explained the events that had occurred and after expressing my concerns, he elected to recondition any product processed after the last acceptable check. US Rejected tag #B34336337 was released when the area was found in an acceptable condition at 2126 hours. The establishment provided me with an approximate weight of pounds of product that was reconditioned and 187 pounds of product that was condemned as a result of the insanitary conditions stated above. The Establishment is in noncompliance with 9 CFR 416.1, 416.2(d), 416.4(b) 416.4(d), and 416.13(c).

Regulation:

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

416.2(d) Ventilation. Ventilation adequate to control odors, vapors, and condensation to the extent necessary to prevent adulteration of product and the creation of insanitary conditions must be provided.

416.4(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

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: 01D01
Violation: 416.1

Citation: At approximately 0550 on July 2, 2012 while in the cafeteria, I observed several roaches in the food serving area. There was a small roach on top of the overhead heating unit where food would have been placed.&nbsp; A larger roach was crawling on the counter top along side a pan of grits. A dead roach was stuck to a ceiling tile near a television just above the microwaves. I observed a roach going into a crack just inside the cafeteria door. A large dead roach on floor next to trash can, one under a counter next to bait discs, dead roach in a small puddle of water in front of the freezer. I observed about 4 roaches going in a corner and one coming from behind a piece of sheet metal on the back wall of the cafeteria near the freezer. In front of that wall was a stand with several loaves of bread and some empty bottles sitting on it. &nbsp;A roach was seen around a steamer and not too far was a batch of cooked biscuits in an oven. I spotted several roaches crawling across the floor in the back of the cooking area. There was a large food cart with several trays covered with parchment paper with crumbs on them. Spilled liquid was observed under the soda dispenser, a bucket with a brown colored liquid in it sitting under one counter. The floor was dirty with grease, water in corners behind sinks, dirty traps that go in the drains. There were several flies in the cafeteria also. I took regulatory control action by applying U.S. Reject/Retain tag #B34336250. &nbsp;I informed the cafeteria staff it was tagged until the problem taken care of. I spoke with the manager around 0550 and informed him why the cafeteria was shut down. This issue has been discussed several times with plant management in weekly meetings. The cafeteria was closed on June 13, 2012 because of roach sightings. On June 22, 2012 a MOI was issued. Response to action plan for pest control is on file. The cafeteria was inspected on July 3, 2012 at approximately 0750 and released. This is in violation of 9 CFR 416.2(a). This document serves as written notification that continued failure to comply with regulatory requirements may result in additional regulatory or administrative actions per 9CFR 500.

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.

Code: 03J04
Violation: 381.65(e)

Citation: At 1950 hours, while performing zero tolerance verification CCP #3 task , I randomly selected 10 birds from Evisceration line I observed fecal material in the back cavity and right thigh area in one of birds The fecal material was green and white in color and pasty in texture.&nbsp; The fecal material covered approximately a 2 in. square area.&nbsp; Mr Eviceration Team Lead nd HACCP Tech was immediately notified of the deviation The establishment was observed taking corrective action per their HACCP plan for CCP #3.&nbsp; A review of the establishment’s zero tolerance log for CCP #3 Evisceration line revealed that the last check performed by HACCP Tech was at1828.&nbsp; That check was found to be acceptable with a qualifiable value of 0/10 and the initials were R.J. . As a results of the deviation, a verification of all regulatory requirements at all&nbsp;CCP’s for the affected lot was performed and found to be acceptable, to include the preshipment review. Mr Evisceration Team Lead, stated that the root cause of the deviation was discovered to be the nozzle in I O washer that was not properly adjusted. Maintenance immediately made adjustments to the nozzle. A recheck was performed at 2001 and found acceptable. Mr Plant Manager, is being notified of the failure to meet the requirements of 9 CFR 381.65, which states that no feces on carcass should enter chilling system. This document serves as written notification that continued failure to comply with the regulatory requirements may result in additional regulatory or administrative actions as per 9 CFR 500.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

Code: 01C02
Violation: 416.2(d), 416.13(c), 416.4(d)

Citation: At approximately 1945 hours while performing SSOP Review &amp; Observation Inspection procedure, the following non-compliances were observed: Condensation was observed dripping from the ceiling onto product and product contact surfaces in the First Processing Paws area on line I immediately stopped the line and placed US Rejected Tag # B34336333 on the line. At this time I requested First Processing Supervisor, come to the area. Upon his arrival, I explained the above issue and he began directing his employees to perform corrective actions. Employees in the area began hanging plastic in an attempt to control the dripping fluid. (HACCP Supervisor) soon arrived in the area. I explained the events that had occurred. After further research, it was found that the last acceptable SSOP check for dripping condensation in this department was performed and recorded at 1939 with initials US Rejected tag # B34336333 was released when acceptable conditions were observed at 2008 hours. The establishment provided me with an approximate weight of 132 pounds of Paws product that was condemned as a result of the insanitary conditions described above. The Establishment is in noncompliance with 9 CFR 416.1, 416.2(d), 416.4(d) and 416.13(c).

Regulation:

416.2(d) Ventilation. Ventilation adequate to control odors, vapors, and condensation to the extent necessary to prevent adulteration of product and the creation of insanitary conditions must be provided.

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

416.4(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

Code: 01B02
Violation: 416.13(c)

Citation: At approximately 0501 hrs while performing pre-op sanitation in the whole bird grading dept I observed the following noncompliance. There was several pieces of meat and fat on the inside metal drop chutes and drip pan under the bird sizing conveyor belts. Also there was a black organic residue and chicken grease on the metal plate of the whole bird kicker. Both the inside metal chutes and bird kicker are product contact surfaces. I notified Mr. /sanitation shift leader, showed him the aforementioned conditions, and rejected the grading area. I initiated regulatory control action by applying U.S. Reject tag # B34336452. I observed as management implemented corrective actions by scrubbing with a soapy pad, water rinse, and sanitize the entire area. After sanitary conditions were restored, I reinspected the metal chutes and bird kicker, found them acceptable, and released the area&nbsp;at 0546 hrs. I reviewed the establishments pre-op sanitation records for documented checks and the chutes and kicker were not randomly selected for inspection.&nbsp; The establishment failed to meet regulatory 416.4(a), 416.13(c), and 416.1 which states: 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.

Regulation:

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

Code: 01C02
Violation: 416.13(c), 416.4(d), 416.2(d)

Citation: At approximately 1528 hours while performing SSOP Review &amp; Observation Inspection procedure, the following non-compliances were observed: Condensation from overhead beams and rails was observed dripping onto product and product contact surfaces in the Second Processing Day Pack area on saddle line I immediately stopped the line and placed US Rejected Tag # B34336334 on the line. At this time I requested Second Processing Shift Leader, come to the area. Upon his arrival, I explained the above issue and he began directing his employees to perform corrective actions. Employees in the area began wiping the condensation and removing product from the shackles on the line to be reconditioned. (HACCP Supervisor) soon arrived in the area. I explained the events that had occurred. After further research, it was found that the last acceptable SSOP check for dripping condensation in this department was performed and recorded at 1517 with initials At 1648 this area was brought back into compliance and US Rejected tag #B34336334 was removed. The establishment provided me with an approximate weight of 800 pounds of product that was reconditioned as a result of the insanitary conditions described above. The Establishment is in noncompliance with 9 CFR 416.1, 416.2(d), 416.4(d) and 416.13(c).

Regulation:

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

416.4(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

416.2(d) ) Ventilation. Ventilation adequate to control odors, vapors, and condensation to the extent necessary to prevent adulteration of product and the creation of insanitary conditions must be provided.

Code: 01B02
Violation: 416.13(a)

Citation: At approximately 0448 hrs while performing pre-op sanitation I observed the following noncompliance in the neck chiller and on elevators.&nbsp; There was several pieces of fat and skin on the inside of the neck chiller and between the metal plates of the elevators which both are product contact surfaces I notified Mr. sanitation supervisor, and showed him the aforementioned conditions and rejected the&nbsp;chiller in the packing department.&nbsp; I initiated regulatory action control action by applying U.S. Reject tag #B24035404. I observed as management implemented corrective actions by scrubbing with a soapy pad, water rinse, and sanitize the entire chiller and elevators. At&nbsp;0515 hrs I reinspected the entire chiller and elevators after sanitary conditions were restored and found acceptable for start up operations.&nbsp; I reviewed the establishments’ pre-op sanitation records for documented&nbsp;procedure checks and the chiller and elevators were not randomly selected for inspection. The establishment failed to meet regulatory requirements 416.4(a), 416.13(c), and 416.1 which states: 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.

Regulation:

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

Code: 01C02
Violation: 416.4(d), 416.4(a)

Citation: At approximately 1505 hours while performing postchill inspection on chiller #1. A noncompliance was observed on the blue product belt. This belt is the first place the product lands after exiting the chiller. On the product belt a streak of thick black grease like substance was found. The greasy black substance was approximately 4 inches in length and a thick pasty consistency. Ms (Grading Supervisor) was notified immediately of the noncompliance. Ms immediately switched the belts so the product would not come into contact with the contaminated belt. Regulatory control action was taken by the stopping of the grading line which is fed by chiller #1. All&nbsp;product on the grading belt was placed in 2 tanks. U.S. Retain Tags #B23886296 and B2388630 were placed on the tanks. The conveyor belt was cleaned and sanitized. After reinspection of the belt the process was released at approximately 1522 hours. After notification of QA supervisor he personally took responsibility of overseeing the reconditioning of the product. The establishment elected to inspect all product that was placed on hold individually by hand. All products at this time was found to be acceptable. The product was released by USDA at 1610 hours. The establishment was in noncompliance of 9 CFR 416.4(a) and 416.4(d).

Regulation:

416.4(a) 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.

416.4(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

Code: 03J04
Violation: 381.65(e)

Citation: At 1945 hours while performing zero tolerance verification task on Evisceration line I observed fecal contamination in one of the ten randomly selected birds for CCP #3. The fecal was grainy in texture and green in color. The fecal matter covered one half of the left lower back cavity and the leaf fat on that same side. I took regulatory action by stopping the line and notified Mr. Evis Team Lead, and QA Tech, &nbsp; Mr. and Mr. was shown the deviation. The establishment was observed taking corrective action per their HACCP plan for CCP #3 by spraying the birds on line and turning on the spray cabinet. A recheck was proformed By QA Tech at 1950 and found acceptable. The affect birds was taken to the reprocessing station were it was cut into parts and reinspected by QA Tech. The regulatory control action was relinquished. Mr. stated that the orange cords were a little loose in the In and Out Birdwasher and adjustments were made. The last acceptable check for zero tolerance was 1817. As a results of the deviation, a verification of all regulatory requirements at all CCPs for the effected lot were performed and found acceptable including the preshipment review. The establishment failed to meet the regulatory requirements of 9CFR part 381.65(e) and 417.2(c)(4). This document serves as written notification to Mr. Processing Business Unit Lead, that continued failure to comply with the regulatory requirements may result in additional regulatory or administrative action as per 9CFR 500.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

Code: 01C02
Violation: 416.13(c), 416.4(d)

Citation: At approximately 1635 while performing Poultry SSOP Review and Observation in the Wing department along with QA/HACCP Tech The following noncompliance was observed: An establishment employee picked a box led off of the floor and threw it into the trash, then went back to the wing line and began to work with the edible product without washing and sanitizing his hands. A regulatory control action was immediately taken as per (500.1) by the stopping of the wing process. USDA Reject Tag # B23886298 was placed on the processing line and down grade belt. Ms. (Wing Dept Supervisor) was immediately notified of the noncompliance. All products on the belts were placed in totes (7 totes) for reconditioning. USDA Retain Tag #B23886304 was placed on the product.&nbsp; A review of the Establishments SSOP Plan, 2nd Processing Operational Sanitation Employee Hygiene States, This is an obvious violation to the establishments SSOP Plan. At approximately 1757 the area was brought back into compliance and released by USDA. After the product was recondition and inspected by QA and USDA it was released at approximately 2114 hrs. The establishment is in noncompliance with 9 CFR 416.4(d) and 416.13(c).

Regulation:

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

416.4(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

Code: 03J04
Violation: 381.65(e)

Citation: At 2020 hours, while performing zero tolerance verification tasks on Evisceration line I observed fecal material on one of the ten randomly selected birds for inspection at CCP #3. The fecal material was greenish color and pasty in texture. It was approximately .5 mm in size and located on the left side of the back cavity. I took regulatory control action by stopping the line and Mr. (Shift Leader) and Mr. (QA Supervisor) was immediately notified and shown the deviation. The establishment was observed taking corrective action per their HACCP plan for CCP #3 by spraying birds at prechill station line The affected carcass was taken to the reprocess station were it was cut into parts and reinspected by QA Technician per HACCP plan. The regulatory control action was relinquished. The last zero tolerance check was performed at 2001 hours by (QA Technician) with 0/10 birds checked and passed. Mr. stated that there were problems with the Machine and Maintenance was working on it. As a result of the deviation, a verification of all regulatory requirements at all CCP for the affected lot was performed and found to be acceptable including the pre-shipment review. The establishment failed to meet the regulatory requirements of 9CFR part 381.65(e) and 417.2(c) (4). This document serves as written notification to Mr. (Processing Business Unit Leader) that continued failure to comply with the regulatory requirements may result in additional regulatory or administrative actions as per 9CFR 500.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

Code: 03J04
Violation: 381.65(e)

Citation: At approximately 0538 hrs while performing zero tolerance testing at CCP#3 pre-chill station, I observedvisible fecal material on1 of 10 randomly selected carcasses.The fecal material was brownish-green in color and smeared approximately 1″ in diameter on the left side of the clavicle area. I notified Ms. QA and showed her the affected carcass and then she notified Ms. evis shift leaderand showed her the affected carcass. I observed as Ms. initiated corrective actions by placing an employee at line 1 pre-chill station to spray wash each bird and take the affected carcass to the salvage station to be washed and cut up into parts as per est. HACCP plan. I reviewed CCP#3 contamination log and the last acceptable check was performed at 0525 hrs. QA began retesting and on line and there was no visible fecal found at approximately 0559 hrs which made the affected lot acceptable for continuous operations. At 1230 hrs I reviewed all CCP’s of the affected lot including the pre-shipment reviewed and verified that all regulatory requirements were met and found acceptable. The establishment failed to meet regulatory requirements 381.65(e) and 417.2 (c)(4).

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

Code: 03J04
Violation: 381.65(e)

Citation: At 1937 hours, while performing the zero tolerance verification task on evisceration line# I observed fecal material on one out of 10 randomly selected carcass for inspection at CCP# 3. The fecal material was greenish and white in color. Greenish part was gritty and whitish area was pasty in texture. Fecal material was approximately 2 inch by 2 inch in size and was located in the lower back cavity. Mr. evisceration team leader and HACCP tech, was immediately notified of the deviation. The establishment was observed taking corrective actions as per their HACCP plan, CCP# 3. A review of the establishments zero tolerance log for CCP# 3 Line revealed that the last check performed by HACCP at 1830 hours, was found to be acceptable and was recorded with a quantifiable value of 0/10 and the initials, . As a result of the deviation, a verification of all regulatory requirements at all CCP&rsquo;s for the affected lot was performed and found to be acceptable including the pre-shipment review. Mr. evisceration team leader stated root cause was discovered to be a nozzle that was not properly adjusted. Maintenance immediately made adjustment to the nozzle and check through the machinery. A recheck was performed at 1950 and found acceptable. Mr. Plant Manager is being notified of the failure to meet the requirements of 9 CFR 381.65 which stated that no feces on carcass should enter chilling system. This document serves as written notification that continued failure to comply with the regulatory requirements may result in additional regulatory or administrative actions as per 9 CFR 500.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

Code: 01C02
Violation: 416.4(b)

Citation: On January 24 2012at approximately 2118 while performing my routine walk through, I observed the following noncompliance in the PawDepartment. Upon entering the department itwas observed that the department was out of compliance with operational sanitation(416.4(b).There was piles of yellow debris ,numerous (to many to count)paws and trash and debrisscattered throughout the entirefloor.Therewas no supervisor in the area at this time to address these issues.Regulatory control action was taken by the stopping of the entire process as per 500.1 Mr (Shift Leader) was immediately notified of the noncompliance,he also observed the noncompliance. At 2132 after sanitary conditions were restored the regulatory control action was released by USDA.The establishment is in noncompliance with 9CFR 416.1.416.4(b).

Regulation:

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: 416.13(c)

Citation: At approximately 0454 hrs while performing pre-op sanitation in the chiller/grading dept. I observed the following noncompliance. The drip conveyor and metal pan had several pieces of fat and meat on them which are food contact surfaces. I notified Mr. /sanitation shift leader, the aforementioned conditions. I initiated regulatory control actions by rejecting the conveyor and applying a US Reject tag #B34336453. I observed as management implemented corrective actions by scrubbing with a soap pad, water rinse, and sanitized the conveyor and pan. After sanitary conditions were restored I reinspected the conveyor and pan, found them acceptable, and removed the tag at 0606 hrs. The establishment failed to meet regulatory requirements 416.13(c), 416.4, and 416.1 which states: 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.

Regulation:

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

Code: 01C02
Violation: 416.4(a), 416.13(c), 416.2(d), 416.4(b), 416.15(a)

Citation: At approximately 1455 hours, while performing routine walk through inspection the following non-compliances were observed: Upon entering the Breast Debone department it was observed that the area was out of compliance in regards to operational sanitation (416.4 a & b). Production was not taking place at this time, however I waited to observe whether or not the night shift supervisor would bring the area back into compliance before resuming production. Quality Assurance was not present at this time. After observing the supervisors allowing production to begin, I immediately notified the area supervisor and Mr. USDA Rejected tag # B19095234 was placed on the line. This allowed me to take regulatory control action in both the Breast Debone and Thin Slice departments. Mr. arrived and was notified at this time. Dried meat parts were visible on product contact surfaces. Meat parts littered the floor throughout the area. Piles of product build-up had formed on the production belt chutes as well as on the floor at the end of the breast trim line and breast tender line where totes are normally placed. Frames were also found littering the floor around the Frame line. As the company began cleaning the area to bring it back into compliance, it was also observed that employees were using a high pressure of water to clean. This caused meat parts from the overspray created by the high water pressure to come into contact with the wing department production belts. Production was not taking place in the wing department at this time. The company cleaned and sanitized these product contact surface(s) and were able to begin production after doing so. Further examination of the department revealed a leaking roof pipe above the Thin Slice line. The company had inadequately placed plastic under the leaking pipe. While the plastic was catching some of the leak, fluid was still dripping onto the production belt used to move whole breasts into the thin slice machine causing product contact surfaces to become contaminated. As the company began to clean the fluid from above the Thin Slice line, they also attempted to clean what was believed to be condensation from the overhead light. The fluid was actually on the inside of the light, however as they attempted to wipe it clean, sponge particles from the mop being used were left behind on the light and also fell on to product contact surfaces. Condensation was also observed on pipes located directly above the Frame line used to move Frames into large bins. When the company began to clean the condensation from the pipes, the condensation began dripping off the pipes and mop and came into contact with the Frames belt. (The employee was observed using a sponge mop wrapped in paper towels at this time.) Mr. elected to condemn all Frames processed. Management provided me with an approximate weight of pounds of Frames, 5 pounds of Trimmed meat parts and 15 pounds of Breast meat that were condemned as a result of the insanitary conditions stated above. After a review of establishment SSOP records, the last acceptable check for dripping condensation was performed at 1223. A review of SOP for sponge mops also indicate that At approximately 1608 hours, the Breast Debone department was brought back into compliance and production was able to resume. USDA Rejected Tag # B19095234 was not removed at this time as it was still being used to maintain control of the Thin Slice department. At 1642 hours the Thin Slice department was found to be back in compliance. USDA Rejected Tag # B19095234 was removed at this time and production was able to begin. The Establishment is in noncompliance with 9 CFR 416.1, 416.2(d), 416.4(a) 416.4(b) 416.13(c), and 416.15(a). This document serves as written notification to Mr. that failure to comply with regulatory requirements could result in additional regulatory or administrative actions as per 9 CFR 500.

Regulation:

416.4(a) 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.

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

416.2(d) Ventilation. Ventilation adequate to control odors, vapors, and condensation to the extent necessary to prevent adulteration of product and the creation of insanitary conditions must be provided.

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.

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).

Code: 03J04
Violation: 381.65(e)

Citation: At approximately 1243 hrs while performing (Poultry Zero Tolerance) on evisceration line I observed visible fecal material on one of the ten birds randomly selected. The fecal material was a 1/2 inch in length on the back thigh area of the carcass, it was brownish in color and a thick pasty consistency. Ms. ( Shift Leader) was immediately notified of the noncompliance. Ms (HACCP Tech) began initiating corrective action as per the HACCP Plan.The affected carcass was taken to the salvage station for reprocessing. A retest was performed at 1255 hrs and found to be acceptable.The last acceptable check documented on the establishments CCP-3 Log prior to the failure was 1132 hrs and initialed by . The establishment failed to meet regulatory requirements of 381.65(e) and 9CFR 417.2 (c) (4).

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

Code: 01C02
Violation: 416.4(d)

Citation: At approximately 0854 while performing postchill on chiller #1. A noncompliance was observed on the white and the blue product belt coming out of the chiller. Both of these belts had black thick grease like substance on them ranging in size 1/2 in to 4 inches.Regulatory control action was taken immediately by stopping chiller#1 which feeds these two belts. All product on the Grading belt (1 tank) that came from chiller #1 was placed into a tank and a US Retain Tag #B39082631 was placed on it.Mr. (Grading Supervisor) was notified immediately of the noncompliance.The conveyor belts were cleaned and sanitized.After inspection of the belts by USDA , the process was released at 0912. The establishment elected to inspect all product that was placed on hold individually by hand.All product at this time was found to be acceptable. The product ws released by USDA at 0957.The establishment is found to be in noncompliance of 416.1,416.4(d) and 4164 (a).This document serves as written notification to Mr. (Plant Manager) that continued failure to comply with regulatory requirements could result in additional regulatory or administrative actions as per 9 CFR 500.

Regulation:

416.4(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

Code: 03J04
Violation: 381.65(e)

Citation: At approximately 0659 hrs while performing (finished product standards) on evisceration line I observed visible fecal material on one of the ten birds randomly selected. The fecal material was on the bottom of the right hock, it was green in color and a thick pasty consistency. I initiated regulatory control action by stopping the affected line. Mr. (Shift Leader) was immediately notified of the noncompliance. Ms (HACCP Tech) began initiating corrective action as per the HACCP Plan. The affected carcass was taken to salvage station for reprocessing. A Retest was performed at 0710 hrs and found to be acceptable. I reviewed the establishments Log for CCP-3 and verified that the last acceptable check prior to the failure was performed at 0608 and was initialed by and found to be acceptable. The establishment failed to meet regulatory requirements of 381.65(e) and 9CFR 417.2 (c)(4).This NR serves as written notification to Mr. (Plant Manager) that continued failure to meet regulatory requirements could result in additional regulatory or administrative action as per 9CFR 500.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

Code: 01B02
Violation: 416.13(c)

Citation: At approximately 0430 hrs I observed the following noncompliance in the evisceration picking room. The over head rail and guide bar had numerous amount of feathers and a dark organic residue on top over picker D on line which are non- product contact surfaces. I notified Mr. anitation shift leader, and showed him the aforementioned conditions. I initiated regulatory control action by rejecting picker D area and applying a U.S. Reject tag #B3882532 to the machine. I observed as management implemented corrective actions by scrubbing with a soap pad, water rinse, and sanitized the over head rail, guide bar, and machine. After sanitary conditions were restored at 0448 hrs, I reinspected the entire picker D area, found it acceptable, and removed the U.S Reject tag. The establishment failed to meet regulatory requirements 416.13(c), 416.4, and 416.1 which states: 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 NR serves as written notification to Mr. that continued failure to meet these requirements could result in additional regulatory or administrative action as per 9CFR 500.

