New York Slaughterhouses

Code: 01C02
Violation: 416.4(d)

Citation: At Approximately 07:40am Hours I CSI while performing my post-mortem inspection, observed the following non-compliance: A plant employee was scraping inedible product off the production floor and placing the contents into the white edible barrel. I applied U.S retain tag # B39795315 to the affected product. This was a non-compliance. This did not meet Reg 416.4(d). Plant manager was notified visually and verbally of the non-compliance. This NR is linked to NR# DQH0911062313N dated 06/13/2012. Continued failure to meet regulatory requirements would lead to further enforcement 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.

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

Citation: At approximately 0610 hrs while performing pre-operative sanitation inspection, CSI [redacted] found the following non-compliance. In the kill room/bleeding area, I found 2 knives, used to kill the birds with blood stains from the previous production day, ranging from 1/8th of an Inch to 1/4th of an inch in circumference. I immediately tagged the knives with a U.S Rejected tag # B39907617. I notified plant Manager [redacted] of the non-compliance. The regulatory control action remained in place until the establishment restored sanitary conditions.

Regulation:

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(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: 01D01
Violation: 416.3(a), 416.3(c)

Citation: At approxatmately 1115 hours in the picking room, I observed a edible barrell with trash and soda bottles. U.S Rejected tag # B39795381 was applied. Plant foreman [redacted] was notified.They are vilolating the proper intent and purpose of the edible barrell, which is to be used for product only. This is a violation of regulations 416.3. No product was affected.

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.

416.3(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: 01D01
Violation: 416.2(b)(1), 416.2(b)(2)

Citation: At approximately 0620hrs after performing pre-op sanitation inspection, CSI [redacted] and SPHV [redacted] observed the following non-compliance: We observed peeling paint approximately 1-2 inches in length/width on the overhead cooler fan at the entrance to the cooler, located in the evicseration room. Product goes in and out of that cooler. We immediately notified plant manager [redacted] of the non-compliance. No product was affected.

Regulation:

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

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

Code: 03J02
Violation: 417.2(c)(4), 417.5(a)(3), 417.5(b)

Citation: SPHV [redacted] observed the following noncompliances while performing a directed HACCP Implementation Procedure:

At approximately 0725 hours, I observed the plant employee monitor CCL 3-B (zero visible fecal). She took ten birds from the line but did not count off birds as she removed them for the line. The HACCP plan for Buddhist poultry states the monitoring procedure for CCP 3-B is: “[redacted] .” The documented random procedures listed under “ for CCP-1, CCP-2, CCP-3 and CCP-4 are: “[redacted] .” This procedure was not performed as written in the HACCP plan, which is a noncompliance with 417.2(c)(4). QC Manager, [redacted] was immediately notified of this noncompliance and Mr. [redacted] manager, was later notified.

Review of the HACCP plan also indicates the establishment lists “[redacted] ” as a monitoring procedure for CCP3. Review of the past month’s records show that the establishment does not record the results of this procedure, which is listed in the HACCP plan as a procedure for monitoring the CCP. This is a noncompliance with 417.5(a)(3). Mr. [redacted] manager, was immediately notified of this noncompliance.

At approximately 0835, I observed the plant employee monitor CCL 2-B (giblet chilling). I observed the employee grab a handful of livers from the bin and not count how many livers there were. She then took a temperature by inserting the thermometer into the handful of product. She then grabbed another handful of livers and took a temperature. The Buddhist poultry HACCP plan states for the monitoring procedure of CCP 2-B: [redacted].” This procedure was not performed as written in the HACCP plan, which is a noncompliance with 417.2(c)(4). QC Manager, [redacted] was immediately notified of this noncompliance and Mr.[redacted] was later notified.

At approximately 1100 hours, I requested records for the calibration of the process-monitoring instruments for CCP 5-B. Manager, Mr. [redacted] stated that there are no records to documenting the calibration of process-monitoring instruments for CC 5-B. The HACCP plan states for CCP 5-B for Buddhist poultry, “[redacted] ” QC Manager, and manager, Mr. [redacted] stated that the calibration is performed more often than monthly but the results are not documented. This is a noncompliance with 9 CFR 417.5(a)(3). Mr. [redacted] was immediately notified of this noncompliance.

At approximately 1225, I reviewed the Buddhist poultry HACCP records from 4/6/12 and saw that the last entry monitoring CCP 5-B was at 9:37 and 9:38am. The HACCP plan states the storage room temperature

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;

417.5(a)(3) Records documenting the monitoring of CCP’s and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment’s HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter production lot. Each of these records shall include the date the record was made.

417.5(b) Each entry on a record maintained under the HACCP plan shall be made at the time the specific event occurs and include the date and time recorded, and shall be signed or initialed by the establishment employee making the entry.

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

Citation: At approximately 06:15 hrs after performing pre-op sanitation inspection, CSI and SPHV observed the following non-compliances: In the picking room we observed that there were
1. 5 holes on the picking room ceilings approximately 1-3 inches
2. 2 ceiling panels pushed to the side exposing a space 2ft by 1inch. 1 panel completely exposed approximately 1ft by 1ft to the side.
3. Pealing paint on the ceiling panel, above the picker belt.
4. In evisceration, Rails and chains above the shackles had flaking rust. Upon further inspection while gently rubbing the rails, we noticed copious amounts of red rust, dirt, and black specks on our hands.
5. Copious amounts of feathers on the ceiling and lights above the scalder.
We immediately notified plant manager of the non-compliances.

Regulation:

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

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

416.2(b)(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: 01C02
Violation: 416.13(b), 416.15(a)

Citation: At approximately 0745 hours, SPHV [redacted] observed the following non-compliance:[newline]A plant employee put 7 chickens from the floor onto the conveyer belt without re-washing. 25 carcasses’s were retained. Plant Manager [redacted] was notified of the non-compliance. U.S retained tag# B37056087 was issued. The establishments ssop plan explicitly states: “ .” CSI [redacted] verified the establishments corrective actions.

Regulation:

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

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), 417.2(c)(4)

Citation: At approxamately 0835 hrs while performing a Zero Tolerance check at the final wash cabinet and before the pre-chill in order to verify if #20138 operations was meeting fsis regulatory requirements. I CSI [redacted] found the following non-compliance-1 bird with fecal material located underneath the tail. This was shown to Plant Manager [redacted] The product in question was condemned, by [redacted] This does not meet 9 CFR 381.65(e). A similar non-compliance was issued 01/10/2012. NR# DQH2310012910N/1. Previous preventative action inaffective. Continued failure to meet the regulatory requirements would lead to further enforcement actions.

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(b), 416.13(c), 416.4(d), 416.5(a)

Citation: At approxatmately 0740 hours, while conducting my post-mortem inspection, I CSI [redacted] observed the following non-compliance: An employee was cleaning the drain near where the area where the birds come into the evisceration area. She neglected to wash her hands and proceeded to pick up the birds out of a metal bin used to hold birds which do not come off the shackels onto the belt which leads to the chill Bin. I stopped the line and followed her and saw that she had placed the birds in question into the final chill bin. I immedietly told Plant manager [redacted] of the non-compliance and issued a U.S Retained tag # B37056587. Product was Re-conditioned/washed. I lifted the tag. A similar non-compliance was issued on 02/10/2012. The establishment’s SSOP states under employee hygiene practice: . Continued failure to meet regulatory requirements would lead to further enforcement action.

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.

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.

Code: 01D01
Violation: 416.2(b)(1), 416.2(b)(2)

Citation: At approximately 0750 hours SPHV [redacted] and CSI [redacted] observed the following non-compliances:The ceiling above the Box table in evisceration had a leak in the ceiling, with water falling onto the box table. Plant manager [redacted] was notified of the non-compliance. A U.S Rejected tag # B40154444 was placed on the table. No product was affected.The vent above the final wash/directly above the line had excessive dust, and rust on the bordering rim. I showed Plant foreman [redacted] No product was affected.

Regulation:

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

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

Code: 01C02
Violation: 416.13(b), 416.13(c), 416.4(d), 416.5(a)

Citation: At approximately 0750 hours, while conducting my post-mortem inspection, I CSI [redacted] observed the following non-compliance: An employee was cleaning the drain, and the floor, afterwards she bi-passed the handwashing sink, neglecting to sanitize her hands, and went to the liver bagging station and proceeded to bag the livers. I immedietly stopped the line and tagged the affected product with U.S Retained tag NO. B37056607, and immedietly notified Plant manager [redacted] of this non-compliance. Product was condemned. The establishment’s SSOP states under employee hygiene practice: “ [redacted]” Continued failure to meet regulatory requirements would lead to further enforcement action.

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.

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.

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

Citation: At approximately 0945 hours, I performed a 10 bird sampling fecal check at the final bird washer cabinet and before the prechill in order to verify that #20138 operations was meeting the regulatory requirements. I found the following non-compliance – 1 bird with fecal material located on the left thigh. This evidence was shown to HACCP floor supervisor, [redacted] US retain tag B37-056608 was applied to affected product. This event did not meet 9 CFR 381.65(e). Continued failure to meet the regulatory requirements would lead to further enforcement actions.

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(a)

Citation: AT APPROXIMATELY 0954 HOURS I DID A UNSCHEDULED O6DO2 WHILE INSECTING CHICKEN ON THE LINE THERE WAS 56-SILKIES AND 7 GUINEAS AND 3 YOUNG CHICKEN WITHOUT THERE EVISCERA,I STOP THE LINE AND INFORMED MRS [redacted] OF THIS PROBLEM AND I ASK DID SHE WANTED TO SLOW THE LINE DOWN AND SHE SAID NO SO THE PROBLEM CONTINUE ON.AFTER LUNCH I INFORMED MRS [redacted] SUPERVISOR] VERBALLY,VISUALLY,AND IN WRITING WITH THIS NR OF NONCOMPLIANCE.THIS IS THE SECOND NR FOR THE SAME PROBLEM PLANT MANAGEMENT SAID THEY WOULD SLOW THE LINE WHEN TRAINING NEW EMPLOYEES SO THAT THEY COULD KEEP UP WHEN RUNNING FOWELS OR SILKIES.NO FUTHER ACTION WAS TAKEN ,I HAVE EXPLAIN TO MRS [redacted] PROPER PRESENTATION IS VERY IMPORTANT AT THIS POINT .YOU HAVE FAILE TO FOLLOW THE REGULATION 381.76[A].MRS [redacted] STATED TO ME SHE WILL SLOW THE LINE DOWN WHEN THEY RUN SILKES CHICKEN

Regulation:

381.76(a) A post-mortem inspection shall be made on a bird-by-bird basis on all poultry eviscerated in an official establishment. No viscera or any part thereof shall be removed from any poultry processed in any official establishment, except at the time of post-mortem inspection, unless their identify with the rest of the carcass is maintained in a manner satisfactory to the inspector until such inspection is made. Each carcass to be eviscerated shall be opened so as to expose the organs and the body cavity for proper examination by the inspector and shall be prepared immediately after inspection as readyto- cook poultry. If a carcass is frozen, it shall be thoroughly thawed before being opened for examination by the inspector. Each carcass, or all parts comprising such carcass, shall be examined by the inspector, except for parts that are not needed for inspection purposes and are not intended for human food and are condemned.

Code: 01C02
Violation: 416.2(b)(2), 416.2(b)(3)

Citation: 12-23-11 O6DO1. AT APPROXIMATELY 12:30 WHILE ON THE FLOOR I WAS STANDING UNDER THE CEILING TILES WHEN I NOTICE A LEAK NEAR THE FINIAL BIRD WASH I NOTIFIED [redacted] [SUPERVISOR] SHE STATED TO DR. WILLS THAT THE CEILING LEAKS WHEN IT RAINS SHE SAID SHE WILL HANDLE THE ISSUE BEFORE IT RAIN AGAIN. [redacted] AS INFORMED THAT THIS WAS A NONCOMPLIANCE VERBALLY, VISUALLY AND IN WRITING WITH THIS NR.NO FUTHER ACTION WAS TAKEN THERE WAS NO FOOD CONTACT OR CONTAMINATION AT THIS TIME

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(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: 01D01
Violation: 416.4(d)

Citation: 12-21-11 O6DO2[newline] [newline]AT APPROXIMATELY 11:28 HOURS I DID A UNSCHEDULED O6DO2 WHILE INSPECTING CHICKEN ON THE LINE I NOTICE SEVERALS CHICKEN COMIMING DOWN THE LINE WITHOUT NO EVISCERA,I INFORM [redacted] OF THIS PROBLEM SO I CONTINUE MY INSPECTING AND STARTED TO COUNT THE BIRDS WITHOUT EVISCERA ,THERE WAS ABOUT 30 OR MORE BIRDS CAME DOWN THE LINE NO EVISCERA,I STOP THE LINE AND INFORM [redacted] OF THE PROBLEM AND THAT THIS IS A NR,OF NONCOMPLIANCE NOT PROPERLY PRESENTED FOR INSPECTION.MRS STATED TO ME THAT SHE WAS ADDIND ANOTHER PERSON TO HELP OUT WITH THE EVISCERA PROBLEM.I NOTIFIED MRS [SUPERVISOR] VERBALLY,VISUALLY, AND IN WRITING WITH THIS NR OF NONCOMPLIANCE.THIS IS A VERY IMPORTANT PRESENTATION PROBLEM BIRDS ARE BEEN HUNG BACK BECAUSE OF THIS ISSUE.THERE WAS NO FUTHER ACTION TAKEN.[newline]

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: 417.2(c)(5), 417.3(a)(1), 417.3(a)(2), 417.3(a)(3), 417.4(a)(2)(ii), 417.5(a)(3)

Citation: 12-20-11 O3JO2[newline]AT APPROXIMATELY 08:18 HOURS WHILE PERFORMING A SCHEDULED O3JO2 PROCEDURE THE FOLLOWING DEFIENCY OCCURRED [1] AN EMPLOYEE WENT TO THE PAPER TOWEL DISPENSER AND TOOK A PAPER TOWEL OUT TO WIPE HER NOSE ,WITH HER GLOVES STILL ON AS I CONTINUE TO WATCH THIS EMPLOYEE DID NOT WASH HER GLOVES WHEN SHE FINISH BLOWING HER NOSE.SHE CONTINUE TO THE LIVER TABLE AND BEGIN PROCESSING LIVERS IN THE PLASTIC BAGS WITHOUT WASHING OR CHANGING GLOVES I IMMEDIATELY STOP THE LINE AND NOTIFIED [redacted] [SUPERVISOR] AND PLACE A U.S. RETAINED TAG ON THE PRODUCT #NO.B37 056599 I ASK WHAT CORRECTIVE ACTION WAS GOING TO BE TAKEN SHE INFORMED ME SHE NEEDED TO CHECK WITH MR. [redacted] [PLANT MANAGER] AFTER BREAK SHE SAID SHE WILL DISCARD THE PRODUCT IN THAT LIVER CONTAINER I VISUALLY WATCH AS SHE PUT THE LIVER IN THE INEDIBLE CAN TO BE TAKEN OUT.I NOTIFIED MRS [redacted] SUPERVISOR]THAT THIS WAS A NONCOMPLIANCE VERBALLY,VISUALLY,AND IN WRITING WITH THIS NR,OF NONCOMPLIANCE NO FUTHER ACTION WAS TAKEN.

Regulation:

417.2(c)(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

417.3(a)(1) The written HACCP plan shall identify the corrective action to be followed in response to a deviation from a critical limit. The HACCP plan shall describe the corrective action to be taken, and assign responsibility for taking corrective action, to ensure: The cause of the deviation is identified and eliminated;

417.3(a)(2) The CCP will be under control after the corrective action is taken

417.3(a)(3) Measures to prevent recurrence are established

417.4(a)(2)(ii) Ongoing verification activities. Ongoing verification activities include, but are not limited to: Direct observations of monitoring activities and corrective actions;

417.5(a)(3) Records documenting the monitoring of CCP’s and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment’s HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter production lot. Each of these records shall include the date the record was made.

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

Citation: 12-8-2011 AT APPROXIMATELY 06:10 HOUR I WAS PERFORMING A O1BO2 PROCEDURE WHEN I NOTICE THESE DEFIENCY[1] IN THE VACCUM PACK ROOM I WAS CHECKING THE PROCESSING TABLE WHEN I NOTICE TWO LARGE STAIN OF BLOOD RESIDUE ABOUT ¾ IN SIZE ON ONE THE SECOND WAS ROUND IN SIDE ABOUT I/4 I HAD AND EMPLOYEE COME AND WASH THE STAIN WITH BLEACH THESE STAIN WAS LEFT FROM THE PREVIOUS DAY.[2] AS I CONTINUE MY INSPECTION I WAS CHECKING THE SQUAB TABLE WHEN I FOUND CHICKEN FAT STUCK IN THE SEAM OF THE TABLE THERE WAS SEVERAL PARTICLE ABOUT 1/8 OF INCHE IN SIZE DARK BLACK IN COLOR.I IMMEDIATELY NOTIFIED [redacted] [SUPERVISOR] VERBALLY,VISUALLY,AND IN WRITING WITH THIS NR,OF NONCOMPLIANCE ON THIS PRE-OPT INSPECTION.THESE WAS FOOD CONTACT AREAS THAT WAS EFFECTED NO FUTHER ACTION WAS TAKEN.

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.

Code: 06D02
Violation: 381.76(a)

Citation: 12-6-2011 AT APPROXIMATELY 9:27 HOURS I WAS INSPECTING CHICKEN ON THE LINE WHEN SEVERALS BIRDS CAME TO ME FOR INSPECTION THAT STILL HAD THE VISCERA ON THE INSIDE THERE WAS 14 CHICKEN THAT I HUNG BACK ON THE HANG BACK RACK THAT WAS NOT PRESENTED TO ME FOR THE PROPER INSPECTION PRESENTATION.I HAD INFORMED MS [redacted] SEVERAL TIME OF THIS PROBLEM SO THAT I WOULD NOT HAVE TO STOP THE LINE OR DISCARD ANY BIRD IN THE INEDIBLE BARELL.THIS PROCEDURE FALLS UNDER THE REGULATION 381.76[A] POST-MORTEM INSPECTION.I NOTIFIED [redacted] [SUPERVISOR] VERBALLY,VISUALLY,AND IN WRITING WITH THIS NR,OF NONCOMPLIANCE.THE BIRDS WAS TAKEN BACK TO THE START OF THE LINE AND RE-HUNG FOR INSPECTION THE EMPLOYEE WAS REMOVE AND REPLACE WITH ANOTHER EMPLOYEE.NO FUTHER ACTION WAS TAKEN.

Regulation:

381.76(a) No poultry used in any research investigation involving an experimental biological product, drug, or chemical shall be eligible for slaughter at an official establishment unless the operator of such establishment, the sponsor of the investigation, or the investigator has submitted to the Inspection Service, or the Veterinary Biologics unit of Veterinary Services, Animal and Plant Health Inspection Service of the Department or the Environmental Protection Agency, or the Food and Drug Administration of the Department of Health, Education, and Welfare, data or a summary evaluation of the data which demonstrates that the use of such biological product, drug, or chemical will not result in the products of such poultry being adulterated, and the Administrator has approved such slaughter.

Code: 01C02
Violation: 416.15(a)

Citation: AT APPROXIMATELY 10:20 HOURS I WAS PERFORMING A UNSCHEDULED O1CO2 WHEN I NOTICE A EMPLOYEE DRAGING A LARGE BROWN BAG WITH PRODUCT ON THE INSIDE THE BOTTOM OF THE BAG WAS SOAKED FROM BEEN PULL OVER THE FLOOR.I IMMEDIATELY NOTIFIED MR. [redacted] AND [redacted] [SUPERVISORS] OF THE INCIDENT THAT HAS OCURRED MR. [redacted] IMMEDIATELY REMOVE THE CHICKEN FROM THE DAMAGE BAG AND CHANGE OUT THE BAG THAT WAS WET FROM BEEN DRAGGED.I NOTIFIED [redacted] VERBALLY,VISUALLY,AND IN WRITING WITH THIS NR,OF NONCOMPLIANCE,NO FUTHER ACTION WAS TAKEN..

Regulation:

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: 01D01
Violation: 381.95(c)

Citation: AT APPROXIMATELY 12:30 HOURS I OBSERVED #20138 EMPLOYEES LEAVING 6 BARRELS OF CONDEMED INEDIBLE MATERIALS WITHOUT DENATURE APPLIED TO EFFECTED PRODUCT I APPLIED US.RETAIN TAG #B37-056617 TO EFFECTED PRODUCT AND NOTIFIED FLOOR SUPERVISOR [redacted] THIS NONCOMPLIANCE DO NOT MEET REG-381.95. CONTINUED FAILURE TO MEET REGULATORY REQUIREMENT WOULD LEAD TO FUTHER ENFORCEMENT ACTION.

Regulation:

381.95(c) Chemical denaturing, which shall be accomplished by the liberal application to all carcasses and parts thereof, of: (1) Crude carbolic acid, (2) Kerosene, fuel oil, or used crankcase oil, or (3) Any phenolic disinfectant conforming to commercial standards CS 70–41 or CS 71–41 which shall be used in at least 2 percent emulsion or solution.

Code: 01C02
Violation: 416.13(b), 416.16(a), 416.16(b)

Citation: AT APPROXIMATELY 10:00 HOUR I WAS PERFORMING A UNSCHEDULED O1CO2 WHILE WALKING THROUGH THE PROCESSING COOLER I NOTICE THAT THE CHILLER CONTAINER WAS FULL OF CHICKEN NOT COVER AND WAS EPOSED TO ANY FALLEN PARTICLE AS I INSPECTED FUTHER I SAW CONDENSATION HANGING FROM THE BLACK FOAM THAT IS WRAP AROUND THE PIPE FROM THE AIR UNIT.THE FOAM WAS ABOUT 3FEET LONG AND 2 INCHES WIDE WITH BEADED CONDENSATION HANGING OVER PRODUCT.I IMMEDIATELY TAG THE PRODUCT WITH A U.S RETAIN TAG NO.B37056601 I NOTIFIED [redacted] [SUPERVISOR] VERBALLY,VISUALLY,AND IN WRITING WITH THIS NR,OF NONCOMPLIANCE. NO FUT5-11HER ACTION WAS TAKEN THERE WAS NO ADULTERATION OR CONTAMINATION TO THE PRODUCT.THIS NR IS LINKED TO NR DQH5611112515N DATED 11-15-2011.CONTINUE FAILURE TO MEET REGULATORY REQUIREMENT WOULD LEAD TO FUTHER ENFORCEMENT ACTION.

Regulation:

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

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.

