Iowa Slaughterhouses

Code:  01001
Violation:  416.1, 416.2(b)(2), 416.4(b), 416.2(b)(1)

Citation:  At 0800 hours I met with [redacted], and we toured the establishment, observing some maintenance and cleaning issues. The following noncompliances were observed by me, which I pointed out to [redacted] and informed  him that I would  write a NR for these: A) In cooker 2&6 area, over the pasta  scale, there is an air vent that had a thick accumulation of dust covering the entire vent.This is directly over an area that product is carried through . B) I n the main North – South hallway and the East – West hallway between the cookers and the trash room, there is flaking paint and rust on many of the overhead structures. C) There is an electrical box in the hallway adjacent to the steps going up to the breakroom that has a covering of dust on the top and front. D) I n Pie 1on the east wall, there were several globs of dough, from approximately 1/4″- 3/4″ in size, between  1/2 and 3/4 of the way up the wall. E)  The frame cross-braces on the east wall have several areas of peeling, flaking paint. F) There is an insulation covered water pipe on the east wall near the north end of the room that had a large (approx.3″ X 4″) patch of what appeared to be cinnamon dust. G) In Pie 2 area, where Pie 1boxes come through the wall, the the ledge above the window and a metal box in the vicin ity both have a coating of dust on their upper surfaces. There is also dust on several pipes in the area. H) The metal wall beams on the east wall in Pie 2 area have areas of rust and bubbling/fla king paint.I) There is what appears to be a ceiling access panel in the area above the finished pies on Pie 2.The frame has caulk around the edges, and there is a cau lk “string” hanging down from one edge. J) The south wall in Pie 2/3 has large electric boxes. Much of the wall and the top of the boxes have a coating of dust and dust “balls”. This does not meet, at a minimum, the requirements of 9 CFR 416.1;416.2(b)(1); 416.2(b)(2); and 416.4(b). [redacted] informed me that he would  get maintenance and sanitation personnel to work on these items over the two holiday weekends. No product was affected, and no further actions were taken by me.

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)(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.

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

Code:  01C01
Violation:  416.16(a)

Citation:  While performing a records review of the operational monitoring forms as required by MPI Regulation 416, I observed that no documentation  was listed on December 8th in the Frozen Foods #2 department that lists anything in reference to the non-compliance that occurred with the dirty ingredient barrel lids, and the potentially adulterated  product.This insanitary condition resulted in Non-com pliance record ZP14507124111N to be written.MPI Regulation 416.16(a) states that “each official establishment shall maintain daily records sufficient to document the implementation and monitoring of the sanitation SOP’s and any  corrective actions taken.”

Regulation:

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

Code: 01802
Violation: 416.13(c), 416.16(a), 416.13(a), 416.l5(b), 416.14

Citation: While performing pre-operational inspection at the scheduled 5:45 am.time in the Combo Dinner Line Department, I observed several defficiencies that resulted in the rejection of the department. My observations were thefollowing:A).1 observed heavily beaded water on the overhead insulated pipes in the combo #3 filler area.This filler had it’s lid open allowing filler to become recontaminated in the product contact zones. 8).This same filler had previous production sauce on the valve that is used by production associates. C). I had several spray nozzles that spray butter/sweet water onto dinners removed from combo #1 and combo #3 dinner l ines, and found traces of product residue and/or discoloration on the inside that contacts the product. D). Combo #3 blenders had what appeared to be mushrooms in two locations on the inside of the south blender that were approximately 1″ X 1/2″.E). The south blender had a yellow substance coming out of the seal on the inside product contact area. F). The Combo #1 east blender had previous production sauce bu ildup in the seal area on several joints that could easily re-enter into the next product run . G).The Combo #1west blender had a brown sauce on the agitator that contacts the product.H). The potato tower had holesthrough the ceiling for the motor brackets with insu lation exposed. I). The heat rollers on the combo #3 had previous operation buildu p of what appeared to be a metal or plastic and/or food scrap. I). Semolina tower for cooker #6 had parts on the floor of tower, and sitting on the curbing.J). The air hose used on the dry feed for cooker #2 was lying across the edible equipment causing a cross contamination . **Combo department was rejected with USDA Reject tag # 816376976. [redacted] was notified and witnessed my findings. **Several of these same issues were addressed on Non-compliance Record ZP 10715101129N dated 10/27/2011, such as; combo #3 blenders, overhead water drips combo #3, semolina equipment parts on tower floor, raw noodle feed hopper cover on curbing. and cooker #2 rubber airhose cross contamination .The preventitive measures given by [redacted] was training for proper clean ing of the blenders (completed 10/30/11), ordered sponges, clamps,and poles to keep condensation on overhead piping wiped down (complete), rubber air hose to be place on the framework on the S’s cart(completed).The tower hopper lid, and the raw hopper lid weren’t answered on the non-compliance record.The spray nozzles were addressed in the weekly USDA Meeting on 12/2/2011. [redacted] stated that the nozzles will be removed nightly after use for cleaning **These preventitive measures have failed to prevent a re-occurrence. **Production was allowed to setup after in-sanitary conditions were restored.

Regulation:

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

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

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

416.l5(b) Corrective actions include procedures to ensure appropriate disposition of product(s) that may be contaminated, restore sanitary conditions, and prevent the recurrence of direct contamination or adulteration of product( s), including appropriate reevaluation and modification of the Sanitation SOP’s and the procedures specified therein or appropriate improvements in the execution of the Sanitation SOP’s or the procedures specified therein.