Regulation:

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

Code: 01D01
Violation: 416.1, 416.5(a), 416.2(h)(1)

Citation: I observed the following instance of noncompliance at approximately 1855 hours while in the Thigh Debone department. I walked into the locker/storage room, which holds employee’s personal effects as well as various utensils and containers including condemn/inedible totes and shovels, ice shovels, and product shovels. The door of the room opens directly into the processing area.The room had a strong odor of urine; this odor was strongest in the far right corner behind a tool cabinet. The establishment is in noncompliance with 416.1, 416.2(h)(1), and 416.5(a). U.S. Reject tag B34336456 was placed on the door. Supervisor was notified. He placed a lock on the door to prevent entry until he could arrange for the room to be sanitized with a bleach solution. I was also told the day shift team will be notified of the situation so they can be sure to sanitize their utensils, which are currently in locked cages, before use. The tag was removed at approximately 2140 hours once I observed that sanitary conditions were restored. This document serves as notification to Mr. that failure to comply with regulatory requirements could result in additional regulatory or administrative actions as per 9 CFR 500.

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.

416.5(a) Cleanliness. All persons working in contact with product, food-contact surfaces, and product-packaging materials must adhere to hygienic practices while on duty to prevent adulteration of product and 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.

Code: 01C02

Violation: 416.13(b), 416.3(c)

Citation: I observed the following instance of noncompliance at approximately 1735 hours while in the wings grading department. There were over a dozen wings scattered on the floor. As I stood there, an establishment employee picked an empty product box from the stack used by the wings grader and proceeded to pick up the wings he found on the floor and drain covers. He placed the box on the work station used by the grader, then collected ice with a white shovel and placed it on the wings before walking away. The establishment is in noncompliance with 416.1, 416.3(c), and 416.13(b). I attached U.S. Retained tag B34336460 to the box and instructed the grader to not allow anyone to touch the box. I notified Mr. Supervisor, who both notified me that Mr. is the Supervisor in charge of the area, and that he would help me until Mr. was found. I showed him what happened, and he chose to condemn the product immediately. U.S. Retained tag was removed at approximately 1745 hours. Approximately 12 pounds of product were condemned. Mr. and I spoke soon after. He indicated that there were 28 boxes of product in the lot, and that these will be reconditioned according to the establishment’s SSOP and verified by QA. This document serves as notification to Mr. that failure to comply with regulatory requirements could result in additional regulatory or administrative actions as per 9 CFR 500.

Regulation:

416.13(b) Each official establishment shall conduct all other procedures in the Sanitation SOP’s at the frequencies specified.

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: 03J04
Violation: 381.65(e)

Citation: Evisceration area: at 1449 &nbsp;hours while performing a finished product standards verification on line # on the seventh bird out of 10 randomly selected birds, I observed approximately ¼ inch of fecal material in three separate droplets on the inside left vent flap. The fecal material was brown in color and pasty in consistency. Since there was no plant employee between the pre-chill station and the chillers, it is reasonable to conclude that the contaminated carcass would have entered the chilling system. HACCP checker Miss was immediately notified as well as Team leader Mrs. and maintenance of the failure to meet the requirements of poultry regulations 417.2(c) (4) and 381.65(e) which requires no visible fecal material to enter the chilling system. Corrective actions were immediately implemented and shipping was stopped as per the plant’s HACCP plan for CCP # 1. A review of the establishment’s zero tolerance logs for CCP # 1 dated 7/9/2012 revealed that the last acceptable check was performed at 1422 hours with a quantifiable value of 0/10 and initialed The affected bird was condemned. The root cause was the probes on the inside / outside bird washer were not going into every bird, do to straight nozzles being used instead of fan nozzles. The water pressure was turned down on the outside of carcasses to increase the water pressure on the inside of carcass. Plant’s further planned action was the straight nozzles were replaced with fan nozzlels during the second half hour break, until then an associate was placed at the end of the evisceration line to check every bird for fecal material. Shipping was released at 1635 hours. s a result of the deviation, I verified that the corrective actions were compliant with 9 CFR 417.3(a). I also verified that all requirements at all CCP’s for that specific lot were performed and found to be acceptable including the pre-shipment review. &nbsp;Ms. Plant manager is being notified through this noncompliance record of the plant’s failure to meet regulatory requirements of 9 CFR 417.2(c) and 9 CFR 381.65(e). This document serves as written notification that continued failure to meet regulatory requirements could result in additional regulatory action(s) as described in 9 CFR 500.4

Regulation:

381.65(e)  Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

Code: 01C02
Violation: 416.4(d)

Citation: Debone Department: At 2341 hours I observed a floor associate picking up product for reconditioning. The associate used the handle type tongs to scrape tenders across the floor into a pile, then scoop the pile of tenders up into his hands placing them on the recondition ice cart. I placed USDA retain tag # B 23886321 on the cart and informed Mr. ebone team leader of the plants failure to follow poultry regulations 9 CFR 416.1 and 9 CFR 416.4(d) operational sanitation which states product must be protected from adulteration during processing, handling, storage, loading and unloading at and during transportation from official establishments, and the establishments product washing procedurefor collection of floor product, collection procedure 3(b) and (c) dated 3/2/2012, which states (b) product will be picked up with one piece in each hand, (c) the product will be placed on the cart, in the ice, separate to prevent each piece from touching, in a single layer and/ or if multiple layers,separate with a sanitary plastic covering with additional layer of ice. Approximatly twenty five tenders were condemned, the ice cart was washed off and new plastic with clean ice was placed on the cart. Regulatory control was released at 2358 hours. Mr. Business Unit Leader Debone/Shipping, is being notified through this NR of the plants failure to meet regulatory requirements. This document serves as written notification that the continued failure to comply with regulatory requirements may result in additional regulatory or administrative action(s). &nbsp; EstId: 2267 EstNbr: P1318 EstName: Perdue Farms, Inc. NR Record: EHL3018043225N-1 Date: 25APR2012 ProcCode: 01C02 Regs Cited: 416.4(d) Debone department At 1457 hours I observed the plant floor associate picking up product for recondition. The associate had three pieces of meat in one hand and tossed&nbsp;them onto the ice cart. I placed USDA retained tag # B23886319 on the cart and informed Mr. area supervisor And Mr. area supervisor of the plants failure to follow poultry regulations 9CFR 416.1 and 9 CFR 416.4 (d) operational sanitation which states product must be protected from adulteration during processing, handling, storage, loading and unloading at and during transportation from official establishments, &nbsp;and the establishments product washing procedure for collection of floor product, collection procedure 3(b) and (c) dated 3/2/2012, which states (b) product will be picked up with one piece in each hand. (c) Product will be placed on the cart, in the ice, separated to prevent each piece from touching, in a single layer and/or if multiple layers, separate with a sanitary plastic covering with additional layer of ice. The product was reconditioned with to ppm chlorinated water, reinspected and released. Tag was removed at 1502 hours. The plant response was that the associate would be given a write up. Mr. , Business Unit Leader Deboning and Shipping, &nbsp;is being notified through this NR of the plants failure to meet the regulatory requirements. This document serves as written notification that the continued failure to comply with regulatory requirements may result in additional regulatory or administrative action(s).

Regulation:

416.4(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

Code: 01C02
Violation: 416.15(b), 416.5(a), 416.5(b), 416.3(a), 416.4(d), 416.4(a)

Citation: At 730hours in the WPL department I observed the improper opening of product from trays and the associate was placing the product into totes The associate was not properly dressed to handle product, no gloves, no plastic apron and she was also using her personal knife to open the packages of product. This unsanitary handling of product could lead to contamination and adulteration of the product. I immediately instructed her to stop what she was doing and asked her to please get her supervisor. I spoke to WPL supervisor Mr. and expressed the USDA concerns of improper handling of product and food safety, no SSOP checks of the product. SSOP #4 accounts for glove/hand and apron hygiene and Perquisite # 10 is for cleaning of knives, tools, or utensils and neither of these were followed. Section 416.1 states: 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. Section 416.3 states: (a) Equipment and utensils used for processing or otherwise handling edible product or ingredients must be of such material and construction to facilitate thorough cleaning and to ensure that their use will not cause the adulteration of product during processing, handling, or storage. Equipment and utensils must be maintained in sanitary condition so as not to adulterate product. Section 416.4 states: (a) 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. (d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments. Section 416.5 states: (a) Cleanliness. All persons working in contact with product, food-contact surfaces, and product-packaging materials must adhere to hygienic practices while on duty to prevent adulteration of  product and the creation of insanitary conditions.(b) Clothing. Aprons, frocks, and other outer clothing worn by persons who handle product must be of material that is disposable or readily cleaned. Clean garments must be worn at the start of each working day and garments must be changed during the day as often as necessary to prevent adulteration of product and the creation of insanitary conditions Section 416.15 states: (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 SOPs and the procedures specified therein or appropriate improvements in the execution of the Sanitation SOPs or the procedures specified therein. Plant decided to condemn the affected product, I observed the condemnation of the affected product, two yellow condemned cans total of assorted pieces and whole chickens. &nbsp;Mr. the Business Unit Leader for the shipping department is being notified through this NR of the plants failure to meet regulatory requirements. This serves as written notification that the continued failure to comply with regulatory requirements may result in additional regulatory or administrative actions.

Regulation:

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

416.5(a) ) Cleanliness. All persons working in contact with product, food-contact surfaces, and product-packaging materials must adhere to hygienic practices while on duty to prevent adulteration of product and the creation of insanitary conditions.

416.5(b) Clothing. Aprons, frocks, and other outer clothing worn by persons who handle product must be of material that is disposable or readily cleaned. Clean garments must be worn at the start of each working day and garments must be changed during the day as often as necessary to prevent adulteration of product and the creation of insanitary conditions.

416.3(a) Equipment and utensils used for processing or otherwise handling edible product or ingredients must be of such material and construction to facilitate thorough cleaning and to ensure that their use will not cause the adulteration of product during processing, handling, or storage. Equipment and utensils must be maintained in sanitary condition so as not to adulterate product.

416.4(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

416.4(a) 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: 01C02
Violation: 416.4(d)

Citation: Whole Bird department: At 1440 hours I observed a plastic cover over a vat of whole birds that had the green sticker from sanitation facing down touching the product in the vat. This issue was discussed at the USDAPlant meeting on 3/7/2012 stating the re-use of the plastic covers could contaminate the product inside the vats. The plant response was that the covers would be reused with the green sticker, which identifies the outside surface, facing outward away from product. I took a regulatory control action by applying USDA retain tag # B23886325 to the vat of product. I informed the line coach Ms. , Mr. HACCP coordinatorand Mr. Team leader of the plants failure to follow their procedure and failure to follow Poultry Regulations 416.1 and 416.4(d) operational sanitation which states product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments . After the vat of product was reconditioned and reinspected, regulatory control was relinquished at 1600 hours. Mr. Plant Manager is being notified through this NR of the plants failure to meet the regulatory requirements. This document serves as written notification that the continued failure to comply with regulatory requirements may result in additional regulatory or administrative action(s).

Regulation:

416.4(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

Code: 03J04
Violation: 381.65(e), 417.2(c)(4)

Citation: Evisceration area: At 1423 hours while performing poultry finished standards on line I observed fecal material in the fifth bird out of a subgroup of ten birds, approximately one inch in size, brown in color and pasty in consistency on the inside back area on the left side of the bird. Since there was no plant employee between the pre chill station and the chilling system, it is reasonable to conclude the contaminated carcass would have entered the chilling system. Evisceration Team Leader, Mrs. and Maintenance Personnel Mr. were immediately informed of the failure. Mrs. HACCP verifier, was also informed of this failure to meet the requirements of Poultry regulations 9CFR 417.2(c) (4) and 9CFR 381.65 (e) which requires no visible fecal material to enter the chilling system. Immediate corrective actions for CCP # 1were initiated as per the plant’s HACCP plan. The affected bird was reconditioned by management. Mrs. informed me that the cause of the deviation was three of the nozzles in the IOBW were clogged. The problem was immediately corrected by maintenance personnel. A review of the Establishment’s CCP # 1 for on line Zero Tolerance Log dated 03/02/2012 revealed that the last acceptable check was performed at 1236 hours by HACCP Technician Ms. on the day shift with a quantifiable value of 0/10. As a result of this deviation all requirements at all CCPs for that specific lot was performed and found to be acceptable including the pre shipment review at 2017. The establishment failed to meet the requirements of 9CFR 417.2 (c) (4) and 9CFR 381.65 (e). Mr. Plant Manager, is being notified through this noncompliance record of the plant’s failure to meet the regulatory requirements of 9CFR 417.2 (c) (4) and 9CFR 381.65 (e) and that a deviation had occurred in their HACCP system. This document serves as written notification that continued failure to comply with the regulatory requirements may result in additional regulatory or administrative action(s) as described in 9CFR 500.4

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

Code: 03J04
Violation: 381.65(e), 417.2(c)(4)

Citation: Evisceration area: At 1450 hours while performing poultry finished product standards on line I observed fecal material on the ninth bird out of a sub group of ten. The fecal was approximately a one inch smear on the right inside back area. The fecal was brown in color and pasty in consistency. Since there was no plant employee between the pre chill station and the chilling system, it is reasonable to conclude the contaminated carcass would have entered the chilling system. Shift Leader, Mr. was immediately notified as well as HACCP Checker Ms. of the failure to meet the requirements of Poultry regulations 9CFR 417.2(c) (4) and 9CFR 381.65 (e) which requires no visible fecal material to enter the chilling system. Immediate corrective actions for CCP # 1 were initiated as per the plant’s HACCP plan. The affected bird was reconditioned by management. The reason given by management for the failure was bird was miscut by venter due to one legged bird. A review of the Establishment’s CCP # 1 for on line Zero Tolerance Log dated 02/09/2012 revealed that the last acceptable check was performed at 1419 hours by HACCP Technician Ms. with a quantifiable value of 0/10. As a result of this deviation all requirements at all CCPs for that specific lot was performed and found to be acceptable including the pre shipment review at 2025 hours. The establishment failed to meet the requirements of 9CFR 417.2 (c) (4) and 9CFR 381.65 (e). Mr. Plant Manager, is being notified through this noncompliance record of the plant’s failure to meet the regulatory requirements of 9CFR 417.2 (c) (4) and 9CFR 381.65 (e) and that a deviation had occurred in their HACCP system. This document serves as written notification that continued failure to comply with the regulatory requirements may result in additional regulatory or administrative action(s) as described in 9CFR 500.4

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

Code: 01D01
Violation: 416.2(b)(1)

Citation: Maintenance shop pre pack area: At approximately 1830 hours. While touring the maintenance shop I observed holes and slits in the wall and ceiling coverings allowing insulation to be exposed. There are several slits all around the upper half of the wall where dust gathers, also around the exhaust fan which could lead to insulation falling on to the maintenance associates who work on the equipment and around the product. This maintenance shop is connected to the production area with a single door separating them, thus when the door is pulled open any insulation that is loose could be pulled in to the production area. I spoke with Mr. NS maintenance supervisor about this issue. Poultry regulations states in 9CFR 416.2(b)(1) that establishment buildings, including their structures, rooms, and compartments must be of sound construction be kept in good repair. Mr. plant manager is being notified of this failure of the regulatory requirements. This document serves as a written notification that the continued failure to comply with regulatory requirements may result in additional regulatory or administrative action(s).

Regulation:

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.

Code: 03J04
Violation: 381.65(e), 417.2(c)(4)

Citation: Evisceration area: At 2006 hours while performing poultry finished product standards on line I observed fecal material on the ninth bird out of a sub group of ten. The fecal was approximately a one inch smear on the left inside back area left of the tail. The fecal was brown in color and pasty in consistency. Since there was no plant employee between the pre chill station and the chilling system, it is reasonable to conclude the contaminated carcass would have entered the chilling system. Evisceration Team Leader, Mrs. was immediately notified of the failure, as well as HACCP Checker, Ms. who was also notified of the failure to meet the requirements of Poultry regulations 9CFR 417.2(c) (4) and 9CFR 381.65 (e) which requires no visible fecal material to enter the chilling system. Immediate corrective actions for CCP # 1were initiated as per the plant’s HACCP plan. The affected bird was reconditioned by management. The reason given by management for the failure was the bird washer pump had kicked out and causing no pressure to the bird washer. A review of the Establishment’s CCP # 1 for on line Zero Tolerance Log dated 12/23/2011 revealed that the last acceptable check was performed at 1908 hours by HACCP Technician Ms. with a quantifiable value of 0/10. As a result of this deviation all requirements at all CC’s for that specific lot was performed and found to be acceptable including the pre shipment review at 2138 hours. The establishment failed to meet the requirements of 9CFR 417.2 (c) (4) and 9CFR 381.65 (e). Mr. Plant Manager, is being notified through this noncompliance record of the plant’s failure to meet the regulatory requirements of 9CFR 417.2 (c) (4) and 9CFR 381.65 (e) and that a deviation had occurred in their HACCP system. This document serves as written notification that continued failure to comply with the regulatory requirements may result in additional regulatory or administrative action(s) as described in 9CFR 500.4

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

Code: 03J04
Violation: 417.2(c)(4), 381.65(e)

Citation: Evisceration Area: At 1544 hours while performing Zero Tolerance Verification on evisceration line I observed fecal material on the ninth bird out of a subgroup of ten. The fecal was located on the left inside back and breast area, brown in color and pasty in consistency and approximately one half inch in size. Since there was no plant employee between the pre chill station and the chilling system, it is reasonable to conclude the contaminated bird would have entered the chilling system. Mrs. HACCP Verifier, Mrs. Team Leader, as well as Shift Leader, Mr. and Maintenance Personnel, Mr. were immediately informed of the failure to meet the requirements of Poultry Regulations 9CFR 417.2 (c) (4) and 9CFR 381.65(e) which requires no visible fecal material to enter the chilling system. Immediate corrective actions for CCP # 1 were initiated as per the plant’s HACCP plan. The affected bird was reconditioned at the recondition station and put back into production. The root cause given by management was after checking the viscera packs, the birds appeared to be off of the feed too long. The immediate corrective actions were initiated and I verified that the corrective actions were compliant with 9 CFR 417.3(a). A review of the establishment’s Zero Tolerance Log for CCP # 1 dated 11/29/2011 revealed that the last acceptable check was performed at 1517 hours with a quantifiable value of 0/10 and initialed As a result of the deviation all requirements at all CCPs for that specific lot was performed and found to be acceptable including the pre shipment review at 1945 hrs. The establishment failed to meet the requirements of 9CFR 417.2 (c) and 9CFR 381.65 (e). Mr. Plant manager is being notified of this failure to meet the regulatory requirements of 9CFR 417.2 (c) (4) and 9CFR 381.65 (e). This document serves as a written notification that the continued failure to comply with regulatory requirements may result in additional regulatory or administrative action(s) as described in 9 CFR 500.4.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

Code: 03J04
Violation: 381.65(e), 417.2(c)(4)

Citation: At approximately 0521 hours while performing a Poultry zero tolerance verification check on evisceration line I observed visible fecal material on the fifth bird out of a subgroup of ten. The fecal was located on the left inside of the thigh area, was brownish green in color, approximately one half inch in size and a pasty consistency. Since there were no plant personnel between the pre-chill stand and the chilling system, it is reasonable to conclude the contaminated carcass would have entered the chilling system. Ms. ( Evisceration Team Leader) and HACCP Checker) were immediately notified of the noncompliance. Immediate corrective actions for CCP#1 were initiated as per the establishments HACCP Plan. The affected bird was reconditioned and placed back into the process. The root cause given by management was that a one legged bird passed the inspectors helper causing a non captured carcass to go through both IOBW and Bird washers. At this time there had been no Zero Tolerance checks performed by the establishment. All corrective actions were verified by USDA. As a result of the deviation all requirements at all CCPs for that specific lot was performed and found to be acceptable including the preshipment review at 0857 hours. The establishment failed to meet the regulatory requirements of 9 CFR 417.2 (c)(4) and 9 CFR381.65 (e). Mr. Plant Manager is being notified of this failure to meet the regulatory requirements of 9 CFR 417.2 (c)(4) and 9 CFR 381.65(e). This document serves as written notification that the continued failure to comply with regulatory requirements may result in additional regulatory or administrative action as described in 9 CFR 500.4.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

Code: 03J04
Violation: 381.65(e), 417.2(c)(4)

Citation: Evisceration Area: At 1500 hours while performing Zero Tolerance Verification on evisceration line I observed fecal material on the third bird out of a subgroup of ten. The fecal was located on the right inside back area, green in color and pasty in consistency and approximately one inch in size. Since there was no plant employee between the pre chill station and the chilling system, it is reasonable to conclude the contaminated bird would have entered the chilling system. Mrs. HACCP Verifier, Mr. , HACCP coordinator, Mrs. Team Leader, as well as Maintenance Personnel, Mr. were immediately informed of the failure to meet the requirements of Poultry Regulations 9CFR 417.2 (c) (4) and 9CFR 381.65(e) which requires no visible fecal material to enter the chilling system. Immediate corrective actions for CCP # 1 were initiated as per the plant’s HACCP plan. The affected bird was reconditioned at the recondition station and put back into production. The root cause given by management was the hose was broke off of the bird washer. Maintenance replaced hose barb and reconnected hose. The immediate corrective actions were initiated and I verified that the corrective actions were compliant with 9 CFR 417.3(a). A review of the establishment’s Zero Tolerance Log for CCP # 1 dated 11/09/2011 revealed that the last acceptable check was performed at 1408 hours with a quantifiable value of 0/10 and initialed As a result of the deviation all requirements at all CCPs for that specific lot was performed and found to be acceptable including the pre shipment review at 1906 hrs. The establishment failed to meet the requirements of 9CFR 417.2 (c) and 9CFR 381.65 (e). Mr. Plant manager is being notified of this failure to meet the regulatory requirements of 9CFR 417.2 (c) (4) and 9CFR 381.65 (e). This document serves as a written notification that the continued failure to comply with regulatory requirements may result in additional regulatory or administrative action(s) as described in 9 CFR 500.4.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

Code: 03J04
Violation: 381.65(e)