416.16(b) Records required by this part may be maintained on computers provided the establishment implements appropriate controls to ensure the integrity of the electronic data.

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

Citation: AT 1130 HOURS WHILE PERFORMING MY 10 BIRDS FECAL CHECK AFTER THE FINAL WASH I NOTICE INSIDE ONE OF THE BIRDS FECES. THERE WAS YELLOW/GREEN SOILD PASTEY FECES INSIDE THE CHICKEN ABOUT 1 INCH WIDE IN SIZE. THIS IS A NONCOMPLIANCE WITH 381.65(e) AND 417.2(c)(4). I IMMEDIATELY NOTIFIED [redacted] [SUPERVISOR] IN WRITEN WITH THIS NR OF NONCOMPLIANCE VERBALLY, VISUALLY. THE ESTABLISHMENT’S HACCP PLAN FOR CCP 3B (ZERO VISIBLE FECAL AFTER FINAL WASH STATION) STATES THA THE ESTABLISHMENT WILL “[redacted] .”

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 7:22 HOURS WHILE PERFORMING MY 10 BIRDS FECAL CHECK AFTER THE FINAL WASH I NOTICE INSIDE ONE OF THE BIRDS FECES. I IMMEDIATELY STOP THE LINE AND REMOVE THE BIRD AND TAG THE PRODUCT AND PLACE A U.S REJECT TAG ON THE PRODUCT NO. B37056580. THERE WAS YELLOW/GREEN SOILD PASTEY FECES UNDER THE FATTY PART OF THE VENT OF THE CHICKEN ABOUT ½ INCHES WIDE IN SIZE. THIS IS A NONCOMPLIANCE WITH 381.65(e) AND 417.2(c)(4). I IMMEDIATELY NOTIFIED [redacted] [SUPERVISOR] IN WRITEN WITH THIS NR OF NONCOMPLIANCE VERBALLY, VISUALLY. NO FURTHER ACTION WAS TAKEN. THE ESTABLISHMENT’S HACCP PLAN FOR CCP 3B (ZERO VISIBLE FECAL AFTER FINAL WASH STATION) STATES THA THE ESTABLISHMENT WILL “ [redacted].”

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(b), 416.4(d)

Citation: 11-1-11 [newline]At approximately 0900 hour I observed #20138 employee removing 5 poultry carasses held at the hang back rack which was contaminated with ingesta and feces and putting them back into production without re-working the contaminated birds with chlorinated water.I applied U.S. Retain tag B37-056619 to affected product.This evidence was shown to floor supervisor [redacted] This noncompliance does not meet Reg 381.6(a)and Reg 416.4(d).This NR is link to NR # DQH2909105103N/1 dated 10-3-11. Continued to failure to to meet regulatory requirement would lead to further enforcement action

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

Citation: At approximately 06:15 I performed a hands-on preoperational sanitation inspection task in order to verify that #20138 was meeting the requirements. I found the following non-compliances (a) in the picking room, picking machine insanitary with several feathers and other debris (b) conveyor belt insanitary with debris on top surface [food contact surface] and beneath the belt [non-food contact surface]. This evidence was shown to floor supervisor, [redacted] This event did not meet Reg 416.13 and 416.4(a). This NR is linked to NR #DQH2909105103N dated 10/3/11 and NR #DQH 1812091630N dated 9/29/11.No food product was directly involved. US reject tag B37-056618 was applied to the equipment. Continued failure to meet regulatory requirements would lead to further enforcement actions.

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.

416.13(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.

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

Citation: At approximately 1200 hours, CSI [redacted] found the following noncompliance: I was doing a scheduled slaughter HACCP task while standing in the production room where chicken are stored in chiller containers. I observed an employee taking chickens from a chill bin and packing product in brown shipping bags. I then looked inside the same chill tank that the employee was packing from when I notice 2 chickens in the chiller. One chicken had large green pasted feces about 1 and 1/4 cm in size laying on the top quarter part of the chicken. The second chicken had feces under it’s wing but smaller in size, green and pasty about 1 cm in size. In the chill tank, there were 26 more birds mixed with ice. I immediately notified Mrs. [redacted] supervisor, verbally and visually. I did not tag the chiller because corrective action was applied immediately, the product was discarded in my presence. [Entered into PHIS on behalf of CSI [redacted]

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: 416.15(a), 416.15(a), 416.4(a), 416.4(d), 416.4(d)

Citation: At approximately 1130 hours, CSI [redacted] found the following noncompliance while performing an operational sanitation review and observation task: [newline][newline]I observed an employee drop a knife on the floor, pick it up and place it back on the stand. As I continued to watch the employee to see what sanitation procedure the employee was going to take, they did not take any. The employee proceeded to start working on tirmming a chicken with the dropped knife. I immediately stopped the line and called the supervisor and showed her the problem. I had the employee discard the product in my presence and I notified Mrs. [redacted] (supervisor) verbally, visually and in writing with this NR, of the noncompliance. No further action was taken. [newline][newline][Entered into PHIS for CSI [redacted]

Regulation:

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

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

Citation: At approx. 0600hrs. while performing pre operational inspection I observed the following:[newline]1. Gizzard rack used for processing product lying on the floor in processing area.[newline]2. Dirt particles 1/4 “ in size on 2 by 2 feet area on top conveyor belt in scalding area.[newline]3. Knife being placed on top of picking machine.[newline]No product in area at time of inspection. Management is reminded that failure to follow USDA[newline]Regulation can lead to adulterated product being produced and can result in further enforcement [newline]of regulation.No US reject tag applied because sanitary conditions restored immediately in my presence.[newline]I formed [redacted] of non compliance

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: 03J02
Violation: 417.2(a)(1), 417.2(a)(2), 417.2(c)(7), 417.4(a)(2)(i)

Citation: At approximately 0830 hours, SPHV [redacted] found the following noncompliance:[newline][newline]In the packing room, I requested [redacted], the packing and shipping supervisor, for a temperature to be taken of carcasses being packed. He took a thermometer from the management office and demonstrated that it was calibrated by placing the thermometer in a Styrofoam cup filled with half ice and half water. After a few seconds, he showed me that the thermometer was below zero and proceeded to take a temperature of the carcass. The carcass temperature was [redacted] F but not frozen. I then asked [redacted] the plant manager and who calibrates the thermometers, to demonstrate how the thermometers are calibrated. I observed Ms. [redacted] take a plastic cup and fill it with half ice and half water. She inserted the thermometer used to monitor CCP 2-B into the ice water slush and waited only about one minute. The thermometer read [redacted] F. The establishment’s HACCP plan under CCP 2-B and 4B states [redacted].” In the plant’s supporting documentation, the [redacted] method is described as, “[redacted].” The establishment is not currently following the verification procedures contained in the HACCP plan.[newline][newline]I showed Ms. [redacted] the “[redacted]” in the HACCP plan and notified her of this noncompliance. I then observed Ms. [redacted] perform the thermometer calibration as in HACCP plan. After approximately 4-5 minutes, the thermometers read[redacted] and [redacted] degrees F. Review of the HACCP records show that three thermometers were calibrated on 9/26/11 and were acceptable. Ms. [redacted] was immediately informed of this noncompliance.

Regulation:

417.2(a)(1) Hazard analysis. Every official establishment shall conduct, or have conducted for it, a hazard analysis to determine the food safety hazards reasonably likely to occur in the production process and identify the preventive measures the establishment can apply to control those hazards. The hazard analysis shall include food safety hazards that can occur before, during, and after entry into the establishment. A food safety hazard that is reasonably likely to occur is one for which a prudent establishment would establish controls because it historically has occurred, or because there is a reasonable possibility that it will occur in the particular type of product being processed, in the absence of those controls.

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

417.2(c)(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.

417.4(a)(2)(i) Ongoing verification activities. Ongoing verification activities include, but are not limited to: The calibration of process-monitoring instruments;

Code: 03J02
Violation: 381.66(b)

Citation: At approximately 0810 hours, SPHV [redacted] found the following noncompliance:[newline][newline]In the vacuum packing area outside Cooler 2, I found a shipping box of approximately 10 chickens packaged in individual immediate containers. The carcasses felt warm and there were no employees seen in the packing area. I immediately asked [redacted] assistant QC manager, for temperatures of the carcasses to be taken with the plant’s calibrated thermometer. The temperatures of four carcasses were taken and they were [redacted]. Mr. [redacted] stated that these birds had already reached the [redacted] critical limit. Mr. [redacted] was immediately notified of this noncompliance with 381.66(b)(1) which states, “Eviscerated poultry to be shipped from the establishment in packaged form shall be maintained at 40 degrees F or less except that during further processing and packaging operations, the internal temperature may rise to a maximum of 55 degrees F: Provided, That immediately after packaging, the poultry is placed under refrigeration at a temperature that will promptly lower the internal temperature of the product to 40 degrees F or less or the poultry is placed in a freezer.”[newline][newline]The establishment’s Buddhist poultry HACCP plan does not identify any food safety hazards reasonably likely to occur at the “Package/label” process step.

Regulation:

381.66(b)(1) General chilling requirements, except for ratites. All poultry that is slaughtered and eviscerated in the official establishment shall be chilled immediately after processing so that the internal temperature is reduced to 40 °F. or less, as provided in paragraph (b)(2) of this section unless such poultry is to be frozen or cooked immediately at the official establishment. Eviscerated poultry to be shipped from the establishment in packaged form shall be maintained at 40 °F. or less, except that during further processing and packaging operations, the internal temperature may rise to a maximum of 55 °F.: Provided, That immediately after packaging, the poultry is placed under refrigeration at a temperature that will promptly lower the internal temperature of the product to 40 °F. or less, or the poultry is placed in a freezer. Poultry which is to be held at the plant in packaged form in excess of 24 hours shall be held in a room at a temperature of 36 °F. or less.

Code: 01D01
Violation: 416.2(b)(1), 416.4(b)

Citation: At approx. 0600hrs while performing pre operation inspection , I observed the following;
1. Flaking rust and peeling paint on several overhead beams directly above shakle line before scalders .No product in area.
2. Cooler off packing room, I observed peeling ceiling sealant behind left fan unit as you enter the cooler. Same fan unit black dust throught out vents . Two inch product residue was also observed on the fan vent. This was directly above product which was covered with plastic.
3. Flaking rust and paint was also observed on overhead box attached to both fan units.Black residue was observed on plastic covering the product directly under box attached to the right fan unit. No product was affected. [redacted] ,plant manager immediately notified of these non compliances.

Regulation:

416.2(b)(1) Construction. 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(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: 03J02
Violation: 417.5(a)(2)

Citation: At approximately 0930 hours, SPHV [redacted] found the following noncompliance while performing a HACCP verification procedure: [newline][newline]I observed [redacted] plant manager, monitor the critical limit of the chlorine at the reprocessing station (CCP 1B) using the [redacted]. She demonstrated how [redacted]. [newline][newline]In the establishment’s Buddhist poultry HACCP plan signed 7/28/11, the critical limit for CCP 1B (reprocess carcass) is “[redacted] and [redacted] ” Also under CCP 1B, the plan states “[redacted] .” Review of past HACCP records for two weeks (Log for Maintenance of chlorine level) shows that the chlorine levels have been recorded as either [redacted] (9/1/11, 9/2/11, 9/5/11, 9/8/11, 9/10/11, 9/12/11, 9/15/11) or [redacted] (9/3/11, 9/5/11, 9/6/11, 9/7/11, 9/9/11, 9/13/11, 9/14/11). [newline][newline]According to the decision making document in the establishment’s HACCP plan, under “Chlorine level monitoring method and frequency”, “[redacted] ” The decision making document does not include support for the selection of the critical limit of [redacted]. [newline][newline]The supporting documentations in the HACCP plan for the [redacted] states that the paper “ [redacted]”. The supporting documents states, “ [redacted].” The supporting documentation does not include how to interpret the ppm if between colors on the color chart and therefore; does not support the plant’s determination that [redacted]. The supporting documentation for the monitoring procedure does not include how the plant determines that the lower limit of the critical limit [redacted]) is being met. [newline][newline]This noncompliance that the decision making documents and supporting documentation does not support the selection of the critical limits and the monitoring procedures as per 417.5(a)(2) was immediately shown to plant president, [redacted]

Regulation:

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

Code: 03J02
Violation: 417.2(c)(7), 417.4(a)(2)(iii), 417.5(a)(3), 417.5(b)

Citation: At approximately 1400 hours, SPHV [redacted] found the following noncompliance while performing a HACCP verification procedure: [newline][newline]On the Buddhist poultry HACCP records, the verification activity record review was not documented as performed for the day for CCP1 B and CCP2B. For CCP 1B and 2B under HACCP system verification, the establishment’s HACCP plan states, “[redacted] ” There were also no time-in entries made for the afternoon lots. Production stopped at approximately 1300 hours. [newline][newline]For the chlorine monitoring at the reprocessing station, there was an entry for chlorine monitoring at 0620 hours but no further entries were recorded. For CCP 1B, the establishment’s HACCP plan states, “[redacted] ” T[newline][newline]hese noncompliances were immediately shown to plant president, [redacted] The establishment employee monitoring the CCPs stated that CCP 4B was monitored for the 0938 lot of carcasses and met the critical limit but it was not recorded. Also, the employee stated that the chlorine was checked at 1045 hours and the chlorine level [redacted] but also not recorded.

Regulation:

417.2(c)(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.

417.4(a)(2)(iii) The review of records generated and maintained in accordance with § 417.5(a)(3) of this part.

417.5(a)(3) Records documenting the monitoring of CCP’s and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment’s HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter production lot. Each of these records shall include the date the record was made.

417.5(b) Each entry on a record maintained under the HACCP plan shall be made at the time the specific event occurs and include the date and time recorded, and shall be signed or initialed by the establishment employee making the entry.

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

Citation: At approximately 0830 hours, SPHV [redacted] found the following noncompliance in the processing room: At the venting station, an employee picked up a chicken carcass that was on the station stand floor and placed the chicken in an edible bin that contained approximately 10 other chickens. These chickens were in a bin to have the feet trimmed according to the plant manager, [redacted] U.S. Retain Tag #B37014175 was applied to the affected product. [redacted] was immediately informed of the noncompliance. Past similar NRs for placing dropped product back into production include NR# DQH3806090606N dated 8/30/11, NR #DQH10120859N dated 8/18/11 and NR# DQH4611083417N dated 8/16/11. Plant’s ineffective further planned action: “All new employees are retrained to stress importance of discarded dropped livers.” This trend of noncompliance was discussed during the weekly meetings on 9/2/11 and 9/9/11. The establishment’s SSOP on p. 13 under reconditioning program states, “[redacted] .”

Regulation:

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

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

416.4(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), 416.2(d), 416.4(b)

Citation: At approximately 08:35 during operations, I found heavy condensation on railings above the moving shackles with edible chicken product [approximately 70 chicken carcasses]. Regulatory control action was applied to affected product by use of US Retain tag B38-033103. Inspection was withheld until EST#20138 addressed this condensation non-compliance. This evidence was shown to floor supervisor, [redacted] This was a violation of Reg 416.13 and 416.2(d) and 416.4(b). Continued failure to meet regulatory requirements would lead to further enforcement actions.

Regulation:

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

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.

Code: 01C02
Violation: 416.13(b), 416.4(d), 416.5(a)

Citation: At approximately 0715 hours on 9/5/2011, CSI [redacted] observed an establishment employee pick up in-edible materials off the production floor and without sanitizing her hands, begin to handle edible product on the line. US retain tag B38033104 was applied to the affected product. This non-compliance was shown to floor supervisor, [newline][newline]The establishment’s SSOP p. 7 under employee hygiene practice states: ” [redacted] .” [newline][newline]Past similar NR# DQH3806090606N dated 8/30/2011. Plant’s ineffective further planned action for hand washing was not written. [newline][newline](Original NR documented by CSI [redacted] on 9/5/2011. Entered into PHIS by SPHV on behalf of CSI [redacted] on 9/6/2011).

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.

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.

Code: 01D01
Violation: 416.2(h)(2)

Citation: At approximately 0840 hours I was performing a unscheduled SPS task, 06D01, I was inspecting #20138 employees restroom. I found the following non-compliances (i) no soap in the dispenser for the employees to wash their hands. I placed a U.S. Reject tag B37056573 on the restroom. This event was a failure to meet Reg 416.2(h)(2). I notified floor supervisor [redacted] about this non-compliance. Continued failure to meet regulatory requirements would lead to further enforcement action.

Past similar NR# DQH3812075129N dated 7/28/2011. Plant’s ineffective further planned action: “Check daily.”

(Original NR written by CSI [redacted] in PBIS format on 9/1/2011. Entered and linked in PHIS by SPHV[redacted] 9/6/2011.)

Regulation:

416.2(h)(2) Dressing rooms, lavatories, and toilets. Lavatories with running hot and cold water, soap, and towels, must be placed in or near toilet and urinal rooms and at such other places in the establishment as necessary to ensure cleanliness of all persons handling any product.

Code: 01C02
Violation: 416.13(b), 416.15(a), 416.4(d), 416.5(a)

Citation: At approximately 0815 hours on 8/30/2011, CSI [redacted] found the following noncompliance:

An employee picked up edible liver product which fell onto the production floor and put it back into production without adequately reconditioning it. The employee left the production line station and handled condemned in-edible barrel and got back to the production line without sanitizing her hands. I applied US Retain tag [B39-XX-XXXX] to affected product. I notified floor supervisor, Ms [redacted] of this noncomplaince.

The establishment’s SSOP p. 7 states under employee hygiene practice: “[redacted] “

Past similar NRs include NR #DQH1012085919N dated 8/18/2011 and NR#DQH4611083417N dated 8/16/2011 for placing dropped product back into production. The plant’s ineffective further planned action: “Plant manager has retrained line employees stressing the importance of following our procedure for dropped product. Plant manager and experienced employees will monitor closely new hires.”


(Original NR written in PBIS format by CSI [redacted] and given to plant on 8/30/2011. This NR was entered into PHIS and linked by SPHV [redacted] and reissued to plant on 9/6/2011).

Regulation:

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

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

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

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.

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

Citation: At approximately 1310 hours while performing an SPS verification procedure, CSI found the following noncompliances:

I went in the packing department and noticed water leaking from a ceiling tile onto large brown paper packaging bags that were sitting on a pallett directely under the leak. No reject tag was needed because I immediately notified Ms. plant manager, verbally and visually of this noncompliance and Ms. and a employee immediately removed the bags and discarded the damage ones in my presence.
As I continued my inspection, I went in the cooler off the processing room, I noticed in the corner a pipe with large beaded drops of water hanging over uncovered product. I found more condensation on the ceiling from wall to wall with large beaded drops of water in the corner where product is stored and not covered. I also found more condensation hanging off the underside of the freezer unit over more uncovered product. I immediately notified Ms. plant manager verbally and visually. The employees restored sanitary conditions by covering the exposed product and wiping the condensation down. No product adulteration was seen.

Regulation:

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

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

416.2(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.

416.4(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(a), 416.4(d)

Citation: At approximately 0830 while performing an operational sanitation inspection, CSI [redacted] found the following noncompliance.
In the picking room, CSI [redacted] noticed an employee at the picking machine bend over and pick up several chickens off the floor and put them back on the conveyor belt with the other chicken carcasses. He immediately applied a U.S Retain tag NO. B38033100 to the product until they could show him what corrective action was going to be taken. He immediately notified Ms. [redacted] plant manager, verbally and visually of the noncompliance.

Past similar NR #DQH4611083417N dated 8/16/11. The plant’s ineffective further planned action: “This employee is new. Plant manager has retrained her as well as other employees on the line stressing the importance of following our procedure for dropped prodcut. Plant manager and experienced employees will monitor closely new hires.”

Regulation:

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

416.4(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(a), 416.4(d)

Citation: At approximately 0815 hours while CSI [redacted] was performing an operational sanitation inspection, he observed the following noncompliance:

An employee took 2-3 chickens out of the reprocessing container that is in the evisceration room and went back into the picking room. As she was going to the conveyor belt off the picking machines, she dropped the 2-3 birds on the floor. She then picked them up from the floor and threw them on the belt with the other product just as more chickens were coming out of the picking machines. CSI [redacted] immediately applied a U.S retained tag NO. B380333098 all the affected product on the belt.

CSI [redacted] immediately verbally and visually notified Ms. [redacted] [supervisor] of the problem. She removed the contaminated product, washed the carcasses with chlorinated water and hung the carcasses back on the line for re-inspection. After the proper corrective action was taken, CSI [redacted] removed the regulatory control action.

Regulation:

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

416.4(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), 416.3(a), 416.3(c), 416.4(a), 416.4(b)

Citation: At approximately 0630 hours while performing preoperational sanitation inspection, CSI [redacted] and SPHV [redacted] found the following noncompliances: [newline][newline][1] In the small picking room, there was a large number of 1-2 inch long chicken feathers (too many to count) inside the picking machine (food contact surface) and on wheel underneath the machine (non-food contact surface). U.S. reject tag No. B38033394 was applied to the machine. [newline][newline][2] The gizzard conveyor belt in the evisceration room was loose and laying on the floor (food contact surface). There was 5-6 1/2 centimenter pieces of dried product residue on the wheel of the conveyer belt (non-food contact). U.S reject tag No. B37014171 was applied to the conveyer belt. [newline][3] About 8 grey barrels in the hallway between the picking room and live hold area were not properly labeled inedible or edible containers. Two of the containers still had watery blood on the inside from the previous day’s production. U.S. reject tag No. B38033400 were applied to the insanitary barrels. [newline]CSI [redacted] and Dr. [redacted] immediately verbally and visually informed Ms. [redacted] supervisor] of these noncompliances. The regulatory control actions were removed when sanitary conditions were restored.

Regulation:

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

416.3(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.

416.3(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.