416.14 Each official establishment shall routinely evaluate the effectiveness of the Sanitation SOP’s and the procedures therein in preventing direct contamination or adulteration of product(s) and shall revise both as necessary to keep them effective and current with respect to changes in facilities, equipment, utensils, operations, or personnel.

Code: 01001
Violation: 416.2(c), 416.4(a), 416.2(b)(2), 416.4(d), 416.4(b), 416.1

Citation: While touring thisfacility over the last few days, I observed numerous construction, cleaning, and/or maintenance issues in several areas that are lacking proper attention, which could lead to adulteration of product. The following is a list of my findings, which were addressed with [redacted]. A).The product feed conveyor for cooker #5 in the [redacted] Room had too much slack in the belting, thus allowing it to drag against the support brace that comes up from the base to the top. B). Insulated piping above the egg feeder for the semolina manufacturing in the [redacted] Room has a large gap in the insulation with rusty iron exposed. C) [redacted] Room Die Lift at Cooker #3 had painted hinges that were rusty and flaking of paint.The hinges are in close proximity to exposed product. D). The Semolina Recieving Tower in the [redacted] Room was missing the shield that covers the product bin under the painted motor to protect from adulteration of paint, rust, etc…(tray was found lying on curb). E). Cooker #3 shaker table or the exit of the cooker has flaking paint on the motor. This motor is in close proximity of exposed product . F). The portable pump labeled FF-3 in the [redacted] Room had the stainless tubing that is put in the barrels and/or tanks for pumping of edible liquids, etc. contacting the floor. The airline used for this pump was lying over the top of this supposedly production sanitary equipment. The pump has no proper way to store it’s parts when not being used . G).White insulated piping through out the [redacted] Room in need of repair allowing exposed insulation, rusty connections, and moisture accumulation. H). The stainless steam wrap over cooker #3 has rusty connections. I). Stainless over head piping above cooker #4 had condensation dripping onto equipment during operations. This piping is not taken down daily for cleaning. so condensation cannot be considered “clean condensation.” J). The large diameter pipe running north and south in the center of the [redacted] Room feeding all the cookers is cracked and peeling. K). Cooker #4 has two drop down pipes at the shakers table with exposed insulation, end caps missing. L). Cooker #5 in the [redacted] Room had the steam coming out of the cooker going upwards, and causing the painted motor at the top of the feed auger to drop water beads that were draining from inside the housing of the motor. This moisture was dripping onto the feeder chute and draining back towards the entry to the cooker. M). The overhead insulated piping in the [redacted] Room had a thick crusty semolina coating from not being cleaned as necessary. N). Combo #1 Kitchen had a exposed hole through the ceiling where a piece of conduit appears to have been removed. 0). Ceiling is very rippley over west side causing ceiling panels/trim/ lights etc.. to pull away allowing for large gaps in ceiling. P). Cooker #5 in the Combo #1 Kitchen has two pipes that have dropped down approx. 3″ from the ceiling hanger, exposing ceiling gaps.Q). Milk Cooler inclined ledges have dust accumulation, and don’t look to have been cleaned on a regular schedule. R).The Battery Charger Room on south end has thick dust accumulation on curbs, shelving, also has debris under and behind the racks. S). Semolina Recieving tower area in the back room of Cooker #6 manufacturing is not in an acceptable condition for any product exposure such as dumping semolina bags. Two 2×4 ceiling panels are completely missing above the tower with several others out of place. Miscellaneous objects lying on curbing aound tower. Equipment stagging area has dis-assembled parts and equipment scattered on the floor, and shipping cartons nearby. Dust accumulation through out this room on equipment and structure. Equipment is not tagged off for not using until pre-op cleaned. This room is not being cleaned as necessary. T). Semolina Manufacturing for Cooker #6 had the hopper cover sitting on the floor of the platfrom during operations. This was addressed to [redacted]gs on NR Record ZP10715101129N dated 10/27/2011. U). The Hopper lid for the dry feed for Cooker #2 was sitting on the curbing, as well as the rubber airhose was lying over this hopper. These were also addressed on NR Record ZP107151101129N dated 10/27/2011. V). Pie line has dust accumulations on piping at the ceiling exhaust. X). Pie line #1- future kitchen area behind [redacted] is being used as a catch all, with parts on the floor, dust, and visible food scrap. Room needs to be organized and put on a regular cleaning schedule.Y) [redacted] fillers have white painted motors on them that show evidence of flaking paint. These motors are at the edge of the product flow with the motor fan venting out over the product flow. This was discussed with [redacted] noted on the weekly usda meeting notes, and re-addressed again with on 12/09/2011. Z).Ceiling over the [redacted] for pie lines 2 and [redacted] had sizable gaps around the trim in two different locations.••• In reviewing operational monitoring records, none of my findings were recently documented by any department monitors.

Regulation:

416.2(c) Light. Lighting of good quality and sufficient intensity to ensure that sanitary conditions are maintained and that product is not adulterated must be provided in areas where food is processed, handled, stored, or examined; where equipment and utensils are cleaned; and in hand-washing areas, dressing and locker rooms, and toilets.

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.

416.2(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.

416.4(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.