Citation: Evisceration area: at 2015 hours while performing a finished product standards task on line on the ninth bird out of 10 randomly selected birds, I observed approximately ¾ inch of fecal material on the inside cavity on the left kidney. The fecal material were brown in color and pasty in consistency. Since there was no plant employee between the pre-chill station and the chillers, it is reasonable to conclude that the contaminated carcass would have entered the chilling system. HACCP checker Miss was immediately notified as well as Team leader Mrs. and maintenance of the failure to meet the requirements of poultry regulations 417.2(c) (4) and 381.65(e) which requires no visible fecal material to enter the chilling system. Corrective actions were immediately implemented and shipping was stopped as per the plant’s HACCP plan for CCP # 1. A review of the establishment’s zero tolerance logs for CCP # 1 dated 11/3/2011 revealed that the last acceptable check was performed at 2002 hours with a quantifiable value of 0/10 and initialed The affected bird was condemned. The root cause was the venter on line # needed adjustment for smaller birds, the venter was lowered to prevent the blade from coming in contact with with the intestine. Plant further planed action will be to perform at least two venter checks during the shift for five days. Shipping was released at 2244 hours. As a result of the deviation, I verified that the corrective actions were compliant with 9 CF 417.3(a). I also verified that all requirements at all CCP’s for that specific lot were performed and found to be acceptable including the pre-shipment review. The establishment failed to meet the requirements of 417.2(c)(4) and 381.65(e). Mr. Plant manager is being notified through this noncompliance record of the plant’s failure to meet regulatory requirements of 9 CFR 417.2(c) and 9 CFR 381.65(e). This document serves as written notification that continued failure to meet regulatory requirements could result in additional regulatory action(s) as described in 9 CFR 500.4

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

Code: 03J04
Violation: 381.65(e), 417.2(c)(4)

Citation: Evisceration Area: At 1514 hours and 1527 hours while performing Finished Product Standards on evisceration line I observed fecal material on the third and fourth bird out of a subgroup of ten. The fecal was located on the left side of the kidney, white and green in color on the first bird, pasty in consistency and approximately one inch in size. The second bird had fecal material on the left inside near the tail area, green in color and pasty in consistency and approximately one half inch in size. Since there was no plant employee between the pre chill station and the chilling system, it is reasonable to conclude the contaminated carcass would have entered the chilling system. Ms. HACCP Checker and Mrs. Team Leader, as well as Maintenance Personnel, Mr. were immediately informed of the failure to meet the requirements of Poultry Regulations 9CFR 417.2 (c) (4) and 9CFR 381.65(e) which requires no visible fecal material to enter the chilling system. Immediate corrective actions for CCP # 1 were initiated as per the plant’s HACCP plan. The affected birds were reconditioned at the recondition station and put back in to production. The root cause given by management was the grower neglected to raise feed trays at specified time. The immediate corrective actions were initiated and I verified that the corrective actions were compliant with 9 CFR 417.3(a). A review of the establishment’s Zero Tolerance Log for CCP # 1 dated 11/01/2011 revealed that the last acceptable check was performed at 1415 hours with a quantifiable value of 0/10 and initialed As a result of the deviation all requirements at all CCPs for that specific lot was performed and found to be acceptable including the pre shipment review at 2145hrs. The establishment failed to meet the requirements of 9CFR 417.2 (c) and 9CFR 381.65 (e). Mr. Plant manager is being notified of this failure to meet the regulatory requirements of 9CFR 417.2 (c) (4) and 9CFR 381.65 (e). This document serves as a written notification that the continued failure to comply with regulatory requirements may result in additional regulatory or administrative action(s) as described in 9 CFR 500.4.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

Code: 03J04
Violation: 381.65(e)

Citation: Evisceration area: At 1443 hours while performing finished product standards on line # on the fifth bird out of 10 randomly selected birds, I observed fecal material under the flap area just above the kidney area, fecal material were brown in color, approximately 1/2 inch smear and pasty in consistency. Since there was no plant employee between the pre-chill station and the chillers, it is reasonable to conclude that the contaminated carcass would have entered the chilling system.Mrs shift leader and Mrs. HACCP verifier as well as maintenance personnel were immediately notified of the failure to meet the requirements of poultry regulations 9CFR 417.2(c) (4) and 9 CFR 381.65(e) which requires no visible fecal material to enter the chilling system. Immediate Corrective actions for CCP # 1 were implemented as per the plants HACCP plan. The affected bird was condemned as the plant had suspended their salvage operation. The root cause was an associate cut the vent open with out lifting the flap cutting the intestine, Plant further planned action was coaching of associate on proper venting procedure. A review of the establishment’s zero tolerance logs for CCP # 1 dated 10/27/2011 revealed that the last acceptable check was performed at 1415 hours with a quantifiable value of 0/10 and initialed As a result of the deviation, I verified that the corrective actions were compliant with 9 CFR 417.3(a). As a result of the deviation all requirements at all CCP’S for that specific lot were performed and found to be acceptable including the pre shipment review at 1827 hours. Mr. Plant manager is being notified through this noncompliance record of the plant’s failure to meet regulatory requirements of 9 CFR 417.2 (c) and 9 CFR 381.65(e). This document serves as written notification that the continued failure to comply with regulatory requirements may result in additional regulatory or administrative action(s) as described in 9 CFR 500.4.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

Code: 03J04
Violation: 417.2(c)(4), 381.65(e)

Citation: Evisceration Area: At 1930 hours while performing Finished Product Standards on evisceration line I observed fecal material on the tenth bird out of a subgroup of ten. The fecal was located on the left, middle and right inside of the back area. The fecal material was brown in color and approximately 1/16 to 1/8 inches in size with a pasty consistency. Since there was no plant employee between the pre chill station and the chilling system, it is reasonable to conclude the contaminated carcass would have entered the chilling system. Ms. HACCP Checker and Mr. Shift Leader, as well as Maintenance Personnel were immediately informed of the failure to meet the requirements of Poultry Regulations 9CFR 417.2 (c) (4) and 9CFR 381.65(e) which requires no visible fecal material to enter the chilling system. Immediate corrective actions for CCP # 1 were initiated as per the plant’s HACCP plan. The affected bird was reconditioned at the recondition station and put back in to production. The root cause given by management was clogged nozzles on the IOBW. The immediate corrective action was done by unclogging the nozzles. I verified that the corrective actions were compliant with 9 CFR 417.3(a). A review of the establishment’s zero tolerance log for CCP # 1 dated 10/20/2011 revealed that the last acceptable check was performed at 1721 hours with a quantifiable value of 0/10 and initialed As a result of the deviation all requirements at all CCPs for that specific lot was performed and found to be acceptable including the pre shipment review at 2222 hrs. The establishment failed to meet the requirements of 9CFR 417.2 (c) and 9CFR 381.65 (e). Mr. Plant manager is being notified of this failure to meet the regulatory requirements of 9CFR 417.2 (c) (4) and 9CFR 381.65 (e). This document serves as a written notification that the continued failure to comply with regulatory requirements may result in additional regulatory or administrative action(s) as described in 9 CFR 500.4.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

Code: 03J04
Violation: 381.65(e), 417.2(c)(4)

Citation: Evisceration Area: At 1928 hours while performing Poultry Zero Verification on evisceration line I observed fecal material on the fourth bird out of a subgroup of ten. The fecal was located on the left inside of the back area. The fecal material was brown in color and approximately one inch in size with a pasty consistency. Since there was no plant employee between the pre chill station and the chilling system, it is reasonable to conclude the contaminated carcass would have entered the chilling system. Mr. QA Supervisor, Ms. HACCP checker and Evisceration Line coach, Mr. were immediately informed of the failure to meet the requirements of Poultry Regulations 9CFR 417.2 (c) (4) and 9CFR 381.65(e) which requires no visible fecal material to enter the chilling system. Immediate corrective actions for CCP # 1 were initiated as per the plant’s HACCP plan. The affected bird was reconditioned at the recondition station and put back in to production. The root cause given by management was the opener was adjusted too low for the bird size. I verified that the corrective actions were compliant with 9 CFR 417.3(a). A review of the establishment’s zero tolerance log for CCP # 1 dated 10/04/2011 revealed that the last acceptable check was performed at 1927 hours with a quantifiable value of 0/10 and initialed As a result of the deviation all requirements at all CCPs for that specific lot was performed and found to be acceptable including the pre shipment review at 2118 Hrs. The establishment failed to meet the requirements of 9CFR 417.2 (c) and 9CFR 381.65 (e). Mr. Plant manager is being notified of this failure to meet the regulatory requirements of 9CFR 417.2 (c) (4) and 9CFR 381.65 (e). This document serves as a written notification that the continued failure to comply with regulatory requirements may result in additional regulatory or administrative action(s) as described in 9 CFR 500.4.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

Code: 06D02
Violation: 381.76(b)

Citation: At approximately 1439 hours, I observed a presentation non-compliance on evisceration line station #B. A nonconformance score of was observed. The nonconformance defects consisted of 2 birds “no viscera” (scoring points) and 1 bird “parts inside” (scoring point). Mr. , Night Shift First Processing Superintendent was immediately notified of the establishment’s failure to meet the regulatory requirements of 9 CFR 381.76(b) of the Meat and Poultry Regulations The line speed was immediately reduced to Birds per Minute as per NELS requirements. At 1445 hours, the retest was performed by QA technician with the initials and was found acceptable and the line speed was increased to B.P.M. A subsequent retest was conducted at the line speed B.P.M. by QA technician with the initials and found to be acceptable for process control. Ms. Plant Manager, is being notified through this NR of the establishment’s failure to meet the regulatory requirements of 9 CFR 381.76 (b). This document serves as written notification that continued failure to comply with regulatory requirements may result in additional regulatory or administrative actions as per 9 CFR 500.

Regulation: There are five systems of post-mortem inspection: Streamlined Inspection System (SIS) and the New Line Speed (NELS) Inspection System, both of which shall be used only for broilers and cornish game hens; the New Turkey Inspection (NTI) System, which shall be used only for turkeys; Traditional Inspection; and Ratite Inspection.

Code: 01D01
Violation:  416.2(e)(3), 416.1

Citation: At approximately 1740 hours, while touring the Evisceration department on Line I observed the Drain had backed up and was not moving. As I proceeded towards the front of the area where the Foods pump and conveyor is located, the guts were piled up and filling up the drain causing it to overflow. The guts were also piled up in the tray to where the gizzard puller was pulling. I immediately took regulatory control by stopping Evisceration line I immediately notified Mr. , Evisceration Line supervisor, who witnessed the insanitary condition. Mr. Night Shift Manager and Mr. Spence were present and did witness the establishment’s failure to comply with 9 CFR 416.1 and 416.2(e)(3) of the regulatory requirements. The establishment is also in violation of their SPS, Page 3 section 5 (e) that states: I observed Mr. washing down the area and freeing the guts in the area to allow the drains to freely flow. I relinquished regulatory control of the line at 1742 hours after sanitary conditions were restored and the drains flowing. The document serves as written notification to Ms. , Plant Manager, that continued failure to comply with the regulatory requirements may result in additional regulatory or administrative actions as per 9 CFR 500.

Regulation:

 416.2(e)(3) Prevent adulteration of product, water supplies, equipment, and utensils and prevent the creation of insanitary conditions throughout the establishment.

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.

Code: 03J04
Violation: 381.65(e), 417.2(c)(4)

Citation: At approximately 1448 pm while performing a zero tolerance procedure on Nels line # I observed fecal material on 1 of the 10 birds randomly selected for zero tolerance check at CCP # 2-B. The fecal material was brown in color, and pasty in consistency. It was approximately 1/2 inch in length and 1/4  inch in width and located on the upper outside of the carcass on the right flap with a intestine attached to the tail of the carcass. Mr. dayshift 1st Processing Superintendent and Andrew OOlajos, nightshift Evis Supervisor was immediately notified and shown the deviation. Approximately 1449 pm, as per the establishments HACCP Plan the line was immediately stopped and a house inspector was put on the line, and the line speed reduced. The affected carcass was then sent to the reprocessing station, reconditioned and placed back in flow as per the establishment’s corrective action. The establishment has failed to meet 9 CFR 417.2 (c) (4) and 9 CFR 381.65 (e) of the regulatory requirements. A review of the of the establishments CCP # 2-B monitoring log for Nels line # was last documented on dayshift. As a result of the deviation, all requirements for all CCP’s for the specified lot (lot # 1-A) was performed and found acceptable, including the preshipment review. The establishment management stated the root cause was the the bird not being fed through the cropper correctly and dragging on the guide bar.  This document serves as written notice that continued failure to comply with the regulatory requirements may result in additional regulatory or administrative action(s) as described in 9 CFR 500.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits.

Code: 03J02
Violation: 318.65(e), 417.2(c)(4)

Citation: Today, July 10, 2012 at approximately 1102 hours, while performing a poultry finished product standard procedure on evisceration line I observed fecal material on the breast area close to the wing of one out of ten randomly selected carcasses. The fecal material was approximately one quarter inch in length, green and pasty in substance. I immediately notified Mr. , Day Shift First Processing Superintendent, who observed the affected carcass. Corrective actions were immediately implemented; line speed was reduced from bpm to bpm. An associate was placed at the end of the affected line, and upon completion of the retest line speed was resumed to bpm per the HACCP plan for CCP 2B. Mr. took the affected carcass to the reprocessing station to be rinsed inside and out ith ppm chlorinated water and placed in the reprocessing tank for reinspection. The last acceptable fecal check was noted at 1047 hours on the establishment monitoring log. The preshipment was reviewed and found acceptable.Mr. , Day Shift First Processing Manager, verbally informed me that the root cause of the deviation was due to improper rinsing of the neck breaker lifter  and the spray water line not being properly aligned after adjustments were made. The establishment failed to meet the regulatory requirements of 9 CFR 417.2(c) (4) and 381.65(e).This document serves as written notification to Mrs. , Plant Manager that continued failure to meet the regulatory requirements could result in additional regulatory enforcement actions per 9 CFR 500.

Regulation:

318.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits.

Code: 01C02
Violation: 416.13(b), 416.4(d)

Citation: Approximately 1745 hours, while walking through the evisceration area, I observed birds too numerous to count laying in the rehang department floor. I immediately took regulatory control action by stopping the kill process on Evisceration lines 1 and 2. I notified Mr. Night Shift First Processing Superintendent and Mr. Andrew Evisceration Supervisor, both who were present and witnessed the noncompliance and the establishment’s failure to comply with the regulatory requirements of 9 CFR 416.13(b) and 416.4(d). This is in violation of the establishment’s SSOP plan which states ” Also, in violation of the SSOP plan for product flow which states, on page I observed the birds being picked up and reconditioned according to the establishments SSOP procedures At 1749 hours, I relinquished regulatory control when the process was brought back under control. This document serves as written notification to Ms. , Plant Manager that your continued failure to comply with the regulatory requirements could result in additional administrative or regulatory actions as per 9 CFR 500.

Regulation:

416.13(b) Each official establishment shall conduct all other procedures in the Sanitation SOP’s at the frequencies specified.

416.4(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

Code: 01C02
Violation: 416.13(b), 416.4(d)

Citation: At 1933 hours, as I was heading towards tray pack from Evisceration, I observed a lot of water cascading down from above. The cascading water was drenching the conveyer belt that was carrying product from the cut-up area to tray pack. The situation had just occurred as I was entering the area. I immediately stopped all processing in the immediate area; I took regulatory control by applying US reject tags # B38203503 to the tray pack department and US Reject tag #B38203504 to the chicken back combo area. Mr. , Night Shift Maintenance Supervisor was present at the time and informed me that a water hose overhead had busted causing the cascading water. Mr. cut the water off and removed the hose. Mr. , Night Shift Manager, Mr. Night Shift QA Manager and Mrs. Night shift Tray pack foreman, was present and did witness the establishment’s failure to comply with the regulatory requirements of 9 CFR 416.4(d) and 416.13(b). This is also out of compliance with the establishment’s SSOP plan. The establishments SSOP plan, which was not upheld during this incident,  states on page Mr. stated that the corrective actions would be as follows: the Belts would be sprayed down and sanitized and the overhead structures were to be air blown and mopped. Approximately 4 bins of backs were to be condemned and all products on the tray pack belt would be taken off, put into tubs to be reworked. The employees who came in contact with the affected product were to re-sanitized gloves and aprons. After I verified that all corrective actions had been taken, I relinquished regulatory control at 1955 hours.This document serves as written notification that continued failure of comply with the regulatory requirements may result in additional regulatory or administrative actions as per 9 CFR 500.

Regulation:

416.13(b) Each official establishment shall conduct all other procedures in the Sanitation SOP’s at the frequencies specified.

416.4(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

Code: 01C02
Violation: 416.13(b)

Citation: At approximately 1450 while verifying sanitary operations as second shift started, Dr. observed a white product contact shovel being stored behind a cabinet in the tender tray-pack area. This is in violation with the establishment’s Operational Sanitation Standard Operating Procedure (SSOP) and Sanitation Performance Standards (SPS) Plan which states on page 1: The shovel was tagged with USDA Rejected tag #B38206484 to remove it from operational use. I informed “LT” Turlington of QA, who promptly sanitized the shovel. Regulatory control was relinquished at 1458. This record serves as written notification to , Plant Manager that continued failure to meet the regulatory requirements could lead to additional regulatory control actions being taken per 9 CFR 500.

Regulation: Each official establishment shall conduct all other procedures in the Sanitation SOP’s at the frequencies specified.

Code: 04C05
Violation: 371.65(b)

Citation: While giving breaks on Evisceration Line at approximately 1630 hours until 1800 hours, CSI observed 10 cadavers birds within the 11/2 hour time frame. Three of the birds she had hung back for Dr. to look at, as they had the head attached and the neck was completely intact without a cut from the kill blade or back up killer, suggesting the bird entered the scalder alive while still breathing. The carcasses were full of blood and the skin was dark red and purple in color. Mr. , Night Shift, Evisceration Supervisor, and Mr. , Night Shift, Picking Supervisor, were notified and did witness the establishment’s failure to meet the regulatory requirements of 9 CFR 381.65 (b) and the the Establishments failure to follow it own GCP’s. Mr. s stated that the root cause was the back up venter was on a 10 minute break. Mr. stated that the preventive measure would be having someone who is trained relieve for breaks. This record serves as written notification to , Plant Manager that continued failure to meet the regulatory requirements could lead to additional regulatory control actions being taken per 9 CFR 500.

Regulation: Poultry must be slaughtered in accordance with good commercial practices in a manner that will result in thorough bleeding of the carcasses and ensure that breathing has stopped prior to scalding. Blood from the killing operation must be confined to a relatively small area.

Code: 01D01
Violation: 416.1, 416.2(e)(4)

Citation: At approximately 1910 pm while touring the wet cooler I observed a pool of water around a drain cover. The drain was located adjacent to the clear wrap machine. I tagged the area where the pooling water was with retain tag # B38206364 and B38206365. I immediately notified , N/S Breast Debone Superintendent, and , N/S Shift Manager who witnessed the noncompliance. The establishment has failed to meet 9 CFR 416.2(e) 4 of the regulatory requirement. The establishment is also in noncompliance of their SPS stating . ‘I observed correct the noncompliance by putting large barrels around the area to avoid product being stored in the area. Mr. informed me that the company will need to call Rotor Rooter to get the drained unclogged. This document serves as written notification that continued failure to comply with regulatory requirement(s) may result in additional regulatory or administrative action(s) as described in 9 CFR 500.

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.

416.2(e)(4) Provide adequate floor drainage in all areas where floors are subject to flooding-type cleaning or where normal operations release or discharge water or other liquid waste on the floor.

Code: 02C02
Violation: 416.4(a), 416.13(c)

Citation: At approximately 1450 pm while touring the wet cooler I observed four large bags of white trays used for packing product with chicken particles and fat on the trays. The white trays were located in the wet cooler under the conveyor belt that carriers boxed product to the wet cooler to be stacked on pallets. I immediately tagged the white trays with retain tag # B38206360 and retain # B38206357. I then notified Tray Pack Foreman, and , Further processing Superintendent of the noncompliance. The establishment has failed to meet 9 CFR 416. 4 (a) and 9 CFR 416.13 (b) of the regulatory requirements. They have also failed to meet their own SSOP stating I observed Tray Pack Foreman take corrective action, removing the affected white trays and throwing them away. This document serves as written notification that continued failure to comply with regulatory requirement(s) may result in additional regulatory or administrative action(s) as described in 9 CFR 500.

Regulation:

416.4(a) 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.

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

Code: 04C05
Violation: 381.65(b)

Citation: Upon touring the Evisceration department at approximately 0900 hours I observed 5 birds on line and that were cadavers all within 3 minutes of each other. I immediately stopped evisceration line 1 and notified Picking Supervisor as well as nbsp; 1st processing Superintendent and assured they observed the cadaver carcasses. 1 of the birds had the head attached and the neck was completely intact without a cut from the kill blade or back up killer suggesting the bird entered the scalder alive while still breathing. The carcasses were full of blood and the skin was dark red and purple in color.  The above mentioned is not meeting the requirements of 9 CFR 381.65 (b) and the Establishments failure to follow its own GCPs.  This record serves as written notification to Plant Manager that continued failure to meet the regulatory requirements could lead to additional regulatory control actions being taken per 9 CFR 500.

Regulation: Poultry must be slaughtered in accordance with good commercial practices in a manner that will result in thorough bleeding on the carcasses and ensure that breathing has stopped prior  to scalding. Blood from the killing operation must be confined to a relatively small area.

Code: 03J04
Violation: 417.2(c)(4), 381.65(e)

Citation: At approximately 1925 pm while performing a zero tolerance procedure on Nels line # I observed fecal material in of the birds I randomly selected for zero tolerance check at CCP # 2-B. The fecal material was light brown in color, and pasty in consistency. It was approximately ó inch in length and . inch in width and located on the upper inside of the carcass on the back next to the tail with a intestine attached to the tail of the carcass. Mr. , 1st Processing Superintendent was immediately notified and shown the deviation. Approximately establishments HACCP Plan the line was immediately stopped and a house inspector was put on the line and line slowed down to BPM. The affected carcass was then sent to the reprocessing station, reconditioned and placed back in flow as per the establishment’s corrective action. The establishment has failed to meet regulatory requirements of 9 CFR417.2 (c) (4) and 381.65 (e). A review of the of the establishments CCP # 2-B monitoring log for line was documented as the last acceptable check was performed at 1812 pm with quantifiable value of 0/10 and was verified by QA technician with the initals….As a result of the deviation, all requirements for all CCPs for the specified lot (lot # 6) were performed by SCSI and found acceptable, including the pre-shipment review. The establishment management stated the root cause was the the back-up venter needed to be retrained. This document serves as written notice that continued failure to comply with the regulatory requirements may result in additional regulatory or administrative action(s) as described in 9 CFR 500.

Regulation:

417.2(c)(4) The contents of the HACCP plan. The HACCP plan shall, at a minimum: (1) List the food safety hazards identified in accordance with paragraph (a) of this section, which must be controlled for each process. (2) List the critical control points for each of the identified food safety hazards, including, as appropriate: (i) Critical control points designed to control food safety hazards that could be introduced in the establishment, and (ii) Critical control points designed to control food safety hazards introduced outside the establishment, including food safety hazards that occur before, during, and after entry into the establishment; (3) List the critical limits that must be met at each of the critical control points. Critical limits shall, at a minimum, be designed to ensure that applicable targets or performance standards established by FSIS, and any other requirement set forth in this chapter pertaining to the specific process or product, are met; (4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits; (5) Include all corrective actions that have been developed in accordance with §417.3(a) of this part, to be followed in response to any deviation from a critical limit at a critical control point; and (6) Provide for a recordkeeping system that documents the monitoring of the critical control points. The records shall contain the actual values and observations obtained during monitoring. (7) 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. (d) Signing and dating the HACCP plan. (1) The HACCP plan shall be signed and dated by the responsible establishment individual. This signature shall signify that the establishment accepts and will implement the HACCP plan. (2) The HACCP plan shall be dated and signed: (i) Upon initial acceptance; (ii) Upon any modification; and (iii) At least annually, upon reassessment, as required under §417.4(a)(3) of this part. (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.