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: 01D01
Violation: 416.1, 416.2(b)(1)

Citation: At approximately 7:30 hours, while conducting a walk through inspection at this establishment in order to verify establishment compliance with Sanitation Performance Standards.I observed the following noncompliances.
In the cooler #2 near the management office, I observed condensation was dripping from the the second fan unit into the floor.No product was exposed and affected at this time.
Plastic strips curtain hanging at the Freezer Door# 1 across the shipping gate, observed in poor repair approximately five of them have been cracked and in need of reconditioning.
Mrs [redacted] floor supervisor was notified of the noncompliances.
This does not meet the above FSIS regulations 9 CFR 416.2 (b) (1) which states that ” Establishment buildings, including their structures, rooms, and compartments must be of sound construction, be kept in good repair, and be sufficient size to allow for processing, handling and storage of production in a manner that does not result in product adulteration or creating of insanitary conditions. “

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)(1) Construction. 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: 01D01
Violation: 416.2(b)(1), 416.2(h)(2), 416.4(b)

Citation: During pre-operational inspection around 0600 hours on July 28th, 2011, CSI [redacted] and SPHV [redacted] found the following noncompliances:
In the large scalding room, the base plate of the picker motor closest to the evisceration room was loose and hanging over the picker fingers, leaving the motor exposed to the picking fingers below. No regulatory control action was taken as the base plate was immediately fixed.
In the evisceration room, the ice machine closest to the shipping scale had areas of rust throughout the ceiling of the ice storage compartment. The ice machines closest to the picking rooms had the doors to the motors open, leaving an open hole leading from the machinery directly into the ice storage areas. These machines also have torn and peeling foam tape adhered to the ice compartment ceilings. The machine closest to the management office had brown dirt and rust throughout the ice storage area ceiling. The machine closest to the entrance to the picking room had rust throughout the ice storage area ceiling and down a pipe hanging from the ceiling and large amounts of dirt in the window tracks. No ice was seen affected.
Plant manager, [redacted] was immediately informed of these noncompliances.

Regulation:

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

416.2(h)(2) Dressing rooms, lavatories, and toilets. Lavatories with running hot and cold water, soap, and towels, must be placed in or near toilet and urinal rooms and at such other places in the establishment as necessary to ensure cleanliness of all persons handling any product.

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: 381.115

Citation: At approximately 0850 hours, SPHV [redacted] found the following noncompliance:
In the packing area, I saw one of the plant employees take birds from the chill tanks and pack approximately 5-8 carcasses directly into two red plastic bags. The plastic bags had no writing on them. I followed the employee to the shipping area where a customer was waiting. The employee handed the customer the two unlabeled red plastic bags of chickens. I immediately retained the product using U.S. Retain Tag #B39794898.
I immediately notified general manger, [redacted] that these red bags were not properly labeled with the establishment’s information. Additionally, Mr. [redacted] informed me that there is no guaranty, or statement of assurance available stating that the packaging material complies with the FFDCA and all applicable food additive regulations.
I returned to the packing area and found approximately 5 more unlabeled red bags with chickens in them. The product was retained using U.S. Retain Tag #B39794897.
This is a noncompliance with 9 CFR 381.144 and 381.115.

Regulation:

381.115 Except as may be authorized in specific cases by the Administrator with respect to shipment of poultry products between official establishments, each shipping container and each immediate container of any inspected and passed poultry product shall at the time it leaves the official establishment bear a label which contains information, and has been approved, in accordance with this subpart.

Code: 03J02
Violation: 417.2(c)(4), 417.2(c)(7), 417.5(a)(1), 417.5(a)(2), 417.5(a)(3), 417.5(b)

Citation: While performing a HACCP verification procedure, I found the following noncompliances:

When reviewing July 18th, 2011 HACCP records for Buddhist poultry, carcasses from lot 3 are recorded as entering the chill tank (time in) at 1156 hours and time out at 505 hours. The carcasses were recorded to be [redacted] and [redacted] degrees Fahrenheit. Carcasses from lot 4 are recorded as entering the chill tank at 1300 hours and time out as 0507 hours. The carcasses were recorded to be [redacted] degrees and [redacted] degrees Fahrenheit. Plant manager, [redacted] stated that the times out were recorded and temperatures monitored the next morning on July 19th, 2011. There is no date on this time out entry for July 19th, 2011. This is a noncompliance with 417.5(b) which states, “Each entry on a record maintained under the HACCP plan shall be made at the time the specific event occurs and include the date and time recorded…” and 417.5(a)(3) which states, “Each of these records shall include the date the record was made.” Additionally, the establishment’s Buddhist HACCP plan states under CCP 4B (chill) the critical limit for carcass chilling to be the [redacted] “

When reviewing the establishment’s Buddhist HACCP plan, the verification activities for CCP 2B (liver/heart/gizzard chill), CCP 4B (chill) and CCP 5B (refrigerator storage) do not include the procedure and frequency for the calibration of the process monitoring instruments. Also, there is no supporting documentation available supporting the verification procedures selected and the frequency of the procedure. Also under the Buddhist HACCP plan, CCP 1B (reprocess carcass) and CCP 3B (final wash) monitoring includes “[redacted]”. The HACCP plan does not list the procedure for monitoring the chlorine concentration critical limit. There is also no supporting documentation available supporting the monitoring procedures and frequency. These are noncompliances with 417.2(c)(4), 417.2(c)(7), 417.5(a)(1) and 417. 5(a)(2).

General manager, [redacted] was immediately informed of these noncompliances verbally and visually.

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;

417.2(c)(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.

417.5(a)(1) The establishment shall maintain the following records documenting the establishment’s HACCP plan: The written hazard analysis prescribed in § 417.2(a) of this part, including all supporting documentation

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

417.5(a)(3) Records documenting the monitoring of CCP’s and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment’s HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter production lot. Each of these records shall include the date the record was made.

417.5(b) Each entry on a record maintained under the HACCP plan shall be made at the time the specific event occurs and include the date and time recorded, and shall be signed or initialed by the establishment employee making the entry.

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

Citation: At approximately 0610 hours while performing pre-operative sanitation inspection, SPHV [redacted] and CSI [redacted] found the following noncompliances:
1. In the packing area, one plastic combo bin had a filmy greasy residue down one corner of the inner food contact surface. Another metal combo bin had three half centimeter spots of dried blood on the bottom food contact surface. These combo bins were rejected with U.S. Reject Tag #B37056064.
2. In the evisceration area, the hand-held venting machine had a 1 inch area of brown rust along the inner surface, which is a food contact surface. This machine was rejected with U.S. Reject Tag #B37056061.
3. In the bleeding area, one of the knives used to slaughter the birds had a ¾ inch area of rust along the blade near the handle. This knife was rejected with U.S. Reject Tag #B37056100.
Sanitation foreman, [redacted] was immediately notified visually and verbally of these noncompliances. The regulatory control actions remained in place until the establishment restored sanitary conditions. The U.S. Reject Tags were removed after reinspection.
The establishment’s SSOP under pre-operative inspection (p. 4) states, “[redacted] .”

Regulation:

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(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: 01D01
Violation: 416.2(b)(1), 416.2(b)(3), 416.4(b), 416.4(d)

Citation: At approximately 0620 hours after performing preoperative sanitation inspection, SPHV [redacted] and CSI [redacted] found the following noncompliances:
1. Off the packing area, there is peeling paint above the cooler entrance below the fan unit. The peeling paint was found all along the bottom edge of the fan unit with flakes ranging from 1×1 inch to 1×4 inches big.
2. In the packing area, a 3 inch round hole was found in the wall about a foot off the ground between the ice machine and the cooler door.
3. In the packing area, there is peeling paint and rust on the gear and casing for the conveyor belt that leads to the chill tanks. This is a non-food contact surface.
4. In the evisceration area, there is rust and peeling paint throughout the surface of the gizzard peeler motor. This is a nonfood contact surface. There is also peeling paint all along the pipes connecting to gizzard peeler. There is also peeling paint all along the pipes on the wall behind the venting area.
5. Near the reprocessing sink, there is peeling paint and rust on the pipes and a 2 x 3 inch area of rust on the wall.
6. Excessive dust was found on the top surface of the two lights above the inspection station.
7. There is peeling paint on the underside of the doorframe that leads to the scalding room from the evisceration area.
8. On the doorway leading to the live hold area from the scalding area, the metal siding closer to the scalding area is in disrepair and hanging off wall exposing insulation, wood and breaking plaster.
9. On the walls behind the picking machines, two holes were found in the plastic siding covering those walls that are approximately 2×2 inches and 2×4 inches large, exposing the underlying concrete.
10. In the evisceration area, there is peeling paint, brown debris and rust throughout the entire length of the rail and chain directly over the shackles. These are non-food contact surfaces but are directly over the shackles that hang product.
These noncompliances were immediately shown to sanitation foreman, [redacted] No product was affected. [

Regulation:

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

416.2(b)(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.

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: 416.4(d)

Citation: On July 6, 2011 about 12:30 p.m. while standing on the inspection station, I noticed bird carcasses laying on the stands in which the pullers and the cutter are located. I stopped the line and asked them why are these carcasses their. They stated because they could not cut the carcass or pull the viscera out of the carcasses they took them of the line. I informed them they is no reason for any bird carcass should be placed on the floor or any stand. If need to take the carcasses of the line they should hang them back on the rehang table or place them in the tank next to them that is used for this purpose. I instructed them to wash these carcasses before placing them on the rehang table. I informed plant management that they are in direct violation of 416.4(d) which states that product must be kept from be adulterated during processing, handling, storage, loading, unloading and transportation. This documents serves and written notification that your failure to comply with regulatory requirements could result in additional regulatory 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.

Code: 01D01
Violation: 416.2(b)(1)

Citation: On May 31, 2011 at about 12:05 in the afternoon, I observed that the curtains on the entrance of cooler number one are ripped and teared. According to Reg. 416.2(b)(1) everything must be kept in good repair to prevent adulteration of product. [newline][newline]This document serves as written notification that your failure to comply with regulatory requirements could result in additional regulatory or administrative action.

Regulation:

416.2(b)(1) Construction. 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: 01D01
Violation: 416.2(b)(2), 416.4(b), 416.4(d)

Citation: At approximately 0740 hours while performing a SPS verification procedure, SPHV [redacted] found the following noncompliance: [newline][newline]At the product cooler adjacent to the processing room packing area, the sliding door leading to the product cooler was left open. Condensation was seen over the entrance to the cooler and down the strip curtains. Within the cooler, there was a 2×2 ft area of condensation on the ceiling above a combo bin (with no product in it) that was stored to the right of the entrance. Condensation was also seen down the cooler wall to the right of the entrance. No product or food contact surface was seen affected. U.S. Reject tag #B38033395 was applied the doorway and [redacted] the plant manager, was immediately verbally notified of this noncompliance with 9 CFR 416.2(b)(2), 416.4(b) and 416.4(d). Sanitary conditions were restored immediately under inspection personnel supervision and the plant employee closed the door to the cooler.

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.

416.4(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(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments. [64 FR 56417, Oct. 20, 1999]

Code: 03J02
Violation: 417.5(a)(3), 417.5(b)

Citation: At 1130 hours while performing a scheduled 03J02, SPHV [redacted] found the following non-compliance: While reviewing the HACCP records dated 4/5/11, records documenting the monitoring of CCP’s and their critical limits and verification procedures did not include the recording of the actual times. Records for CCP1 (Reprocessing Carcass) had an initialed entry of no contamination at 1156 hrs and verification by “record observation” initialed at 1218 hrs. “HACCP preshipper” was signed at 1223 hrs. Records for CCP5 (Storage Room Temp) contained monitoring records at 1322 hrs ([redacted] F) and 1323 hours ([redacted] F). Records for verification activities by “record observation” included entries at 1348 and 1349 hours. “HACCP preshipper” was signed at 1141, 1351, and 1402 hours. These recorded times had not yet occurred as these records were checked at 1130 hours on 4/5/11. [redacted] Plant Supervisor, was immediately notified of this noncompliance. 9 CFR 417.5(b) states that “Each entry on a record maintained under the HACCP plan shall be made at the time the specific event occurs and include the date and time recorded, and shall be signed or initialed by the establishment employee making the entry.”

Regulation:

417.5(a)(3) Records documenting the monitoring of CCP’s and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment’s HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter production lot. Each of these records shall include the date the record was made.

417.5(b) Each entry on a record maintained under the HACCP plan shall be made at the time the specific event occurs and include the date and time recorded, and shall be signed or initialed by the establishment employee making the entry.

Code: 03J02
Violation: 417.2(a)(2), 417.2(c)

Citation: At approximately 09:30 hours, I observed #20138 employees removing birds from the hang-back rack during operations and putting them back unto the production line without USDA re-inspection- [affected birds were not adequately re-processed]. US retain tag B39-593567 was applied to affected product. This violation was a failure to follow the HACCP flow chart and 9CFR 417.2(a)2 and 417.2(c)2. This evidence was shown to HACCP floor supervisor, [redacted] This NR is linked to NR#2-2011 dated 3/2/2011. Continued failure to meet regulatory requirements would lead to further enforcement actions.

Regulation:

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

417.2(c) The contents of the HACCP plan. The HACCP plan shall, at a minimum: List the critical control points for each of the identified food safety hazards, including, as appropriate

Code: 06D01
Violation: 416.5(b)

Citation: At approximately 09:00 hours during operations, I observed #20138 employees leaving the slaughter production line to handle trash cans and inedible insanitary barrels and return to the edible slaughter line without changing their hand gloves or sanitizing the hand gloves, thus creating an insanitary condition. No edible product was directly involved. This was a violation of 9CFR 416.5(b). This was shown to floor supervisor, [redacted] This NR is linked to NR#3-2011 dated 3/5/2011. Continued failure to meet reguloatory requirements would lead to further enforcement actions.

Regulation:

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.

Code: 01B02
Violation: 416.13(a)

Citation: At approximately 06:00 hours, I performed an unscheduled hands-on verification of pre-operational sanitation inspection task 01B02 in order to verify that #20138 was meeting the regulatory requirements. I found the following non-compliances (a)Picking machines in scalding room areas with feathers and other debris too many to count (TMTC)-food contact surfaces (b) conveyor belt insanitary -food contact surfaces (c ) area walls with splattered blood from previous day operation- non-food contact surface (d) floor drains insanitary with debris from previous day operation- non-food contact surface (e) shackles insanitary with debris from previous day operation -food contact surface. I applied US Reject tag B39-593566 to affected areas. No edible product was directly involved. This was a violation of 9CFR 416.13 and 416.4(b). This evidence was shown to floor supervisor [redacted] This NR is linked to NR#10-2010 dated 12/28/2010. Continued failure to meet regulatory requirements would lead to further enforcement actions.

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)

Citation: On March 3, 2011 around 1:30 p.m. I looked across in front of the inspection station and noticed many poultry carcasses falling on the floor off the unloader of the final chiller. I also noticed poultry carcasses laying under the table next to the final chiller. I stopped the line; called plant management and informed them they are in violation of 416.4(d) processing and handling because of poultry laying on the floor and not picked up and cleaned in a timely manner. I watched while plant employees picked up and cleaned each carcass individually before restarting the slaughter line. This document serves as written notification that your failure to comply with regulatory requirement (s) could result in additional regulatory 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. [64 FR 56417, Oct. 20, 1999]

Code: 03J02
Violation: 381.66(a)

Citation: On March 2, 2011 about 8:30 a.m. while heading to the inspection office for my required 15 minutes break I noticed on the table next to the final chiller a pile of poultry carcasses. After I came back I noticed that these poultry carcasses were still left on this table. I notified plant management they are in violation of Reg. 381.66 (a) because they failed to chill these carcasses. All carcasses were placed immediately into the final chiller. This document serves as written notification that your failure to comply with regulatory requirement (s) could result in additional regulatory or administrative action.

Regulation:

381.66(a) General. Temperatures and procedures that are necessary for chilling and freezing ready-to-cook poultry, including all edible portions thereof, must be in accordance with operating procedures that ensure the prompt removal of the animal heat, preserve the condition and wholesomeness of the poultry, and assure that the products are not adulterated.

Code: 04B04
Violation: 381.132

Citation: On 1/11/2011, EST#20138 did not have approval on file for their pre-printed brown paper bags (labeling) used for shipping USDA exempt product. This is a non-compliance with 9 CFR 381.132(a) and 9 CFR 381.11(b) which indicates that although this product is religious exempt from certain regulations, it is subject to all other applicable provisions of the PPIA Act and the regulations. The labeling requirements for religious exempt poultry processing are laid out in Directive 6030.1,Rev1 EST#20138 Mr. [redacted] was notified of this non-compliance.

Regulation:

381.132(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, accompanied by FSIS Form, Application for Approval of Labels, Marking, and Devices, except for generically approved labeling authorized for use in § 381.133(b) (2)–(9). The management of the official establishment or establishment certified under a foreign inspection system, in accordance with subpart T of this part, must maintain a copy of all labeling used, along with the product formulation and processing procedure, in accordance with subpart Q of this part. Such records shall be made available to any duly authorized representative of the Secretary upon request.

Code: 03J02
Violation: 381.65(a), 381.65(e)

Citation: At 0715 the following condition was observed at this establishemnt: A random sample of 10 birds were inspected after the final wash and before the chiller in order to verify compliance with both FSIS regulatory requirements and the Est. HACCP plan, which is signed and dated 3/16/10. Visible fecal material was observed on the head/neck of one bird. Ms. [redacted] was immediately made aware of this. This condition did not fulfill the regiments of both the establishemnt HACCP Plan (signed and dated 3/16/10) CCP 3-B which states that there will be “[redacted] ” and FSIS Regulations 9 CFR 318.65(a) & (e) which requires that: (a) Operations and procedures involving 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 products that are not adulterated. And (e) Poultry carcasses contaminated with visible fecal material shall be prevented from entering the chilling tank. Continual failure to meet regulatory requirements could lead to further enforcement actions.

Regulation:

381.65(a) Operations and procedures involving 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 products that are not adulterated.

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

Code: 01B02
Violation: 416.2(b)(1), 416.2(b)(2), 416.4(d), 416.13(c), 416.4(a), 416.4(b)

Citation: At approximately 0615 hours I was informed by establishment Production Supervisor Ms. [redacted] of the completion of pre-operational inspection and that all areas were found acceptable. I then performed PBIS task 01BO2 hands on pre-operational sanitation inspection, in order to verify that establishment 20138 met regulatory requirements. The following non-compliances were found. 1. In the establishment processing room where final washed poultry product; is conveyed to the chilling preparation area. Observed visible dried on product residue from previous day’s production; embedded in the grooves of the conveyor unit rollers. This is a non-product contact zone. Processing room conveyor unit rejected, tag #B39593516 applied. 2. In the establishment “Picking Room”: (a)Finger pickers in the picking unit, where feathers are removed from poultry product; contain dried on brown residue throughout the unit. This is a direct product contact zone. “Picking unit” rejected, tag # B39593510 applied. (b) There is a conveyor unit where product is conveyed by shackling and movement into the line area for evisceration and inspection. Observed visible dried on product residue from previous day’s production; embedded in the grooves of the conveyor unit rollers. Further inspection revealed visible dried on product residue on the surface of the conveyor unit located beneath the rollers. These are non product contact zones. Conveyor unit rejected, tag#B39593519 applied. 3. In the “Killing Room”: (a)There are “Bleed Cones” where poultry product is bleed after each kill. Observed dried on product residue from previous days production; on the inside bottom portions of several cones. This is a direct product contact zone. Bleeding unit rejected, tag#B39593521 applied. (b)Observed visible dust on a wall mounted fan guard, a non-product contact zone. At the time of inspection no product was observed affected by the above mentioned non-compliances. Establishment SSOP Plan signed and dated 3/16/2010, under” Pre-operational Inspection, Monitoring, Frequency and Documentation” states; [redacted]” Establishment Production Supervisor Ms. [redacted] immediately shown all non-compliances observed and informed regulatory action will remain in effect until corrective action has been performed. Ms. [redacted] was also informed of failure to meet 9CFR416.1; 416.13(c); 416, 4(a); 416.4(b). Continued failure to meet regulatory requirements could lead to further enforcement actions

Regulation:

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

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

416.4(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.

416.4(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: 06D01
Violation: 416.3(c), 416.1, 416.4(b), 416.4(d)

Citation: At 0905 hours, the following condition observed in the inedible holding area was unacceptable. I observed inedible barrels condemned products were overflowed and scattered onto the floor creating insanitary condition in the room . The room was rejected using FSIS Tag # B39593584 respectively to affected area. *Past similar NR was written on 07/12/20, NR # 0003-2010 plant corrective action was ineffective. Plant Supervisor Mrs. [redacted] was notified of the non-compliance.No product was involved. This condition do not fulfill the requirements of the above cited FSIS regulations 9CFR 416.(d) and 381.95 which requires that ” Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments”. Continuous failure to comply with the above regulatory requirements could result in additional regulatory or administrative action.

Regulation:

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.

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.

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

Code: 06D01
Violation: 416.1, 416.4(b), 416.4(d)

Citation: At 0615 hours, after management conducted their pre-operational procedures and records indicated that, all areas and equipments were acceptable.I found the following non-compliance: Ice maker machine located in the right hand side of the evisceration room,while opening up the top cabinet door,I observed inside the ice machine upper silver metal showing signs of being rusted. Additionally,there is a second ice maker machine located in the same room on the opposite side of the chill tank water.I observed foreign substance materials in the upper plating metal inside the ice machine, and the upper right surface showing signs of being rusted as well. Both ice maker machines were not fully completed with ice at the time.I did not observe any product adulteration.Therefore, both machines were Rejected using FSIS Tag # B 38264436,B 38264452 ,respectively. Plant management Mr. [redacted] was immediately notified of this non-compliance.

Regulation:

416.1 Each official establishment must be operated and maintained in a manner sufficient to prevent the creation of insanitary conditions and to ensure that product is not adulterated.

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

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

Code: 06D01
Violation: 416.1, 416.4(b)

Citation: At 0815 hours,while performing inspection at this establishment above in order to verify Sanitation Performance Standards requirements.The condition observed was unacceptable: There is clogged drain in the cooler # 2 allowing waste water to back up onto the floor.There was two ( 2 ) combo bins full of products (approximately 1400 lbs each ) properly covered with plastic liner inside that room.No product was directly affected at this time. The room was Rejected using FSIS tag # B 38033115 respectively. This non-compliance was shown to the supervisor Mrs. This condition do not fullfill the requirement of the above cited regulation 9 CFR 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.

Regulation:

416.1 Each official establishment must be operated and maintained in a manner sufficient to prevent the creation of insanitary conditions and to ensure that product is not adulterated.

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

Code: 06D01
Violation: 416.1, 416.2(b)(1)

Citation: At approximately 0730 hours,while conducting a walk through inspection at this establishment in order to verify compliance with sanitation performance standards.The following noncompliance was observed: 1) Cooler # 1 is not maintained in acceptable manner,the bottom door frame needs to be reconditioned,there is a piece of metal tear off the door. 2) Plastic strips curtain hanging in the main entrance of the cooler # 2 in poor repair 3) Both plastic strips curtains observed in the washing bird’s station # 1 and # 2 in poor repair as well. 4) Exhaust filter in the scalding room,and the overhead pipe located in the celling had accumulation of dust on the surface. No product was affected at this time. This noncompliance was shown to supervisor Mrs. [redacted] and [redacted] This condition do not fufill the requirement of the above cited FSIS regulation 9 CFR 416.2 ( b )(1) which requires that “Establishment buildings, including their structures, rooms, and compartments must be of sound construction, be kept in good repair, and be sufficient size to allow for processing, handling and storage of production in a manner that does not result in product adulteration or creating of insanitary conditions.”