416.1 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: 416.13(b)

Citation: While monitoring operations in the Frozen Foods #2 department at approximately 2:20 pm., I observed the top lids of the liquid margarine barrels(4) with black dust, wood pieces, and miscellaneous scrap. It was apparent that no attempt was made to clean them off prior to my observation. One barrel that was partially empty, and that had the lid off contained what appeared to be an adulterants floating on the top surface. I requested for a supervisor to discuss my findings, and to also get a corrective and preventitive measure. While waiting on a supervisor, the kitchen associate tried to clean the barrel lids with paper towels in which I told him that it was already being addressed [redacted] arrived, and was given the details of what I observed. I informed [redacted] that the barrels are rejected from the room, and that the partial barrel is being retained with USDA Retain Tag #816376943 for potential adulteration. As a corrective action [redacted] had the three full barrels removed from the production area for proper cleaning. The partial barrel was dumped in inedible pe [redacted]. The preventitive measure given by [redacted], was that a review of the verification policy, and where it failed will be conducted. Any training or re-training will be given once the scope of failure is determined. This will be completed by Decemeber 23rd, 2011. Until training or such is completed, ingredients will be closely monitored prior to going into production area by supervison. “*As a response to a non-compliance written on August 4th, 2011 for debris on barrel lids, and given as a preventitive measure a “Plastic Barrel Cleaning Procedure Train ing” policy was created. Also, part of the preventitive measure was that a usage verifier will inspect all barrels prior to entering the production room.Training was completed with all cooks, line drivers, and verifiers. **Prod uction was allowed to resu me in the kitchen after acceptable preventitive measures were given.

Regulation:

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

Code: 01802
Violation: 416.4(a), 416.1, 416.13(c), 416.4(b)

Citation: At approximately 0110 hours, after being informed by [redacted] that they were ready for me to inspect and prior to commencement of operations, I performed a pre-operational sanitation inspection on Pie line 1.I observed the following noncompliances:1) On the [redacted] incline conveyor belt inside surface, there were two pieces of meat, approximately 1/8″ diameter each, left over from prior production. There also were two black specks about the size of a pin head, that appeared to be grease, on the belt.This is a food contact surface. 2) On the outer side of the side flaps of that belt (a non food-contact surface), there were at least 5 more black specks. These specks could easily be smeared with a finger, and left a smudge. It had the appearance of machine grease. 3) The top dough roller had 2 approximately 1/16″ pieces of dough on the food contact surface, and both ends of the roller (non food-contact) had dough smeared over approximately 3/4 of the surface. 4) Where the underside of the top dough belt rides over the metal guide surface (non food-contact), there was a a layer of dough, approximately 1/8″ – 1/4″ thick, between the two surfaces. This does not meet, at a minimum, the requirements of 9 CFR 416.1;416.4(a)&(b); 416.13(c); or the establishment ‘s SSOP’s, which says on page 4 that a designated, trained employee will perform an organoleptic Pre-Operational inspection of each processing area after equipment has been cleaned. Establishment employees failed to observe these insanitary conditions. [redacted] accompanied me on my inspection, so I pointed out each item as I observed them, and informed him that I would write a NR. Each item was cleaned in my presence as I pointed it out, so no tags were used. No product was affected, and no further actions were taken by me.

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.

416.1 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(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: 01802
Violation: 416.1, 416.4(a), 416.13(c), 416.3(a), 416.4(b)

Citation: At approximately 0120 hours, after being informed by [redacted] that the Pie 2/3 [redacted] was ready for me to pre-op but prior to start of operations, I performed a pre-operational sanitation inspection on [redacted] the I observed the following noncompliances:1) The mixing paddle had a smear of dough on the back side, between the paddle and the door, that amounted to approximately 1/2 tsp. 2) The dough belt had 3 dough particles, approximately 1/8″ diameter, on its surface. 3) The hopper on top of thelil had 5 particles, approximately 1/16″ to 1/8″ diameter, on the surface.These are all food contact surfaces, and these particles were left over from prior production. Additionally, there were several (>5) flou r/shortening/dough particles on the exterior (non food-contact) surfaces of the machine, motor, and auger housing.Left over organic particles can harbor pathogen ic bacteria which can be harmf ul to consumers.This does not meet, at a minimum, the requirements of 9 CFR 416.1;416.3(a); 416.4(a); 416.4(b), 416.13(c), and the plant’s SSOP’s, which state on page 4 that [redacted] Establishment employees failed to observe these insanitary conditions. Since this equipment had already been “pre-opped ” by establishment employees, it is reasonable to assume that this equipment would have been used without any additional cleaning being performed. I pointed out each of these noncompliances to [redacted] as I observed them, and he cleaned the equipment and restored sanitary conditions in my presence , so no USDA tags were used.No product was affected, so no further actions were taken by me.

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.

416.3(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(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: 01802
Violation: 416.13(c), 416.l5(b), 416.13(a), 416.14