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

Code: 04B01
Violation: 381.123

Citation: At approximately 1812 hours, while performing a labeling-product standards check in the wet cooler, I observed a pallet of whole birds (805’s) with numerous labels torn and the ink on the label smudged. The labels were not legible as well as the inspection mark was not legible. I immediately tagged the pallet of product with US Retain tag #B38206332. Mr. , Cut-Up Supervisor was immediately notified of the establishments failure to comply with 9 CFR 381.123 of the regulatory requirements. He informed me that the root cause was the scale person was not putting the label on correctly, causing the glue that seals the boxes to smudge the ink on the label. He stated that the boxes would be re-labeled. CSI  verified the corrective action at 1934 hours and regulatory control of the product was relinquished. Ms. , Plant Manager is being notified through this non-compliance record that continued failure to meet the regulatory requirements could lead to additional regulatory control or administrative actions being taken as per 9 CFR 500 Rules of Practice.

Regulation: The immediate container of every inspected and passed poultry product shall bear: (a) The official inspection legend; and (b) The official establishment number of the official establishment in which the product was processed under inspection and placed as follows: (1) Within the official inspection legend in the form required by subpart M of this part; or (2) Outside the official inspection legend elsewhere on the exterior of the container or its labeling, e.g., the lid of a can, if shown in a prominent and legible manner in a size sufficient to insure easy visibility and recognition and accompanied by the prefix ‘‘P’’; or (3) Off the exterior of the container, e.g., on a metal clip used to close casings or bags, or on the back of a paper label of a canned product, or on other packaging or labeling in the container, e.g., on aluminum pans and trays placed within containers, when a statement of its location is printed contig- uous to the official inspection legend, such as ‘‘Plant No. on Package Closure’’ or ‘‘Plant No. on Pan’’, if shown in a prominent and legible manner in a size sufficient to ensure easy visibility and recognition; or (4) On an insert label placed under a transparent covering if clearly visible and legible and accompanied by the prefix ‘‘P’’.

Code: 06D02
Violation: 381.76(b)

Citation: At 1516 hours, while performing a Presentation procedure on evisceration line station A, I observed a non-compliance. A nonconformance score of was observed. The nonconformance defects consisted of 1 “viscera in the front”(scoring points), two birds “no viscera” (scoring points) and one bird “opening cut”(scoring point). Mr. Evisceration Line supervisor was immediately notified of the establishment’s failure. The establishment immediately reduced the line speed to B.P.M. as per requirements. At 1528 hours, the retest was preformed by the QA Technician with the initials and found to be acceptable and line speed was increased to B.P.M. At 1542 hours, a subsequent retest was performed by QA and nonconformance levels were found to be acceptable for process control.Ms. , Plant Manager is being notified through this Noncompliance record of the establishment’s failure to meet the regulatory requirements of 9 CFR 381.76(b) and that offical control was initiated as per the Rules Of Practice 9 CFR Section 500.  This document serves as written notification that continued failure to comply with regulatory requirements may result in additional regulatory or administrative actions.

Regulation: There are five systems of post- mortem inspection: Streamlined Inspection System (SIS) and the New Line Speed (NELS) Inspection System, both of which shall be used only for broilers and cornish game hens; the New Turkey Inspection (NTI) System, which shall be used only for turkeys; Traditional Inspection; and Ratite Inspection.

Code: 03J02
Violation: 417.2(c)(4), 381.65(e)

Citation: Today, at approximately 1111 hours, while performing a poultry finished product standards task on evisceration line I observed fecal material on the inside upper back area of one out of ten randomly selected carcasses. The fecal material was approximately  a half inch in length, pasty and brownish color. I immediately notified Mr. , Day Shift First Processing Superintendent, who observed the affected carcass. Corrective actions were immediately implemented per the establishments HACCP plan for CCP 2B. Line speed was reduced from birds per minute to The affected carcass was taken to the reprocessing salvage area, washed inside and outside and placed in the salvage tank. The last acceptable check was documented on the establishments zero tolerance log at 1046 hours. Mr. verbally stated the root cause was due to the liver puller not turning the bird around before it reached the crop machine. The establishment failed to meet the regulatory requirements of 9 CFR 417.2(c))(4) and 381.65(e). This document serves as written notification to Mrs. , Plant Manager, that continued failure to meet the regulatory requirements could result in additional regulatory enforcement actions per 9 CFR 500.

Regulation:

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits.

381.65(e)  Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank. List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits.

Code: 02B02
Violation: 416.4(a), 416.13(c)

Citation: Today, June 8, 2012 at approximately 0456 hours while performing a Pre- Operational SSOP Review and Observation task in evisceration area three, I observed a white, greasy residue inside the piping from the previous day’s production on the heart and liver harvester for line  I notified Mr. Sanitation Manager and Mr. , Day Shift Production Manager of this direct product contact surface noncompliance. The unit was tagged with U.S. Reject Tag #B38206132, the pipes were disassembled, washed, and santitized. The pipes were reinspected and regulatory control was relinquished at 0506 hours.The establishment has failed to comply with Sanitation Performance Standard 9 CFR 416.4(a) and Sanitation Standard Operating Procedure 9 CFR 416.13(c) regulatory requirements. Also violated was the establishments SSOP Plan, page 1 which addresses the cleaning of pipes.This noncompliance serves as written notification to Ms. Plant Manager, that continued failure to meet the regulatory requirements could result in further regulatory enforcement actions per 9 CFR 500. (b)(6)(b)(7)(C)

Regulation:

416.4(a) 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.

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

Code: 03J02
Violation: 381.65(e), 417.2(c)(4)

Citation: Today, May 30, 2012 at approximately 0540 hours, while performing a poultry finished product standard procedure on evisceration line I observed visible fecal material on the left hock joint of one out of ten randomly selected carcasses.  The fecal material was approximately 1/8 of inch in length, green and pasty in substance. I immediately notified Mr. , Day Shift First Processing Superintendent, who observed the affected carcass. Corrective actions were immediately implemented, line speed was reduced from bpm to bpm. An associate was placed at the end of the af cted line, and upon completion of the retest line speed was resumed to bpm per the HACCP plan for CCP 2B. The affected carcass was taken to the reprocessing area to be reprocessed. The Slaughter HACCP Verification procedure was performed for the pertinent CCPs including the pre-shipment review, and found acceptable.  Mr. , First Processing Superintendent, verbally informed me that the root cause of the deviation was broken viscera being placed in shackle on top of hock joint by the puller.  The establishment failed to meet the regulatory of of 9 CFR 417.2(c)(4) and 381.65(e).  This document serves as a written notification to Mrs. , Plant Manager, that continued failure to meet the regulatory requirements could result in additional regulatory enforcement actions per 9 CFR 500.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits; Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

Code: 03J04
Violation: 417.2(c)(4), 381.65(e)

Citation: At 1454, while performing PHIS inspection task for “Poultry Zero Tolerance Verification”, I observed visible fecal material on the wing tip area of the 8th bird I checked, from evisceration line The lightbrown colored fecal material was of a semi-solid consistency and approximately ¼ inch in diameter. Ms. (Evisceration Supervisor) was present during the check and observed the fecal contamination noncompliance as well. Ms. initiated the plant’s corrective action procedure for CCP #2B by reducing the line speed on line from B/M to B/M. &nbsp;In addition, an associate was placed at the end of the affected line which is in accordance with their HACCP plan. The affected carcass was taken to the plant’s reprocessing station, reconditioned and worked back into production. (Quality Assurance Tech.) performed two fecal retest on line at 1455 and 1458. Both retests were acceptable. The last acceptable fecal test on evisceration line was performed at 1332 and the checks were authenticated with the initial Mr. (1st Processing Superintendent) verbally informed me that the cause of deviation was that the motor to the gut cutter on line stopped working allowing the wings of the birds to drag over the non-working blade area. The establishment failed to meet the regulatory requirements of 9 CFR 417.2(c) and 381.65(e). As a result of the deviation, all requirements for all CCP’s for the specified lot was performed and found acceptable including preshipment review. This document serves as written notification to Mrs. , Plant Manager that continued failure to meet the regulatory requirements could result in additional regulatory enforcement actions per 9 CFR 500.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

 417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to
monitor each of the critical control points to ensure compliance with the critical limits;

Code: 03J04
Violation:  417.2(c)(4), 381.65(e)

Citation: Approximately 1513 pm while performing a zero tolerance procedure on line I observed fecal material inside one of the 10 birds I randomly selected for zero tolerance check at CCP # 2-B. The fecal material was brown in color, and pasty in consistency. It was approximately 1/8 inch in length and 1/8 inch in width and located on the upper inside of the carcass under the tail&nbsp; with a intestine attached to the tail of the carcass. Mr. 1st Processing Superintendent and Plant Manager was notified and witnessed the feces. Approximately establishments HACCP Plan the line was immediately stopped and a house inspector was put on the line. &nbsp; line was then reduced from to mph. The affected carcass was then sent to the reprocessing station, reconditioned and placed back in flow as per the establishment’s corrective action. The establishment has failed to meet regulatory requirements of 9 CFR417.2 (c) (4) and 381.65 (e). A review of the of the establishments CCP # 2-B monitoring log for line was documented as the last acceptable check was performed at 1450 pm with quantifiable value of 0/10 and was verified by QA technician with the initals As a result of the deviation, all requirements for all CCP’s for the specified lot (lot # 1-B) was performed and found acceptable, including the pre-shipment review. The establishment management stated the root cause was a hose was loose on the vent cutter. &nbsp;This document serves as written notice that continued failure to comply with the regulatory requirements may result in additional regulatory or administrative action(s) as described in 9 CFR 500.

Regulation:

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

Code: 01C02
Violation: 416.13(c), 416.2(a), 416.4(d)

Citation: While performing post-mortem inspection in the Evisceration Department at approximately 1255 hours on 5/22/2012, Food Inspector observed a roach on the leg of a carcass arriving at inspection station 1A. The roach was dark brown in color and approximately 1.5 inches in length. Food Inspector ; immediately stopped the line and notified line supervisor who witnessed this regulatory noncompliance. The establishment implemented corrective action in accordance to 9 CFR 416.15 by condemning the affected carcass as well as the five carcasses on each side of it and washed the shackles. The line was allowed to resume after the corrective action requirements were met with a downtime time of approximately 3 minutes. , Plant Manager, informed Dr. that the localized area including the old bathroom would be heavily fogged the weekend of 5/26/12. Due to the roach sighting and the contamination of product the establishment failed to meet the regulatory requirements of 9 CFR 416.13(c), 416.1, 416.2(a), and 416.4(d). Also violated was Section 1, page 1, of the establishment’s SSOP plan which addresses product contamination. This Noncompliance Record is written documentation to Plant Manager, that the failure to comply with regulatory requirements could result in additional enforcement action per 9 CFR 500.

Regulation:

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

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.

416.4(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

Code: 03J04
Violation: 417.2(c)(4), 381.65(e)

Citation: Today, May 18, 2012 at approximately 0539 hours while performing a zero tolerance check on Evisceration line I observed fecal on one of ten randomly selected carcasses.&nbsp; The fecal material was located on the back of the wing, brownish in color and pasty in substance I immediately notified Mr. , First Processing Superintendent, who observed the affected carcass. Corrective actions were immediatel implemented line speed was reduced from bpm to bpm. An associate was placed at the end of the affected line, and upon completion of the retest line speed was resumed to bpm per the HACCP plan for CCP 2B. The affected carcass was taken to the reprocessing area to be rinsed. Mr. verbally informed me that the cause of the deviation was the bird &nbsp;flipper before the final washer was bent. The establishment failed to meet the regulatory requirements of 9 CFR 417.2(c) (4) and 381.65(e). This document serves as written notification to Mrs. , Plant Manager that continued failure to meet the regulatory requirements could result in additional regulatory enforcement actions per 9 CFR 500. &nbsp;

Regulation:

 417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

Code: 03J04
Violation: 417.2(c)(4), 381.65(e)

Citation: Approximately&nbsp; 2015 pm while performing a zero tolerance procedure on line # I observed fecal material on 1 of the 10 birds I randomly selected for zero tolerance check at CCP # 2-B. The fecal material was brown in color, and pasty in consistency. It was approximately 1 inch in length and&nbsp;1/4 inch in width and located on the upper inside of the carcass next to the tail with a intestine attached to the tail of the carcass. Mr. 1st Processing Superintendent and Nightshift Evis Supervisor Line was immediately notified and shown the deviation. Approximately&nbsp; as per the establishments HACCP Plan the line was immediately stopped and a house inspector was put on the line. The affected carcass was then sent to the reprocessing station, reconditioned and placed back in flow as per the establishment’s corrective action. The establishment has failed to meet regulatory requirements of 9 CFR417.2 (c) (4) and 381.65 (e). A review of the of the establishments CCP # 2-B monitoring log for line # was documented as the last acceptable check was performed quantifiable value of 0/10 and was verified by QA technician with the initals As a result of the deviation, all requirements for all CCP’s for the specified lot (lot # 6-A) was performed and found acceptable, including the pre-shipment review. The establishment management stated the root cause was the back-up venter was cutting too deep. This document serves as written notice that continued failure to comply with the regulatory requirements may result in additional regulatory or administrative action(s) as described in 9 CFR 500.

Regulation:

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

Code: 06D02
Violation: 381.76(b)

Citation: At 1548 hours, while performing presentation on line station B&nbsp; I observed a non-conformance level of The nonconformance defects consisted of three birds (No Viscera) scoring NS First Processing Superintendent was immediately notified of the establishment’s failure. Mr. immediately reduced the line speed from Birds per minutes to B.P.M. and notified Q.A for a retest as per the presentation requirements. At 1558 hours the QA personal performed a retest, and the conformance levels was found acceptable with score of or line # stations A, B and C. The line speed was then increased to BPM. A subsequent retest was performed and nonconformance levels found to be acceptable. The line speed was increased to B.P.M. The establishment has failed to meet 9 CFR 381.76 (b) of the regulatory requirements. This document serves as written notification that continued failure to comply with regulatory requirement(s) may result in additional regulatory or administrative action(s) as described in 9 CFR 500.

Regulation:

381.76(b) ) The operator requests SIS and the Administrator determines that the system will result in no loss of inspection efficiency.

Code: 03J04
Violation: 417.2(c)(4), 381.65(e)

Citation: Approximately 1602 pm while performing a zero tolerance procedure on line # observed fecal material on 1 of the 10 birds I randomly selected for zero tolerance check at CCP # 2-B. The fecal material was brown in color, and pasty in consistency. It was approximately 1/2 inch in length and&nbsp;1/8 inch in width and located on the outside of the left wing of the carcass. Mr. , 1st Processing Superintendent and Plant Manager was immediately notified and shown the deviation. Approximately 1604 pm, as per the establishments HACCP Plan the line was immediately stopped and a house inspector was put on the line. The affected carcass was then sent to the reprocessing station, reconditioned and placed back in flow as per the establishment’s corrective action. The establishment has failed to meet regulatory requirements of 9 CFR417.2 (c) (4) and 381.65 (e). A review of the of the establishments CCP # 2-B monitoring log for line # was documented as the last acceptable check was performed at 1555 pm with quantifiable value of 0/10 and was verified by QA technician with the initals As a result of the deviation, all requirements for all CCP’s for the specified lot (lot # 2-B) was performed and found acceptable, including the pre-shipment review. The establishment management stated the root cause was the blade motor on the gut cutter stopped, causing the guts to drag and the feces fell onto the wing. Maintenance reset the cutter. &nbsp;This document serves as written notice that continued failure to comply with the regulatory requirements may result in additional regulatory or administrative action(s) as described in 9 CFR 500.

Regulation:

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

Code: 01C02
Violation: 416.13(c), 416.4(d)

Citation: At approximately 1630 hours, while touring the tray pack area&nbsp; adjacent to the Cone Debone Department, I observed trays too numerous to count piled up in orange tubs on the end of each line. (lines At the end of line trays for rework were piled up on the belt going to the mezzanine and had overflowed onto the floor. As I walked towards the front of the lines, trays were piled up and out of control on all the lines and were stacked up in trays to be put back on the line. No establishment personnel were attending the overflowed product at the time I entered into the area. I &nbsp;immediately took regulatory control action of rejecting the tray pack process with US reject tag # B38206269 and rejecting the Cone Debone process that feeds tray pack lines through ;with US Reject tag #B38206274. Mr. Day Shift Breast Debone Superintendent and Ms. Day Shift Further Processing Superintendent were present and did witness the establishment’s failure to meet the regulatory requirements of 9 CFR 416.4(d) and 416.13(c). Regulatory control action was relinquished at approximately 1641 hours when sanitary conditions were restored to the area and the salvage product was cleared from areas. This document serves as written notification to Ms. , Plant Manager, that continued failure to meet the regulatory requirements could result in additional regulatory or administrative actions.

Regulation:

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

416.4(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

Code: 04B04
Violation: 381.125(b)

Citation: At approximately 2004 hours, while touring tray pack lines through I observed packages of Jumbo Tenders being put on trays and packaged on line of the department. Upon further observation of the finished packaged product, I noticed that the safe handling label was not &nbsp;legible. It was not likely to be able to be read or understood by the ordinary individual under conditions of purchase and use. I immediately rejected the Tray Pack Line 11 process, with US Reject tag # 38206333 Mr. , Night Shift Tray Pack Foreman, had the label machine was reset to show a large and improved safe handling label on the product &nbsp; as the corrective action and regulatory control was relinquished at approximately 2007 hours after the label was reset on the product. Mr. Night Shift Manager and Mr. , Night Shift Further Processing Superintendent, were both present and did witness the establishment’s failure to meet the regulatory requirements of 9 CFR 381.125(b). As a result of this noncompliance, a check of the dry cooler found approximately 165 boxes of Jumbo Tenders (approximately 1600 trays) that had the ineligible safe handling labels on them. I took regulatory control by placing US Retained tag # B38206334 on the product found in the Dry Cooler. Mr. stated that the product that was produced prior to 2004 hours would be reworked by placing a safe handling sticker on them. After verifying the corrective actions were completed, regulatory control was relinquished and the product was released for shipment. This document serves as written notification that continued failure to meet the regulatory requirements could result in further administrative of regulatory actions as per 9 CFR 500.

Regulation:

381.125(b) Safe handling instructions shall be provided for all poultry products not processed in accordance with the provisions of §381.150(a) or that have not undergone other processing that would render them ready-to-eat, except as exempted under paragraph (b)(4) of this section.

Code: 03J04
Violation: 417.2(c)(4), 381.65(e)

Citation: Today, March 28, 2012 at approximately 0546 hours, while performing a poultry finished product standard procedure on evisceration line I observed fecal on the back of one out of ten randomly selected carcasses. The fecal material was approximately one quarter inch in diameter, green and pasty in substance. I immediately notified Mr. &nbsp; First ; Processing Superintendent, who observed the affected carcass. Corrective actions were immediately implemented; line speed was reduced from bpm to bpm. An associate was placed at the end of the affected line, and upon completion of the retest line speed was resumed to bpm per the HACCP plan for CCP 2B. Mr. took the affected carcass to the reprocessing station to be rinsed with ppm chlorinated water and put back in the flow of product. The Slaughter HACCP was performed by verification of records for the pertinent CCPs. Mr. First Processing Superintendent, verbally informed me that the root cause was due to shortage of maintenance personnel to monitor the machines. ;The establishment failed to meet the regulatory requirements of 9 CFR 417.2(c) (4) and 381.65(e).

This document serves as written notification to Mrs. , Plant Manager that continued failure to meet the regulatory requirements could result in additional regulatory enforcement actions per 9 CFR 500.

Regulation:

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

Code: 06D02
Violation: 381.76(b)

Citation: At approximately 2030 hours, while performing presentation on the line # station C (NELS) I observed defects that exceeded the action level of greater than with a nonconformance score of The defects consisted of 2 birds with viscera on the shackle (scoring and 2 birds with no viscera (scoring I immediately notified Mr. Evisceration line 1 supervisor, and Mr. Night Shift First Processing Superintendent of the nonconformance levels. An immediate line reduction from birds per minute to birds per minute was implemented as per the regulatory requirements for the NELS system. At 2040 hours a retest was performed at Line # station C with a score of The line speed was increased to birds per minute. At 2055 hours a retest was performed, found acceptable with process control. Mr. and Mr. were present and did witness the establishment’s failure to comply with 9 CFR 381.76 (b) of the regulatory requirements and that official control was initiated as per the Rules of Practice 9 CFR Section 500. This document serves as written notification that continued failure of comply with the regulatory requirements may result in additional regulatory or administrative actions.

Regulation:

381.76(b)(1) There are five systems of post- mortem inspection: Streamlined Inspection System (SIS) and the New Line Speed (NELS) Inspection System, both of which shall be used only for broilers and cornish game hens; the New Turkey Inspection (NTI) System, which shall be used only for turkeys; Traditional Inspection; and Ratite Inspection.

Code: 01D01
Violation: 416.4(b)

Citation: Approximately 1445 while touring the wet cooler coming from the stretch bag area I observed a plant employee standing on top of the pallet that had box lids on it. The box lids were being used for boxed whole birds coming from the whole bird packing area. The plant employee stood on the pallet of box lids leaving wet bloody footprints on the pallet. He then slid the box lids from the back end of the pallet to the front of the pallet where the employee was standing. I immediately tag the pallet of box lids with retain tag # B38206492. I then notified Dayshift wet cooler supervisor, and Dayshift Second Processing Superintendent. The establishment has failed to meet regulatory requirements 9 CFR 416.4(b) Dayshift wet cooler supervisor removed the affected box lids and the pallet. This document serves as written notification that continued failure to comply with regulatory requirement(s) may result in additional regulatory or administrative action(s) as described in 9 CFR 500.

Regulation:

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: 03J04
Violation: 417.2(c)(4), 381.65(e)

Citation: Today, February 27, 2012 at approximately 0555 hours, while performing a zero tolerance task for evisceration line I observed fecal material on the left leaf fat area of one out of ten randomly selected carcasses. The fecal material was approximately one half inch in length, green and pasty in substance. I immediately notified Mr. , Day Shift Supervisor, who observed the affected carcass. Corrective actions were immediately implemented; line speed was reduced from bpm to bpm. An associate was placed at the end of the affected line, and upon completion of the retest line speed was resumed to bpm per the HACCP plan for CCP 2B. Mr. took the affected carcass to the reprocessing area to be rinsed with ppm chlorinated water and put back in the flow of product. The cause of the deviation documented on the establishment monitoring log was, the vacuum pump was down on the vent machine causing the intestines to be cut. The establishment failed to meet the regulatory requirements of 9 CFR 417.2(c)(4) and 381.65(e). A similar noncompliance was documented on NR #KYN4212022708N/1, dated 2/8/2012. The preventive measures that were given in response to that NR by the establishment were that maintenance would be monitoring the eviscerator for the remainder of the shift and each time there is a lot change maintenance will be notified to make sure the eviscerator is properly adjusted.The preventive measures were implemented by the establishment as stated and the establishment documentation did not show any deviations for the period of additonal monitoring. However, these preventive measures were ineffective in preventing recurrence of this regulatory noncompliance.This document serves as written notification to Mrs. , Plant Manager, that continued failure to meet the regulatory requirements could result in additional regulatory enforcement actions per 9 CFR 500.