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)(1) 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: 06D01
Violation: 416.1, 416.4(b), 416.4(d)

Citation: At approximately 1105 Am on 7/12/2010, I performed an unschedule PBIS Task 06D01 in order to verify That, establishment #20138 was meeting the requirements. The following noncompliance was Observed. 1) The condemned inedible holding area (Housing) had condemned inedible materials scattered on the floor creating an insanitary condition. Regulatory control action was applied by using US rejected tag # B395993563 to affected area. This noncompliance was shown to supervisor [redacted] and [redacted] This event is a violation of Regulation381.95 and Regulation 416.4(b) No edible product was directly involved. Continious failure to meet regulatory requirements would lead to further enforcement 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.

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

Code 04C02

Violation:  313.15

Citation: HATS Category VIII: Stunning effectiveness[newline][newline]On May 17, 2012 at approximately 1030 hours while I, SPHV was performing a livestock humane handling task I observed the following noncompliance.  Establishment Owner, Mr. John Britt was attempting to stun a swine that had been loaded into the cattle knock box.  The cattle knock box did not limit the free movement of the swine, so that Mr. Britt was able to accurately apply the stunning blow.  When Mr. Britt applied his first stun, the swine was hit in the head, but was not stunned.  Mr. Britt took immediate corrective actions by reloading his captive bolt gun and successfully applied the second stun within 20 seconds of the first stun attempt.  After the second stun, the swine remained unconscious throughout the bleed out period.  Mr. Britt was verbally notified of the noncompliance.   [newline][newline] 9 CFR 313.15 requires that the captive bolt stunner is applied to livestock so that they are rendered immediately unconscious with one attempt, prior to shackling, hoisting, and bleeding.  9 CFR 313.15 also requires that the stunning area is designed to limit the free movement of animals so that the operator can apply the stunning blow with a high degree of accuracy.   [newline]Since Mr. Britt took immediate corrective actions after his first stun attempt, and the swine was effectively stunned on the second attempt, this was not considered to be an egregious action.  One additional swine was slaughtered following this noncompliance.   Mr. Britt restrained the second swine in the swine knocking pen located near the cattle knock box.  This swine was stunned effectively with one stun attempt.  A review of previous noncompliances did not reveal a noncompliance of similar cause.  This document serves as written notification that failure to comply with regulatory requirements may result in further enforcement actions.  

Regulation:

313.15(a) Application of stunners, required effect; handling. (1) The captive bolt stunners shall be applied to the livestock in accordance with this section so as to produce immediate unconsciousness in the animals before they are shackled, hoisted, thrown, cast, or cut. The animals shall be stunned in such a manner that they will be rendered unconscious with a minimum of excitement and discomfort.

313.15(a)(3) Immediately after the stunning blow is delivered the animals shall be in a state of complete unconsciousness and remain in this condition throughout shackling, sticking and bleeding.

Code 04C02
Violation:  313.1

Citation: HATS Category 3: Water and Feed Availability. At aproximately 0715 hours, while conducting Ante Mortem inspection on the one Hog present, the following Humane Handling non-compliance was observed with District Medical Veterinary Specialist, Dr. , and Supervisory Public Health Veterinarian, Dr. . Although the establishment provided water for the Hog, which was located in the south pen, the container was insufficient because the Hog was able to easily push it under the bottom rung of the pen and out of reach. Owner, Mr. Britt was immediately notified of this non-compliance and took corrective actions by sliding the container back into the pen. It was also observed that there was no cover on the drain in the middle pen, and Hogs that were being driven into the pen were stepping into the drain.

Regulation:

313.1(b) Floors of livestock pens, ramps, and driveways shall be constructed and maintained so as to provide good footing for livestock. Slip resistant or waffled floor surfaces, cleated ramps and the use of sand, as appropriate, during winter months are examples of acceptable construction and maintenance.

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 01D01
Violation:  416.2(a), 416.2(b)(2)

Citation: At approximately 9:30 am, while performing this Sanitation Performance Standard (SPS) procedure, the following non-compliances were observed. While inspecting the outside perimeter of the establishment I observed a whole in the concrete wall where a pipe enters into the front of the building. The hole is about 5” x 5” and is located several feet left of the front entrance, about 6 feet up from the ground. A hole about 4” x 2” that goes under the front of the building was also abserved a few feet to the right of the entrance area to the inedible entrance from the outside. The small storage room attached to the front of the establishment is cluttered with miscelaneous items to the extent that a thorough inspection of the room could not be conducted. The grass and weeds on the south side of the establishment are overgrown. There is a large pile of lumber and other building materials on the west side of the establishment, immediately behind the holding pens. While inspecting the interior perimeter of the establishment, I observed two holes about 2” x 2” and the wall floor juncture in the employee welfare area. All areas identified are potential areas for rodents, but no rodent activity observed during this inspection. Also observed on this day, were several cobwebs in the slaughter department of the facility. Cobwebs were observed on some pipes on the wall above the hand wash sink, on the large splitting saw hanging from the ceiling, metal beams, and wall/ceiling juncture. Owner, Mr. Britt was notified of all deficiencies observed.

Regulation:

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)(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 01B02
Violation:  416.13(c)

Citation: At approximately 0720 hours, while performing this task, after the establishment had conducted their pre-operational sanitation inspection, and found everything acceptable, the following monitoring non-compliance was observed. The stainless steel edible offal tree used to hang the hearts, livers and tongues, the stainless steel edible offal tray of the gut cart had product residue from the previous days production on the food contact surfaces. Also, the plastic bags that the establishment wraps around the two electric hoist controls had a build-up of product residue on them. All pieces of equipment found insanitary were rejected with US Retain/Reject Tag # B20439600. Owner, Mr. John Britt was notified and observed the above listed non-compliance.

Regulation:

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

Code: 01B02
Violation:  416.13(c)

Citation: At 0705 hours, while performing a Review and Observation Pre-operational Sanitation Inspection, after the establishment had conducted their Pre-operational Sanitation monitoring, the following non-compliance was observed. The small splitting saw used to split the beef carcasses had product residue measuring approximately 1/2″ on one side of the blade, and approximately 1″ on the other side of the blade. The splitting saw was rejected with US Reject/Retain Tag #B36674115. Mr. was notified and observed this regulatory non-compliance.

Regulation:

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

Code: 01D01
Violation:  416.2(b)(1)

Citation: At approximately 0900 hours, the following Sanitation Performance Standard non-compliance was observed. The steel door of the establishment’s only restroom will not latch shut. The door is warped and does not seal shut when closed. A sliding latch is on the door to keep the door sealed shut when in use. The latch has a round steel rod that slides into a hole of the door frame. The latch no longer prevents the door from opening. Without the door latching closed, there is a large gap that allows for looking in. This bathroom is used by both men and women, and is not being maintained in good repair. Owner Mr. John Britt was notified and observed the above stated non-compliance.

Regulation:

416.2(b)(1) Construction. 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: 01D01
Violation:  416.2(b)(3)

Citation: At approximately 0930 hours, the following non-compliance was observed. While exiting the custom and retail processing room of the official establishment, I observed the bottom of the fron entrance steel door is not tight fitting, and has a gap at the bottom large enough that it will not prevent the entrance of pests, such as insects and rodents. At the far right end of the bottom of the door, the gap is at least 1/4″ or more, and extends approximately 4 inches. Daylight can be observed nearly the entire length of the bottom of the door. No pest activity was observed within the official establishment. Plant owner, Mr. John Britt ws notified and observed the above stated non-compliance. A review of past non-compliance reports revealed no trend developing at this time.

Regulation:

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:  417.5(a)(3)

Citation: At 0900 hours while performing this 03J02 procedure, the following recordkeeping non-compliances were observed. The establishment is not documenting the results of their record review verification procedure for ccp-1, ccp-2, or ccp-3, and there are no times documented of when the events occurred. The establishment’s HACCP plan states: [redacted]. Owner, Mr. John Britt, who performs this verification procedure was notified of these recordkeeping non-compliances.

Regulation:

417.5(a)(3) Records documenting the monitoring of CCP’s and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment’s HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter production lot. Each of these records shall include the date the record was made.

Code: 01B01
Violation:  416.13(c)

Citation: At 0800 hours, while reviewing the daily SSOP records, the following recordkeeping non-compliances were observed. The establishment is not documenting the results of the monitoring of the pre-operational sanitation and operational sanitation monitoring on form E-4530 as listed in their SSOP program. The pre-operational sectional states: [redacted]. The Operational Sanitation section states: [redacted]. The establishment has been documenting the results on a calendar. This non-compliance was discussed with Mr. who is the one who performs the pre-operational and operational sanitation monitoring.

Regulation:

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

Code: 06D01
Violation:  416.4(b)

Citation: Throughout today, while conducting routine slaughter inspection I made inspections related to the 06D01 task, Facilities and Equipment. In doing so I applied criteria set forth in 9CFR 416.2-416.5. Certain things were deemed to be insanitary conditions which could lead to the adulteration of product, and are described below: 1) Plastic bags have been taped to the button control units that are used to manipulate electric hoists during the dressing of animals on the kill floor. The bags have accumulated proteinaceous debris and need to be changed; 2) The electrical wires suspended from the hoists (described in (1)) have accumulated dirt/debris and need to be cleaned; 3) There are accumulations of debris (hair, fat,dirt) in various places on the walls of the kill floor, most notably behind the head inspection station and in the area where the pressure washer is located; 4) The rack which supports the pressure washer is littered with debris, and needs to be cleaned. Also the plastic rack which holds the pressure washer hose is in need of cleaning; 5) In the bathroom there is an accumulation of dead flies and spiders, which need to be swept/vacuumed. I discussed these issues with owner/operator John Britt on this day. This document serves as notice and record that conditions described are not adequate to meet regulatory requirements cited in block six (6) of this report. The method to appeal a decision to document noncompliance is outlined in 9CFR 306.5.

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: 06D01
Violation:  416.2(a), 416.2(h)(1), 416.4(b)

Citation: Today I conducted an inspection of facilities at est. 4530 in Middleport, NY I applied criteria related to the Sanitation Performance Standards (SPS) set forth in 9CFR 416.2 through 416.5. My observations included: A) Southernmost side of the building: weeds/grass are grown up to app. two feet. The weeds/grass are dense enough to permit harborage/concealment/breeding of pests, and such that a thorough inspection of the building perimeter is not possible; B) Outside storage room adjacent to the retail processing area: an accumulation of trash/debris throughout this room, to the point that inspection of the floor/wall junctures is impossible. Conditions are such that harborage/concealment/breeding of pests (mice) could readily occur. Retail packaging materials were being stored in this room at the time of my inspection, as well as non-related (to slaughter/processing) items. The accumulation of trash is most notable, and as described, does not permit thorough inspection of the room; C) In the windows (employee welfare area, slaughter floor, inspection office), there are active spider webs/accumulations of dead flies. In addition, there is evidence of active spider activity in the bathroom. I discussed these matters with Mr. on this day. This report serves as notice/record of the failure to maintain conditions required by regulation(s) cited in block 6 of this report. Failure to achieve/maintain compliance can result in additional regulatory/administrative action(s). The method to appeal this decision to document noncompliance is outlined in 9CFR306.5.

Regulation:

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

416.2(h)(1) ) Dressing rooms, lavatories, and toilets. Dressing rooms, toilet rooms, and urinals must be sufficient in number, ample in size, conveniently located, and maintained in a sanitary condition and in good repair at all times to ensure cleanliness of all persons handling any product. They must be separate from the rooms and compartments in which products are processed, stored, or handled.

416.4(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:  416.4(d)

Citation: On May 30, 2012, at approximately 13:10 hours, Inspector notified me that the equipment sterilizer beside the USDA inspection station had a water temperature was at 110 degrees.  I affixed U.S. Rejected Tag No. B40171125 and informed the affected employees to discontinue use of the sterilizer until it was brought back into compliance. I then informed HACCP Manager, of the situation. This is in non-compliance with 9 CFR 416.4(d) and the establishments SSOP program. This document serves as a written notice that failure to comply with regulatory requirements could result in further regulatory action.9 CFR 416.4(d) states: Product must be protected from adulteration during processing, handling,storage, loading, and unloading at and during transportation from official establishments.

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: 01D01
Violation:  416.2(b)(3)

Citation: At approx. 11:40 while performing the SPS grounds verification, I observed that the water hose insert for the outside door in the old boning room was not in place. This is non-compliant to 9 CFR 416.2(b)(3). Mr. HACCP Manager, was notified of the non-compliance. This document serves as a written notification of your failure to comply with regulatory requirements. Further failure to remain compliant could result in additional regulatoty or administrative action.

Regulation:

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: 04B04
Violation:  316.5

Citation: At approximately 0900 hours while performing sanitation inspection of the coolers, the following noncompliance was observed.   A majority of the marks of inspection on the quarter carcasses of beef in the cooler are  illegible.  Some carcasses have only faint purple ink marks where the  brand  was applied and in others the ink appears to have run making the brand imprint illegible.   There were approximately  ten carcass quarters with illegible brand imprints  in the trailer being loaded for shipping.   This is a noncompliance of 9 CFR 316.5 (f).  Regulatory control action was  taken  and the  truck trailer was tagged U.S. Rejected # B40171216.  Mr. HACCP manager, was notified of the noncompliance and he  re-stamped the carcasses with the inspection legend.  This document serves as written notification that your failure to comply with the regulatory requirements could result in additional regulatory or administrative action.

Regulation:

316.5 (f) Ink used must assure legibility and permanence of the markings and the color of ink shall provide acceptable contrast with the color of the product to which it is applied.

Code: 01C02
Violation:  310.22(c)

Citation: At 14:30 hours, Dr. and myself were in the front office and noticed that there was a box from a delivery for denaturant. The box stated  “Caution: Contains .”  Upon further inspection it was noted that there was no other type of liquid denaturant in use at  the plant at this time. This is in non-compliance with 9 CFR 310.22(c) as it states: [newline]”Specified risk materials must be removed from the carcasses of cattle, segregated from edible materials, and disposed of in accordance with § 314.1 or § 314.3 of this subchapter. The spinal cord from cattle 30 months of age and older must be removed from the carcass at the establishment where the animal was slaughtered.”.[newline]9 CFR 314.3(a) states: [newline]”Carcasses, parts of carcasses, and other products condemned at an official establishment which has no facilities for tanking shall, except as provided in paragraph (b) of this section or elsewhere in this part, be destroyed in the presence of an inspector by incineration, or denatured with crude carbolic acid, or cresylic disinfectant, or a formula consisting of one part FD&C No. 3 green coloring, 40 parts water, 40 parts liquid detergent, and 40 parts oil of citronella or any other proprietary material approved by the Administrator in specific cases. When such product is to be denatured, it shall be freely slashed before the denaturing agent is applied, except that, in the case of dead animals that have not been dressed, the denaturant may be applied by injection. The denaturant must be deposited in all portions of the carcass or product to the extent necessary to preclude its use for food purposes.”.[newline][newline]Mr. HACCP Manager was notified of the non-compliance. This document serves as written notification that your failure to comply with regulatory requirement(s) could result in additional regulatory or administrative action.

Regulation:

310.22(c) Specified risk materials must be removed from the carcasses of cattle, segregated from edible materials, and disposed of in accordance with §314.1 or §314.3 of this subchapter. The spinal cord from cattle 30 months of age and older must be removed from the carcass at the establishment where the animal was slaughtered.

Code: 04C02
Violation:  313.15

Citation: HAT Category VIII Stunning Effectiveness[newline]At approximately 0930 hours while performing humane handling verification, the following noncompliance was observed.   Plant employee, Mr. , attempted to stun a Holstein dairy cow with the non-penetrating captive bolt, however the cow remained standing.  He attempted to stun the cow a second time with the non-penetrating captive bolt and again the cow remained standing.  During both of these failed attempts I  saw the non-penetrating  captive bolt  impact the cow’s head and heard the  pneumatic sound of the device deploying.  Mr.   then used  a penetrating captive bolt and the cow  dropped to the  floor and was rendered unconscious.  Immediate regulatory control action was taken and the knock box was rejected (U.S. Reject/Retain Tag No. B40171242) until the establishment  gave  corrective actions and preventative measures. Mr. HACCP Manager, was notified of the establishment’s failure to comply with the regulatory requirements prescribed in 9 CFR 313.15. The knocking area was subsequently released after Mr.  gave immediate corrective actions and preventative measures to ensure compliance with 9 CFR 313.15. Mr. nbsp; had the cows’s skull sawed in half   to view the  captive bolt placement in relation the brain.  Examination of the animal’s head revealed  two defects in the skull indicating employee error with regard to placement of the non-penetrating captive bolt stunner. This document serves as written notification that your failure to comply with regulatory requirements could result in additional regulatory of administrative action.

Regulation:

313.15 (a)(1) The captive bolt stunners shall be applied to the livestock in accordance with this section so as to produce immediate unconsciousness in the animals before they are shackled, hoisted, thrown, cast, or cut. The animals shall be stunned in such a manner that they will be rendered unconscious with a minimum of excitement and discomfort.

Code: 01C02
Violation:  310.22(c)

Citation: At approximately 1330 hours while conducting operational inspection, the following noncompliance was observed. Skulls from cattle over 30 months of age from the prior days production were not denatured.   9 CFR 310.22 (c) states that: ”Specified risk materials must be removed from the carcasses of cattle, segregated from edible materials, and disposed of in accordance with  314.1 or  314.3 of this subchapter. The spinal cord from cattle 30 months of age andolder must be removed from the carcass at the establishment where the animal was slaughtered.”  

Regulation:

310.22(c) Specified risk materials must be removed from the carcasses of cattle, segregated from edible materials, and disposed of in accordance with §314.1 or §314.3 of this subchapter. The spinal cord from cattle 30 months of age and older must be removed from the carcass at the establishment where the animal was slaughtered.

Code: 03C02
Violation:  417.5(c)

Citation: On March 16, 2012, while reviewing HACCP records related to E coli O157:H7 positive product from March 5, 2012, the following non compliance was found. The establishment failed to assure that the product received appropriate disposition at the receiving location to render it no longer adulterated (by cooking) prior to signing the pre-shipment review. The establishment took appropriate controls to move the affected product to another Federal establishment and is awaiting proper disposition (cooking). However, The Raw Not Ground HACCP Pre-Shipment Review for the positive product was signed on March 6, 2012. The establishment is not meeting the regulatory requirements of 417.5 (c ).

Regulation:

417.5(c) Prior to shipping product, the establishment shall review the records associated with the production of that product, documented in accordance with this section, to ensure completeness, including the determination that all critical limits were met and, if appropriate, corrective actions were taken, including the proper disposition of product. Where practicable, this review shall be conducted, dated, and signed by an individual who did not produce the record(s), preferably by someone trained in accordance with §417.7 of this part, or the responsible establishment official.

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

Citation: During the course of the establishments Food Safety Assessment, following non-compliances were noted by EIAO The establishment failed to conduct a hazard analysis to address the reconditioning step, and failed to include in the flow chart a reconditioning step addressing the carcasses that have fallen onto the floor. The establishment is not meeting the regulatory requirements of 9 CFR 417.2(a)(1) and 417.2(a)(2). Also, the establishment failed to document a direct observation verification result for the titration of the ppm on the Slaughter Cooler Records. This non-compliance applies to the Raw Product Record as well. The establishment is not meeting the regulatory requirements of 9 CFR 417.5(a)(3).

Regulation:

417.2(a)(1) Every official establishment shall conduct, or have conducted for it, a hazard analysis to determine the food safety hazards reasonably likely to occur in the production process and identify the preventive measures the establishment can apply to control those hazards. The hazard analysis shall include food safety hazards that can occur before, during, and after entry into the establishment. A food safety hazard that is reasonably likely to occur is one for which a prudent establishment would establish controls because it historically has occurred, or because there is a reasonable possibility that it will occur in the particular type of product being processed, in the absence of those controls.

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

417.5(a)(3) Records documenting the monitoring of CCP’s and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment’s HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter production lot. Each of these records shall include the date the record was made.

Code: 01D01
Violation:  416.2(b)(2)

Citation: While conducting the establishments Food Safety Assessment, EIAO made the following observation. The floor in the boning room has cracks approximately 1/8 inch wide by 10-15 feet in length which run from the wall to the drain and are difficult to clean, thus creating an insanitary condition. The establishment is not meeting the regulatory requirements of 9 CFR 416.2(b)(2).

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: 01C01
Violation:  416.16(a)

Citation: During the course of the establishments Food Safety Assessment, the following non-compliances were noted by EIAO The establishment failed to maintain daily records to document the implementation and monitoring of the SSOP’s to include [redacted]. Also, on November 14, 2011, there was no sterilizer temperature documented for the raw SSOP report. HACCP Coordinator, Mr. stated that the temperature was taken, however, he forgot to document the result on the SSOP report.

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: 01D01
Violation:  416.1, 416.2(h)(2)

Citation: On November 16, 2011, while performing a SPS verification of the facilities, I found there were no paper towels in the employee restroom. This is non-compliant with 9 CFR 416.2(h)(2): Hot and cold running water, soap, and towels. I checked again two hours later and the towel holder had not been refilled. I then Notified Mr. who took immediate action by installing a new roll of paper towels, thus bringing the restroom back into compliance. This notice servers as a written documentation of your failure to remail compliant with federal requirements. Further failure could result in additional regulatory or administrative action. You have the right to appeal this Non-compliance Record.

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)(2) Lavatories with running hot and cold water, soap, and towels, must be placed in or near toilet and urinal rooms and at such other places in the establishment as necessary to ensure cleanliness of all persons handling any product.

Code: 06D02
Violation:  416.4(b), 416.4(c)

Citation: On October 21, 2011, at approximately 13:30, while doing a plant walk through with Dr. Dr. and Dr. the following non-compliances were found; In the boning room on the bottom shelf there was an opened box of unused vacuum pack bags with the bags exposed which was right next to a bottle of Chlorox bleach and a bottle of meat marking ink. This is non-compliant with the code 9 cfr 416.4(c) . Mr. took immediate corrective action by removing the chemicals from the area and moving the box to a higher shelf, thus bringing the situation back into compliance. Also in the inedible cooler floor was covered in blood and had not been washed causing insanitary conditions and is not in compliance with 9 cfr 416.4(b). This document serves as a written notification of your failure to comply with regulatory requirement(s). Further failure could result in additional regulatory or administrative action. You have the right to appeal this Non-compliance Record.