Citation: While performing pre-operational inspection in the Combo Dinner Line Department and in the Noodle/Rice Cookers Department, I found in-sanitary conditions existing throughout both departments that resulted in my rejections with USDA Tag #816376941 and #816376942. The following defficiencies were observed in the Combo Dinner Lines Department: A). Upon entering the department, I observed [redacted] both hosing down the floor around the combo #2 dinner line. [redacted] was also observed using a red inedible shovel removing scraps from the floor. I continued to monitor as both [redacted] followed me to the line, and contacted equipment that they said was ready for operations. Both of these [redacted] weren’t following their own policy to avoid cross contamination onto production equipment that associates have to follow. Sanitation associates wear the shorter frocks when cleaning equipment and floors, and change out to the longer smocks when setting up production equipment. B). The e-stop button on the combo#2 line had past production sauce smeared on it. C). Combo 1, 2, and 3 had water in the bearing cups that are under the bearings on the heat rollers. When the water is in these cups, and the line shakes during prod uction the potential for it to splash into a dinner is likely. D). The Combo #3 blender had past production scrap on the inside by the agitator. E).Stainless buckets on the rack had past production scrap attached. F). The stainless production shelf used by the associates for paperwork was lying on the catwalk. G). Filler parts on the rack in the back of Combo 2 weren’t production ready and were said to be obsolete parts. H). Overhead piping above the Combo 3 filler area had beaded water over production ready equipment. I). The hemas were assembled prior to allowing me to inspect. [redacted] stated that he had thought that I previously okayed them for setup). The Cooker Department consisted of the following defficiencies: J).The semolina tower had exposed product in the front auger that feeds the blender hopper. This product was wet from washdown. K). A stainless buckets was sitting face down on the floor of the semolina tower. L). The semolina hopper lid was lying on the semolina tower floor. M). A stainless measuring pitcher was hanging on the S’s board on the semolina tower, but was half full of acid chemical. N). The overhead of the semolina tower was dripping beaded condensation throughout. O). The extruder housing had several past production scraps on the inside product contact area. P). The stainless chiller recirculating pipe used on cooker 6, had past production buildup throughout the inside. Q). Inedible parts (air hose) was hanging on the S’s board by Cooker 2, and was contacting edible equipment. R). The raw noodle feed hopper lid was leaning against the wall and sitting on the curb. **Several of these combo dinner line deficiencies are repetitive issues that were addressed on Non-compliance record # ZPl3114102422N dated 10/21/2011. Those preventitive measures of training haven’t been effective or training hasn’t been completed prior to this Non-compliance.The completion date for that training was 10/31/2011. **The corrective and preventitive measures given for this Non-compliance by [redacted], and [redacted] was that equipment was re-cleaned and sanitized. The preventitive measures given was that xtra parts will be removed from production areas if not needed, work orders were written to build storage racks/boards to keep parts off any inedible surfaces. Sanitation Supervisors will follow the frock policy that’s in place for all the other sanitation associates when going from inedible to edible, and training will be completed per linked Non-compliance from 10/21/2011. **Areas were released after brought into compliance at approximately 6:35 a.m.

Regulation:

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

416.l5(b) Corrective actions include procedures to ensure appropriate disposition of product(s) that may be contaminated, restore sanitary conditions, and prevent the recurrence of direct contamination or adulteration of product( s), including appropriate reevaluation and modification of the Sanitation SOP’s and the procedures specified therein or appropriate improvements in the execution of the Sanitation SOP’s or the procedures specified therein.

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

416.14 Each official establishment shall routinely evaluate the effectiveness of the Sanitation SOP’s and the procedures therein in preventing direct contamination or adulteration of product(s) and shall revise both as necessary to keep them effective and current with respect to changes in facilities, equipment, utensils, operations, or personnel.

Code:  01802
Violation:  416.13(c), 416.14, 416.13(a), 416.15(b)

Citation:  While performing pre-operational inspections in the Combo Dinner Line Department at 5:30 a.m ., I found numerous in-sanitary conditions that lead to the rejection on the department. The in-sanitary conditions that I observed were the following:A). The (-chan nel on the line belt of Combo 3 dinner line had past production residue and scrap throughout. 8). The bearing cups on the Combo 3 dinner line heat rollers were full of water. C). The overhead stainless Spray butter supply line leading to Combo 1dinner line was holding stagnant water.( I was told by sanitation [redacted] that this supply line is never used anymore).D). The potato and/or sauce filler sitting near Combo   dinner line had past production  residue in the discharge hole. E).The agitator was removed from the inside of the potato filler for the Combo 3 dinner l ine, and was lying on the in-sanitary surface decking along with the leveling probles contacting the electrical cords. F). The blender for the combo 3 dinner line had past production  residue on the grating. G). The white edible tubs had a greasy buildup on the insides of the ones I checked.H). Several parts for equipment and/or that are used by production associates are sitting on in-edible surfaces, such as; the paperwork shelf used by the potato blender, part of the potato auger sitting on catwalks, and miscellanous pieces that sanitation personel had no idea what they were for. I).The enclosed line belt sprayer on the Combo 3 dinner line had past production scrap accumulated on the belt near the roller, but access to remove wasn’t conven ient to remove and properly clean.**The department was rejected  with USDA Tag #816376250 **The corrective and prevent itive measures given by [redacted] was that all equipment and parts with past production residue and/or scraps were re-cleaned and sanitized. *The bearing cups were addressed on a previous non-compliance that they will be emptied prior to USDA Inspection. [redacted] stated that training with sanitation  leads will  be completed  and signed off by 10/31/2011.*The overhead butter/sweetwater  lines were reviewed for dead ends and non used pipe and removed from system. *Training with the leads and hourly associates about keeping equipment parts off the floor will be completed by 10/31/2011. * Training for accountable associates about the removal of the enclosed line cleaner pan on the Combo 3 dinner line will be completed by 10/31/2011. **The production area was released to production at approximately 6:25 a.m . after above noted issues were brought into compliance and acceptable preventitive measures were given by Establishment Management .

Regulation:

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

416.14 Each official establishment shall routinely evaluate the effectiveness of the Sanitation SOP’s and the procedures therein in preventing direct contamination or adulteration of product(s) and shall revise both as necessary to keep them effective and current with respect to changes in facilities, equipment, utensils, operations, or personnel.

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

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.