Regulation:

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

Code: 01C02
Violation: 416.4(d), 416.13(c)

Citation: While touring the establishment at approximately 1845 hours, I observed carcasses too numerous to count piled up under the Cone Debone dumper conveyor and also on the floor under the dumper. The regulatory control action of stopping all lines feeding the cone debone department was put into place to prevent product contamination. Mr. and Mr. Night Shift Cone Debone Supervisors witnessed the noncompliance and were notified of the failure to meet the regulatory requirements of 9 CFR 416.13 (c) and 416.4(d). The process was rejected with US Reject tag #B38206275 and the affected carcasses were washed in accordance with the SSOP plan for contaminated product handling. Regulatory control action was relinquished at approximately 1848 hours when sanitary conditions were restored. This document serves as written notification to Plant Manager, that continued failure to meet regulatory requirements could result in additional regulatory or administrative actions.

Regulation:

416.4(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

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

Code: 03J04
Violation: 381.65(e), 417.2(c)(4)

Citation: At 2008 hours, while performing a zero tolerance procedure on NELS Line I observed fecal material on 1 out of 10 of my randomly selected carcasses for inspection at CCP #2B. The fecal material was brown in color, pasty in consistency, approximately 1/4 inch in width and length. The fecal material was located on the inside back near the kidneys. Ms. and Ms. Night Shift Evisceration Supervisors, were present and witnessed the deviation. I observed the establishment perform corrective actions as per their HACCP plan. The affected carcass was sent to the reprocessing station, reconditioned and place back into flow. Since there are no interventions between the prechill station and the chiller, it is reasonable to conclude that the contaminated carcass would have entered the chiller. A review of the establishment’s zero tolerance log for CCP #2B, line revealed that the last acceptable check performed at 1950 hours, was found to be acceptable and was recorded with a quantifiable value of 0/10 and the initials for the QA technician. As a result of the deviation, all requirements at all CCP’s for that specific lot was performed and found to be acceptable including the pre-shipment review. Mr. Maintenance Supervisor, stated that the root cause was that one nozzle on the Inside/Outside Bird Washer was off and the other two nozzles were turned half way off. The nozzles were adjusted and turned on. Ms. Plant Manager, is being notified of the failure to meet the requirements of 9 CFR 417.2(c)(4) and 381.65(e). This document serves as written notice that continued failure to comply with the regulatory requirements may result in additional regulatory or administrative actions as per 9 CFR 500.

Regulation:

 381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

Code: 03J04
Violation: 381.65(e), 417.2(c)(4)

Citation: Approximately 1555 pm while performing a zero tolerance procedure on line I observed fecal material on 1 of the 10 birds I randomly selected for zero tolerance check at CCP # 2-B. The fecal material was brown in color, and pasty in consistency. It was approximately1/2 inch in length and1/4 inch in width and located on the upper inside of the carcass on the left flap with a intestine attached to the tail of the carcass. Mr. 1st Processing Superintendent and Nightshift Evis Supervisor Line was immediately notified and shown the deviation. Approximately per the establishments HACCP Plan the line was immediately stopped and a house inspector was put on the line. The affected carcass was then sent to the reprocessing station, reconditioned and placed back in flow as per the establishments corrective action. The establishment has failed to meet regulatory requirements of 9 CFR417.2 (c) (4) and 381.65 (e). A review of the of the establishments CCP # 2-B monitoring log for Nels line was documented as the last acceptable check was performed at 1537 pm with quantifiable  value of 0/10 and was verified by QA technician with the initals As a result of the deviation, all requirements for all CCPs for that specified lot (lot # 2-B) was performed and found acceptable, including the pre-shipment review. The establishment management stated the root cause was the Ball valve was left open causing the machine to drop. The machine was adjusted. This document serves as written notice that continued failure to comply with the regulatory requirements may result in additional regulatory or administrative action(s) as described in 9 CFR 500.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

Code: 01C02
Violation: 416.13(c), 416.4(a), 416.4(d)

Citation: Approximately 1950 pm while touring the Evis department I observed a plant employee taking a intestine off the top of the livers on line # and line # at the liver harvesting table, throw the intestine on the floor and continuing to put livers in the liver shot that carries the livers to the second processing area. I immediately stop the line and notified line Nightshift Evis Supervisor, and N/S First Processing Superintendent. The livers on the liver harvesting tables were thrown down the drain and a plant employee used a hose to rinse down the liver harvesting tables. I then informed , N/S First Processing Superintendent that the establishments SOP procedure for handling product contaminated with guts states . A chlorine test done by a QA technician indicated there was no chlorine in the water from the hose used to wash the liver harvesting table. Establishments management stop both lines again to remove the liver from the liver harvesting tables on lines sanitized the tables as per their SOP procedure. To ensure no contaminated product entered the commerce establishment management condemned lbs. of liver accumulated from the time the gut contaminated the livers until the liver harvesting tables were sanitized as per the establishments SOP procedures. The plant has failed to meet 9 CFR 416. 4(a) and 9 CFR 416. 4(d) & 416.13(c)of the regulatory requirements. This document serves as written notice that continued failure to comply with the regulatory requirements may result in additional regulatory or administrative action(s) as described.

Regulation:

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

 416.4(a) 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.

416.4(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

Code: 03J04
Violation: 381.65(e), 417.2(c)(4)

Citation: At approximately 2003 hours, while performing a zero tolerance procedure on evisceration line I observed fecal material on the outside of five different carcasses.Two of the carcasses were part of the ten randomly selected carcasses and three were observed on the line. The fecal material was found as follows: the first carcass the fecal was on the middle left side, the second carcass fecal was found on the leg on the right front side, the third carcass fecal was found on the top right side of the back, the fourth carcass fecal was found on the left wing and the fifth carcass fecal was found on the right wing. The fecal material was all light brown in color and pasty in substance. The size of the fecal material ranged from a quarter inch in length to one half inch in length. I immediately notified Mr. Night Shift First Processing Superintendent and also Ms. Plant Manager who were both present and observed the affected carcasses. Corrective actions were immediately implemented as per the establishment’s HACCP plan. I observed Mr. take the carcasses to the reprocessing station to be reconditioned and placed back into flow. A review of the establishments zero tolerance log for CCP # 2B, Line revealed that the last acceptable check was performed at 1946 hours, was found to be acceptable and recorded with a quantifiable value of 0/10 and the initals BB for the QA technician. As a result of the deviation, all requirements at all CCP’s for that specific lot was performed and found to be acceptable including the pre-shipment review.A extra person was stationed at the end of the line, for the duration of the shift, to look for fecal due to the amount of fecal that was found. Mr. Director of Processing Operations, statedon 02/09/2012 that the root cause was theInside/Outside bird washer had a nozzle that was notturned on. The establishment failed to meet the regulatory requirements of 9 CFR 417.2(c)(4) and 381.65(e). This document serves as written notice that continued failure to comply with the regulatory requirements may result in additional regulatory or administrative actions as per 9 CFR 500.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

Code: 03J04
Violation: 381.65(e), 417.2(c)(4)

Citation: Approximately 1506 pm while performing a zero tolerance procedure on line # I observed fecal material on 1 of the 10 birds I randomly selected for zero tolerance check at CCP # 2-B. The fecal material was brown in color, and pasty in consistency. It was approximately 1/2 inch in length and1/4 inch in width and located on the upper inside of the carcass close to the tail. Mr. Nightshift Evis Suprvisor, line # and Nightshift Plant Manager was immediately notified and shown the deviation. Approximately 1508 pm, as per the establishments HACCP Plan the line was immediately stopped and a house inspector was put on the line. The affected carcass was then sent to the reprocessing station, reconditioned and placed back in flow as per the establishment’s corrective action. The establishment has failed to meet regulatory requirements of 9 CFR417.2 (c) (4) and 381.65 (e). A review of the of the establishments CCP # 2-B monitoring log for line # was documented as the last acceptable check was performed at 1443 pm with quantifiable value of 0/10. As a result of the deviation, all requirements for all CCPs for the specified lot (lot # 1-A) was performed and found acceptable, including the pre-shipment review. The establishment management stated the root cause was the back-up vent cutters were still in training. This document serves as written notice that continued failure to comply with the regulatory requirements may result in additional regulatory or administrative action(s) as described in 9 CFR 500.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

Code: 03J04
Violation: 381.65(e), 417.2(c)(4)

Citation: Approximately2114 pm while performing a zero tolerance procedure on line I observed fecal material on 1 of the 10 birds I randomly selected for zero tolerance check at CCP # 2-B. The fecal material was dark brown in color, and pasty in consistency. It was approximately1 inch in length and1 inch in width and located on the upper inside of the carcass close to the tail. Mr. 1st Processing Superintendent and Nightshift Evis Supervisor, Line # was immediately notified and shown the deviation. Approximately 2116 pm, as per the establishments HACCP Plan the line was immediately stopped and a house inspector was put on the line. The affected carcass was then sent to the reprocessing station, reconditioned and placed back in flow as per the establishment’s corrective action. The establishment has failed to meet regulatory requirements of 9 CFR417.2 (c) (4) and 381.65 (e). A review of the of the establishments CCP # 2-B monitoring log for line # was documented as the last acceptable check was performed at 2044 pm with quantifiable value of 0/10. As a result of the deviation, all requirements for all CCP’s for the specified lot (lot # 7-B) was performed and found acceptable, including the pre-shipment review. The establishment management stated the root cause was the back-up venter was in training,an additional back-up venter was added. This document serves as written notice that continued failure to comply with the regulatory requirements may result in additional regulatory or administrative action(s) as described in 9 CFR 500.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

Code: 03J04
Violation: 381.65(e), 417.2(c)(4)

Citation: Approximately2114 pm while performing a zero tolerance procedure on line I observed fecal material on 1 of the 10 birds I randomly selected for zero tolerance check at CCP # 2-B. The fecal material was dark brown in color, and pasty in consistency. It was approximately1 inch in length and1 inch in width and located on the upper inside of the carcass close to the tail. Mr. 1st Processing Superintendent and Nightshift Evis Supervisor, Line # was immediately notified and shown the deviation. Approximately 2116 pm, as per the establishments HACCP Plan the line was immediately stopped and a house inspector was put on the line. The affected carcass was then sent to the reprocessing station, reconditioned and placed back in flow as per the establishment’s corrective action. The establishment has failed to meet regulatory requirements of 9 CFR417.2 (c) (4) and 381.65 (e). A review of the of the establishments CCP # 2-B monitoring log for line # was documented as the last acceptable check was performed at 2044 pm with quantifiable value of 0/10. As a result of the deviation, all requirements for all CCP’s for the specified lot (lot # 7-B) was performed and found acceptable, including the pre-shipment review. The establishment management stated the root cause was the back-up venter was in training,an additional back-up venter was added. This document serves as written notice that continued failure to comply with the regulatory requirements may result in additional regulatory or administrative action(s) as described in 9 CFR 500.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

Code: 01C02
Violation: 416.4(b)

Citation: Approximately 1730 pm while touring the Tray-Pack warehouse I observed a pack of yellow tray-pack on the floor. The plastic cover was torn open leaving the trays exposed. I tagged the trays with retain tag # B38206500. I also observed a bag of yellow trays that were wet and had blood, meat and fat particles on them. I retain the bag of trays with retain tag # B38206496. I also observed a pallet of yellow trays that had a pack of yellow trays leaning on the rodent trap # 78. I immediately informed Night Shift Manager and Night Shift Q.A. Supervisor. I observed take corrective actions, removing the affected trays and throwing them in the trash bin. The establishment has failed to meet 9 CFR 416.4(b) of the regulatory requirement. This document serves as written notification that continued failure to comply with regulatory requirement(s) may result in additional regulatory or administrative action(s) as described in 9 CFR 500.

Regulation:

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: 01C02
Violation: 416.13(b), 416.4(a), 416.4(d)

Citation: At approximately 15:10 pm on Thursday, January 19, 2012 while touring the second processing department in Breast Debone the following noncompliance was noted. I observed a plant employee washing down the dirty floor with water which was also splashing (from the dirty floor) directly onto an uncovered “cone head” of the breast debone conveyer belt line There was no water washing down the “cone head” nor the conveyer belt to Breast debones line at the time of Inspection. Regulatory control action was initiated by stopping the line, and the products were retained by the application of a US retained tag numbered B38206174. I immediately notified Mr. Day shift Breast Debone Superintendent of this noncompliance and that a regulatory control actions were taken. The requirements of parts 416.13(c); 416.4(a &d) of the meat and poultry regulations were not met. Ms. Plant manager is being notified through this noncompliance record of the plant failure to meet the regulatory requirements, and that official control action was initiated. Upon restoration of the sanitary conditions regulatory control action was relinquished and operation resumed as normal. This document serves as a written notification that your failure to comply with the regulatory requirement(s) could result in additional regulatory or administrative action described in 9 CFR 500

Regulation:

416.13(b) Each official establishment shall conduct all other procedures in the Sanitation SOP’s at the frequencies specified.

416.4(a) 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.

416.4(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

Code: 01C02
Violation: 416.13(b), 416.13(c), 416.4(d)

Citation: At 1901 hours, while the eviseration department Lines and were going through midshift cleanup and Lines the savage station, and the Gizzard Table were still in operation, I observed debris from Lines and being sprayed into a salvaged product tote of breasts and then into a salvaged product tote of leg quarters (from different directions), adulterating the breasts and the leg quarters. This is a noncompliance with 9CFR416.4d. I took a regulatory control action (9CFR500) by applying US Retain tag #B21-187721 retaining adulterated product (Breasts) and US Retain tag #B21-187722 retaining adulterated product (Leg Quarters). I notified Supervisor and Supervisor Robert Tull of the noncompliance, that product integrity was impacted, and of my action. Supervisor Chambers proceeded with corrective action for the adulterated product. Regulatory control was released at 1930 hours. This document serves as written notification to Ms. (Plant Manager) of the noncompliance with 9CFR416.1, 416.13(b), and 416.13(c). Continued failure to meet regulatory requirements could result in additional regulatory action per 9CFR500.4

Regulation:

416.13(b) Each official establishment shall conduct all other procedures in the Sanitation SOP’s at the frequencies specified.

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

416.4(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

Code: 01D01
Violation: 416.1, 416.2(b)(3)

Citation: Approximately 1955 pm while in the USDA supervisory office with Dr. and CSI- I observed a roach approximately 1 & 1/2 inches long that had come from under the file cabinet and ran under the desk. The roach was dark brown in color. There was also sitetings of roaches in the USDA lounge area on Monday January 16th. I immediately informed Q.A technician who witness the roach and removed it from under the desk. The establishment has failed to comply with 9 CFR 416.1 and 9 CFR 416.2(b) (3) of the regulatory requirements. This document serves as written notification that continued failure to comply with regulatory requirement(s) may result in additional regulatory or administrative action(s) as described in 9 CFR 500.

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.

416.2(b)(3) Walls, floors, ceilings, doors, windows, and other outside openings must be constructed and maintained to prevent the entrance of vermin, such as flies, rats, and mice.

Code: 03J02
Violation: 417.2(c)(4), 381.65(e)

Citation: Today, January 5, 2012 at approximately 1112 hours, while perfor g a poultry finished product standard procedure on evisceration line I observed fecal material inside the left wing of one out of ten randomly selected carcasses. The fecal material was approximately one quarter inch in length, green and pasty in substance. I immediately notified Mr. Day Shift Supervisor, who observed the affected carcass. Corrective actions were immediatel implemented, line speed was reduced from bpm to bpm. An associate was placed at the end of the affected line, and upon completion of the retest line speed was resumed to bpm per the HACCP plan for CCP 2B. Mr. took the affected carcass to the salvage area lung gunned out and washed with ppm chlorinated water, put back in the flow of product. The last acceptable fecal check was documented at 1039 hours on the establishment monitoring log. The Slaughter HACCP verification was performed for the pertinent CCPs including the pre-shipment review, and found acceptable. Mr. First Processing Superintendent, verbally informed me that the root cause of the deviation was, the pac-man gizzard puller machine was out of time. The establishment failed to meet the regulatory requirements of 9 CFR 417.2(c)(4) and 381.65(e). This document serves as written notification to Mrs. Plant Manager, that continued failure to meet the regulatory requirements could result in additional regulatory enforcement actions per 9 CFR 500.

Regulation:

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

Code: 01C02
Violation: 416.4(d), 416.13(c), 416.13(b)

Citation: At 1849 hours, while the eviseration department Lines and were going through midshift cleanup and Lines and the savage station, and the Gizzard Table were still in operation, I observed debris from Lines and being sprayed onto the Gizzard Table creating an insanitary condition as well as adulterating the gizzards. This is a noncompliance with 9CFR416.4d. I took a regulatory control action (9CFR500) by applying US Reject/Retain tag #B19-184982 (stopping that operation): rejecting the Gizzard Table as an insanitary product contact surface, and retaining adulterated product (Gizzards). I notified Supervisor and Supervisor of the noncompliance, that product integrity was impacted, and of my action. Supervisors Chambers and Tull proceeded with corrective action for the adulterated product (gizzards impacted were condemned) and brought the Gizzard table back in compliance (product contact surfaces were cleaned). Regulatory control was released at 1849 hours. This document serves as written notification to Ms. (Plant Manager) of the noncompliance with 9CFR416.1, 416.13(b), and 416.13(c). Continued failure to meet regulatory requirements could result in additional regulatory action per 9CFR500.4

Regulation:

416.4(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

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

416.13(b) Each official establishment shall conduct all other procedures in the Sanitation SOP’s at the frequencies
specified.

Code: 01C02
Violation: 416.4(a), 416.4(d), 416.13(c)

Citation: At approximately 2:10 Am on 12/31/2011 hours while touring the second processing department in Breast Debone the following noncompliance was sighted. In Breast Bebone area, I observed a plant associate washing down the floor with a high volume water hose, the water was touching the soiled floor and splashing directly onto an uncovered “cone head” of the breast debone conveyer belt line There was no water washing down the “cone head” nor the conveyer belt to all four Breast debone lines at the time of Inspection. There was no supervisor present in the area and no one was addressing the continual contamination of products. Regulatory control action was initiated by stopping the line, and the products were retained by the application of a US retained tag numbered B38206330. I immediately notified Mr. night shift Breast Debone Superintendent and Ms. night shift Cone Debone Supervisor of this noncompliance and that a regulatory control actions were taken. The requirements of parts 416.13(c); 416.4(a & d) of the meat and poultry regulations were not met. Ms. Plant manager is being notified through this noncompliance record of the plant failure to meet the regulatory requirements, and that official control action was initiated. Upon restoration of the sanitary conditions official action was relinquished and operation resumed as normal. This document serve as a written notification that your failure to comply with the regulatory requirement(s) could result in additional regulatory or administrative action described in 9 CFR 500

Regulation:

416.4(a) 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.

416.4(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

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

Code: 06D02
Violation: 381.76(b)

Citation: At 1535 hours, while performing presentation on line # station B I observed a nonconformance score of The nonconformance defects consisted of two birds “No Viscera” (scoring . Ms. , line # supervisor and , NS First Processing Superintendent was immediately notified of the nonconformance levels. The establishment immediately reduced the line speed from Birds per minutes to B.P.M. as per the Nels Presentation log requirements. The establishment has failed to meet 9 CFR 381.76 (b) of the regulatory requirements. At 1545 hours I performed a retest and the conformance levels was found acceptable with score of The line speed was increased to BPM. A retest was performed and nonconformance levels found to be acceptable. The line speed was increased to B.P.M. This document serves as written notification that continued failure to comply with regulatory requirement(s) may result in additional regulatory or administrative action(s) as described in 9 CFR 500.

Regulation:

381.76(b) There are five systems of post- mortem inspection: Streamlined Inspection System (SIS) and the New Line Speed (NELS) Inspection System, both of which shall be used only for broilers and cornish game hens; the New Turkey Inspection (NTI) System, which shall be used only for turkeys; Traditional Inspection; and Ratite Inspection.

Code: 03J04
Violation: 381.65(e), 417.2(c)(4)

Citation: At 1555 hours, while performing a zero tolerance verification on NELS line I observed fecal material on 1 out of 10 of my randomly selected carcasses for inspection at CCP # 2 B. The fecal material was brown in color, pasty in consistency, approximately 1/4 in width and length. The fecal material was located on the inside back of the carcass. Ms. , Line Evisceration Supervisor and Mr. Night Shift First Processing Superintendent was verbally notified and shown the deviation. I observed the establishment perform corrective actions as per their HACCP plan. The affected carcass was sent to the reprocessing station, reconditioned and placed back into flow. Since there are no interventions between the pre-chill station and the chiller, it is reasonable to concluded that the contaminated carcass would have entered the chiller. A review of the establishment’s zero tolerance log for CCP # 2 B, line # revealed that the last acceptable check performed at 1539 hours, was found to be acceptable and was recorded with a quantifiable value of 0/10 and the initials for the QA technician. As a result of the deviation, all requirements at all CCP’s for that specific lot was performed and found to be acceptable including the preshipment review. Mr. , Maintenance Supervisor, stated that the root cause was the inside/outside bird washer had dropped out of time. Ms. , Plant Manager, is being notified of the failure to meet the requirements of 9 CFR 417.2(c)(4) and 381.65(e). This document serves as written notice that continued failure to comply with the regulatory requirements may result in additional regulatory or administrative actions as per 9 CFR 500.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

Code: 03J04
Violation: 381.65(e), 417.2(c)(4)

Citation: Approximately 1520 pm while performing a zero tolerance procedure on line # I observed fecal material on 1 of the 10 birds I randomly selected to verify CCP # 2-B. The fecal material was light yellow in color, and pasty in consistency. It was approximately 1/4 inch in length and ¼ inch in width and located on the inside of the carcass next to the tail. The cloaca and intestine was also attached to the carcass. Mr. , 1st Processing Superintendent and , Night Shift Line # Evisceration Supervisor was immediately notified and shown the deviation. Approximately 1521 pm, as per the establishments HACCP Plan the line was immediately stopped and the line speed was reduced from birds per minute to birds per minute. A house inspector was also put on the end of the line. The affected carcass was then sent to the reprocessing station, reconditioned and placed back in flow as per the establishment’s corrective action. The establishment has failed to meet regulatory requirements of 9 CFR 417.2 (c) (4) and 381.65 (e). A review of the of the establishments CCP # 2-B monitoring log for line # was documented as the last acceptable check was performed at 1449 pm with quantifiable value of 0/10. As a result of this deviation, all requirements for all CCP’s for the specified lot (lot 2) was performed and found acceptable, including the pre-shipment review. The establishment management stated the root cause was the bird flipper was going backwards. This document serves as written notice that continued failure to comply with the regulatory requirements may result in additional regulatory or administrative action(s) as described in 9 CFR 500.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

Code: 416.4(d)
Violation: 01C02

Citation: Approximately 1810 while touring the tray-Pac area I observed a plant employee removing product from trays that had been previously packed with product in the salvage area. The product was then placed in plastic totes, and the used trays were put back in the cardboard shipping container. When the shipping container was filled with dirty trays the plant employee then emptied the cardboard shipping container in a large gray trash bin and then used the empty shipping container to push down the dirty trays in the trash filled bin. The same shipping container was then placed on a wooded pallet on top of two other empty shipping containers. The wood pallet also had approximately ten other cardboard shipping containers that were full of dirty used trays. I asked the plant employee what he was going to do with the shipping containers. He replied “he put the shipping container that he was going to take to mezzanine to be re-used on top of each other on this side of the pallet”. The three cardboard shipping containers had meat particles and fat inside and outside of the shipping container s. The containers were also wet and used to push trash down in the large gray trash bin. I immediately retained the pallet of shipping containers with retain tag # B38206254. I then notified Night Shift Tray pack Foreman, and Night Shift Tray pack Foreman, . The plant has failed to meet 9 CFR 416.4(d) of the regulatory requirement. This document serves as written notice that continued failure to comply with the regulatory requirements may result in additional regulatory or administrative action(s) as described in 9 CFR 500.