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.

416.4(c) Cleaning compounds, sanitizing agents, processing aids, and other chemicals used by an establishment must be safe and effective under the conditions of use. Such chemicals must be used, handled, and stored in a manner that will not adulterate product or create insanitary conditions. Documentation substantiating the safety of a chemical’s use in a food processing environment must be available to FSIS inspection program employees for review.

Code: 06D01
Violation:  416.4(d)

Citation: On 9/29/11 at approximately 1130 hours while performing the operational sanitation procedure, the following noncompliance was observed by CSI and SVMO Dr. 4 fan guards on the refrigeration units on the south side of the Beef Chill Cooler appeared to have surface rust. this is in noncompliance of 9 CFR 416.4(d). I notified of the noncompliance. This document serves as a written notification and failure to comply with regulatory requirements could result in further regulatory control action. You have the right to appeal.

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: 01B02
Violation:  416.13(c)

Citation: At approximately 08:10 while performing the Preoperational Sanitation Inspection, after the establishment had completed their Preoperational Sanitation Inspection and found the slaughter floor to be acceptable I observed the following; particles of fat on the inside opening of the first steam vacuum. This is noncompliance with 416.4(a). This is a direct food contact surface. I informed Mr. and he took immediate corrective action in restoring sanitary conditions by removing the fat and sanitizing the affected equipment. This document serves as a written notification of your failure to comply with regulatory requirement(s) could result in additional regulatory or administrative action.

Regulation:

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

Code: 04C02
Violation:  313.15

Citation: HAT Category VIII (Stunning Effectiveness) At approximately 1325 hours while performing a check for stunning effectiveness, I observed the following. A Jersey cow was standing in a turned around direction in the knock box (facing the pens). After waiting for the cow’s head to be in a position to place the captive bolt, plant employee, Mr. , discharged the hand-held captive bolt on the forehead of the cow. The cow dropped to the floor and the plant employee checked the cow’s eyes for a blink reflex. Mr. then proceeded to shackle and hoist the cow. He made a cut to the throat to bleed the cow and then exited to the pen area to bring another cow into the knock box. I observed the cow blinking her eyes and her mouth opening and closing. I informed the floor manager, Mr. of the observation and immediate corrective action was taken with a second application of the captive bolt rendering the cow unconscious. Immediate regulatory control action was taken and the knock box was rejected (U.S. Reject/Retain Tag No. B39711878) per 9 CFR 313.50 (c) and 9CFR 500.2 (a) (4) until the establishment proffered immediate corrective actions and preventative measures. The knocking area was subsequently released after Mr. HACCP Manager, proffered immediate corrective actions and preventative measures to ensure compliance with 9 CFR 313.15. Mr. was advised of the aforementioned noncompliance, as well as the establishment’s failure to comply with the regulatory requirements prescribed in 9 CFR 313.15. This document serves as written notification that your failure to comply with regulatory requirements could result in additional regulatory of administrative action.

Regulation:

313.15 (a)(1) Application of stunners, required effect; handling. The captive bolt stunners shall be applied to the livestock in accordance with this section so as to produce immediate unconsciousness in the animals before they are shackled, hoisted, thrown, cast, or cut. The animals shall be stunned in such a manner that they will be rendered unconscious with a minimum of excitement and discomfort.

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

Citation: On 4/20/11 at approximately 1330 hours while performing a 01C02 procedure the following noncompliance was observed by Dr. and myself. Condensation was observed on three refrigeration fan units in the hot cooler. Two units in the first hot cooler, and one in the second cooler. The two in the first cooler had condensation built up in a area approximately 6 inches by 1 1/2 feet. The condensation in the second cooler was across the front of the unit and the rail and was blowing on to multiple hanging carcasses. Dr, and I informed and showed him the condensation. took immediate corrective action to rework the affected hanging beef while under supervision of Dr. This is a noncompliance of 9CFR 416.13(c) , 416.2(d) , and 416.4(d) and the plants own SSOP plan. This document serves as written notification that failure to comply with regulatory requirements could result in further regulatory action. As always you have the right to appeal.

Regulation:

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) 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: On 4/12/11 at approximately 1500 hours while performing a 01C02 procedure the following noncompliance was observed. The knife sanitizer at the sink in the blood pit was not at degrees as stated in the plants SSOP plan. I checked the temperature and the thermometer read 125 degrees. I told the employee working in the blood pit, not to use the sanitizer until it gets fixed. I informed of my findings. This is a noncompliance of 9 CFR 416.13(c) and 416.4(d) and the plants own SSOP plan. This document serves as written notification that failure to comply with regulatory requirements could result in further regulatory action. As always you have the right to appeal.

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: On 4/4/2011 at approximately 1045 hours while performing inspection duties at Establishment # 08547 the following noncompliance was observed. The rail scale was not being wiped down between carcasses. Condensation had built up on the rail from spraying the previous carcass. I stopped production and asked the employee at the final wash station why he was not wiping the condensation down. He replied he had no squeegee. I notified of my findings .This is a noncompliance of 9 CFR 416.4(d) and 416.13(c) and the plants SSOP condensation control plan. This document serves as written notification that failure to comply with regulatory requirements could result in further regulatory action. As always you have the right to appeal.

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:  416.4(d)

Citation: On 3/25/11 at approximately 1445 hours the following noncompliance was observed. The knife sanitizer next to the sink at the head station was not at degrees as stated in the plants SSOP plan. I checked the temperature and it was 140 degrees, This is a noncompliance of 9CFR 416.4(d) and the plants own SSOP plan. I informed of my finding and told the employees that might use the knife sanitizer at this station not to use it until it was fixed. This document serves as written notification that failure to comply with regulatory requirements could result in further regulatory action. As always you have the right to appeal.

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: 06D01
Violation:  416.2(b)(2), 416.4(b)

Citation: On 3/17/2011 at approximately 1400 the following noncompliance was observed by CSI and SVMO Dr. . 8 out of 10 fan covers on the cooling units in the first carcass cooler against the wall near the retain cage have what appear to be dust and surface rust on them. Also the white wall board in the blood pit has a large hole about 8 inches in circumference that needs to be repaired. This is a noncompliance of 9 CFR 416.2(b) and 416.4(d) and the plants own plan. I notified about the noncompliance’s. This document serves as written notification that failure to comply with regulatory requirements could result in further regulatory action. As always you have the right to appeal.

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.

416.4(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(b)

Citation: On 2/28/11 at approximately 0810 while performing a 01B02 procedure the following noncompliance was observed. One of the hydraulic hoses connected to the carcass spreader at the evisceration station had meat, bone, and blood particles on it. The contamination measured about 1 foot in length down the hose. This is a noncompliance of 9CFR 416.4(b) and the plants own SSOP plan. was notified of this noncompliance and addressed it at this time. This document serves as written notification that failure to comply with regulatory requirements could result in further regulatory action. As always you have the right to appeal.

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.

Code: 01C02
Violation:  416.4(d)

Citation: On 02/16/11 at approximately 1320 hours while performing a 01C02 procedure the following noncompliance was observed. The knife sanitizer in the boning room was not holding a temperature of [redacted] degrees as stated in the plants SSOP plan. I checked the temperature and it was at 120 degrees. I told the employees not to use the knife sanitizer until it came up to [redacted] degrees. I notified of my findings. This is a noncompliance of 9 CFR 416.4(d) and the plants own SSOP plan. This document serves as written notice that failure to comply with regulatory requirements could result in further regulatory action. As always you have the right to appeal.

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: 03J01
Violation:  310.18

Citation: On 1/19/2011 at approximately 1600 hours while conducting a hands on verification to check the establishments procedure to ensure that the carcasses are free of fecal material, ingesta, and milk I observed the following noncompliance in the hot cooler. One side of beef had fecal contamination on the inside flap. Carcass (#4404) had fecal material that was greenish brown and fibrous 2 inches in circumference and spread out across the flap and thoracic cavity approximately 5 inches in diameter. This contamination poses a risk which could adversely affect public health. I immediately notified of my findings. The areas of visible contamination was trimmed under my supervision, The carcass was re-inspected and released. This is a noncompliance of 9 CFR310.18 as well as the plants own HACCP plan. This document serves as written notification that failure to comply with regulatory requirements could result in further regulatory action. As always you have the right to appeal. Past Similar NRs – Previous Ineffective Plant Actions: The plant said they would have a training session with a employee and also have a meeting with all employees on sanitary dressing procedures. NR: 1-2011 dated 1/7/2011

Regulation:

310.18(a) Carcasses, organs, and other parts shall be handled in a sanitary manner to prevent contamination with fecal material, urine, bile, hair, dirt, or foreign matter; however, if contamination occurs, it shall be promptly removed in a manner satisfactory to the inspector.

Code: 03J01
Violation:  310.18, 417.2(c)(4)

Citation: At approximately 1530 hours while conducting a hands-on verification procedure to assess the adequacy of the establishment’s procedure to ensure that carcasses are free of fecal material, ingesta, and milk I observed the following noncompliance in the hot cooler. One side of beef had fecal contamination on the outer surface. Specifically, I observed a carcass (#277) that had fecal contamination on the flank area. The fecal material was brown in color, with fibrous material. Upon closer inspection, the area of fecal contamination was focal, well defined, and measured approximately 1/4 of an inch in greater linear dimension. I immediately notified Mr. HACCP manager, of the aforementioned noncompliance. At that time he was in the cooler with Dr. Dr. also observed the fecal contamination and observed three firm black particles measuring approximately 1/16 of an inch on the foreleg. Upon closer examination of other carcasses in the cooler a few had similar firm black flecks. The areas of visible contamination were trimmed under our direct supervision. The carcasses were re-inspected and released upon removal of visible contamination. A review of the establishment’s Zero Tolerance Carcass Check CCP 1B showed that the last monitoring check was performed at 1509 hours, with no deviation documented. This noncompliance is a failure to comply with regulatory requirements prescribed in 9 CFR 310.18(a) and 417.2(c)(4), as well as their failure to effectively implement the plant’s own Slaughter HACCP Plan. This document serves as written notification that your failure to comply with regulatory requirement(s) could result in additional regulatory or administrative action as outlined in 9 CFR 500.4. As always you have the right to appeal.

Regulation:

310.18 Carcasses, organs, and other parts shall be handled in a sanitary manner to prevent contamination with fecal material, urine, bile, hair, dirt, or foreign matter; however, if contamination occurs, it shall be promptly removed in a manner satisfactory to the inspector.

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), 416.2(d), 416.4(d)

Citation: On 12/23/10 at approximately 1400 hours the following noncompliance was observed. Beaded condensation in multiple spots on the rails and ceiling of the hot cooler. I notified Mr. of my findings and he proceeded to wipe down the condensation as I pointed it out. No product was effected at this time, although an insanitary condition exists that could lead to product contamination or adulteration. This is a noncompliance of 416.13 (c), 416.2 (d), 416.4 (d) and the plants own SSOP plan. This document serves as a written notification that failure to comply with regulatory requirements could result in further regulatory action. As always you have the right to appeal. Past Similar NRs – Previous Ineffective Plant Actions: The futher planned action of having one of the boning room employees monitor the beams for water build up throughout the day was either not implemented or was ineffective in preventing recurrence of condensation in the hot cooler. NR: 23-2010 dated 10/19/2010

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: 01B02
Violation:  416.4(a), 416.4(b)

Citation: On 12/15/2010 at approximately 0815 hours requested USDA to perform pre- operational inspection and the following noncompliance was observed. The pull down handle at the tailing station had brown crusty build up from the day before. There were fat particles on the wall above the scale read out and fat residue in the split saw from the previous days production. I showed my findings and he addressed the issues as I pointed them out. This is a noncompliance of 9CFR 416.4(a) and 416.4(b) and the plants own plan. This document serves as written notification that failure to comply with regulatory requirements could result in further regulatory action. As always you have the right to appeal.

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(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:  416.4(d)

Citation: On 11/22/2010 at approximately 1530 hours the following noncompliance was observed. Grease spots were observed on the insides and outsides of multiple sides of beef in the hot cooler. I showed Mr. the grease spots and drips on several carcasses that had just been pushed into the cooler. This is a noncompliance of 9 CFR 416.4(d) and the plants own plan.9 CFR 416.4(d) states Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments. This document serves as written notification that failure to comply with regulatory requirements could result in further regulatory or administrative action. As always you have the right to appeal. Past Similar NRs – Previous Ineffective Plant Actions: The plants further planed action was ineffective in preventing grease contamination of the carcasses. NR: 24-2010 dated 11/9/2010

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: 01B02
Violation:  416.4(b)

Citation: On 11/18/10 at approximately 0815 hours while performing a 01B02 procedure the following noncompliance was observed. The sink at the tailing station had dirt, hair ,and feces particles in and on the sink. The rails on the tailing station that hold the hooks had hair and rust on them. The wall above the head racks were the plant processes the head and cheek meat had pieces of fat from the previous days production. I showed Mr. my findings and he washed the tailing station rails and sink. He also had and employee scrub the wall over the head station. This is a noncompliance of 9 CFR 416.4(b) and the plants own SSOP plan. This document serves as written notification that failure to comply to with the regulatory requirements could result in further regulatory or administrative action. As always you have the right to appeal.

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:  416.4(d)

Citation: On 11/09/2010 at approximately 0845 hours Dr. observed the following noncompliance in the upper carcass cooler. Eight quarter carcasses had areas of brown/black grease. Six of the carcasses had an area of grease measuring «” to 1″ in diameter. Two of the carcasses had drips of grease approximately 4″ long. Mr. HACCP manager, was immediately notified of these findings which were in noncompliance with SSOP monitoring, 9 CFR 416.13(c) and SPS product protection, 9 CFR 416.4 (d). The affected carcasses were reconditioned by trimming. This document serves as written notice that a failure to comply with regulations could result in further regulatory or administrative action. As always you have a right to appeal.

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:  416.4(d)

Citation: On 10/19/10 at approximately 1330 hours while doing a 01C02 procedure the following noncompliance was observed. Condensation had accumulated on three rails in the hot cooler. I asked to come down from the loading cooler to the hot cooler and showed him that water had built up on three rails . Mr. had an employee wipe down the condensation. No product was effected at this time. This is a noncompliance of 9CFR 416.4(d) and the plants own plan. This document serves as written notice that failure to comply with regulatory requirements could result in further regulatory action. As always you have the right to appeal.

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: 01B02
Violation:  416.4(a)

Citation: On 10/07/10 at approximately 0840 hours the following noncompliance was observed. requested per-op in the boning room. I found multiple pieces of fat and meat particles on the frame and legs of the boning room table This is a non compliance of 9CFR 416.4(a) and the plants own SSOP plan..I showed and an employee in the boning room my findings. instructed the employee to scrub and rewash the table. No product was effected at this time. I re inspected the table and passed it for production. This document serves as written notification that failure to comply with regulatory requirements could result in additional regulatory or administrative action. As always you have the right to appeal.

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.

Code: 06D01
Violation:  325.13(a)

Citation: On 9/30/10 at approximately 1630 hours while performing a 06D01 procedure the following noncompliance was observed. I went out to the gut room to make sure that a cow condemned at ante mortem was injected with dye. I could not locate the cow so I asked an employee if he knew were it was, he said it was on the gut trailer. I asked if it was denatured , he said he did not know. I proceeded to open the two doors to get to the trailer door that was shut, I observed the cow in question and a inedible combo of bones from the days production were not denatured. This is a noncompliance of 9CFR325.13(a) and the plants own plan. I went and found and told him about my findings. injected the condemned cow and denatured the bones. This document serves as written notice that failure to comply with regulatory requirements could result in further regulatory action. As always you have the right to appeal.

Regulation:

325.13(a) Carcasses, parts thereof, meat and meat food products (other than rendered animal fats) that have been treated in accordance with the provisions of this paragraph shall be considered denatured for the purposes of the regulations in this part, except as otherwise provided in part 314 of this subchapter for articles condemned at official establishments.

Code: 01C02
Violation:  416.4(d)

Citation: On 09/24/10 at approximately 1500 hours the following noncompliance was observed. The knife sanitizer on the wall after the eviscerating station that is used for knifes and to sanitize the steam vacuum was not holding a temperature of degrees as stated in the plants SSOP plan. I checked the water temperature and it was at 130 degrees.This station is before the final wash and antimicrobial spray. I told the employees to stop using the sanitizer until could address the problem. I informed of the situation and told him he was in noncompliance of 9CFR 416.4(d) and the plants own SSOP plan. This document serves as written notice that failure to comply with regulatory requirements could result in further regulatory action. As always you have the right to appeal.

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: 06D01
Violation:  416.2(a), 416.2(b)(2)

Citation: On 9/1/2010, at approximately 0930 hours Dr. and Inspector observed the following noncompliance in the inedible room. The tailgate of the truck used to collect blood from the blood pit was covered in a dense matt of live maggots measuring approximately twenty four inches long by six inches high. Maggots were falling onto the floor and crawling under the truck and along the adjacent wall. This is a noncompliance of 9 CFR 416.2 (a), establishments must have in place a pest management program to prevent the harborage and breeding of pests on the grounds and within establishment facilities. Also, per 9 CFR 416.2 (b) (2), establishment rooms must be kept in good repair and be cleaned and sanitized as necessary to prevent the creation of insanitary conditions. On the morning of 8/30/10, the blood truck was not parked in the inedible room and the room was clean with no maggots observed. HACCP manager, Mr. was notified of the situation. A bleach solution was applied to kill the maggots. Similar noncompliance was documented on NR 13-10, dated 07/02/10 andNR-15-10, dated 7/21/10. Continued failure to meet these regulatory requirements could result in additional regulatory or administrative action. Past Similar NRs – Previous Ineffective Plant Actions: The preventative measures of fogging the inedible room each night and daily washing of the inedible floor was apparently ineffective in preventing recurrence. NR: 15-2010 dated 7/21/2010; NR: 13-2010 dated 7/2/2010

Regulation:

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)(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: 06D01
Violation:  416.2(b)(2), 416.2(b)(3)

Citation: While performing the SPS component of an unscheduled O6DO1 task at Establishment # 08547M, Champlain Beef Company, the following noncompliance was observed. The four foot wide door to the outside lot on the east side of the old boning room shows damage to the casing and the door. The damage prevents the casing and door jamb from being water tight and impervious for cleaning, and the damage to the steel door has left the top and right edge with a gap to the outside of approximately 1/4 inch wide by 12 inches long. The gap is up the side of the door and on the top edge. This gap will not preclude the potential of insect entrance into the establishment. The door opens into the area called the old boning room, but this area is now only used for a pass through area to other parts of the establishment. 9 CFR Meat and Poultry regulations state in part “(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. (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.” You have been advised verbally and by this written document of the noncompliance and of your right to appeal. You are also advised that additional noncompliance from the route cause could result in further regulatory action by the U.S.D.A. Past Similar NRs – Previous Ineffective Plant Actions: The cracks in the floor wall junction were sealed and a door sweep was replaced on the door. The openings and other exterior door casings and gaps were not checked and or repaired at that time. NR: 15-2010 dated 7/21/2010

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(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: 06D01
Violation:  416.2(a)

Citation: On 8/11/10 at approximately 1660 hours the following noncompliance was observed. The garage that the plant uses to store metal hooks, assorted machine parts and other plant maintenance material and the room that the plant uses to store old files, paperwork, and other plant property are so full I could not properly inspect the two rooms. These rooms are connected to the building against the boning room wall, however there is no direct access to the boning room by a door or a window. The rooms have so much material stored in them that I was not able to see wall to wall for signs of harborage. I showed this noncompliance of 9CFR 416.2(a) and the plants own SPS plan. Mr. said he will address the problem and he started to clean out the garage of some of the old metal and equipment.

Regulation:

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.

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

Citation: On 7/29/10 the following noncompliance was observed while Dr. and Dr. were performing a scheduled PBIS task 01C02 at approximately1100 hours. Condensation was being blown by the long cooling unit on the ceiling of the “Hot Cooler” onto six sides of USDA inspected beef. Mr. HACCP supervisor, was immediately notified of the direct contamination of product. The condensation water may contain pathogens that can lead to adulteration of product. These findings were in noncompliance with 9 CFR 416.13(c) due to the establishment’s failure to adequately monitor the implementation of the Sanitation SOP and 9 CFR 416.4 (d) product protection. Mr. took corrective actions by turning off the fans of the cooling unit, mopping the condensation off the ceiling and rails, thoroughly rinsing the carcasses with hot water, and spraying the affected carcasses with anti-microbial solution. Continued failure to meet these regulatory requirements could result in additional regulatory or administrative action. As always you have the right to appeal.

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: 06D01
Violation:  416.2(a), 416.2(b)(1), 416.2(b)(3)

Citation: At approximately 0830 hours, Dr. was performing a 06D01 procedure and observed the following non compliance. Multiple live maggots were seen emerging from and crawling around a crack at the floor wall junction and drain near the dump truck in the inedible room. This is a violation of 9 CFR 416.2 (a), establishments must have in place a pest management program to prevent the harborage and breeding of pests on the grounds and within establishment facilities. Also, per 9 CFR 416.2 (b)(1), establishment rooms must be kept in good repair and be cleaned and sanitized as necessary to prevent the creation of insanitary conditions. Additionally, the door to the ante mortem pen has a half inch gap between the floor and bottom of the door. This is a non compliance of 9CFR 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. Mr. interim HACCP manager, was notified of the situation. The inedible room area was then re-sanitized with bleach. Upon re-inspection the condition of the inedible room was satisfactory. Similar noncompliance was documented on NR 13-10, dated 07/02/10. The preventive measures of fogging the inedible room each night and washing down the floor each night were ineffective in preventing recurrence. Continued failure to meet these regulatory requirements could result in additional regulatory or administrative action. As always you have the right to appeal. Past Similar NRs – Previous Ineffective Plant Actions: The actions the plant took the fix and monitor the problem was not effective NR: 13-2010 dated 7/2/2010

Regulation:

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

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

416.2(b)(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: 06D01
Violation:  416.2(b)(2), 416.2(e)(3)

Citation: On 7/9/2010 at approximately 0815 hours the following noncompliance was observed by IIC and Dr. Pen #1 in the holding area which had dairy cows to be presented for ante mortem inspection was flooded with dirty water from drainage backup. There were two large puddles of dirty water standing water about 6 feet in diameter and approximately 3 inches deep above both drain covers. This is a noncompliance of 9CFR 416.2(b)(2) and 416.2(e)(3) and the plants own SPS plan. This document serves as written notification that failure to comply with regulatory requirements could result in additional regulatory action. As always you have the right to appeal.