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

Citation: While monitoring operations in the Combo Dinner Line Department at approximately 8:05 a.m., I inspected the contents in the holding tank for the #3 production line.In doing my observation, I noticed rusty water streaks going down the agitator shaft from the motor at the top. The rusty streaks went down to at least the level of the sauce inside the holding tank. I immediately suspended operations and contacted [redacted].I informed [redacted] of my findings, and that the cook tank was rejected with USDA Tag #816376243.[redacted] was informed of the situation, and I informed him that all dinners produced since the production shift startup, plus all the sauce in the holding tank was retained with USDA Tag #816376245. After discussing this with [redacted], I allowed them to remove the motor and agitator assembly from the holding tank, and re-clean all piping and line fillers, so that production could resume later in the production shift.**This tank with rust streaks going down the agitator shaft was address on a pre-operational non-compliance record on 10/11/2011. That non-compliance record number was ZP12308104312N, and the preventative measure was that the seal on the motor shaft was replaced along with nightly inspections being performed by the sanitation associates. I did verify that the seal had been replaced, and that the inspections had been completed prior to production. The cause has been determined to be more extensive than originally thought, which led to this re-occurrence. The new preventative measure given by [redacted] was that the entire gear box was replaced along with new couplings, and o-rings on the agitator shaft. A new preventative maintenance schedule adding this gear box was created, and that replacement parts will be on hand for any future issues.Additionally, Once per hour a Quality Tech will inspect the agitator shaft looking for possible contamination coming from the gear box. The Quality Techs will log their checks onto their daily report, and reviewed by Quality Specialist for a period of one week or until further notice. **Production equipment without the motor and agitator was re-cleaned and re-inspected allowing production to resume at 10:30a.m. **449 cases of finished product and 42001bs was retained.

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. (b)

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:  01001
Violation:  416.1, 416.3(a), 416.4(b)

Citation:  At approximately 0110 hours, while observing overall sanitation of facilities and equipment, I observed the following noncompliance: The hydraulic fluid tank and motor assembly on Pie 1111111 contained several areas of rust and flaking paint. I observed two loose paint chips; one approximately 11/4″ diameter and the other approximately 3/4″ diameter.Paint was pulling away from the equipment in several spots. This does not meet, at a minimum, the requirementsof 9 CFR 416.1; 416.3(a); and 416.4(b), as this equipment is not being maintained in a sanitary condition. Although this equipment has guards around the sides during operation, the bottom  is open. This is not a food contact surface, but because raw materials for pie crust dough is moved through this vicinity, paint particles could find their way into product and be harmful to consumers. I showed this equipment to [redacted],and informed  them that I would write a NR. [redacted] immediately called a maintenance man over, who removed the loose paint in my presence, so no tags were used informed me that they would monitor this equipment in the future to ensure that sanitary conditions are maintained. No product was affected, and no further actions were taken by me.

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.

416.4(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: 01802
Violation: 416.13(a), 416.13(c), 416.4(a)

Citation: While performing pre-operational sanitation in the Combo Dinner line Department at 5:30 a.m.,I found several deficiencies throughout the department. They are as follows: A). The hemas on the Combo Line #1 were all assembled for production with no oppurtunity for inspection. B). Bearing cups for the heat rollers on Combo Line #1 were full of wash down water. CJ . Overhead piping,drip pans etc.. had water droplets dripping over prod uction ready equipment. D). Butter/sweet water delivery lines for the Combo #1 and #2 line sprayers had internal past production residue, and/or a dead end pipe holding adulterated water. E). Potato filler for the Combo Line #1 had several cleaning brush bristles inside the chamber that contacts product. F). The equipment/handwash sink near the Combo Line #1 line had past production scrap. G). Combo #3 Holding tank had rust streaking down the agitator and also had rust from the agitator bearing leaving a dust coating on the top lid of the tank. **The department was rejected with U.S.D.A. Tag #816376248. ***The corrective and prevent itive measures given by [redacted] for the above items were as follows:AJ. Hemas setup prior to USDA Pre-op Inspection were dis-assembled and re-presented for inspection. [redacted] were coached on proper setup times, and it was discussed that there will be no reason why they are set up early. Additionally, crews will be determined to own the setup of the hemas to establish expectations.BJ. Bearing cups were blown out with air, and will be blown out prior to USDA line Inspections going forward. CJ. Condensation/water dripping from piping etc… over Combo Line [redacted] was wiped down, then all equipment was re-rinsed and sanitized. Training to be conducted with the associates that are assigned to the position of removing condensation from the production overheads. Training will be completed and a copy given to the USDA IIC by 10/21/2011.DJ. The dead end piping was re-cleaned on insides. The deadend piping was removed from production system, and a full inspection of all the sweet water systems will be conducted for similar issues. EJ. Brush Bristles were removed from inside the potato filler, washed and sanitized. All cleaning brushes were inspected, and four were removed and thrown away. Brush inspections will be added to the Master Cleaning Schedule for inspection monthly. FJ. The handwash/Equipment wash sinks had scrap removed and were re-rinsed. Inspection of sinks will be routinely completed nightly after lines are cleaned. GJ. The bearing dust and leaking residue on agitator shaft on the Combo #3 Holding tank Motor was cleaned and re-sanitized. The 3rd shift maintenance associates replaced the seal on the agitator shaft. Preventitive maintenance will be changed to inspect and replace bearing at an increased interval, and inspection of the tank will be conducted nightly by the sanitation associate cleaning the tank. **Production department was released at approximately 6:40a.m., after all issues were brought into compliance.

Regulation:

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

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.

NOTICE of DEFERRAL:

On June 14, 2013, the Food Safety and Inspection Service (FSIS) issued to your Establishment M085O, Cargill Meat Solutions Corp., a “Notice of Intended Enforcement.” This action was taken by FSIS in accordance with FSIS Rules of Practice Title 9 of Code of Federal Regulations (9 CFR) 500.3 (b), which indicates that FSIS can take a regulatory control action, if it is handling or slaughtering animals inhumanely such as, that which occured at your establishment on June 14, 2013.