Regulation:

416.4(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

Code: 03J02
Violation: 381.65(e), 417.2(c)(4)

Citation: Today, November 7, 2011 at approximately 0548 hours, while performing a poultry finished product standard procedure on evisceration line I observed fecal material inside tail area of one out of ten randomly selected carcasses. The fecal material was approximately one half inch in length, green and pasty in substance. I immediately notified Ms. , Day Shift Supervisor, who observed the affected carcass. Corrective actions were immediately implemented line speed was reduced from bpm to bpm. An associate was placed at the end of the affected line, and upon completion of the retest line speed was resumed to bpm per the HACCP plan for CCP 2B. Mr. took the affected carcass to the reprocessing station to be rinsed with ppm chlorinated water and put back in the flow of product. The last acceptable fecal check was noted at 0905 hours on the establishment monitoring log. The HACCP Slaughter was performed for the pertinent CCPs including the pre-shipment review, and found acceptable. Mr. Day Shift Processing Manager, verbally informed me that the root cause of the deviation was one of the circular blades had fell off. The establishment failed to meet the regulatory requirements of 9 CFR 417.2(c)(4) and 381.65(e). This document serves as written notification to Mrs. Plant Manager that continued failure to meet the regulatory requirements could result in additional regulatory enforcement actions per 9 CFR 500.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

Code: 03J04
Violation: 381.65(e), 417.2(c)(4)

Citation: Approximately 1502 pm while performing a zero tolerance procedure on line # I observed fecal material on 1 of the 10 birds I randomly selected for direct observation at CCP # 2-B. The fecal material was brown in color, and pasty in consistency. It was approximately 1/4 inch in length and 1/4 inch in width and located inside the carcass next to the tail with the cloaca and intestine attached to the tail. 1st Night Shift Line # Evisceration Supervisor was immediately notified and shown the deviation. Approximately 1503 pm, as per the establishments HACCP Plan the line was immediately stopped and a house inspector was put on the line at the final trim station. I observed the Q.A technician take the affected carcass to the reprocessing station, reconditioned the carcass and placed back in flow as per the establishment’s corrective action. The establishment has failed to meet regulatory requirements of 9 CFR417.2 (c) (4) and 381.65 (e). A review of the of the establishments CCP # 2-B monitoring log for line # was documented as the last acceptable check was performed at 1446 pm with quantifiable value of 0/10. As a result of the deviation, all requirements for all CCP’s for the specified lot (lot # 1) was performed and found acceptable, including the pre-shipment review. The establishment management stated the root cause was the back-up venter missed an improperly vented bird. This document serves as written notice that continued failure to comply with the regulatory requirements may result in additional regulatory or administrative action(s) as described in 9 CFR 500.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

Code: 03J04
Violation: 381.65(e), 417.2(c)(4)

Citation: At 1501 hours, while performing a zero tolerance on line I observed fecal material on 1 out of 10 birds randomly selected for inspection at CCP #2 B. The fecal material was brown in color, pasty in consistency, approximately 1/4 inch in length and 1/4 inch in width and located on the inside back of the carcass. Ms. , line evisceration and Mr. ,Night Shift First Processing Superintendent was verbally notified and shown the deviation. I observed the establishment perform corrective actions as per their HACCP. The affected carcass was sent to the reprocessing station, reconditioned and placed back into flow. A review of the establishment’s zero tolerance log for CCP # 2B , Line revealed that the last acceptable check performed at 1450 hours, was found to be acceptable and was recorded with a quantifiable value of 0/10 and the initials BB for the QA technician. As a result of the deviation, all requirements at all CCP’s for that specific lot was performed and found to be acceptable including the pre-shipment review. Mr. Maintenance Supervisor, stated the root cause was the Up/Down adjustments on the Inside Outside bird washer were not adjusted properly for the size of the birds. Ms. Plant Manager, is being notified of the failure to meet the requirements of 9 CFR 417.2(c)(4) and 381.65(e). This document serves as written notice that continued failure to comply with the regulatory requirements may result in additional regulatory or administrative actions as per 9 CFR 500.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

Code: 03J04
Violation: 381.65(e)

Citation: Approximately 1530 pm while performing a zero tolerance procedure on line # I observed fecal material on 1 of the 10 birds I randomly selected for direct observation at CCP # 2-B. The fecal material was brown in color, and pasty in consistency. It was approximately ½ inch in length and ¼ inch in width and located on the upper outside leg (drumstick). Mr. 1st Processing Superintendent and Night Shift Line # Evisceration Supervisor was immediately notified and shown the deviation. Approximately 1532 pm, as per the establishments HACCP Plan the line was immediately stopped and a house inspector was put on the line. The affected carcass was then sent to the reprocessing station, reconditioned and placed back in flow as per the establishment’s corrective action. The establishment has failed to meet regulatory requirements of 9 CFR417.2 (c) (4) and 381.65 (e). A review of the of the establishments CCP # 2-B monitoring log for line # was documented as the last acceptable check was performed at 1453 pm with quantifiable value of 0/10. As a result of the deviation, all requirements for all CCP’s for the specified lot (lot # 2) was performed and found acceptable, including the pre-shipment review. The establishment management stated the root cause was the gizzard puller was incorrectly removing the gizzards. This document serves as written notice that continued failure to comply with the regulatory requirements may result in additional regulatory or administrative action(s) as described in 9 CFR 500.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

Code: 04B04
Violation: 381.126

Citation: At approximately 1500 hours, while touring the Stretch Bag department with Dr. We observed a packaged whole bird coded date of pack “1200” stamped on it. Code 1200 corresponds to July 19, 2011. Coded Pack date of “1300” should have been used for the date of today, 10/27/2011. We immediately rejected the process of the stretch bag department, with US Reject tag #B38206268.The label machine was reset and regulatory control of the lines was relinquished at approximately 1513 hours after the correct date was applied. Approximately 1070 boxes of 40 lb whole birds which was produced between the time of 7:00 AM to 3:00 pm were retained with US Retain tags #B38206161, #B38206297, and #38206300. Mr. , Stretch Bag Supervisor was present and did witness the establishment’s failure to meet the regulatory requirements of 9 CFR 381.126 of the Meat and Poultry regulations. As a result of this noncompliance, the corrective actions were initiated by reworking the whole birds that were produced in the stretch bag department prior to 1500 hours on 10/27/2011. After verifying the corrective actions were completed, regulatory control was relinquished and the product was release for shipment. This document serves as written notification that continued failure to meet the regulatory requirements could result in further administrative or regulatory actions as per 9 CFR 500.

Regulation:

381.126 The immediate container for dressed poultry shall be marked with a lot number which shall be the number of the day of the year on which the poultry was slaughtered or a coded number.

Code: 01D01
Violation: 416.2(b)(2), 416.2(d), 416.2(e)(3), 416.4(b), 416.2(b)(1),
416.2(e)(4)

Citation: While touring the establishment at approximately 2400 hours, Dr. and I observed numerous noncompliance through out the establishment. The following was observed: Large tray pack Lines room: the paint was peeling from the walls through out the whole room, this included the room with lines and There was no drainage on line under the wrap machine allowing water to flow over the floor and create a puddle. There were cracks around the spiral doors where insulation was hanging down from. In the dry cooler: condensation was found overhead. A large metal pipe was found to be leaking a substance on the floor. Standing water was pooled in the floor right outside of the tray pack line area. The water was brown in color and approximately 4 feet by 2 feet long. In the wet cooler: a door going into the dry cooler was hanging on the hingles. Large metal vents leading into the dry cooler were found to be insanitary and some were broken and hanging down. Cut up scale side area: found holes in the wall. This noncompliance record is written notification to the establishment of it’s failure of the regulatory requirements of 9 CFR 416.2(b)(2), 416.4(b),416.2(e)(4),416.2(e)(3), 416.2(d), and 416.2(b)(1). This document serves as a written notification that your failure to comply with regulatory requirements could result in additional regulatory or administrative actions as per 9 CFR 500.

Regulation:

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(d) Ventilation. Ventilation adequate to control odors, vapors, and condensation to the extent necessary to prevent adulteration of product and the creation of insanitary conditions must be provided.

416.2(e)(3) Prevent adulteration of product, water supplies, equipment, and utensils and prevent the creation of insanitary conditions throughout the establishment;

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.

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 ofproduct in a manner that does not result in product adulteration or the creation of insanitary conditions.

416.2(e)(4) Provide adequate floor drainage in all areas where floors are subject to flooding-type cleaning or where normal
operations release or discharge water or other liquid waste on the floor;

Code: 01C02
Violation: 416.13(c), 416.2(d), 416.4(d)

Citation: Thursday, October 20, 2011 At approximately 2145 hours, while performing Operational SSOP Review and Observation task in the 2nd processing over the both Chillers, I observed heavily beaded condensation on the concrete ceiling above the right and left whole bird chillers. The condensation was about 7 to 9 feet long & 2 feet wide and was dripping directly on both chillers that contained whole bird. U.S. rejects tags #B38206302 and B38206302 were placed on the both Chillers. I immediately notified the NS Grading/Packing/Giblet Supervisor as well as Mr. NS Shift manager, about the Establishment’s failure to meet the requirements of 9 CFR 416.13(c), 416.4(d), and 416.2(d). Sanitary conditions were restored by dabbing the condensated concrete ceiling, increased hot air flow, as well as increasing water flow to both chillers. At this time I removed the regulatory control and released both chiller back to the flow after I verified Establishment corrective action implimentation. Mr. NS shift Manager and Ms Plant manager are being notified through this non-compliance record of the plant’s failure to meet the regulatory requirements. This document serves as a written notification that your failure to comply with regulatory requirements could result in additional regulatory and/or administrative action described in 9CFR 500.

Regulation:

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

416.2(d) Ventilation. Ventilation adequate to control odors, vapors, and condensation to the extent necessary to prevent adulteration of product and the creation of insanitary conditions must be provided.

416.4(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

Code: 01C02
Violation: 416.13(c), 416.4(d)

Citation: While touring the establishment at approximately 0920 hours, Dr. Blakeney and I observed carcasses piled up on the Stretch Bag conveyor belt and drip pan and falling onto the floor. Approximately 30 carcasses were observed on the floor with water dripping from the drip pan further contaminating them. The regulatory control action of stopping the conveyor belt was put in place to prevent further product contamination. Further Processing Superintendent and Stretch Bag Supervisor, witnessed the noncompliance and were notified of the failure to meet the regulatory requirements of 9 CFR 416.13(c) and 9 CFR 416.4(d). The process was rejected with US Reject tag #B38206246 and the affected carcasses were washed in accordance with their SSOP plan for contaminated product handling. Regulatory control action was relinquished at approximately 0930 hours when sanitary conditions were restored. This document serves as written notification to Plant Manager, that continued failure to meet regulatory requirements could result in additional regulatory or administrative actions.

Regulation:

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

416.4(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

Code: 01C02
Violation: 416.13(c), 416.4(d)

Citation: While touring the establishment at approximately 2350 hours, Dr. and I observed in the wet cooler, one box of drumsticks that had busted open on a pellet. Also, one box of chicken livers that the box had busted open and the immediate containers of product were spilled unto the floor. I immediately tagged the boxes with US Retain tags # B38206213 and # B38206214. Mr. , Line Leader for the wet cooler witnessed the noncompliance and was notified of the failure to meet the regulatory requirements of 9 CFR416.13(c) and 9 CFR 416.4(d). Mr. had the product condemned. Regulatory control was relinquished at approximately 2355 hours when sanitary conditions were restored. This document serves as written notification to , Plant Manager, that continued failure to meet regulatory requirements could result in additional regulatory or administrative actions.

Regulation:

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

416.4(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

Code: 06D02
Violation: 381.76(b)

Citation: At 2040 hours, I observed a Presentation non-compliance on evisceration line station C. A conformance score of was observed. The conformance defects consisted of two birds No Viscera (scoring points) . Ms. (Evisceration line supervisor) was immediately notified of the establishment’s failure. The establishment immediately reduced the line speed to B.P.M. as per NELS requirements. At 2050 hours I performed a retest and the conformance level was found to be acceptable. The line speed was then increased to B.P.M. Ms. , Plant Manager is being notified through this NR of the establishment’s failure to meet the regulatory requirements of 9 CFR 381.76 (b). This document serves as written notification that continued failure to comply with regulatory requirement(s) may result in additional regulatory or administrative action(s) as per 9 CFR Section 500.

Regulation:

381.76(b) There are five systems of post- mortem inspection: Streamlined Inspection System (SIS) and the New Line Speed (NELS) Inspection System, both of which shall be used only for broilers and cornish game hens; the New Turkey Inspection (NTI) System, which shall be used only for turkeys; Traditional Inspection; and Ratite Inspection.

Code: 01C02
Violation: 416.4(d), 416.13(c)

Citation: At Approximately 1020 hours while touring the cone debone department I observed an overhead water line dripping onto an orange hose below which was dripping directly onto front halves on a conveyor belt. I immediately asked DS Cone Debone Supervisor, Mr. to stop the conveyor belt to prevent further product contamination. I rejected the process with US Reject Tag # B38206285. Establishment Maintenance did hang plastic to prevent the product from being contaminated. The Establishment Management also decided to condemn the affected product on the conveyor. While in the same area I also observed an establishment employee passing a tote over the tender conveyor belt as well as the same aforementioned front halve conveyor and the tote was dripping unclean condensate from the bottom of the tote onto the same affected product. The establishment’s failure to meet the requirements of 9 CFR 416.4(d), and 416.13(c) were also witnessed by Plant Manager, Mrs. The plastic was hung and the affected product was condemned and regulatory control was relinquished at approximately 1025 hours. This document serves as written notification that continued failure to meet regulatory requirements could lead to further regulatory actions.

Regulation:

416.4(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

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

Code: 03J04
Violation: 381.65(e)

Citation: At 1519 hours, while performing a zero tolerance procedure on line I observed fecal material on 1 out of 10 birds randomly selected for inspection at CCP #2- B. The fecal material was brown in color, pasty in consistency, approximately ¾ inch in length and ½ inch in width and located on the inside of the left wing. Mr. Night Shift 1st processing Superintendant) was verbally notified and shown the deviation. At approximately 1520 hours, I observed the establishment perform corrective actions as per their HACCP plan. The affected carcass was sent to the reprocessing station, reconditioned and placed back into flow. A review of the establishment’s zero tolerance log for CCP #2-B, Line revealed that the last acceptable check performed at 1445 hours, was found to be acceptable and was recorded with a quantifiable value of 0/10 and the initials (HACCP technician). As a result of the deviation, all requirements at all CCP are for that specific lot was performed and found to be acceptable, including the pre-shipment review. The establishment stated the root cause was the ½ inch ball valve for the hand pump to the bird washer was bad. It has been replaced. Ms. Plant Manager is being notified of the failure to meet the requirements of 9 CFR 417.2(c) (4) and 381.65(e). This document serves as written notice that continued failure to comply with the regulatory requirements may result in additional regulatory or administrative action(s) as described in 9 CFR 500.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

Code: 06D02
Violation: 381.76(b)

Citation: At approximately 2009 hours, I observed a line speed non-compliance of birds per minute on evisceration line CSI was also timing evisceration line and observed the line speed of birds per minute. Regulation 381.76(b) states in part: “The maximum inspection rate for shall be birds per minute per eviscerating line.” The lines were immediately stopped and Mr. (Night Shift First Processing Superintendent) was notified of the establishment’s failure to meet the regulatory requirement. The lines were immediately reset by the establishment. A subsequent re-timing of the lines resulted in a speed of b.p.m. Ms. (Plant Manager) is being notified through this noncompliance record of the establishment’s failure to meet the regulatory requirements of part 381.76(b) of the Meat and Poultry regulation and that official control action was initiated per 9 CFR 500.1 This document serves as written notification that your failure to comply with regulatory requirements could result in additional regulatory or administrative actions.

Regulation:

381.76(b) The Administrator determines that the establishment has the intent and capability to operate at line speeds greater than 70 birds per minute, and meets all the facility requirements in §381.36(d).

Code: 03J04
Violation: 381.65(e), 417.2(c)(4)

Citation: At 2014 hours, while performing a zero tolerance procedure on line I observed fecal material on 1 out of 10 birds randomly selected for inspection at CCP #2- B. The fecal material was brownish green in color, pasty in consistency, approximately a 1/2 inch in width and a ¼ inch in length and located on the outside of the right wing. The line was immediately stopped and Ms. (lines Supervisor) was verbally notified and shown the deviation. At approximately 2015 hours, I observed the establishment perform corrective actions as per their HACCP plan. The affected carcass was sent to the reprocessing station, reconditioned and placed back into flow. A review of the establishment’s zero tolerance log for CCP #1-B, Line revealed that the last acceptable check performed at 1957 hours, was found to be acceptable and was recorded with a quantifiable value of 0/10 and the initials (HACCP technician). As a result of the deviation, all requirements at all CCP’s for that specific lot was performed and found to be acceptable, including the pre-shipment review. The establishment stated the root cause was the water to the inside outside bird washer nozzles were turned off. Ms. Plant Manager is being notified of the failure to meet the requirements of 9 CFR 417.2(c)(4) and 381.65(e). This document serves as written notice that continued failure to comply with the regulatory requirements may result in additional regulatory or administrative action(s) as described in 9 CFR 500.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

Code: 03J04
Violation: 381.65(e), 417.2(c)(4)

Citation: At 2248 hours, while performing a finished product standards procedure on line I observed fecal material on 1 out of 10 birds randomly selected for inspection at CCP #2- B. The fecal material was brownish green in color, pasty in consistency, approxmately ½ inch in diameter and located in the lower adominal area of the carcass. Ms. (lines Supervisor) was verbally notified and shown the deviation. At approximately 2249 hours, I observed the establishment perform corrective actions as per their HACCP plan. The affected carcass was sent to the reprocessing station, reconditioned and placed back into flow. A review of the establishment’s zero tolerance log for CCP #1-B, Line revealed that the last acceptable check performed at 2147 hours, was found to be acceptable and was recorded with a quantifiable value of 0/10 and the initials (HACCP technician). As a result of the deviation, all requirements at all CCP’s for that specific lot was performed and found to be acceptable, including the pre-shipment review. Ms. Plant Manager is being notified of the failure to meet the requirements of 9 CFR 417.2(c)(4) and 381.65(e). This document serves as written notice that continued failure to comply with the regulatory requirements may result in additional regulatory or administrative action(s) as described in 9 CFR 500.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

Code: 03J04
Violation: 417.2(c)(4), 381.65(e)

Citation: At 2226 hours, while performing a zero tolerance procedure on line I observed fecal material on 1 out of 10 birds randomly selected for inspection at CCP #2- B. The fecal material was brownish green in color, pasty in consistency, approxmately ¼ inch in length and ¾ inch in width and located on the inside of the right wing. Ms. , (lines and Supervisor) was verbally notified and shown the deviation. At approximately 2228 hours, I observed the establishment perform corrective actions as per their HACCP plan. The affected carcass was sent to the reprocessing station, reconditioned and placed back into flow. A review of the establishment’s zero tolerance log for CCP #1-B, Line revealed that the last acceptable check performed at 2143 hours, was found to be acceptable and was recorded with a quantifiable value of 0/10 and the initials (HACCP technician). As a result of the deviation, all requirements at all CCP’s for that specific lot was performed and found to be acceptable, including the pre-shipment review. The establishment stated the root cause was the brush was not properly working. Ms. , Plant Manager is being notified of the failure to meet the requirements of 9 CFR 417.2(c)(4) and 381.65(e). This document serves as written notice that continued failure to comply with the regulatory requirements may result in additional regulatory or administrative action(s) as described in 9 CFR 500.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

Code: 01C02
Violation: 416.2(d), 416.4(d), 416.13(c)

Citation: At approximately 2145 hours, while performing General Labeling Task in the 2nd processing area, I observed heavily beaded condensation on several white galvanized overhead pipe that runs directly over product contact surfaces of Giblet area, Cut up breast area ( Dapec 1 & 2), leg and back processing area as well as small tray pack area. The condensation was about 7 to 15 feet long and were dripping directly on the Conveyor belts. A regulatory control action was taken specially on tray pack line by stoping the line. I immediately notified Mr. the 2nd Shift plant manager, about the Establishment’s failure to meet the requirements of 9 CFR 416.13(c), 416.4(d), & 416.2(d). The contaminated Conveyor belts were cleaned and sanitized immediately. Sanitary conditions were also restored by dabbing the condensated pipe. Ms. Plant Manager, is being notified through this noncompliance record of the plant’s failure to meet the regulatory requirements. This document serves as a written notification that your failure to comply with regulatory requirements could result in additional regulatory and/or administrative action described in 9 CFR 500.

Regulation:

416.2(d) Ventilation. Ventilation adequate to control odors, vapors, and condensation to the extent necessary to prevent adulteration of product and the creation of insanitary conditions must be provided.

416.4(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments

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

Code: 03J04
Violation: 417.2(c)(4), 381.65(e)

Citation: At 1520 hours while performing a zero tolerance procedure on line I observed fecal material on 1 out of 10 birds randomly selected for inspection at CCP #2- B. The fecal material was brownish green in color, pasty in consistency, approxmately ½ inch in diameter and located within the kidney crypt of the carcass. Ms. (lines and 4 Supervisor) was verbally notified and shown the deviation. At approximately 1522 hours I observed the establishment perform corrective actions as per their HACCP plan. The affected carcass was sent to the reprocessing station, reconditioned and placed back into flow. A review of the establishment’s zero tolerance log for CCP #1-B, Line revealed that the last acceptable check performed at 1449 hours was found to be acceptable and was recorded with a quantifiable value of 0/10 and the initials (HACCP technician). As a result of the deviation, all requirements at all CCP’s for that specific lot was performed and found to be acceptable, including the pre-shipment review. Ms. Plant Manager is being notified of the failure to meet the requirements of 9 CFR 417.2(c)(4) and 381.65(e). This document serves as written notice that continued failure to comply with the regulatory requirements may result in additional regulatory or administrative action(s) as described in 9 CFR 500.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits;

Code: 06D02
Violation: 381.76(b)

Citation: At 1940 hours, I observed a Presentation non-compliance on evisceration line station A. A nonconformance score of was observed. The nonconformance defects consisted four of birds “viscera on shackle” (scoring points), one bird “viscera not uniform” (scoring points) and one 1 bird “not reflected” (scoring points). Ms. (Evisceration line supervisor) was immediately notified of the establishment’s failure. The establishment immediately reduced the line speed to B.P.M. as per NELS requirements. At 2000 hours the retest performed by the Q.A. Technician with the initials ( was found to be acceptable and line speed was increased to B.P.M. Ms. Plant Manager is being notified through this NR of the establishment’s failure to meet the regulatory requirements of 9 CFR 381.76 (b) and that official control action was initiated as per Rules of Practice 9 CFR Section 500. This document serves as written notification that continued failure to comply with regulatory requirement(s) may result in additional regulatory or administrative action(s).