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

Code: 06D01
Violation:  416.2(a)

Citation: At approximately 1530 hours while performing a 06D01 procedure the following noncompliance was observed. Dr, and IIC found large amounts of fly larva going from the inedible room door all along the wall to the gut trailer and across the back wall. The larva were hatching in spots and in different stages. This is a noncompliance of 9 CFR 416.2 (a) and the plants own plan. This document serves as written notification that failure to comply with regulatory requirements could l result in additional regulatory action. As always you have the right to appeal.

Regulation:

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.

Code: 01D01
Violation:  416.1, 416.2(e)(2)

Citation: On 5/24/2012 at approximately 1210 hrs as I toured the facilitate, I observed the following noncompliance on the Kill/Process floor. Under the product wash sink, that is located against the far wall opposite the front entrance, the left side’s sewage joint connection is leaks every time there is any use of the sink. This allows any waste that has accumulate in the drain to seep onto the production floor; this in turn causes an insanitary condition. Regulatory Tag#B39161251 was applied , in order to stop usage of drain.This is in violation of 9 CFR 416.2(e) (2) which states”) properly convey sewage and liquid disposable waste from the establishment”. As well as 9 CFR 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”.The establishment manager, Mr. was informed of the noncompliance immediately,no product was affected at the time.

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)(2) Properly convey sewage and liquid disposable waste from the establishment;

Code: 01D01
Violation:  416.2(a)

Citation: On 4/3/2012 at approximately 0630hrs while conducting a tour of the establishment it was observed the following noncompliance concerning the outside perimeter. There were two areas outside on the front side of the build that could allow pest to harbor; and if were to find entry into the establishment can cause an in sanitary condition. [newline]1-There were 6 wooden palettes leaning against the wall located between the offal room and freezer doors.[newline] 2-On the outside wall located between the front door and holding pen, there were two plastic crates and assortment of paper and plastic wrappers. [newline]These were in violation of 9CFR regulation 416.2(a) which states:”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.” The establishment’s  manager, Mr was informed of the noncompliance immediately. Since no product was affected, no regulatory tags were issued.[newline] 

Regulation:

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.

Code: 01C02
Violation:  416.4(b)

Citation: On Tuesday, November 29, 2011 at approximately 10:00am during slaughter operations the bags that are used to protect the hoist operating equipment in the slaughter area was observed to contain liquid and residue from a previous production. USDA reject tag #B39161267 was placed on the equipment restricting it’s use until corrective action was taken. 9CFR416.4(b) states non-food contact surface(s) 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. Document #8 in establishments SSOP states [redacted]. Mr. plant manager was immediately informed of the non-compliance, his immediate action was to remove all product from the area, he removed the bags, sanitized the equipment and replaced with fresh bags. The equipment was re-inspected, passed, USDA reject tag was removed, the product was returned to the area, inspected, and passed.

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:  381.115, 381.116

Citation: On Thursday, October 6, 2011 at approximately 0800 hours while conducting pre-operational sanitation task the following non-compliance was observed. In the freezer to the right of the entrance there was a rack that contained five boxes with safe handling instructions and the word “chicken” written in black marker. While inspecting the contents of these boxes they contained loose chicken leg quarters. The product inside was not fully labeled (this being bulk product). I immediately informed plant designee of the non-compliance. He explained that during unloading of the product the pallet broke which destroyed the originating shipping container that contained the label. The unadulterated product was then transferred into a sanitary container where they wrote “Chicken” and placed a safe handling label on the box. This product has been retained with US retain tag #B39161277. You have not complied with the following regulations..9CFR381.115 Containers of inspected and passed poultry required to be labeled & 9CFR381.116 Wording on labels of immediate containers.

Regulation:

381.115 Except as may be authorized in specific cases by the Administrator with respect to shipment of poultry products between official establishments, each shipping container and each immediate container of any inspected and passed poultry product shall at the time it leaves the official establishment bear a label which contains information, and has been approved, in accordance with this subpart.

381.116(a) Each label for use on immediate containers for inspected and passed poultry products shall bear on the principal display panel (except as otherwise permitted in the regulations), the items of information required by this subpart. Such items of information shall be in distinctly legible form. Except as provided in §381.128, all words, statements and other information required by or under authority of the Act to appear on the label or labeling shall appear thereon in the English language: Provided, however, That in the case of products distributed solely in Puerto Rico, Spanish may be substituted for English for all printed matter except the USDA inspection legend.

Code: 03B02
Violation:  417.4(a)(2)(ii), 417.5(a)(3), 417.5(b)

Citation: On October 3, 2011 while conducting a record review of the frozen storage temperature chart for the last operational day of September 30, 2011 which is to be it was observed only one observation and documentation took place at 08:45 on non-intact product (chopmeat). CCP#3B is in non-compliance. Upon observation of the failure to document this on the chart Meat Manager was immediately informed of the non-compliance. We immediately went into the freezer and took temperatures of both intact and non-intact product to assure the product remained wholesome. You have failed to comply with the following regulations 9CFR417.4(a)(2)(ii) direct observation, 417.5(a)(3) Records documentation and monitoring of CCP’s and critical limits and 417.5(b) Annotates at time of the event.

Regulation:

417.4(a)(2)(ii) Direct observations of monitoring activities and corrective actions;

417.5(a)(3) Records documenting the monitoring of CCP’s and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment’s HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter production lot. Each of these records shall include the date the record was made.

417.5(b) Each entry on a record maintained under the HACCP plan shall be made at the time the specific event occurs and include the date and time recorded, and shall be signed or initialed by the establishment employee making the entry.

Code: 06D01
Violation:  416.3(a)

Citation: On Tuesday, September 20, 2011 at 0610 while walking through the facility conducting a pre-operational procedure the following non-compliances(s) were observed: There are two plastic white meat tubs in the grinding room cooler that contain deep score marks throughout this equipment. The equipment and utensils used for processing and otherwise handling edible product or ingredients must facilitate thorough cleaning. No product was involved at the time of observance. A U.S. reject tag #B 24791170 was placed on this equipment restricting it’s use in production. Also the hot water pasteurization hose located to the left of the cooler door in the processing area has melted due to the extreme heat passing through it. This hose is sticky to the touch which prohibits proper sanitation of this equipment, use was restricted by placing a U.S. reject tag #B 24791174. Mr. was immediately informed of these non-compliance(s) and informed me that the meat tubs will be removed from production immediately. The hose will be ordered and replaced. 9CFR416.3(a) states..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.

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.

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

Citation: On August 11, 2011 at 0910 hours after the plant had completed pre-operational sanitation inspection and prior to the start of operations I observed the following non-compliance(s): The Viscera Truck located in the dressing area was observed to have a soapy residue on the top shelf, the bottom shelf contained standing soapy water with debris floating in this water. Regulatory Control Action was immediately initiated rejecting this equipment with USDA Reject tag# B23779043. There were two gambrels (product contact surface) laying on the final wash stand in the wash and weigh area, there was no barrier between where the gambrels were laying and where employees feet come in contact with this surface. A regulatory control action was immediately initiated by placing a USDA Reject tag #B34 488927 on the gambrels. Mr. Plant Manager was immediately informed of these non-compliance(s). The above non-compliance(s) are in violation of 9CFR416.4(a) which states “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 unsanitary conditions and the adulteration of product. (CFR416.13(c) states Each official establishment shall monitor daily the implementation of the procedures in the Sanitation SOP’s. There was no product involved, this was a pre-operational procedure. Past Similar NRs – Previous Ineffective Plant Actions: The hooks will not be placed on the stand in future before start of slaughter. Paunch Truck will be more closely monitored in the future. NR: 3-2011 dated 7/12/2011; NR: 2-2011 dated 7/7/2011

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: 06D01
Violation:  416.2(b)(1), 416.4(b)

Citation: On July 12, 2011 at approximately 0815 hrs. while conducting an unscheduled 06D01 procedure the following non-compliance was observed: There are six spots of exposed insulation. The exposed insulation above the cooler door contains debris and mold adhered to it. The molded/debris area is approximately 6 inches long by 3 inches wide. There are two pipes located above the hog dehairing equipment that has approximately 16 inches of exposed insulation. There is a disconnected piece of insulation outside the hallway to the boiler room where it has broke free from the tape that was holding it together. To the left of the head inspection station there is 2 inch long by one inch wide spot of exposed insulation. Behind the band saw there is an insulated pipe that contains approximate 4 holes that are about an inch in diameter a piece that is exposing the insulation. Mr. meat manager was informed of the areas where these deficiencies were observed. No product was involved, no USDA tag was issued. Exposed insulation creates an insanitary condition and cannot be properly sanitized which violates 9CFR416.4(b) relating to non-food contact surface, cleaning & sanitizing and also 9CFR416.2(b)(1) which states in part….establishment buildings, including their structures, rooms, and compartments must be of sound construction, be kept in good repair…..

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.

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), 416.2(a), 416.4(a), 416.4(b)

Citation: On July 12, 2011 at 0730 hours after the plant had completed pre-operational sanitation inspection and prior to the start of operations I observed the following non-compliance(s): Approximately eight one inch insects were observed in the sticking/bleed area, five appeared to be deceased on the floor while three were observed to be crawling up the wall in this area. There were an additional four deceased insects in the product dressing area. A regulatory control action was immediately initiated restricting the use of these areas with USDA Reject tag #B30430772 this is in non-compliance with 9CFR416.2(a) addressing grounds and pest management. There were two carcass hooks that were to be used in this days production lying on the final wash stand, there was no barrier between where the hooks were lying and where employees feet come in contact with this surface. A regulatory control action was immediately initiated by placing a USDA Reject tag#B38033344 on this equipment restricting its use. Also the viscera truck was observed to have product residue approximately 4 black spots from previous operations adhered to it. It also contained a soapy water residue. A regulatory control action was immediately initiated by placing a USDA reject tag #B38033340 restricting the use of this equipment. The above two non-compliance(s) are in violation of 9CFR416.4(a) addressing sanitary operation of food contact surface, cleaning and sanitizing. It was observed throughout the establishment there is product residue adhered to the walls and the ceiling from previous production, there was fat from a previous production adhered to the door of the offal room, a three inch piece of fat was adhered to a pipe to the right of the offal room door. A regulatory control action was immediately initiated in this area to restrict it’s use by placing USDA reject tag#B24791611. This is in violation of 9CFR416.4(b) addressing non-food contact surface, cleaning & sanitizing. This establishment is in non-compliance of 9CFR416.13(c) which states…Each official establishment shall monitor daily the implementation oft the procedures in the sanitation SOP’s. At the time there was no product involved, this was a pre-operational procedure. Mr. Meat Manager and Mr. Assistant Butcher was immediately notified of all non-compliance(s). Managements reaction was to cancel the slaughter and address all deficiencies by sanitizing the areas and equipment mentioned. Past Similar NRs – Previous Ineffective Plant Actions: They will try to be more thorough in the future. NR: 2-2011 dated 7/7/2011

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

Citation: On July 7, 2011 at 0820 after the plant had completed pre-operational sanitation inspection and prior to the start of operations I observed the brisket saw. There was a brown residue from the previous day ‘s operation at the base of the blade, on the blade, and on the housing about a half inch in diameter and also some smaller specs on the tip of the blade. A regulatory control action was initiated to restrict use of the brisket saw until corrective action could be implemented (Tag # B 21 179835). Mr. was informed immediately. The Regulations in Section 416.13(a) states “Each official establishment shall conduct the pre-operational procedures in the Sanitation SOP’s before the start of operations.” The Regulations in Section 416.4(a) states “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 unsanitary conditions and the adulteration of product.” The Regulations in Section 416.13(a) and 416.4(a) have not been met.

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

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.

Code: 06D01
Violation:  416.1, 416.2(b)(1)

Citation: On February 16, 2011 at 1130hrs while on my inspection tour of the cooler and freezer areas I found a number of non-compliances. On the base of the cooler door the kick plate was missing, exposing the base with a number of holes and rust-like protions. Since no product was directly affected or adulterated no tags were issued. Mr. manager, was immediately informed of the non-compliance . He explained that the bottom plate came off during cleaning and was being sent out for repair. While inspecting the freezer, the left side of the room’s boxed product were leaning against the freezer wall. This denied accessed to inspecting that side of the freezer’s area of product. U.S. Mr. was immediately informed of this non-compliance. He explained that they were working on reorganizing the freezer and have not completed the task yet. These non-compliances are both in violation of the following regulations: Regulation 9CFR 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 9CFR 416.2((b)(1) which states “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.

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)(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: 06D01
Violation:  416.4(b)

Citation: On November 23, 2010 at 1300 while doing a facilities check of the premises I observed a white residue on the door gasket going into the cooler. It is about one foot long and one inch wide. Also, there is a brown/tan residue on the outside of the door in various spots and streaks. Mr. was informed immediately. The Regulations in Section 416.4(b) state “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.”

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: 06D01
Violation:  416.2(b)(1), 416.4(b)

Citation: At approximately 0800 hrs., I observed the following. In the Inedible Room, the walls are stained with dried denaturant, numerous barrels are soiled and strewn on the floor, the ceiling is stained and has peeling paint. At the rear an overhead fan housing is rusted. Their is a foul odor when the door is first opened. The inner door handle needs repair and is rusted. The door gasket has visible dried protein on its exposed surface. U.S. Reject tag No. B39907603 was applied. In the Product Holding Cooler, (right side just inside entrance), the overhead black pipe insulation is visibly severed and frayed over an approximate 12″ area. The adjacent sections of the rail and switch are rusted. In the rear Freezer (overhead right side) approximately eight vertical support rods are rusted. Mr. plant manager was informed. This is in noncompliance with Title 9CFR 416.4(b) which requires non-food- contact surfaces of facilities, equipment, and utensils used in the operation of the establishment to be cleaned and sanitized as frequently as necessary to prevent the creation of insanitary conditions and the adulteration of product. Title 9CFR 416.2(b)(1) requires in part that establishment buildings, including their structures, and compartments should be of sound construction and be kept in good repair.

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.

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(b), 416.13(c), 416.2(a), 416.13(a)

Citation: On October 28, 2010 at 0850 after the plant had finished pre-operational sanitation inspection and prior to the start of operations I observed the stuffer on the cutting table. There was an old white product residue on the inside (product contact surface) covering about two thirds of the equipment. A regulatory control action was initiated to restrict use of the stuffer until corrective action could be performed (Tag # B 11 303142). Mr. was informed immediately. The Regulations in Section 416.13(a) state ” Each official establishment shall conduct the pre-operational procedures in the Sanitation SOP’s before the start of operations.” The Regulations in Section 416.13(a) have not been met.

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.

416.2(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.

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

Code: 06D01
Violation:  416.4(b)

Citation: On October 14, 2010 at 0700 while doing a pre-operational sanitation inspection I observed the scale at the end of the slaughter line. There is a brown (rust) residue on the weights and at the base measuring about one half inch to one inch in diameter at several different places. A regulatory control action was initiated to restrict use of the scale until corrective action could be performed (Tag # B 23789745). Mr. was immediately informed. The Regulations in Section 416.4(b) state “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 unsanitary conditions and the adulteration of product.” The Regulations in Section 416.4(b) have not been met.

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: 06D01
Violation:  416.1, 416.2(a)

Citation: On September 28, 2010 at 0720 while walking to the Live Holding Pens to watch the employees move the pigs into the killing area I observed beside the main entrance to the slaughter house a ladder laying on its side that has leaves and debris around it. Next to the Live Holding Pens there are two garden hoses, several fence logs, a broken squeeze chute, a broom and a shovel. Mr. was informed immediately. The Regulations in Section 416.1 state “Each official establishment must be operated and maintained in a manner sufficient to prevent the creation of unsanitary conditions and to ensure that product is not adulterated.” The Regulations in Section 416.2(a) state “The grounds about an establishment must be maintained to prevent conditions that could lead to unsanitary conditions, adulteration of product, or interfere with inspection by FSIS program employees.” The Regulations in Section 416.1 and 416.2(a) have not been met.

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.

Code: 01B02
Violation:  416.13(a)

Citation: On September 9, 2010 at 0645 after the plant had performed pre-operational sanitation inspection and prior to the start of operations I observed the head racks for the beef (FCS). There were many blood spots on the rack about one fourth of an inch in diameter and several hairs. A regulatory control action was initiated to restrict use of the racks until corrective action could be performed (Tag # B 24791175). Mr. was informed immediately. The Regulations in Section 416.13(a) state “Each official establishment shall conduct the pre-operational procedures in the Sanitation SOP’s before the start of operations.” The Regulations in Section 416. 13(a) have not been met.

Regulation:

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

Code: 06D01
Violation:  416.2(b)(2)

Citation: On September 8, 2010 at 1400 while walking through the freezer I observed as you enter on the left side there is an ice bundle about one to two inches long and about four inches in diameter hanging down from the ceiling. There is also another one on the right hand side about the same size. There is no product contamination and no boxes or product are under the ice. Mr. and Mr. were informed immediately. The Regulations in Section 416.2(b)(2) state “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 unsanitary conditions.” The Regulations in Section 416.2(b)(2) have not been met.

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: 04B04
Violation:  319.1(a)

Citation: On September 2, 2010 at 1100 while doing a label check in the freezer I observed ten boxes of ground beef that had a check off label on them but the check off label was not marked to identify what the product was in the box. On the outside of the box outside the check off label was hand writing on the box which says “chop meat”. A regulatory control action was initiated to restrict use of the product until corrective action could be performed (Tag # B 23789724). Mr. and Mr. were informed immediately. The Regulations in Section 319.1(a) state ” Labels for products for which standards of identity or composition are prescribed in this part shall show the appropriate product name.” The Regulations in Section 319.1(a) have not been met.

Regulation:

319.1(a) Labels for products for which standards of identity or composition are prescribed in this part shall show the appropriate product name, an ingredient statement, and other label information in accordance with the special provisions, if any, in this part, and otherwise in accordance with the general labeling provisions in part 317 of this subchapter, and such products shall be prepared in accordance with the special provisions, if any, in this part and otherwise in accordance with the general provisions in this subchapter. Any product for which there is a common or usual name must consist of ingredients and be prepared by the use of procedures common or usual to such products insofar as specific ingredients or procedures are not prescribed or prohibited by the provisions of this subchapter.

Code: 01C02
Violation:  416.13(c), 416.14, 416.4(d)

Citation: On August 24, 2010 at 0700 I went into the meat grinding room and observed two plastic tubs of ground beef trimmings that have a white off color (freezer burn) on them. A regulatory control action was initiated to restrict use of the product until corrective action could be performed (Tag # B39161269 and B 36105807). Mr. and Mr. were informed immediately. The Regulations in Section 416.13(c) state “Each official establishment shall monitor daily the implementation of the procedures in the Sanitation SOP’s.” The Regulations in Section 416.4(d) state “Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.” The Regulations in Section 416.14 state “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.”

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.

416.4(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 0715 hrs., and prior to the start of production subsequent plant managers preoperational sanitation inspection, I observed the following. In the Evisceration room. on the band saw; the backside of the flywheel in the upper housing has visible meat particles and a greasy film adhered to its surface. Plant manager Mr. cleaned immediately. In the processing room, the first boning board upon entering, has several visible black stains of unknown origin on its exposed product contact surface. U.S. Reject tag No.B39831074 was applied. The establishments SSOP plan signed and dated, 6/18/07 on page 1, under Pre-Operational Sanitation, states, “. Plant manager Mr. was informed. This is in noncompliance with Title 9CFR 416.13(c) which requires each official establishment to monitor daily the implementation of the procedures in the Sanitation SOP’s.

Regulation:

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

Code: 06D01
Violation:  416.2(b)(1), 416.2(b)(2)

Citation: On July 19, 2010 at 1230 while reviewing your facilities I observed in the Grinding Room a brown residue on the overhead structures in various places about one to two inches long . No product is underneath the residue and no contamination was observed. Mr. and Mr. were verbally informed. The Regulations in Section 416.4(b)(1) state ” 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.” The Regulations in Section 416.2(b)(2) state ” 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.” The Regulations in Section 416.2(b)(1) and (2) have not been met.

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.

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: 06D01
Violation: 416.1, 416.4(b)

Citation: On July 8, 2010 at 0645 above the chill tanks at the end of the Evisceration Line there is a water hose that fills the chill tanks with water. The water hose has a product residue from the previous days operation sticking to it covering about one half of the hose (product contact zone). A regulatory control action was initiated to restrict use of the fill hose until corrective action could be performed (Tag # B39133838). Mr. was verbally informed immediately. The Regulations in Section 416.1 state ” 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. The Regulations in Section 416.4(b) state ” 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.” The Regulations in Section 416.1 and 416.4(b) have not been met.

Regulation:

416.1 Each official establishment must be operated and maintained in a manner sufficient to prevent the creation of insanitary conditions and to ensure that product is not adulterated. 

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

Code: 06D02
Violation: 381.76(a), 381.76(b)

Citation: At approximately 0900 hrs the inspection line had to be stopped due to insufficient presentation of carcasses. , plant manager was immediately informed. He was shown how the birds are being hung by one leg, by the head or in some instances completely upside down. This establishment is traditional line inspection and proper presentation of birds is to be shackled by both feet with the back side of the bird facing the inspection stand. Inspector hung back 43 birds to be re-hung and properly presented. Line speed was running at birds per minute. 9CFR381.76 in part states: (ii) General…For the establishment to run it’s processing line at maximum speed, optimal conditions must be maintained so that inspection may be conducted efficiently. (iii) Presentation (b) An establishment employee shall present each bird to the inspector properly eviscerated with the back side toward the inspector and the viscera uniformly trailing or leading. In speaking to , president, later in the day he informed me he will trace back the situation and try to pinpoint and correct the problem in that area. There was no USDA reject/retain tag involved.

Regulation:

381.76(a) A post-mortem inspection shall be made on a bird-by-bird basis on all poultry eviscerated in an official establishment. No viscera or any part thereof shall be removed from any poultry processed in any official establishment, except at the time of post-mortem inspection, unless their identify with the rest of the carcass is maintained in a manner satisfactory to the inspector until such inspection is made. Each carcass to be eviscerated shall be opened so as to expose the organs and the body cavity for proper examination by the inspector and shall be prepared immediately after inspection as ready- to-cook poultry. If a carcass is frozen, it shall be thoroughly thawed before being opened for examination by the inspector. Each carcass, or all parts comprising such carcass, shall be examined by the inspector, except for parts that are not needed for inspection purposes and are not intended for human food and are condemned.

381.76(b) (ii) General. (a) Under SIS, one inspector inspects the outside, inside, and viscera of each bird. There may be two inspectors on one processing line, each inspecting every other bird. For the establishment to run its processing line(s) at maximum speed, optimal conditions must be maintained so that inspection may be conducted efficiently. The inspector in charge determines the speed at which each processing line may be operated to permit inspection. A variety of conditions may affect this determination including the health of each flock and the manner in which birds are being presented to the inspector for inspection.