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NOTICE of INTENDED ENFORCEMENT:

This letter confirms verbal notification given to you by [redacted] Des Moines District, Food Safety and Inspection (FSIS) on June 14, 2013 at approximately 0645 hours, of our decision to issue a Notice of Intended Enforcement (NOIE) for slaughter operations at your firm, Cargill Meat Solutions Corp., Est M850, located in Ottumwa IA. This action is taken in accordance with the Rules of Practice 9 CFR 500.3 (b), which indicates that FSIS can take a regulatory control action, the program employee will immediately notify the establishment orally or in writing of the action and the basis for the action, if it is handling or slaughtering animals inhumanely such as, that which occured at your establishment on June 14, 2013.

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NOTICE of SUSPENSION HELD in ABEYANCE:

On December 26,2013, a “Notice of Suspension” was issued to Dakota Pack, Inc., Establishment M2!898, located at 2421 9’h Avenue South, Estherville, Iowa. This action was based on your failure to handle animals humanely. This letter confirms the verbal notification you were provided on December 27,2013, by the Food Safety Inspection Service (FSIS), Des Moines District Office, that the suspension of the assignment of inspection personnel for slaughter operations at Dakota Pack, Inc., Establishment M21898, is now held in abeyance, pending verification by FSIS personnel.

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NOTICE of SUSPENSION:

This letter confirms verbal notification given to you, (b) (7)(C) (b) (6) b~nd Des Moines District, Food Safety and Inspection Service (FSIS) on December 26, 2013 at approximately 1500hours, ofour decision to suspend the assignment of inspectors for slaughter operations at your firm, Dakota Pack, Inc. Establishment # M 21898, located at 2421 9th Avenue South; Estherville, lA. 51334 This action is taken in accordance with the Rules of Practice 9 CFR 500.3(b ), which indicates that FSIS can take a withholding action or impose a suspension without providing an establishment prior notification if it is handling or slaughtering animals inhumanely such as, that which occurred at your establishment on December 26, 2013.

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NOTICE of SUSPENSION HELD in ABEYANCE:

On June 28, 2013, a “Notice of Suspension” was issued to Dakota Pack Inc., Establishment M21989, located at 2421 9th Ave South, Estherville, IA. This action was based on your failure to handle animals humanely. This letter confirms the verbal notificiation you were given on June 28, 2013, by the Food Safety and Inspection Service (FSIS), Des Moines District Office, that the suspension of the assignment of inspectors for slaughter operations at Dakota Pack Inc., Establishment M21989, is now held in abeyance, pending verification by FSIS personnel.

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NOTICE of SUSPENSION:

This letter confirms verbal notification given to you, by the SPHV/IIC, of the Des Moines District, Food Safety and Inspection Service (FSIS) on June 28, 2013 at approximately 0950 hours, of the decision to suspend the assignment of inspectors for slaughter operations at your firm, Dakota Pack Inc. Est. M21898 located at 2421 9th Ave South, Estherville, IA. This action is taken in accordance with the Rules of Practice 9 CFR 500.3(b), which indicates that FSIS can take a withholding action or impose a suspension without providing an establishment prior notification if it is handling or slaughtering animals inhumanely such as, that which occured at your establishment on June 28, 2013.

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Code: 01802
Violation:  416.13(c), 416.13(a), 416.4(b), 416.4(a)

Citation:  On January 4, 2012 at approximately 0535 hou rs,wh ile verifying the adequacy of the establishment’s Sanitation SOP (Pre-operational Sanitation) for [redacted]) grind department and the procedu res specified therein during the performance of Pre-operational Sanitation Inspection, after the establishment”s pre-operational inspection and release of equipment/areas for production but prior to the start of production, the following non-compliance(s) were observed by FSIS personnel.     1.) Numerous areas of fat build-up, ranging in size from a pin head to two inches wide and three inches long, from the previous day’s production  was observed on the paddles in the fat and lean blenders and on the metal grate located on top of the fat blender.     2.) Fat build-up from the previous day’s production was observed on the vacuum air lines for the doors of the fat and lean blenders.     3.) Specks of fat and meat,from the previous day’s production was observed on the paddles of both final blend ing machines.    4.) An area of fat build-up measuring approximately one-quarter of an inch wide and two inches long, from the previous day’s production, was observed on the east blender auger.   This does not meet regulatory requirement(s)  including but not limited to 9 CFR 416.1,416.4(a), 416.4(b), 416.13(a), and 416.13(c). This also does not meet the establishment’s own SSOP (Pre-operational Sanitation) for Zone/Dept.- FOF production  area, dated 5/17/2010,wh ich states; [redacted] Regulatory control was initiated per 9 CFR 500.2 by applying U.S. Reject Tag #827057434 to both the lean and fat blenders and by applying U.S. Reject Tag # 827057435 to both of the final blenders and the auger for the east blender. [redacted] 3rd Shift) was visually shown the non-compliance(s) as described above and verbally notified of the basis for this N R. [redacted] initiated immediate corrective action by instructing the sanitation personnel to re-wash and re-sanitize all of the affected areas stated above. All equipment was re-inspected  by FSIS personnel prior to being released for production. You are hereby notified of your right to appeal this decision as delineated by 9 CFR 306.5.