Regulation:

381.76(b) SIS may be performed by one inspector (SIS–1) or two inspectors (SIS– 2). SIS–1 requires that the establishment provide one inspection station for each line and adequate reinspection facilities so carcasses can be removed from each line for evaluation. The maximum line speed for SIS–1 is 35 birds per minute. SIS–2 requires that the establishment provide two inspection stations for each line and adequate reinspection facilities so carcasses can be removed from each line for evaluation. The maximum line speed for SIS–2 is 70 birds per minute.

Code: 03J04
Violation: 417.2(c)(4), 381.65(e)

Citation: Evisceration Line At 1015 hours while performing task Poultry Finished Product Standards on evisceration line I observed fecal material on the inner surface of 1 of 10 randomly selected carcasses selected for inspection. The fecal material was on two locations within the kidney region; both were approximately 1/8 inch in size, oval in shape, greenish-brown in color and semi-pasty in consistency. I informed and showed Mr. , 1st Processing Superintendent who was in the area. Mr. 1st Processing Superintendent implemented corrective actions as described in the HACCP Plan for CCP #2. Mr. was also informed of the establishments failure to meet the regulatory requirements 9 CFR 381.65(e) and 9 CFR 417.2(c) 4. A review of the establishment Zero Tolerance Check sheet dated 07/05/2012 revealed that the last acceptable check was performed at 1000 hours by QA Tech, An acceptable retest was performed by at 1036 hours. A review of the establishments pre-shipment review was performed at 1335 hours for the affected lot and all affected CCP’s ;and were found to be acceptable and complete at 1300 hours, signed by , Q.A. Technician. This NR serves as written notification to Mr. , Plant Manager of the establishments failure to meet the regulatory requirements and that continue failure could result in enforcement action as per 9 CFR 500.4.

Regulation:

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits.

381.65(e) Poultry carcasses contaminatedwith visible fecal material shall be prevented from entering the chilling tank.

Code: 03J04
Violation: 417.2(c)(4), 381.65(e)

Citation: Evisceration line At 1518 hours while performing Zero tolerance for visible fecal material entering chiller, I observed fecal material on the outside surface from one of the ten randomly selected carcasses. The fecal material was located on the left wing area approximately 1/4 inch width by 1/4 length in size, semi pasty in consistency and brownish color. Mr. , N/S Evisceration Supervisor & Mr. 1st Processing Superintendent, were immediately notified & shown the fecal material, and of the establishments failure to meet the regulatory requirements of 9 CFR381.65(e) and 9 CFR417.2(c)(4). I observed the establishment immediately implement the corrective action as per the HACCP Plan for CCP#2. A review of the establishments Zero Tolerance Log dated 06/06/12 revealed that the last acceptable check was at 1504 hours with a quantifiable value of 0/10 and initiated by Q.A Technician A retest was performed at 1545 hours and no fecal was observed. A review of establishment records, for the affected lot at all CCP’s including pre-shipment review and the results were found acceptable. This NR serves as written notification to Mr. , Plant Manager of the establishments failure to meet the regulatory requirement and that continued failure could result in enforcement action as per 9 CFR 500.4

Regulation:

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits.

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

Code: 381.76(b)
Violation: 06D02

Citation: PHIS Task: Other Inspection Requirement (Presentation), SIS Line# At 2052 hours, station 1A obtained a nonconformance score of that consisted of 1 viscera not uniformed  points), 1 no viscera points) 1 membrane points) and birds with contamination inside points). This exceeded the process control limit of . Station 1B scored oints consisting of 2 viscera’s on the shackle (16 points) and 1 membrane points). Ms. , Evsiceration Supervisor and Mr. , Superintendent for 1st Processing were notified of the noncompliance and the line speed was immediately reduced from BPM to BPM as per the streamlined inspection system requirements. After adjustments were made, a retest was performed at 2111 hours. Stations 1A and 1B each received acceptable scores of  points. The original line speed resumed back to BPM. At 2133 hours, another test was performed to ensure compliance at BPM with acceptable scores of and respectively. The establishment failed to meet the requirements of 9 CFR 381.76 (b) of the Meat and Poultry Regulations where it states in part that “for the establishment to run processing line(s) at maximum speed, optimal conditions must be maintained so that inspection may be conducted efficiently”. This document serves as written notification to Mr. ; Plant Manager that failure to comply with regulatory requirement(s) could result in additional administrative action.

Regulation: There are five systems of postmortem inspection: Streamlined Inspection System (SIS) and the New Line Speed (NELS) Inspection System, both of which shall be used only for broilers and cornish game hens; the New Turkey Inspection (NTI) System, which shall be used only for turkeys; Traditional Inspection; and Ratite Inspection. 

Code: 06D02
Violation:  381.76(b)

Citation: Evisceration Line At 1527 hours while performing Other Inspection Task (presentation check), a nonconformance score of 26 ;observed on Streamline Inspection System (SIS)  evisceration line which exceeds the conformance level of Deficiencies observed were; 1 no viscera points) and 1 contamination inside bird points). Mr. Evisceration N/S Supervisor, was notified that a retest would be performed in 10 minutes. At 1537 hours a retest was performed, a nonconformance score of was observed at station 1A. Deficiencies observed at 1A were 2 viscera not uniform oints each), 1 no viscera points) and 1 contamination inside bird points). Mr. First Processing N/S Superintendent, was notified and the line speed was immediately reduced from birds per minute to birds per minute. At 1552 hours a retest was performed at both station; 1A and 1B; and scored and points. The line speed resumed back to BPM. At 1602 hours, another test was performed to ensure compliance at BPM with acceptable scores of and espectively. The establishment failed to meet the requirements of 9 CPR 381.76 (b) of the Meat and Poultry Regulations where it states in part that ” for the establishment to run processing line(s) at maximum speed, optimal condition must be maintained so that inspection may be conducted efficiently”. This document serves as written notification to Mr. Plant manager that failure to comply with regulatory requirement(s) could result in additional administrative action.

Regulation: There are five systems of postmortem inspection: Streamlined Inspection System (SIS) and the New Line Speed (NELS) Inspection System, both of which shall be used only for broilers and cornish game hens; the New Turkey Inspection (NTI) System, which shall be used only for turkeys; Traditional Inspection; and Ratite Inspection.

Code: 01B02
Violation: 416.4(a), 416.13(c), 416.1

Citation: After the establishment had completed pre-operational sanitation procedures and lock/tag out was satisfactorily completed, but before the start of operations, the following noncompliances was observed. Area 1, Wing Dip Tank (IU#39): At 0502 hours too numerous to count feathers from the previous day operation were observed inside the scalder braces, once filled with water the feathers would break loose (direct product contact surfaces). Mr. , QSI Manager was immediately shown the aforementioned condition and was notified of the establishments’ failure to meet the regulatory requirements of 9 CFR 416.13 (c), 416.4(a) and 416.1 as well Pre-operational Sanitation Procedures as outlined on pages 1 and 2 of the Pre-operational Procedures.The equipment was rejected with U.S. Rejected Tag #B38205360 as per 9 CFR 500.2(a)(1). A review of the establishments QA Pre-operational Check Sheet dated 05/11/2012 revealed that QA did randomly select the aforementioned IU and found it to be acceptable.At 0524 hours after restoration of sanitary conditions by the establishment the regulatory control action was relinquished. No product was involved.Area 3, First one third of Main Chiller #1 (IU#41): At 0618 hours several pieces of meat and fat of various sizes were observed on top of the entry chute from the previous days operation (direct product contact surfaces). Mr. , QSI Manager  was immediately shown the aformentioned condition and was notified of the establishments failure to meet the regulatory (requirements of 9 CFR 416.13(c), 416.4(a) and 416.1 as well Preoperational Sanitation Procedures as outlined on pages 1 and 2 of the Pre-operational procedures. The IU was rejected with U.S. Rejected Tag #B38205355 as per 9 CFR 500.2(a)(1). A review of the establishments QA Pre-operational Check Sheet dated 05/11/2012 revealed that QA did not randomly select the aforementioned IU. At 0633 hours after restoration of sanitary conditions by the establishment the regulatory control action was relinquished. No product was involved. This document serves as written notification to Mr. , Plant Manager of the establishments failure to meet the regulatory requirements and that continued failure could result in additional regulatory or administration action as per 9 CFR 500.4. After the establishment had completed pre-operational sanitation procedures and lock/tag out was satisfactorily completed, but before the start of operations, the following noncompliances was observed. Area 1, Wing Dip Tank (IU#39): At 0502 hours too numerous to count feathers from the previous day operation were observed inside the scalder braces, once filled with water the feathers would break loose (direct product contact surfaces). Mr. , QSI Manager was immediately shown the aforementioned condition and was notified of the establishments’ failure to meet the regulatory requirements of 9 CFR 416.13 (c), 416.4(a) and 416.1 as well Pre-operational Sanitation Procedures as outlined on pages 1 and 2 of the Pre-operational Procedures.The equipment was rejected with U.S. Rejected Tag #B38205360 as per 9 CFR 500.2(a)(1). A review of the establishments QA Pre-operational Check Sheet dated 05/11/2012 revealed that QA did randomly select the aforementioned IU and found it to be acceptable.At 0524 hours after restoration of sanitary conditions by the establishment the regulatory control action was relinquished. No product was involved.Area 3, First one third of Main Chiller #1 (IU#41): At 0618 hours several pieces of meat and fat of various sizes were observed on top of the entry chute from the previous days operation (direct product contact surfaces). Mr. , QSI Manager  was immediately shown the aformentioned condition and was notified of the establishments failure to meet the regulatory (requirements of 9 CFR 416.13(c), 416.4(a) and 416.1 as well Preoperational Sanitation Procedures as outlined on pages 1 and 2 of the Pre-operational procedures. The IU was rejected with U.S. Rejected Tag #B38205355 as per 9 CFR 500.2(a)(1). A review of the establishments QA Pre-operational Check Sheet dated 05/11/2012 revealed that QA did not randomly select the aforementioned IU. At 0633 hours after restoration of sanitary conditions by the establishment the regulatory control action was relinquished. No product was involved. This document serves as written notification to Mr. , Plant Manager of the establishments failure to meet the regulatory requirements and that continued failure could result in additional regulatory or administration action as per 9 CFR 500.4.

Regulation:

416.4(a) 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.

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

416.1Each 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.

Code: 01D01
Violation: 416.2(a)

Citation: Offal Room: At approximately 0605 hours while up stairs of the offal room inspecting the denaturing process, I observed the front portion of a rat (the head and some of the body) approximately 4 inches in length. The rat then disappeared. A few minutes later another rat was seen approximately six feet from my location, walking toward the western wall. The rat was approximately eight inches in length was seen walking the grates. The grates had an accumulation of meat and fat from previous day(s) operation on the top portion. At that point I left the offal room and informed Mr. , Maintenance Manager of the establishments failure to meet the regulatory requirements of 9 CFR 416.2(a). A review of the establishments Pest Control Log revealed that the contracted pest control company last visited the establishment on 05/02/2012 and no sightings (evidence) of rats were noted. This NR serves as written notification to Mr. , Plant Manager of the establishments failure to meet the regulatory requirements and that continued failure could result in enforcement action as per 9 CFR 500.4.

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: 01C02
Violation: 416.13(c), 461.4(d)

Citation: Directed Operational SSOP Task (Review & Observation): At 1613 hours, as I was touring through leg debone lines & and walking behind an employee, I observed the employee up from the floor, floor scraps (skin and meat) at the end of line by  the drip pan under the leg quarter conveyor belt. He then threw the floor product directly on the belt running edible leg quarter bones. The edible  leg quarter bones lead to and dropped directly into a  large vat that is to be processed at the mechanically separated chicken (MSC) department. I immediately informed Ms. , Supervisor for Leg Debone of the noncompliance and applied U.S retain tag #B38205314 to the vat of leg quarter bones. I observed the affected line stopped, sanitized and rinsed. Management chose to condemn the product that totaled 1060 pounds. A review of the establishment’s SSOP Operational Monitoring Form dated May 4, 2012, revealed that the last check or “product protected from contamination” was performed at 1458 hours and found acceptable by QA Technician with the initials RB. The establishment failed to meet the requirements of 9 CFR 416.13 (c) and 9 CFR 416.4 (d), as well as their own SSOP Implementation Guidelines pages 1-3 section VI. This document serves as written notification to Mr. , Plant Manager, that failure to comply with the regulatory requirement(s) could result in administrative action as described in 9 CFR 500.4.

Regulation:

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

461.4(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

Code: 03J04
Violation: 381.65(e), 417.2(c)(4)

Citation: Evisceration line At 0912 hours while performing a Poultry Zero Tolerance Task, fecal material was inside one of ten randomly selected carcasses. I immediately notified the Mr. , Evisceration Supervisor of the establishments failure to meet the regulatory requirements of 9 CFR 381.65(e) and 9 CFR 417.2(c) (4). Mr. commenced implementing corrective actions as per the HACCP Plan. Mr. Shift Manager also observed the fecal material. The fecal material was greenish-brown in color, semi-pasty in texture, approximately 3/8 inch in diameter and located in the kidney region of the carcass. A review of the establishment CCP#2 Zero Tolerance Check sheet dated 05/02/2012 revealed that the last acceptable check was performed at 0830 hours and initial by with a quantifiable value score of 0/10. At 1300 hours a review of the pre-shipment review revealed that all the regulatory requirements had been met at applicable CCP’s for the affected lot(s). This NR serves as written notification to Mr. , Plant Manager of the establishments failure to meet the regulatory requirements and that continued failure to meet said requirements could result in enforcement action as per 9 CFR 500.4.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be pre- vented from entering the chilling tank.

417.2(c)(4) List the procedures, and the fre- quency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits.

Code: 04A06
Violation: 381.76(b)

Citation: Evisceration Line At 1015 hours while performing procedure task finish product standards on evisceration line a score of was attained in the trim category, thus reaching the action number (15) indicating that the process is out of control. Mr. Evisceration Supervisor was immediatley informed of the failure to meet the regulatory requirements of 381.76(b). Random Pre-chill testing for the trim category was suspended as well as random post-chill testing. At 1030 hours random post-chill testing using the pre-chill critieria commenced and was complete at 1312 hours with scores of and A review of the Finish Product Standards checksheet revealed that the last acceptable check was performed at 0926 hours.Two retest was performed at 1028 hours and 1036 hours and with conformance scores of and respectively. This NR serves as written notification to Mr. Plant Manager of the establishment’s failure to meet the regulatory requirements.

Regulation: There are five systems of post- mortem inspection: Streamlined In- spection System (SIS) and the New Line Speed (NELS) Inspection System, both of which shall be used only for broilers and cornish game hens; the New Turkey Inspection (NTI) System, which shall be used only for turkeys; Traditional Inspection; and Ratite In- spection.

Code: 03J04
Violation: 381.65(e), 417.2(c)(4)

Citation: At 1123 hours while performing FPS procedures on evisceration line I observed fecal material on one of the ten randomly selected birds. The fecal material was located on the upper pectoral muscle just beneath a flap of skin, brownish in color, pasty in texture, and approximately 1/8″ in diameter. I immediately notified Ms. (Evisceration Supervisor) who notified Mr. (1st Shift Manager). Mr. initiated corrective actions as per the establishment HACCP plan. A review of the Zero Tolerance Log revealed that the last acceptable check had been conducted at 1015 hours and signed by (QA Tech). A retest was performed at 1138 hours and no fecal was observed. A review of establishment records, including pre-shipment review for all CCPs revealed that all regulatory requirements had been met. This NR serves as written notification to Mr. , Plant Manager that regulatory requirements 9 CFR 381.65(e) and 417.2(c) (4) were not met. Continued failure to met regulatory requirements could result in further enforcement action as per 9 CFR 500.4.

Regulation:

381.65(e) Operations and procedures involv- ing the processing, other handling, or storing of any poultry product must be strictly in accord with clean and sanitary practices and must be conducted in a manner that will result in sanitary processing, proper inspection, and the production of poultry and poultry prod- ucts that are not adulterated.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits.

Code: 01B02
Violation: 416.1, 416.4(a), 416.13(c), 416.4(b)

Citation: Breast Debone Area- At 0735 hours after pre-operational sanitation was complete by QSI and the establishment, while QSI was spraying sanitizer the area I observed clumps of meat and fat on the floor under table #1 rib-cage conveyor. I asked a QA Technician that was in the area to walk with me between tables (lines) and As we walked I observed meat and fat from the previous day operation on conveyor belts, cones, overhead support structures (direct product contact surfaces) as well as indirect product contact surfaces. I informed the QA Technician to get her supervisor as well as the QSI Plant Manager, Mr. . When they arrived I showed them the meat and fat on the direct and indirect product contact surfaces. Mr. was notified of the establishment failure to meet the regulatory requirements of 9 CFR 416.1, 416.4(a), 416.4(b) and 416.13(c) and that a regulatory control action was being assumed as per 9 CFR 500.2(a)(1) on breast debone tables #1 and #2. Both tables (lines) were rejected with U.S. Rejected Tag #B 34351476. I then proceeded to the other two tables (#3 and #4) where meat and fat from the previous day operation that was consistent with what was observed on (tables #1 and #2. I informed Mr. that the same U.S. Rejected Tag will be applied for the entire Breast Debone Area. At 0750 hours Mr. informed me that tables #1 and #2 were ready for re-inspection. Due to meat and fat still present on direct product surfaces the area remained rejected. At 0803 hours after sanitary conditions were restored as per the QSI re-cleaning procedures the regulatory control action was relinquished in the breast deboning area. A review of the QA Preoperational Sanitation Check Sheet dated March 13, 2012 revealed that though QA did randomly selected IU’s within the area, none with meat and fat from the previous day operation was observed on direct product contact surfaces. Had it not been for my intervention wholesome product would have been contaminated with the aforementioned product on direct product contact surfaces from the previous day operation. During the weekly meeting dated February 22, 2012 we discussed a similar finding in the breast deboning area but a NR was not generated. The establishment response to that topic was, “The line leader that was responsible for this area was removed from their position and replaced with a new line leader. In addition, personnel have been instructed to continue inspecting in the area for any deficiencies, even after release by QA or USDA, prior to start up of production”. Mr. , Plant Manager is being notified through this NR of the establishments failure to meet the regulatory requirements and that continued failure could result in enforcement action as per 9 CFR 500.4.

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(a) 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.

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

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: 416.4(a), 416.13(c), 416.4(b), 416.1

Citation: Evisceration Line at 0525 hours: After plant pre-op procedures had been completed, but before start of operations, I observed noncompliance at the neck breaker machine (Area I, IU#16). There were numerous pieces of fat from the previous day’s operation on the prongs that go inside the cavity of poultry carcasses. Fat and debris was observed on three of the prongs and also on the associated guide bars and surrounding framework. (QSI Manager) was immediately notified, equipment was rejected and USDA Tag #B34351489 was applied. Mr. was also shown meat, fat and blood on the gizzard pump and adjacent equipment. At 0543 Mr. requested that the aforementioned machinery be reinspected. The machinery was found to be clean as per QSI cleaning procedures outlined in QSI-0044 and regulatory control was relinquished. A review of the QA Pre-operational Sanitation Check Sheet revealed that QA did not randomly select the aforementioned IU. The requirements of Meat and Poultry regulations 416.1, 416.4(a), 416.4(b), and 416.13(c) were not met. Mr. , Plant Management is hereby notified in writing of this NR for noncompliance. Continued failure to meet regulatory requirements can lead to enforcement actions described in 9 CFR Part 500.4.

Regulation:

416.4(a) 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.

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

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.

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.

Code: 03J04
Violation: 417.2(c)(4), 381.65(e)

Citation: At 1554 hours while performing a zero tolerance task on SIS line I observed of randomly selected carcasses with fecal material on the inside cavity. There were two pieces of fecal material directly to the right of the bursa of fabricius, an 1/8 inch and an 1/4 inch in size, respectively. Upon further inspection, a smaller 1/16 inch sized piece was located under the bursa of fabricius. All were of a pasty consistency and greenish brown in color. I immediately showed Mr. , 1st processing superintendent, the fecal material and notified him of the establishment’s failure to meet the regulatory requirements of 9 CFR 381.65(e) and 417.2(c). Mr. implemented corrective actions as per the HACCP plan at CCP 2. A retest was performed, and passed,at 1614 hours, after the cause of the deviation, a bent vent machine blade, had been corrected. A review of the Zero Tolerance Log, dated 3/7/2012, showed the last acceptable check was performed at 1512 hours and initialed by QA Tech L.Caban. A review of the establishment’s records for all CCP’s including Post Chill and Pre Shipment review were found to be in compliance. This document serves as written notification to Mr. Plant Manager, of the establishment’s failure to meet the regulatory requirements and that continued failure could result in enforcement action as per 9 CFR 500.4.

Regulation:

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits.

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

Code: 03J04
Violation: 381.65(e), 417.2(c)(4)

Citation: At 1427 hours while performingPHIS task Zero Tolerance on evisceration line I observed one of ten randomly selected carcasses with visible fecal material on the outer surface. The fecal material was located on the inside of the right wing tip, greenish-brown in color, semi pasty in texture, approximately1/4″ in size and oval in shape. I immediately notified Ms. Evisceration Supervisor who notified Mr. , 1st Processing Superintendent who was shown the fecal and was notified of the establishments failure to meet the regulatory requirements of 9 CFR 381.65(e) and 417.2(c) 4. Mr. immediately implemented corrective actions as per the HACCP Plan. A review of the Zero Tolerance Log dated 2/23/2012 revealed that the last acceptable check was performed at 1408 hours and signed by A. with results of zero of A retest was performed at 1452 hours with results of zero of ten indicating that the CCP was in control. A review of the establishment records revealed that the regulatory requirements at all the CCP’s including the pre-shipment review was found to be acceptable. This NR serves as written notification to Mr. , Plant Manager of the establishments failure to meet the regulatory requirements and that continued failure could result in enforcement action as per 9 CFR 500.4.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits.