381.76(b) (iii) Post-mortem inspection. (a) Facilities: Each inspection station must comply with the facility requirements in §381.36(c).

381.76(b) Presentation: Each inspector shall be flanked by an establishment employee assigned to be the inspector’s helper. The one inspector on the SIS–1 line shall be presented every bird. Each inspector on the SIS–2 line shall be presented every other bird on the line. An establishment employee shall present each bird to the inspector properly eviscerated with the back side toward the inspector and the viscera uniformly trailing or leading. Each inspector shall inspect the inside, viscera, and outside of all birds presented.

Code: 06D01
Violation: 416.2(b)(1)

Citation: While performing an unscheduled walk thru (06D01) procedure on July 22, 2010 at 1330 hours the following sanitation non-compliance issues were found: 1) Cob Webs around the power boxes located in the inside holding pen. 2) Dust on the overhead pipes running through the facility. 3) On the air vent located in the rendering room there is rust on the underside of the air vent, also a rusty hole 1 and 1/2 inches in length on this vent. 4) On the underside of the table in front of the sorting bins there is a bar approximately 7 feet long that contains rust. 5) There is dust and cob webs in the scalder motor room. 6) There is exposed insulation in ladies locker room. 7) There is debris located underneath lockers in the men’s locker room. 8) There is an electric cord connected to microwave in men’s locker room that contains residue. Regulation 9CFR 416.2(b) Construction. (1) states..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. Upon finding these conditions Mr. , President was immediately notified. There was no product involved, all deficiencies found on non-food contact surfaces, no tags were applied. Mr. advised establishment will be closed for operations tomorrow and maintenance will take place.

Regulation:

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

Code: 06D01
Violation: 416.2(b)(1), 416.2(b)(2)

Citation: On July 29th at 1400 hrs while conducting an unscheduled (06D01) procedure, a walk through, I observed the following: The blast freezer ceiling is in disrepair, there are gaps between ceiling tiles, the length of these tiles, not allowing for proper sanitizing of structure, there is a bent ceiling tile, there are scuff marks on the walls, there are pieces of pallet debris strewn about the floor. The bottom of the swinging doors appear to be worn. The product is too close to the walls not allowing for an inspectable perimeter. I immediately informed , plant manager of these deficiencies. We then checked on product that is stored in this freezer and observed no adulteration, boxed product and boxes themselves appear intact and free of debris. No tag was applied. This is in noncompliance with Title 9CFR 416.2(b)(1) which requires establishment buildings, including their structures, rooms and compartments to be of sound construction and kept in good repair. (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.

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.

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

Citation: On August 3, 2010 at approximately 0730 while conducting a scheduled 01B02 pre-operational procedure, prior to operations the following deficiencies were observed that were not conveyed on the pre-operational records: Grease residue was observed to be on the pinning table. Product contact surface. USDA Reject tag no. B39133816 applied. There were two faucets on the pinning table that contain rusty nuts. Product contact surface. USDA Reject tag no. B39133815 applied. No product involved at this time. Mr. , president was immediately. Title 9CFR 416.13(c) which requires each official establishment to monitor daily the implementation of the procedures in the sanitation SOP’s. Title 9CFR 416.4(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.

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: 06D01
Violation: 416.2(b)(1), 416.2(b)(3), 416.4(b)

Citation: On August 3, 2010 at approximately 0800 hours while conducting an unscheduled 06D01 procedure, a walk through, the following deficiencies were observed: In the box storage room located upstairs adjacent to the ice storage unit there is a window in the dock area located down two steps that has ply wood rather than paned glass which is in disrepair containing holes in the corners and gaps along the bottom of the window allowing vermin and pest to enter establishment. In this same dock area there is a screen is disrepair, separating itself from it’s intended use, this screen also contains dust/debris adhered to it. Upstairs in the box storage room there is a concrete wall adjacent with a wooden wall with debris and dust adhered to it without enough space between these two walls allowing for proper sanitation. In the same box storage area there is a fan duct that has dust/debris adhered to it, this duct is located approximately in the middle on the back wall of this area. In the shipping area there is a roll down door that is in disrepair containing a hole in the bottom right hand corner approximately 4.5 inches in length allowing for the possibility of vermin and pest to enter facility. The ceiling in the slaughter area between the conveyor belt and the wall of the kill area located directly above the shackle line was observed to have previous production residue. The pulley support wheels throughout the shackle system in all areas of the establishment had residue on the top surface (facing the ceiling ) of these support wheels. Equipment rejected with USDA Tag no. B39133832. Shrink wrap packer contains residue under the chain covering the bottom of this equipment, there is residue in the drain bin and on the drains of this equipment. Equipment rejected with USDA Tag no. B39133817. The wax area and equipment were observed to have a buildup of wax and dust on the temperature boxes, power lines. Equipment rejected with USDA tag no. B39133833. Mr. was immediately notified. Title 9CFR416.2(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. Title 9CFR416.2(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. Title 9CFR 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 adulteration of product.

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.

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: 01B02
Violation: 416.13(c)

Citation: On August 10, 2010 at 0650 hrs while conducting a scheduled 01B02 pre-operational review and observation procedure the following non-compliances were observed on product contact surfaces: -1 yellow ice scoop was observed to contain residue from previous production adhere to it. There were six spots approximately 1/10 of an inch in diameter scattered inside the ice scoop. -2 stainless steel strainers were observed to contain previous production residue and dried blood adhered to it. There were approximately 15 spots about 1/10 of an inch in diameter. -1 plastic fabricating tub/bucket had a greasy residue to the touch on the inside of this tub/bucket. In reviewing pre-operation records it was observed this equipment had been marked acceptable. A regulatory control action was immediately taken with USDA reject tag #B39133806. , plant manager was informed. Mr. immediately took action and removed this equipment from production and re-sanitized, I re-inspected and released. At this time there was no product involved. 9CFR416.13(c) Procedures in the Sanitation SOP’s that are to be conducted prior to operations shall be identified as such, and shall address, at a minimum, the cleaning of food contact surfaces of facilities, equipment, and utensils.

Regulation:

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

Code: 01B02
Violation: 416.13(a)

Citation: On August 17, 2010 at 0635 after the plant had performed pre-operational sanitation inspection and prior to the start of operations I observed the Wax Reclaim Tank. Inside the tank were about 20 feathers, a brown residue on the inside bottom, and some old wax from the previous days operation. A regulatory control action was initiated to restrict use of the tank until corrective action could be performed (Tag # B 24791394). Mr. and Mr. were verbally informed immediately. The Regulations in Section 416.13(a) state “Each official establishment shall conduct the pre-operational procedures in the Sanitation SOP’s before the start of operations.” The Regulations in Section 416.13(a) have not been met.

Regulation:

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

Code: 06D01
Violation: 416.1, 416.4(b)

Citation: On August 17, 2010 at 0650 during pre-operational sanitation inspection while checking the sorting bins I observed a brown residue covering about one fourth of the bins. A regulatory control action was initiated to restrict use of the sorting bins until corrective action could be performed (Tag # B 39133830). Mr. and Mr. were informed immediately. The Regulations in Section 416.1 state “Each official establishment must be operated and maintained in a manner sufficient to prevent the creation of unsanitary conditions and to ensure that product is not adulterated.” The Regulations in Section 416.4(b) state ” 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 unsanitary conditions and the adulteration of product” The Regulations in Section 416.1 and 416.4(b) have not been met.

Regulation:

416.1 Each official establishment must be operated and maintained in a manner sufficient to prevent the creation of insanitary conditions and to ensure that product is not adulterated.

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

Code: 04B04
Violation: 381.126, 381.129

Citation: On August 19, 2010 at 1445 while checking the production date on the boxes I observed that the product code date is 8462,(which is February 24, 2010) when in fact it should be 8562 (August 19, 2010) that is today’s date. The Julian date is on the package which is 231,but it does not state the year, so the 231 could be seen as last years Julian date 231. The packing date is misleading. Mr. and Mr. were informed immediately. A regulatory control action was initiated to restrict use of the 700 boxes until corrective action could be performed (Tag # B 39133809). The Regulations in Section 381.126 state ” Date of packing and date of processing (a) Either the immediate container or the shipping container of all poultry food products shall be plainly and permanently marked by code or otherwise with the date of packing.” The Regulations in Section 381.129(a) state ” No poultry product subject to the Act shall have any false or misleading labeling.” The Regulations in Section 381.126 and 381.129 have not been met.

Regulation:

381.126 (a) Either the immediate container or the shipping container of all poultry food products shall be plainly and permanently marked by code or otherwise with the date of packing. If calendar dating is used, it must be accompanied by an explanatory statement, as provided in §381.129(c)(2).

381.129 (a) No poultry product subject to the Act shall have any false or misleading labeling or any container that is so made, formed, or filled as to be misleading. However, established trade names and other labeling and containers which are not false or misleading and which are approved by the Administrator in the regulations or in specific cases are permitted.

Code: 03C02
Violation: 417.4(a)(2)(ii)

Citation: On September 8, 2010 at approximately 10:00am I was returning to the inspection station from conducting a fecal check and passed the container that holds the chlorine for the final wash and salvage station, I subsequently tilted the container to measure the contents to find that this container was empty. I immediately informed plant manager, and reminded him that this is a CCP. I took regulatory control action by placing USDA Retain Tag #B39133831 on a full tank of eviscerated duckling and placing Retain Tag #B39133811 on 1/2 tank of eviscerated duckling between both tanks approximately 240 in head in total. Mr. ‘s immediate actions were to fill the chlorine container and determined the level to be between 20-50ppm. He then orally advised corrective actions were to be implemented at the conclusion of the slaughter. The retained ducklings were rehung and passed through the final wash containing 20-50ppm of chlorine. Both tanks were then released as inspected and passed. I then checked all applicable CCP’s, record review and direct observation for the day’s production to verify compliance. Pre-shipment review will be conducted prior to shipping. Regulation 9 CFR 417.4(a)( Every establishment shall validate the HACCP plan’s adequacy in controlling the food safety hazards identified during the hazard analysis, and shall verify that the plan is being effectively implemented. Regulation 9 CFR 417.4(a)(2)(ii) Direct observations of monitoring activities and corrective actions

Regulation:

417.4(a)(2)(ii) (a) Every establishment shall validate the HACCP plan’s adequacy in controlling the food safety hazards identified during the hazard analysis, and shall verify that the plan is being effectively implemented. (2) Ongoing verification activities. Ongoing verification activities include, but are not limited to: (ii) Direct observations of monitoring activities and corrective actions;

Code: 01B02
Violation: 416.13(a)

Citation: On September 13, 2010 at 0640 after the plant had finished pre-operational sanitation inspection and prior to the start of operations I observed the bleeding area. On top of the paper towel dispenser was a pair of green gloves that had numerous blood spots and a brown residue from the previous days slaughter. A regulatory control action was initiated to restrict use of the gloves until corrective action could be performed (Tag # B 39918006). Mr. was informed immediately. He took corrective action as soon as he was informed. The Regulations in Section 416.13(a) state “Each official establishment shall conduct the pre-operational procedures in the Sanitation SOP’s before the start of operations.” The Regulations in Section 416.13(a) have not been met.

Regulation:

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

Code: 06D01
Violation: 416.4(b)

Citation: On September 20, 2010 at 0700 while doing a Facilities inspection I observed the overhead pipes above the lung gun. There is a three foot section of the pipes with an old product residue covering about one fourth of the pipes. Mr. and Mr. were verbally informed immediately. The Regulations in Section 416.4(b) state “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 unsanitary conditions and the adulteration of product.” The Regulations in Section 416.4(b) have not been met.

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: On October 5th, 2010 while conducting pre-operational procedures at 0646 hours the following non-compliance was observed on the neck splitting gun located to the left of the giblet table. This equipment had a residue adhered to it that was greasy to the touch, it was dark grey to black in color. This equipment is a product contact surface, although no product was involved at this time. A USDA reject tag was applied no. B34 488572. , floor manager was immediately notified. His immediate reaction was to disconnect gun and sanitize. In reviewing the pre-operational records this equipment had been deemed acceptable. Upon USDA re-inspection of equipment it appeared to be sanitized, USDA tag was then removed by me and equipment passed and released. 9CFR 416.13(c) states…Procedures in the sanitation SOP’s that are to be conducted prior to operations shall be identified as such, and shall address, at a minimum, the cleaning of food contact surfaces of facilities, equipment, and utensils.

Regulation:

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

Code: 06D01
Violation: 416.2(e)(3)

Citation: On October 19th at 0650 hrs while conducting an unscheduled pre-op (01B02) procedure the following non-compliance was found in the scalding room. There is a leaking valve connected to a pipe located between the right side of the scalding machine and the wall. This water is dripping out of the valve onto the floor where it can possibly lead to an insanitary condition. This is not a product contact surface and no product was in the vicinity at the time of observation. A reject tag has not been placed at this time although the pipe needs to be repaired in a reasonable amount of time or the scalding room will have to be rejected. was notified upon observation. 9CFR 416.2(e)(3) states..Plumbing systems must be installed and maintained to prevent adulteration of product, water supplies, equipment, and utensils and prevent the creation of insanitary conditions throughout the establishment.

Regulation:

416.2(e)(3) Plumbing. Plumbing systems must be installed and maintained to: Prevent adulteration of product, water supplies, equipment, and utensils and prevent the creation of insanitary conditions throughout the establishment;

Code: 06D01
Violation: 416.4(b)

Citation: On December 8, 2010 at 06:38 while conducting pre-operational sanitation procedures the following non-compliances were observed: There is chipping paint on the legs of the grading table, creating an insanitary condition. USDA tag #B39133819 was applied to table until corrective action is taken. In the meantime floor was swept clean of the paint chips . Underneath the pinning table on the crossbar supporting the table there is product residue and dried blood present. plant manager was immediately notified. Corrective action was immediately taken on pinning table were it was sanitized and released (no tag was applied). The above are non-food contact surfaces, at the time (pre-op) there was no product in the area. 9CFR 416.4(b) states…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.

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(a)

Citation: On December 28, 2010 at 0635 after the plant had performed pre-operational sanitation inspection and prior to the start of operations I observed the Wax Reclaim Tank. Inside the tank were about 20 feathers, a brown residue on the inside bottom, and some old wax from the previous days operation. A regulatory control action was initiated to restrict use of the tank until corrective action could be performed (Tag # B 39161261). Mr. and Mr. were verbally informed immediately. The Regulations in Section 416.13(a) state “Each official establishment shall conduct the pre-operational procedures in the Sanitation SOP’s before the start of operations.” The Regulations in Section 416.13(a) have not been met

Regulation:

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

Code: 06D01
Violation: 416.4(b)

Citation: On January 6, 2011 at 0710 while going to the Evisceration Line I passed by the Contamination Clean Up Table. There is a white residue on the back, left and right side. A regulatory control action was initiated to restrict use of the table until corrective action could be performed (Tag # B 39133820). Mr. and Mr. were informed immediately. This table is not being used for product but it is in the processing area and is used to hold the chlorine. The Regulations in Section 416.4(b) state “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.” The Regulations in Section 416.4(b) have not been met.

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: 06D01
Violation: 416.2(b)(1)

Citation: On January 19, 2011 while doing a facilities check I observed several fractures in the floor, the largest are about three inches long and one eight of an inch wide by the hot wax dipping and wax reclaim tank. Mr. was informed immediately. The Regulations in Section 416.2(b)(1) state “Establishment buildings, including their structures, rooms, and compartments must be of sound construction and be kept in good repair to allow for processing, handling, and storage of product in a manner that does not result in product adulteration or the creation of unsanitary conditions.” The Regulations in Section 416.2(b)(1) have not been met.

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: 06D01
Violation: 416.3(a)

Citation: On February 2, 2011 at 1300 while observing the stainless steel tanks used to chill down ducks I observed welds on the inside bottom of 10 tanks that were uneven. The Regulations in Section 416.3(a) state “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.” The Regulations in Section 416.3(a) have not been met.

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.

Code: 01B02
Violation: 416.13(a)

Citation: On February 3, 2011 at about 0630 after the plant had performed pre-operational sanitation and prior to the start of operations I observed 3 discrepancies 1. The second picker had a white and brown residue on the inside top about 2 inches in diameter. 2. The packing table has several brown spots about one fourth in diameter 3. There are white spots on the inside surface of a stainless steel tank in the holding cooler about one fourth inch in diameter. All are food contact surfaces. A regulatory control action was initiated to restrict all surfaces until corrective actions could be performed. The picker B 26859538, the packing table, B39918065 and the stainless steel tank B 23789733. Mr. was informed immediately. The Regulations in Section 416.13(a) state “Each official establishment shall conduct the pre-operational procedures in the Sanitation SOP’s before the start of operations.” The Regulations in Section 416.13(a) have not been met.

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: 416.13(b), 416.13(c), 416.4(d)

Citation: On February 3, 2011 at 1005 I observed the ducks on the Evisceration line outside the USDA office. These ducks which are not inspected yet were swinging over the drip pan and dripping water into a tank of inspected and passed duckling, and also were dripping into a tank of ice that will be used to chill the ducks. Both of the tanks were directly under the drip pan. A regulatory control action was initiated to restrict use of the ducks in the tank and the tank of ice until corrective action could be performed ( Tag # B 19897599 for the tank of ducks and Tag # B 24791530 for the tank of ice). Mr. was informed immediately. The Regulations in Section 416.13(b) and (c) states “Each official establishment shall conduct all other procedures in the Sanitation SOP’s at the frequencies specified. Each official establishment shall monitor daily the implementation of the procedures in the Sanitation SOP’s.” The Regulations in Section 416.4(d) states ” Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.” The Regulations in Section 416.13(b), (c) and 416.4(d) have not been met.

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: 06D01
Violation: 416.2(a), 416.3(a), 416.4(a)

Citation: On February 3, 2011 at 0745 while observing the receiving area I saw a gap in the overhead door on the bottom right side about two inches long and one inch wide. At 0905 while USDA personnel were in the Inspectors office a cockroach was observed crawling on the wall. The Regulations in Section 416.2(a) state “The grounds about an establishment must be maintained to prevent conditions that could lead to unsanitary 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.” The Regulations in Section 416.2(a) have not been met. At 0700 while observing the dry storage area I saw a pair of white boots which are used in the Ice room laying on top of a dusty box . A regulatory control action was initiated to restrict use of the boots until corrective action could be performed (Tag # B 39161268). The Regulations in Section 416.4(a) state “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 unsanitary conditions and the adulteration of product.” The Regulations in Section 416.4(a) have not been met. At 0710 I observed on the packing line after the bag shrinker is a table that has rough and uneven welds. The Regulations in Section 416.3(a) state “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.” Mr. was informed immediately of all the deficiencies.

Regulation:

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.

416.3(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(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: 01B02
Violation: 416.13(a), 416.4(a)

Citation: On February 8, 2011 at 0635 after the plant had finished pre-operational sanitation inspection and prior to the start of operations I observed two knives that were laying on the packing table. There was an old product residue on both of the blades about one inch long and one fourth of an inch wide. A regulatory control action was initiated to restrict use of the knives until corrective action could be performed (Tag # B 19897563). Mr. was informed immediately. The Regulations in Section 416.13(a) state ” Each official establishment shall conduct the pre-operational procedures in the Sanitation SOP’s before the start of operations.” The Regulations in Section 416.4(a) state” 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 unsanitary conditions and the adulteration of product.” The Regulations in Section 416.13(a) and 416.4 (a) have not been met.

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.

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

Citation: On February 16, 2011 at 0635 after the plant had completed pre-operational sanitation inspection and prior to the start of operations I observed the packing conveyor. There was one dime sized and several smaller grey areas which were located in the center of the belt and were adhering to the surface of the packing conveyor belt (product contact surface). A regulatory control action was initiated to restrict use of the packing conveyor belt until corrective action could be performed (Tag # B 39133802). Mr. was informed immediately. The Regulations in Section 416.13(a) state “Each official establishment shall conduct the pre-operational procedures in the Sanitation SOP’s before the start of operations.” The Regulations in Section 416.4(a) state “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 unsanitary conditions and the adulteration of product.” The Regulations in Section 416.13(a) and 416.4(a) have not been met

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.

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

Citation: On February 22, 2011 at 0935 while coming back from the Evisceration Line on break I observed an employee picking duck feet off the floor and putting them into a community bath. A regulatory control action was initiated to restrict use of the product (ten pounds) until corrective action could be performed (Tag # B 36105800). Mr. was informed immediately. The Regulations in Section 416.4(d) state “Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.” The Regulations in Section 416.13(b) state “Each official establishment shall conduct all other procedures in the Sanitation SOP’s at the frequencies specified.” The Regulations in Section 416.4(d) and 416.13(b) have not been met.

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: 01B02
Violation: 416.13(a), 416.4(a)

Citation: On March 16, 2011 at 0630 after the plant had completed pre-operational sanitation inspection and prior to the start of operations, I observed the House Inspector’s table. There was an old meat residue from the previous days production on the inside edge of the table (product contact zone) about one eighth of an inch wide and three inches long. Also there was a piece of a muscle from the previous days production, about an eighth of an inch in diameter laying on the inside surface of the table. A regulatory control action was initiated to restrict use of the House Inspector’s table until corrective action could be performed (Tag # B 39133833). Mr. was informed immediately. The Regulations in Section 416.13(a) state ” Each official establishment shall conduct the pre-operational procedures in the Sanitation SOP’s before the start of operations.” The Regulations in Section 416.4(a) state “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 unsanitary conditions and the adulteration of product.” The Regulations in Section 416.13(a) and 416.4(a) have not been met.

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.

Code: 06D01
Violation: 416.4(b)

Citation: On March 30, 2011, at 0645 while doing a Facilities inspection I observed the overhead heater fan by the spin pickers. There is a dust build up on the inside covering over half of the fan tines. Mr. was informed immediately. The Regulations in Section 416.4(b) state ” 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 unsanitary conditions and the adulteration of product.” The Regulations in Section 416.4(b) have not been met.

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(a), 416.4(a)

Citation: On April 4, 2011, at 0635 after the plant had completed pre-operational sanitation inspection and prior to the start of operations I observed the Grader’s table. There is a brown residue about one half inch in diameter and several pin sized spots on the top surface in the middle of the table (product contact surface). A regulatory control action was initiated to restrict use of the table until corrective action could be performed (Tag # B 39133816). Mr. was informed immediately. The Regulations in Section 416.13(a) state: “Each official establishment shall conduct the pre-operational procedures in the Sanitation SOP’s before the start of operations.” The Regulations in Section 416.4(a) state “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 unsanitary conditions and the adulteration of product.” The Regulations in Section 416.13(a) and 416.4(a) have not been met.