Regulation:

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

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

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) 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: 01001
Violation:  416.2(b)(1)

Citation:  At approximately 1210 hours, FSIS personnel observed water d ripping from the northwest corner of the exhaust unit and ceiling support beam located at the northeast end of the  grind department. The water was dripping into the raw product traff ic area between the raw product storage cooler  an:fJWI grind  departments. This does not meet regulatory requirement(s) including but not limited to 9 CFR 416.2(b)( 1). Regulatory control was initiated  by cordoning off the area and applying U.S. Retain  Tag #827057433, thereby  prohibiting the flow of raw meat and/or establishment personnel from traveling through this area.  was visually shown the non-compliance as described above and verbally notified of the basis for this                                initiated immediate corrective action by contacting maintenance  person nel to perform a temporary fix of hanging plastic to catch the dripping water. Upon further investigation maintenance discovered that the outside doors to the make up air unit were open . Maintenance proceeded to close these doors thereby prevent ing any rain from entering the air unit and dripping into the area below.   You are hereby notified of your right to appeal thisdecision as delineated by 9 CFR 306.5.

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: 01802
Violation:  416.13(a), 416.4(a), 416.13(c), 416.4(b)

Citation: On November 9, 2011 at approximately 0615 hours, while verifying the adequacy of the establishment ‘s Sanitation SOP (Pre-operational Sanitation) for K8D department and the procedures specified therein during the performance of Pre-operational sanitation Inspection, after the establishment ‘s pre-opera tional inspection and release of equipment/areas for production but prior to the start of production, the following non-compliance(s) were observed by FSIS person nel. 1.) The product conveyor roller bars, on the return side, located under cook line #1 had fat build-up from the previous day’s production .The d rip pan located below this conveyor was also observed with pieces of meat/fat from the previous day’s production as well. 2.) Fat build-up from the previous day’s production was observed on the plastic guides/frame work of the product incline conveyor located between freezer #1 and the mezzanine of K8D pack-off department. This does not meet regulatory requirement(s) including but not limited to 9 CFR 416.1, 416.4(a), 416.4(b), 416.13(a), and 416.13(c). This also does not meet the establishment ‘s own SSOP (Pre-operational Sanitation) for Zone/Dept .- K8D production area,dated 5/17/2010, which states: [redacted] Regulatory control was initiated per 9 CFR 500.2 by applying U.S.Reject Tag # 827057431to cook line #1and U .S.Reject Tag #827057432 to the incline conveyor [redacted]) was visually shown the non-compliance as described above and verbally notified of the basis for this NR. [redacted] initiated immediate corrective action by instructing the sanitation personnel to re-wash and re-sanitize the incline conveyor and the roller bars, production belt, and drip pans of cook line #1. All equipment was re-inspected by FSIS person nel prior to being released for production . You are hereby notified of your right to appeal this decision as delineated by 9 CFR 306.5.

Regulation:

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

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:  04804
Violation:  317.8

Citation:  On November 4, 2011 at approximately 1800 hours, I [redacted] received a phone call from [redacted] at OSI Oakland (Est. 1041 M). At this time [redacted] stated the the establishment had produced and shipped Fully Cooked Marinated Seasoned & Shaved Angus Beef Steak to Dunkin’ Donuts. [redacted] also informed [redacted] that the label failed to state in the ingredients statement that this product contained the alergent milk.At this time [redacted] informed [redacted] that this does not meet regulatory requirement( s) including but not limited to 9 CFR 317.8. [redacted] stated that he would initiate immed iate corrective action by contacting Dunkin’ Donut management staff and having all product either recalled or disposed of.At this time [redacted], notified [redacted] that all product should be returned and not disposed of and that all product needed to be accounted for.A meeting was set at thistime for 0700 hours on saturday, November 5th, 2011. On Saturday, November 5th, 2011 FSISwas informed that 5918 cases of #1 Beef Steak product had been produced and 951 case of #2 Beef Steak had been produced. FSIS was also informed that 1109 cases of the 5918 cases of #1s were still in inventory and that all 951 cases of the #2s were in inventory. At this time FSIS initiated regulatory control by issu ing U.S. Retain Tag #827057428 for all product currently in stock and for all product in route to the establishment. On Monday, November 7, 2011, FSIS was informed and presented documentation to support that all 4809 cases of #1 Beef Steak product, which had been shipped to distribution centers in Groveland, Florida and Bellingham, Massachusetts, had been accounted for.The establishment created a new label with all ingredients including milk listed on it and presented it to FSIS for examination prior to relabeling the 1109 cases of #1 Beef Steak product still in stock. All returned product will be re-inspected upon arrival, re-labeled and re-inspected prior to being shipped. You are hereby notified of your right to appeal this decision as delineated by 9 CFR 306.5.

Regulation:

317.8(a) No product or any of its wrappers, packaging, or other containers shall bear any false or misleading marking, label, or other labeling and no statement, word, picture, design, or device which conveys any false impression or gives any false indication of origin or quality or is otherwise false or misleading shall appear in any marking or other labeling. No product shall be wholly or partly enclosed in any wrapper, packaging, or other container that is so made, formed, or filled as to be misleading.

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

Citation: On 11/05/2011 at approximately 0930 hours FSIS personnel observed that the plastic cover on the top of a combo of ends and pieces was only covering on-third of the combo. This combo was situated in the middle of the second tier along the west side of the product storage racks in the north product storage cooler with other combos of ends and pieces situated above it. Upon further investigation, numerous specs of black dirt like particles were observed inside the combo on the bacon ends and pieces. This does not meet regulatory requirement(s) including but not limited to 9 CFR 416.4(d), 416.13(b), and 416.13(c). This also does not meet the establishment’s own SSOP for (Product Storage ares & Shipping/Receiving Docks) dated 5/17/10 which states: [redacted]. Regulatory Control was initiated per 9 CFR 500.2(a)(2) by applying U.S.Retain tag #827057429 to the combo of ends and pieces. [redacted] visually shown the non-compliance as described above and verbally notified of the basis of NR. [redacted] initiated immediate corrective action by removing the top one-third portion of the combo of ends and pieces and disposing it to inedible rendering. Product was re-inspected prior to being placed back into storage. Note: A new piece of plastic was also placed on top of the remainder of the combo prior to being placed back into storage. A review of the establishment’s records revealed the following preventative measure:”The large combos used for ends and pieces will no longer be placed on the second tier of the storage racks”.You are hereby notified of your right to appeal this decision as delineated by 9 CFR 306.5.