Code: 01D01
Violation: 416.1, 416.2(h)(1)

Citation: At 2318 hours, while performing Sanitation Performance Standards task, the following noncompliance was observed: At live hang’s restroom, all of the three sinks did not have drain pipes, allowing hand washing water to splash onto the floor, and used paper towels were thrown in the sinks. The three stalls’ toilet paper holders were broken and one of the stalls has a leak from the pipe connecting to the flush handle. There is paint chipping and flaking off of the wall that the third stall is attached to. In addition, in both deboning area ladies’ restroom, the base board area of the vestibules were dirty with black substance, creating insanitary condition. , Live hang supervisor, was shown the aforementioned insanitary conditions and was notified of the establishment’s failure to meet the requirements of 9 CFR 416.2 (h)(1) and 416.1 of the Meat and Poultry Regulations, as well as the establishment’s written SPS plan; This documentation serves as written notification to Mr. , Plant Manager that continued failure to meet the regulatory requirements could result in additional regulatory or administrative action.

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.

416.2(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.

Code: 01C02
Violation: 416.4(a), 416.13(c), 416.2(d), 416.4(d), 416.4(b)

Citation: At 0740 hours in the Paws Department after Pre-op procedures had been completed and production had begun, I observed the following SSOP noncompliance. There was heavily beaded dripping condensation on the fan near the giblet (paws, gizzards, and liver) chillers. The condensation from the fans was falling directly into two ice bins. The ice was then being shoveled into the chillers. The conditions of the fans were dusty, with remnants of previous days operations clinging to them. I took an immediate regulatory control action by applying USDA tag #B34511495 to reject the giblet chillers, belts and packing areas. USDA retain tag #B34351490 was applied to all affected product (14 totes of gizzards and 20 totes of paws). Mr. (Evisceration Superintendent) was notified. Condensation was mopped and plastic was hung on the fans to divert any further condensation. found on page 2 of the Operational SSOP Plan. At 0845 hours, after sanitary conditions were restored regulatory control action was relinquished. Affected gizzard and paw products were released at 0935 and 1317 hours, respectively. Review of Pre-op records revealed that the area had been released at 0718 hours. Review of establishment SSOP records revealed that a check had not yet been conducted before the noncompliance was discovered. The requirements of Meat and Poultry regulations 416.13(c), 416.2(d), 416.4(a), 416.4(b), 416.4(d), and 416.1 were not met. Mr. , Plant Manager is hereby notified in writing of this NR for SSOP noncompliance. Continued failure to meet regulatory requirements can lead to enforcement actions described in 9 CFR Part 500.4.

Regulation:

416.4(a) 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.

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

416.2(d) Ventilation adequate to control odors, vapors, and condensation to the extent necessary to prevent adulteration of product and the creation of insanitary conditions must be provided.

416.4(d), 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: 416.13(c), 416.4(a), 416.1

Citation: After the establishment had completed pre-operational sanitation procedures and lockout/tag out was satisfactorily completed, but before the start of operations, the following noncompliance was observed. Pieces of meat and fat of various sizes from previous day’s operation were observed in two areas. At 0721 hours in Leg Deboning Dept. IU #22, on the Leg Skinner lines Belts. At 0739 hours in Cut-Up Dept. IU #12, on the Breast Machine and Belt. Mr. , QSI Manager and , QA Manager were immediately shown the aforementioned condition and were notified of the establishment’s failure to meet the regulatory requirements of 9 CFR 416.13(c), 416.4(a) and 416.1 as well as their Preoperational Sanitation Procedures as outlined on pages 1 and 2. The equipments were rejected with U.S. Rejected Tags #B34351429 for Leg Deboning Dept. and #B34351426 for Cut-up Dept., as per 9 CFR 500.2 (a)(1). A review of the establishment’s QA Pre-operational Check Sheet dated 12/29/2011 revealed that QA did randomly select the aforementioned belts (IU #22) in Leg Deboning and found them to be acceptable but did not randomly select the IU #12 in Cut-up. The establishment restored sanitary condition and regulatory control action was relinquished at 0735 hours from Leg Deboning Dept., and at 0750 hours from Cut-Up Dept. No product was involved. This document serves as written notification to Mr. , Plant Manager, of the establishment’s failure to meet the regulatory requirements and that continued failure could result in additional regulatory or administration action as per 9 CFR 500.4.

Regulation:

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

416.4(a) 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.

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.

Code: 01C02
Violation: 416.4(d), 416.13(c)

Citation: At approximately 2200 hours, while the cut-up department was on break and employees were using pressure hoses to wash down the area, I observed an employee carrying a grey tray with one layer of about 9 leg quarters walking through the overspraying of wash fluid to the product reconditioning station for second processing. I immediately notified Debone Supervisor, and walked with her to the reconditioning station. , Debone Superintendent was also notified. There was no employee at the reconditioning station. In addition to the product on the grey tray, there was an uncovered box of boneless breasts, an uncovered blue tote of leg quarters, and mixed product on the rack of the reconditioning table. Splashes from employees washing down the area were visibly overspraying on the aforementioned products (cross-contamination). US Retained Tag # B23885374 was applied to the area. , Second Processing Superintendent, came to the area and was notified of the establishment’s failure to comply with 9 CFR 416.1, 9 CFR 416.13(c), 9 CFR 416.4(d) which states, in part, that product must be protected from adulteration during processing, handling, storage, loading, and unloading, as well as the failure to follow procedures outlined on pages 1-3 of the establishment’s written b) (6) Sanitation Standards Operating Procedures (SSOP) Operational plan. Mr. chose to condemn all affected product (95 lbs). The retain tag was relinquished. This NR serves as a written notification to Mr. Plant Manager, of the establishment’s failure to meet regulatory requirements and that continued failure could result in further regulatory or administrative action as per 9 CFR 500.4.

Regulation:

416.4(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

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

Code: 06D02
Violation: 381.76(b)

Citation: At 1533 hours while performing Other Inspection Requirements task on Streamlined Inspection System line the following presentation noncompliance was observed at the two inspection stations: Station 1A recorded a nonconformance score of consisted of: – One viscera not uniform points), – One viscera below the wing points), and – One no viscera points.) Station 1B recorded a nonconformance score of consisted of: – One viscera not uniform points), – One out of sequence points), and – One contamination inside bird points.) I immediately notified Mr. , 1st Processing Superintendent, of the failure to meet regulatory requirements 9 CFR 381.76(b). The line was immediately slowed by from birds per minute (BPM) to BPM in accordance with the Rules of Practice 9 CFR 500.2(b). At 1543 hours, a presentation retest was performed with the line speed at BPM and was found acceptable with conformance scores of and at stations 1A and 1B, respectively. The line speed was increased back by and another retest was performed at 1556 hours, to ensure compliance at BPM, and recorded acceptable conformance scores of and at stations 1A and 1B, respectively, indicating process control. This document serves as a written notification to Mr. , Plant Manager, of the failure to meet regulatory requirements, and that continued failure could result in additional regulatory or administrative action.

Regulation: There are five systems of postmortem inspection: Streamlined Inspection System (SIS) and the New Line Speed (NELS) Inspection System, both of which shall be used only for broilers and cornish game hens; the New Turkey Inspection (NTI) System, which shall be used only for turkeys; Traditional Inspection; and Ratite Inspection.

Code: 01C02
Violation: 416.4(d), 416.13(c)

Citation: At approximately 1919 hours, while touring the leg debone department with QA tech , I observed a floor person using a hose to wash down the floor near line and the wash fluid was splashing off the floor and into a blue lined tote with edible whole leg bones, pieces of meat, fat and skin product (cross-contamination). A plant associate then carried the tote and emptied it into a conveyor belt leading to a bin of edible product to be processed as MSC. This is a failure to comply with 9 CFR 416.1, 9 CFR 416.13(c), 9 CFR 416.4(d) which states, in part, that product must be protected from adulteration during the processing, handling, storage, loading, and unloading, as well as the establishment’s Implementation Guidelines Procedure for ” outlined on pages 1-3 of the establishment’s Sanitation Standards Operating Procedures (SSOP) plan. I immediately notified Ms. , Cut up Supervisor, who in turn informed Mr. , 2nd processing Superintendent, of the failure. Mr. chose to immediately condemn all product in the affected MSC bin, replaced the totes on lines and also and washed down the possibly affected rake used to level product in the bin. QA Tech wrote a corrective action on the incident as per the establishment’s SSOP plan. This NR serves as a written notification to Mr. , Plant Manager, of the establishment’s failure to meet regulatory requirements and that continued failure could result in regulatory or administrative action as per 9 CFR 500.4.

Regulation:

416.4(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

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

Code: 03J04
Violation: 381.65(e), 417.2(c)(4)

Citation: Evisceration Line At 1536 hours, while performing FPS task (Finished Product Standards), fecal material was observed on the tail on the right side of the oil gland area in one of the 10 randomly selected carcasses. The fecal material was about . inch in diameter, brownish in color and pasty in consistency. Since there are no plant interventions between the sampling site and the chiller, it is reasonably likely to assume that the contaminated carcass would have entered the chill system violating 9 CFR 381.65(e). I immediately notified , Evisceration Supervisor, who immediately notified , 1st Processing Superintendent for N/S, of the fecal material which he witnessed, and of the establishment’s failure to meet the regulatory requirements of 9 CFR 381.65(e) and 417.2(c)(4). I observed as the establishment immediately implemented corrective actions as per the HACCP Plan for CCP #2. A review of the establishment’s Zero Tolerance Monitoring log for CCP #2, dated November 23, 2011, revealed the last acceptable check was performed at 1518 hours and initialed by QA technician . A review of the establishment records verified that regulatory requirements at all of the CCP’s including pre-shipment review of the affected lot were found acceptable. The affected bird was removed from production and taken to the salvage reprocessing station. This NR serves as a written notification to Mr. , Plant Manager, of the establishment’s failure to meet regulatory requirements and that continued failure could result in enforcement action as per 9 CFR 500.4.

Regulations:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the critical control points for each of the identified food safety hazards, including, as appropriate: (i) Critical control points designed to control food safety hazards that could be introduced in the establishment, and (ii) Critical control points designed to control food safety hazards introduced outside the establishment, including food safety hazards that occur before, during, and after entry into the establishment.

Code: 01C02
Violation: 416.13(c), 416.4(d), 416.4(b), 416.4(a) 

Citation: At approximately 0610 hours, I observed SSOP noncompliance in the paw picker area. A maintenance employee was standing on the side of the angled paw belt with his boots comining in contact with the belt and product. He then proceeded to climb up the framework to the horizontal paw belt, again with his boots coming in contact with the belt and product. I immediately took regulatory action by stopping both lines. I informed , and of the noncompliance. Management chose to condemn all affected product. Both belts were sanitized. At 0618 the area was released after sanitary conditions were restored. The requirements of Meat and Poultry regulations 416.1, 416.4(a), 416.4(b), 416.4(d), and 416.13(c) were not met. Mr. , Plant Manager is hereby notified in writing of this NR for SSOP noncompliance. Continued failure to meet regulatory requirements can lead to enforcement actions described in 9 CFR Part 500.4.

Regulations:

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

416.4(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

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.

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

Code: 01C02
Violation: 416.13(c)

Citation: At 0555 hours after pre-operational sanitation was complete but prior to product entering the mid-chillers the following noncompliances were observed. Mid-Chiller #1; fat was observed floating near the unloader for mid-chiller #1. I requested Mr. , 1st Shift Manager and Mr. , Maintenance Manager to come to the area. Once there I asked Mr. to turn off the aeration system so I could see the water. Once off, meat, fat and feathers that was approximately 3/8” – 1 ½” in size was observed floating throughout chiller. Since no product had been introduced to the mid-chiller it is reasonable to conclude that the aforementioned derived from the previous day(s) operation and would have contaminated the wholesome birds entering the mid-chiller. Mr. , QSI Plant Manager was immediately notifed of the establishment’s failure to meet the regulatory requirements of 9 CFR 416.1, 416.4(a) and 416.13(c) and that mid-chiller #1 was rejected with U.S. Rejected Tag #B 34351454 as per 9 CFR 500.2(a)(1). After rejecting mid-chiller #1, I requested Mr. to turn off the aeration system for mid-chiller #2. Mid-Chiller #2; meat, fat and feathers approximately 3/8” – 1 ½” in size was observed floating throughout chiller. Since no product had been introduced to the mid-chiller it is reasonable to conclude that the aforementioned derived from the previous day(s) operation and would have contaminated the wholesome birds entering the mid-chiller. Mr. QSI Plant Manager was immediately notifed of the establishment’s failure to meet the regulatory requirements of 9 CFR 416.1, 416.4(a) and 416.13(c) and that mid-chiller #2 was rejected with U.S. Rejected Tag #B 34351455 as per 9 CFR 500.2(a)(1). While waiting for the mid-chillers to re-inspected I observed QSI employees sanitizing the two mid-chiller exit conveyors, as I looked closer at the conveyor belts I observed meat and fat from the previous day operations. Additionally both conveyors and stainless side rails was greasy to the touch (when touched chicken grease was on yur fingers). The aforementioned Rejected Tags were used to reject the exit conveyors. Mr. QSI Manager was notifed of the establishment’s failure to the regulatory requirement of 9 CFR 416.1, 416.4(a) and 416.13(c). At 0703 hours both chillers were re-inspected, sanitary conditions were restored in accordance to QSI -0044 re-cleaning procedures and the regulatory control action was released. At 721 hours after re-inspection of the two exit conveyors, sanitary conditions were restored as per QSI-0044 re-cleaning procedures and the regulatory control action was relinquished. A review of the establishments QA Preoperational Sanitation CheckSheet dated 10/28/11 revealed that QA did not check the neither mid-chiller or the exit conveyors. This NR serves as written notification to Mr. Plant Manager that continued failure could result in enforcement action as per 9 CFR 500.4.

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

Code: 03J04
Violation: 417.2(c)(4), 381.65(e)

Citation: Evisceration Line At 2036 hours, while performing FPS task (Finished Product Standards), fecal material was observed inside the left corner above the cloaca area in one of the 10 randomly selected carcasses. The fecal material was . inch, brownish in color and pasty in consistency. Since there are no plant interventions between the sampling site and the chiller, it is reasonably likely to assume that the contaminated carcass would have entered the chill system violating 9 CFR 381.65(e). I immediately notified 1st Processing Superintendent for N/S, of the fecal material which he witnessed, and the establishment’s failure to meet the regulatory requirements of 9 CFR 381.65(e) and 417.2(c)(4). I observed the establishment immediately implemented corrective actions as per the HACCP Plan for CCP #2. A review of the establishment’s Zero Tolerance Monitoring log for CCP #2, dated October 20, 2011, revealed the last acceptable check was performed at 1906 hours and initialed by QA technician . A review of the establishment records verified that regulatory requirements at all of the CCP’s including pre-shipment review of the affected lot were found acceptable. The affected bird was removed from production by Mr. I was verbally informed later the root cause of the noncompliance was a bent blade on the vent cutter. This NR serves written notification to Mr. , Plant Manager , of the establishment’s failure to meet regulatory requirements and that continued failure could result in enforcement action as per 9 CFR 500.4.  

Regulation:

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits.

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

Code: 06D02
Violation: 381.76(b)

Citation: Evisceration Lin At 1551 hours while performing presentation check task on Meyn Maestro Inspection System, conformance scores of and were recorded at inspection stations 2B, 2C, and 2D respectively and a nonconformance score of at inspection station 2A. Inspection station 2A consisted of one contamination points) and two no viscera points each) for a total nonconformance of oints. This exceeds the conformance level of Mr. , Evisceration Supervisor was notified who immediately notified Mr. , N/S 1st Processing Superintendent. Mr. was notified of the establishments’ failure to meet the regulatory requirements of 9 CFR 381.76(b) which requires an immediate line reduction of ten percent (10%) from 140 BPM to 126 BPM in accordance with the Rules of Practice 9 CFR 500.2(b). At 1607 hours a retest was performed and found acceptable at BPM with a conformance score of at stations 2A and 2B and a conformance score of  stations 2C and 2D. The line speed was increased by ten percent from BPM to BPM. At 1613 hours a final retest was performed to ensure compliance at BPM and a conformance score of was recorded at inspection stations 2A, 2B, and 2D, and a conformance score of at inspection station 2C, indicating process in control. This document serves as written notification to Mr. , Plant Manager, that continued failure to meet regulatory requirements could result in regulatory or administrative action.

Regulation: There are five systems of post-mortem inspection: Streamlined Inspection System (SIS) and the New Line Speed (NELS) Inspection System, both of which shall be used only for broilers and cornish game hens; the New Turkey Inspection (NTI) System, which shall be used only for turkeys; Traditional Inspection; and Ratite Inspection.

Code: 01B02
Violation: 416.13(c), 416.4(a), 416.4(b)

Citation: After the establishment had completed pre-operational sanitation procedures and lockout/tag out was satisfactorily completed, but before the start of operations, the following noncompliance was observed. Area 9, Breast Marel M-Tek Machines 2 & 3 Horns and Belts: At 0741 hours to numerous too count meat, fat and black unidentificable foreign materials of various sizes were observed on top of the belts and in the Horns of the machines from the previous day’s operation (direct product contact surfaces). Mr. , QSI Manager was immediately shown the aforementioned conditions and was notified of the establishments failure to meet the regulatory requirements of 9 CFR 416.13(c), 416.4(a) and 416.1 as well Pre-operational Sanitation Procedures as outlined on pages 1 and 2 of the Pre-operational procedures. The equipment was rejected with U.S. Rejected Tag #B34351430 as per 9 CFR 500.2 (a)(1). A review of the establishments QA Pre-operational Check Sheet dated 10/18/2011 revealed that QA did randomly select the aforementioned machines and found indirect deficiencifies. At 0752 hours hours after restoration of sanitary conditions by the establishment the regulatory control action was relinquished. No product was involved. This document serves as written notification to Mr. , Plant Manager of the establishment’s failure to meet the regulatory requirements and that continued failure could result in additional regulatory or administration action as per 9 CFR 500.4.

Regulations:

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

416.4(a) 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.

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:  416.13(c), 416.4(a)

Citation: After the establishment had completed pre-operational sanitation procedures and lockout/tag out was satisfactorily completed, but before the start of operations, the following noncompliance was observed. Area 9, Breast Marel M-Tek Machines 2 & 3 Horns and Belts: At 0741 hours to numerous too count meat, fat and black unidentificable foreign materials of various sizes were observed on top of the belts and in the Horns of the machines from the previous day’s operation (direct product contact surfaces). Mr. , QSI Manager was immediately shown the aforementioned conditions and was notified of the establishments failure to meet the regulatory requirements of 9 CFR 416.13(c), 416.4(a) and 416.1 as well Pre-operational Sanitation Procedures as outlined on pages 1 and 2 of the Pre-operational procedures. The equipment was rejected with U.S. Rejected Tag #B34351430 as per 9 CFR 500.2 (a)(1). A review of the establishments QA Pre-operational Check Sheet dated 10/18/2011 revealed that QA did randomly select the aforementioned machines and found indirect deficiencifies. At 0752 hours hours after restoration of sanitary conditions by the establishment the regulatory control action was relinquished. No product was involved. This document serves as written notification to Mr. , Plant Manager of the establishment’s failure to meet the regulatory requirements and that continued failure could result in additional regulatory or administration action as per 9 CFR 500.4.

Regulation:

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

416.4(a) 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: 03J04
Violation: 381.65(e), 417.2(c)(4)

Citation: Evisceration Line At 1329 hours while performing task Poultry Finished Product Standards on evisceration line I observed fecal material on the outside surface of 1 of 10 randomly selected carcasses selected for inspection. The fecal material was greenish-brown in color, semi-pasty in consistency, approximately 3/8 inch in size and oval in shape. Once I observed the fecal I touch a portion of it and it smeared. I informed the QA Tech who was next to me to inform a member of management. Mr. 1st Shift Manager was notified and shown the fecal and implemented corrective actions as described in the HACCP Plan for CCP #2. Mr. was also informed of the establishments failure to meet the regulatory requirement s 9 CFR 381.65(e) and 9 CFR 417.2(c) 4. A review of the establishment Zero Tolerance Check sheet dated 10/18/2011 revealed that the last acceptable check was performed at 1223 hours by QA Tech, . An acceptable retest was performed by at 1344 hours. A review of the establishments pre-shipment review was performed at 1445 hours for the affected lot and was found to be acceptable. This NR serves as written notification to Mr. , Plant Manager of the establishments failure to meet the regulatory requirements and that continue failure could result in enforcement action as per 9 CFR 500.4.

Regulation:

381.65(e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank.

417.2(c)(4) List the procedures, and the frequency with which those procedures will be performed, that will be used to monitor each of the critical control points to ensure compliance with the critical limits.

Code: 04A06
Violation: 381.76(b)

Citation: Evisceration Line At 1329 hours while performing task Finish Product Standards, a total 10 bird sub group numerical score of was reached which exceeded the absolute limit of tolerance plus for the processing category). The deficiencies were not specifically one category but, varied. A retest was performed at 1344 hours for sample validity which resulted in a total numerical score of exceeding the tolerance of indicating that the process was not in control. Mr. , 1st Processing Manager was immediately notified of the establishments failure to meet the regulatory requirements of 9 CFR 381.76(b). Random pre-chill sampling for the processing category was suspended as well as post-chill sampling. At 1412 hours after passing four consecutive prechill samples with conformance e score of and random prechill sampling resumed. Post-chill sampling using the pre-chill criteria commenced at 1329 hours, was complete and found acceptable with conformance scores of and at 1628 hours. This document serves as written notification to Mr. Plant Manager of the establishments failure to meet the regulatory requirements and that continue failure could result in enforcement action as per 9 CFR 500.4.

Regulation: There are five systems of postmortem inspection: Streamlined Inspection System (SIS) and the New Line Speed (NELS) Inspection System, both of which shall be used only for broilers and cornish game hens; the New Turkey Inspection (NTI) System, which shall be used only for turkeys; Traditional Inspection; and Ratite Inspection.

Code: 01C02
Violation: 416.13(c), 416.4(d)

Citation: At 1630 hours as I was heading towards the receiving department, I observed an accumulation of birds in the catch pan of line auto rehanger and were trapped and not flowing. Directly underneath, on the floor and on top of the drain covers, were approximately birds of overflowed birds. There was no one monitoring the area at this time so I went to Mr. , Supervisor for Evisceration who was nearby and showed him the aforementioned conditions. He immediately brought it to the attention of a floor employee who began picking up birds from the floor, rinsing them off using chlorinated water and putting them on conveyor belt for line I then observed the same floor employee picked up four birds from the top of a drain cover (2 in each hand), rinsed them off and threw them in on line conveyor belt mixing them with other birds flowing on the belt. I immediately went to Mr. again and informed him of the noncompliance and failure to follow the establishment’s SOP written procedures 6010 (revised on 8/31/11), which states, Line was stopped and all of the affected birds from table #2 were tanked off in two large bins. U. S. retained tags # B34351473 and B34351484 were applied to the bins. A review of the establishment’s SSOP Monitoring Log for receiving dated October 10, 2011 revealed that the last check for “product protected from contamination” was performed at 1503 hours and found acceptable by QA Technician The establishment failed to meet the requirements of 9 CFR 416.1, 9 CFR 416. 13(c) and 9CFR 416.4(d) as well as their own SSOP Implementation Guideline Procedure This document serves as a written notification to Mr. , Plant Manager, of the establishment’s failure to comply with the regulatory requirement(s) and that continued failure could result in administrative action as described in 9 CFR 500.4

Regulation:

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

416.4(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.