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:  01802
Violation:  416.13(a), 416.13(c), 416.4(a), 416.1, 416.4(b)

Citation: On November 2, 2011 at approximately 0610 hours, while verifying the adequacy of the establishment’s Sanitation SOP (Pre-operational Sanitation) for Bacon (lines B and the procedures specified therin during the performance of Pre-operational Sanitation Inspection, after the establishment’s pre-operational inspection and release of equipment/areas for production but prior to the start of production, the following non-compliance(s) were observed by FSIS personnel. 1.) Several areas of bacon grease, with the largest measuring approximately three inches long and one inch wide, from the previous day’s production, was observed on the north ends of the air knives located at thewest end of production line # [redacted] 2.) Several areas of grease build-up, from the previous day’s production, were observed on the south ends of the air knives located at the west end of production line # [redacted] 3.) A glob of bacon grease measuring approximately one half square inch in diameter and approximately one-sixteenth of an inch in thickness, from the previous day’s production, was observed on the south end of the production belt support bracket located at the east end of production line # [redacted] 4.) A piece of bacon measuring approximately three inches long and one inch wide, from the previous day’s production, was observed in the horseshoe conveyors support brackets located in the southeast section of the loop. This does not meet regulatory requirement(s) including but not limited to 9 CFR 416.1, 416.4(a), 416.4(b), 416.13(a), and 416.13(c). This also does not meet the establishment’s own [redacted] ng U.S. Reject Tag #827057426 to production lines [redacted] and [redacted] and the horseshoe conveyor.[redacted]) was visually shown the non-compliance as described above and verbally notified of the basis for this NR. [redacted] initiated immediate corrective action but instructing the sanitation personnel to re-wash and re-sanitize the air knives and production belts for line [redacted] and [redacted] and the horseshoe conveyor located in the pack-off department. Allares were re-inspected by FSIS personnel prior to being released for production. You are hereby notified of your right to appeal this decision as delineated by 9 CFR 306.5.

Regulation:

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

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.

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:  01802
Violation:  416.4(a ), 416.1, 416.13(a), 416.13(c), 416.4(b)

Citation: On October 7, 2011 at approximately 0540 hours, while verifying the adequacy of the establishment’s Sanitation SOP (Pre-operational Sanitation) for the third floor Bacon department (specifically line 2) and the procedures specified therin during the performance of Pre-operational Sanitation Inspection Verification, after the establishment’s pre-operational inspection and release of equipment/areas for production but prior to the start of production, the following non-compliance(s) were observed by FSIS personnel: 1.) Fat build-up, from the previous day’s production, was observed on the west half of the production belt roller bars of line #2 located under the north end of production belt #2 inside the cook room. 2.) Fat build-up, from the previous day’s production, was observed on the frame work a long the northwest end of prod uction belt #2. 3.) One whole slice of roasted bacon, from the previous days production, wasobserved on top of the frame work at the southwest end of production belt #2. This does not meet regulatory requirement(s) including but not limited to 9 CFR 416.1,416.4(a),416.4(b), 416.13(a ), and 416.13(c). This also does not meet the establishment’s own SSOP [redacted] or Zone/Dept/Are. – Bacon Third Floor production area, dated 5/17/10, which states: [redacted].” and [redacted].” Regulatory control was initiated per 9 CFR 500.2 by applying U.S. Reject tag #827057430 to production line #2.) [redacted] was visually shown the non-compliance as described above and verbally notified of the basis for this NR.[redacted] initiated immediate corrective action by instructing the sanitation person nel to rewash and re-sanitize the production belt roller bars and all affected frame at the northwest and southwest ends of production belt #2. Allo areas were re-inspected by FSIS personnel prior to being released for production. You are hereby notified of your right to appeal this decision as delineated by 9 CFR 306.5.

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.

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

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.

NOTICE of DEFERRAL:

On April 18, 2013, the Food Safety and Inspection Service (FSIS), Des Moines District Office issued to your Establishment M21069, Premium Iowa Pork, a “Notice of Intended Enforcement.” This was based on your establishment’s failure to slaughter animals humanely as describe in CFR Part 13.

On April 26, 2013 and other dates, your firm provided written assurances of corrective and preventive actions, which included immediate corrective actions taken and proffered long term corrective and preventive measures to prevent reoccurrence of the egregious humane handling non-comliance observed by FSIS in plant personnel on April 18, 2013.

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NOTICE of INTENDED ENFORCEMENT:

This letter confirms verbal notification given to you, by [redacted] Des Moines District, Food Safety and Inspection Service (FSIS) on April 18, 2013, at approximately 0700 hours, of our decision to issue a Notice Intended Enforcement (NOIE) for slaughter operations at your firm, Premium Iowa Pork, Est. M21069, Hospers, Iowa. This action is taken in accordance with the Rules of Practice 9 CFR 500.3(b), which indicates that FSIS can take a regulatory control action, the program employee will immediately notify the establishment orally or in writing of the action and the basis for the action, if it is handling or slaughtering animals inhumanely such as, that which occurred at your establishment on April 17, 2013.

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