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.

Code: 04C04
Violation: 381.65(b)

Citation: On April 13, 2011 at 08:15 while watching the ducks enter the scalder I observed one duck with its neck arched up and breathing before entering into the scalder. It had been stuck with the knife but it was not dead. A regulatory control action was initiated and corrective action was done at that moment. Mr. was informed. The duck was removed from the bleeding line immediately and re-stuck. The Regulations in Section 381.65 (b) state “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.” The Regulations in Section 381.65 (b) have not been met.

Regulation:

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

Citation: On April 18, 2011 at 1345 while the bagged ducks were being packed into boxes the sizing line backed up and the ducks could not be packed into the boxes fast enough to keep up with the sizing line, so the ducks backed up into the shrinker. An employee then dropped a duck on the floor The employee continued to pack boxes with the product on the floor. A regulatory control action was initiated to stop the bagging of the ducks until corrective action could be performed (Tag # B26855882). They rang the bell twice but with no response, They rang the third time and then Mr. was informed immediately. The Regulations in Section 416.13 (b) state “(b) Each official establishment shall conduct all other procedures in the Sanitation SOP’s at the frequencies specified.” The Regulations in Section 416.4(d) state “Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.” The Regulations in Section 416.13(b) and 416.4(d) have not been met.

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: On May 4, 2011 at 1310 while checking the lot code on the packaged ducks in a box I observed one duck in a box that had black marks covering about one fourth of the bag and a black residue on the inside of the box. An employee had picked up the bag from the floor and put the bag in a box without cleaning it. A regulatory control action was initiated to restrict use of the box and the ducks in the box until corrective action could be performed (Tag # B 19897568). Mr. was informed immediately. The Regulations in Section 416.13 (b) state “Each official establishment shall conduct all other procedures in the Sanitation SOP’s at the frequencies specified.” The Regulations in Section 416.4(d) state “Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.” The Regulations in Section 416.13(b) and 416.4(d) have not been met.

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: 06D01
Violation: 416.4(b)

Citation: On May 23, 2011, at 0645 after the Establishment had completed pre-operational sanitation inspection and prior to the start of operation, I observed packing conveyor belt. There was some build-up of old material on the underside of the conveyor unit where the belt could have made contact during the operation. A regulatory control action is initiated and an U.S. Reject Tag was applied (#39918071) to restrict the use of the packing conveyor until corrective action could be performed. Mr. was informed immediately. The Regulation in Section 416.4 (b) state “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 unsanitary conditions and the adulteration of product.” The Regulation in Section 416.4 (b) has not been met.

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: 06D01
Violation: 416.2(b)(2), 416.4(b)

Citation: On June 8, 2011 at 0700 while observing the Holding cooler I noticed a white residue on the metal back and sides covering about one third of the metal on the walls. No product contamination was observed. Mr. was informed immediately. The Regulations in Section 416.2(b)(2) states ” 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 unsanitary conditions.” The Regulations in Section 416.4(b) states ” 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 unsanitary conditions and the adulteration of product.” The Regulations in Section 416.2(b)(2) and 416.4(b) have not been met.

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.

416.4(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(a), 416.4(a)

Citation: On June 13, 2011 at 0640 after the plant had completed pre-operational sanitation and prior to the start of operations I observed the boots used to walk in the ice bin. They were on a plastic bag and there is a grey and black residue on the heel and bottom of the boots about one inch in diameter, with several smaller specs of grey and black residues. An inspection of the ice bin revealed no contaminated ice. A regulatory control action was initiated to restrict use of the boots until corrective action could be performed (Tag # B 18871542). Mr. was informed immediately. The Regulations in Section 416.13(a) states ” Each official establishment shall conduct the pre-operational procedures in the Sanitation SOP’s before the start of operations.” The Regulations in Section 416.4(a) states “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 unsanitary conditions and the adulteration of product.” The Regulations in Section 416.13(a) and 416.4(a) have not been met.

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.

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

Citation: On June 14, 2011 at 1240 while the employees were packing the packaged ducks in boxes an employee got behind and dropped four packaged ducks on the floor, he then kicked them under the packing bins so that someone else would pick them up and kept working. A regulatory control action was initiated to stop the packing line (Tag # B 39918066) until corrective action could be performed. Mr. was informed immediately. Mr. was called and the situation was explained to him. Your SSOP #16 states ” The Regulations in 416.13(b) states ” Each official establishment shall conduct all other procedures in the Sanitation SOP’s at the frequencies specified.” The Regulations in Section 416.4(d) states “Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.” This is a repetitive noncompliance Past Similar NRs – Previous Ineffective Plant Actions: Employee retrained to insure product flowing properly and not allow any packaged product to stay on the floor for non immediate duration. NR: 15-2011 dated 4/18/2011 The further planned actions were ineffective in or were not implemented in a way that is preventing the noncompliance from reoccurring. Continued failure to meet regulatory requirements can lead to further enforcement actions.

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: 06D01
Violation: 416.2(a)

Citation: On June 14, 2011 at 14:40 while USDA personnel were in the Inspectors office a cockroach was observed crawling on the floor to the right of the window. Mr. was informed immediately. The Regulations in Section 416.2(a) state “The grounds about an establishment must be maintained to prevent conditions that could lead to unsanitary 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.” The Regulations in Section 416.2(a) have not been met. This is a repetitive NR. Previous NR 0007 dated 02/03/2011. Past Similar NRs – Previous Ineffective Plant Actions: Cracks and any spots of harborage were sealed in that office. The office was thoroughly cleaned. Bait stations were place through the office. Crescent will closely monitor the situation for any activity. Pest control program was reviewed and updated on 02/03/2011. The further planned actions were ineffective in or were not implemented in a way that is preventing the noncompliance from re-occurring. Continued failure to meet regulatory requirements can lead to further enforcement actions.

Regulation:

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.

Code: 04B04
Violation: 381.117

Citation: On June 15, 2011 at 1530 I observed employees packing boneless duck breasts and labeling them duck legs. There were 8 boxes that were already packed. A regulatory control action was initiated to retain the boxes until corrective action could be performed (Tag # B 340126). Mr. was informed immediately. The Regulations in Section 381.117 states “The label shall show the name of the product, which, in the case of a poultry product which purports to be or is represented as a product for which a definition and standard of identity or composition is prescribed in subpart P, shall be the name of the food specified in the standard, and in the case of any other poultry product shall be the common or usual name of the food, if any there be, and if there is none, a truthful descriptive designation.” The Regulations in Section 381.117 have not been met.

Regulation:

381.117(a) The label shall show the name of the product, which, in the case of a poultry product which purports to be or is represented as a product for which a definition and standard of identity or composition is prescribed in subpart P, shall be the name of the food specified in the standard, and in the case of any other poultry product shall be the common or usual name of the food, if any there be, and if there is none, a truthful descriptive designation.

Code: 06D01
Violation: 416.4(b)

Citation: On June 20, 2011 at 0650 after the Establishment had completed pre-operational sanitation inspection and prior to the start of operation, I observed weight scale station. The surface of the weight scale where the boxes pass through was not properly cleaned with old and dry-out material on it. Also the table holding the scale has some material/dirt built on it. A regulatory control action is initiated and an U.S. Reject Tag was applied (#B 36105854) to restrict the use of the weight scale until corrective action could be performed. Mr. was informed immediately. The Regulation in Section 416.4(b) state “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 unsanitary conditions and the adulteration of product.” The Regulation in Section 416.4(b) has not been met.

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: 06D01
Violation: 416.2(e)(3)

Citation: On June 22, 2011 at 1330 while conducting an unscheduled 06D01 procedure, I observed water leaking from a pipe under the Grading Station Table while the grading activity was going on, and stapling of boxes by stapling machine was about two feet away. This leakage of pipe, mainly from the duck dripping water collected on the drip pan, has resulted in an insanitary condition. An U.S. Reject Tag (#B18 871534) was applied to restrict the area. Mr. was verbally informed immediately. No products or food contact surfaces were contaminated / adulterated. A temporary corrective action was initiated by the establishment management to prevent further creation of insanitary conditions. Repair of pipe will be scheduled during production down time. 9 CFR 416.2 (e)(3) state ” Plumbing systems must be installed and maintained to prevent adulteration of product, water supplies, equipment, and utensils and prevent the creation of insanitary conditions throughout the establishment.”

Regulation:

416.2(e) Plumbing. Plumbing systems must be installed and maintained to: (3) Prevent adulteration of product, water supplies, equipment, and utensils and prevent the creation of insanitary conditions throughout the establishment;

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

Citation: On June 29, 2011 at 0640 after the establishment’s pre-operational inspection and before the start of operations, I performed procedure 01B02. I observed the following noncompliance: a dead house fly was found on the surface of giblet flume by the giblet harvest table. No product was involved. A regulatory control action was initiated and an U.S. Reject Tag was applied (# B 24887885) to restrict use of the giblet flume until corrective action could be performed. Mr. was informed immediately. The giblet flume was then properly cleaned to restore sanitary conditions. The Regulation in Section 416.13 (a) state “Each official establishment shall conduct the pre-operational procedures in the Sanitation SOP’s before the start of operations.” The Regulation in Section 416.4 (a) state “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 unsanitary conditions and the adulteration of product.” The Regulations in Section 416.13 (a) and 416.4 (a) have not been met.

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.

Code: 06D01
Violation: 416.2(b)(1), 416.2(b)(2)

Citation: At approximately 0640hrs while performing a walk-thru it was observed the following non-compliances in the plant. 1-the freezer door in the receiving area had a trail of rust and rusty discoloration running from the door handle to the bottom of the door. It was a 1″-1 1/2″ wide and 2′-2 1/2′ long stream. 2-on both sides of the cooler door frame the strips of metal connecting to the wall had the appearance of rust and rusty discoloration on them. The left side had traces and spots of rust and rusty discoloration that ran approximately 4′ from the top to the bottom of the frame, sporting a sorted spots; blotches and strips ranging from 1″ to 3″in width and 1″ to 1′ in length. The right side had traces and spots of rust and rusty discoloration that ran approximately 2′ from the top to the bottom of the frame, sporting a sorted spots; blotches and strips ranging from 1″ to 2″in width and 1″ to 2′ in length. Mr. Douglas Corwin (owner) immediately was informed of the non-compliances. No product was adulterated or food contact surface contaminated at the time. These non-compliances are in violation of: 9 CFR 416.2(b) (1) which states :”( b) construction. (1) Establishment buildings, including their structures, rooms, and compartments must be of sound construction, be kept in good repair, in a manner that does not result in product adulteration or the creation of insanitary conditions.” 9 CFR 416(b)(2) which states:”(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.”

Regulation:

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

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: 06D01
Violation: 416.2(b)(3), 416.4(b)

Citation: At approximately 1230 hrs., I observed the following. In the evisceration room four flies are hovering around the equipment, tools and utensils etc. and in the adjacent shipping area. (No exposed product in these areas at this time). In the processing area, two or three flies are evident in the exposed product area. U.S. Reject tag No. B18871538 was applied. In the inedible room several flies were observed. In the second floor dry storage area two or three flies were observed. Mr. Douglas Corwin plant owner/manager, was immediately informed. On the right wall of the evisceration room (from the entrance to the establishment) just past the shipping area, the stainless steel panels along the archway of the freezer window/chute have visible black residuals of unknown origin on their exposed surfaces. Mr. Douglas Corwin / Mr. , plant managers were informed. This is in noncompliance with Title 9 CFR 416.2(b)(3) which requires walls, floors, windows, and other outside openings to be constructed and maintained to prevent the entrance of vermin, such as flies, rats and mice. Title 9 CFR 416.4(b) requires non-food-contact surfaces of facilities, equipment and utensils used in the operation of the establishment to be cleaned and sanitized as frequently as necessary to prevent the creation of insanitary conditions and the adulteration of product.

Regulation:

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: 01B02
Violation: 416.13(a)

Citation: On August 31, 2011 at 0640 hour while conducting a pre-operation inspection, I observed the following. (1) There was an one inch meat/feather residue on the surface of the shaft inside the spin picker (Tag#B39036521); (2) There was a dead fly on top of the grading table (Tag#B39036522); and (3) there was a dead fly on the edge of the roller (where the ducks come out) of the shrinker (Tag#B39036523). U. S. Reject Tags were applied to restrict the use of these equipments until corrective action could be performed. Mr. was informed immediately. No products were involved. Regulations 416.13 (a) state “Each official establishment shall conduct the pre-operational procedures in the Sanitation SOP’s before the start of the operations.” Regulation 416.4 (a) state “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 unsanitary conditions and the adulteration of product.” Regulation 416.13 (a) and 416.4 (a) have not been met.

Regulation:

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

Code: 04B01
Violation: 381.126, 381.129

Citation: On August 31, 2011, at 1400 hour I observed that the lot# on the boxes of the products packed out today was “8787” instead of “8789”. I immediately notified Mr. . A total of 45 boxes were labeled with wrong code date. Products with wrong code date were then isolated in a rack and an U.S. Retained Tag (#B39036518) was applied until corrective action could be performed. Regulation 381.126 state “Date of packing and date of processing (a) Either the immediate container or the shipping container of all poultry food products shall be plainly and permanently marked by code or otherwise with the date of packing.” Regulation 381.129 (a) state “No poultry product subject to the Act shall have any false or misleading labeling.” Regulation 381.126 and 381.129 (a) have not been met.

Regulation:

381.126 (a) Either the immediate container or the shipping container of all poultry food products shall be plainly and permanently marked by code or otherwise with the date of packing. If calendar dating is used, it must be accompanied by an explanatory statement, as provided in §381.129(c)(2).

381.129 (a) No poultry product subject to the Act shall have any false or misleading labeling or any container that is so made, formed, or filled as to be misleading. However, established trade names and other labeling and containers which are not false or misleading and which are approved by the Administrator in the regulations or in specific cases are permitted.

381.129 (c)(2) Immediately adjacent to the calendar date shall be a phrase explaining the meaning of such date in terms of ‘‘packing’’ date, ‘‘sell by’’ date, or ‘‘use before’’ date, with or without a further qualifying phrase, e.g., ‘‘For Maximum Freshness’’ or ‘‘For Best Quality’’, and such phrases shall be approved by the Administrator as prescribed in §381.132. 

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

Citation: On September 1, 2011, at 0645 hour after the plant had finished pre-operational sanitation inspection and prior to the start of operations, I observed bag vacuum nozzles (four of them). All of the four vacuum nozzles have quite a few pieces of meat residue built up inside. Cleaning procedure of the nozzles, outlined in establishment’s SSOP#11 Packing Operation, apparently were not properly followed. An U. S. Reject Tag (#B39036519) was applied to restrict the use of these nozzles until corrective action could be performed. Mr. was immediately notified. No products were involved. 416.13 (c): Each official establishment shall monitor daily the implementation of the procedures in the sanitation sop. 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 unsanitary conditions and the adulteration of product.” Regulation 416.13 (c) and 416.4 (a) have not been met.

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: 06D01
Violation: 381.95(c)

Citation: On September 1, 2011, at 1330 hour while walking around the facility, I noticed that no chemical denaturing agent was applied to the inedible poultry products stored in several red barrels just outside the offal room. Mr. and Mr. were immediately notified. No U.S. Retained Tag was applied as these material was not sold for human consumption by the establishment. No product was involved. Regulation 381.95 state “All condemned carcasses, or condemned parts of carcasses, or other condemned poultry products, except those condemned for biological residues shall be disposed of by one of the following methods, under the supervision of an inspector of the Inspection Service. (a) Steam.—- (b) Incineration or complete destruction by burning. (c) Chemical denaturing, which shall be accomplished by the liberal application to all carcasses and parts thereof, of: ——–.” Regulation 381.95 has not been met.

Regulation:

381.95(c) Chemical denaturing, which shall be accomplished by the liberal application to all carcasses and parts thereof, of:
(1) Crude carbolic acid, (2) Kerosene, fuel oil, or used crankcase oil, or (3) Any phenolic disinfectant conforming to commercial standards CS 70–41 or CS 71–41 which shall be used in at least 2 percent emulsion or solution.

Code: 01D01
Violation: 416.1, 416.2(b)(1), 416.2(b)(2)

Citation: On 12/02/2011 while conducting my tour of the facilities I noticed the following non-compliances in the establishment. 1) At approximately 1230hrs while examining the ladies lounge it was observed that the two outer screens in the windows were filled with dirt and old webs. Along the wall, which runs below the window, approximately 10 feet across and 4 feet high, were covered with black markings that looked like dirt and mold. These are in violation of regulations: 9CFR 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.” Also 9CFR 416.2(b)(2) which states” 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. 2) At approximately 1245hrs while examining the upstairs stockroom it was observed that in the back by the bay receiving area contained empty boxes and garbage. This is in violation of regulation: 9CFR 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.” As well as regulation: 9CFR 416.2(a) which states” (a) 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.” 3) At approximately 1300hrs while examining the receiving area it was noticed that the freezer door had a trail of rust and rusty discoloration running from the door handle to the bottom of the door. It was an approximately 1” wide and 2”-3” long stream. Mr. Douglas Corwin (owner) and Mr. (floor manager) were immediately notified of the non-compliances. No Product was adulterated or food contact surface contaminated at the time. So No tags were applied..

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

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

Code: 01D01
Violation: 416.1, 416.2(h)(1), 416.4(b)

Citation: On 12/28/2011 while conducting my tour of the facilities I noticed the following non-compliances in the establishment.[newline]1) At approximately 1315hrs while examining the receiving area it was noticed that the freezer door had a trail of rust and rusty discoloration running from the door handle to the bottom of the door. It was an approximately 1” wide and 2”-3” long stream. This is in violation of 9CFR 416.4(b) which states” 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.”[newline]2 ) At approximately 1345hrswhile conducting a tour of the ladies lounge’s restroom it was observed that the 1st stall’s door was missing. This made it ususable to the employees and in violation of 9CRF 416.2(h)(1) which states”) 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.”[newline]They are both in violation of 9CFR 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.”Mr. Douglas Corwin (owner) and Mr. (floor manager) were immediately notified of the non-compliances. No Product was adulterer or food contact surface contaminated at the time, so no tags were issued.[newline]

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) 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: 01C02
Violation: 416.13(c), 416.3(a)

Citation: On Monday, January 9, 2012 while on the inspection line at approximately 0800hrs I observed an employee store the steel used to sharpen clippers for hock splitting in the trough that contains insanitary water. I stopped the line informed management of the situation who addressed this with the employee, steel was and clippers were then sanitized. This incident occurred prior to final wash, no ducks were removed from the line since they would be going through final wash which is in place to sanitize the ducks. This is in violation of 9CFR416.3(a) which states in part…ensure that equipment and utensil use will not cause the adulteration of product during processing, handling, or storage. Equipment and utensils must be maintained in a sanitary condition as not to adulterate product. SSOP#13 in your plan addresses hand used utensils. Secondly, I observed a break wash down at approximately 1030hrs begin while the ducks were still on the line. Management is aware that wash down cannot be conducted while product is in the area this may cause product adulteration from splash water. The line was immediately stopped, , plant manager informed. The ducks were not removed from the line since this was conducted prior to ducks entering the final wash. A re-inspection was taken of the ducks prior to entering the chill tank by both management and inspection personnel. SSOP#15 in your plan addresses break time wash down which states .

Regulation:

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.

Code: 01D01
Violation: 416.1, 416.2(d)

Citation: On February 2, 2012 at 0635 while doing a pre-operational sanitation inspection I observed an accumulation of dust covering about one third of the overhead Heater core in the Picking Area. Mr. was informed immediately. The Regulations in Section 416.1 and 416.2(b) have not been met.

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(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.

Code: 01C02
Violation: 416.4(d)

Citation: On February 16, 2012 at 0925 while returning from a company break I observed the ducks on the evisceration line outside the USDA office. These ducks which are not inspected yet were swinging over the drip pan and dripping water into a barrel of inspected and passed duckling whichwas directly under the drip pan. A regulatory control action was initiated to restrict use of the ducks in the barrel until corrective action could be performed (Tag # B 24791605). Mr. was informed immediately. The Regulations in Section 416.4(d) have not been met.

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: 01D01
Violation: 416.2(b)(2)

Citation: At approximately 0640 hours while conducting pre-operational inspection I observed a square piece of rusted metal approximately 4 inches wide by 4 inches long in the right hand corner of the USDA suspect holding pen, creating an insanitary condition, this also has the potential to injure ducks if they were to be placed in this area, there were two rusted bolts located in the left hand corner of the samepen. This pen is located adjacent to the slaughter area. A US Reject tag #B39036555 was placed on the entrance door to the inside holding pen restricting its use until corrective action could be taken. , plant managerwas immediately informed, where he removed the debris and washed down the holding pen and surrounding area. I removed the US Reject tag at that time, andthe ducks were then able to be loaded into the inside holdingpen. 9CFR416.2(b)(2) states…Walls, floors, and ceilings within the establishment 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.

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: 01D01
Violation: 416.2(a)

Citation: On March 19,2012 at approximately 0900 hours while in the USDA office a cockroach was observed to be walking up the doorframe of the USDA bathroom, which is located inside the USDA office. IIC’s immediate action was to attempt to kill this cockroach. , plant manager was informed. There was no product involved at the time of the observation. Establishment SSOP#18 declares . If corrective action need be taken it will be documented on establishments operational SSOP form. 9CFR416.2(a) states the grounds about an establishment must be maintained to prevent conditions that lead to insanitary conditions, adulteration of product, or interfere with inspection by FSIS employees. Establishment must have in place a program to prevent the harborage and breeding of pests on the ground and within the establishment facilities. Pest control substances used must be safe & effective under the conditions of use and not be applied in a manner that will result in the adulteration of product or the creation of insanitary conditions. This is a repetitive NR. NR#0021-2011-13373 dated 6/14/11 stated non-effective corrective action(s). Exterminator to be consulted. Added observations to be continued until felt that problem is under control.

Regulation:

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.

Code: 01D01
Violation: 416.2(b)(2), 416.4(b)

Citation: On May 18, 2012 at approximately 0915 hrs while conducting an SPS verification the following non-compliances were found:  There is a painted metal rail that runs from the cooler doors to the small access door to the freezer with dust and debris adhered to this rail.  Above the small access door to the freezer, along the top of the door frame contains a layer of dust/debris.  U.S. Reject tag #B39036545 was placed on the small access door to the freezer prohibiting access to this area until sanitary conditions are restored.  No product is affected at this time since the product is stored inside the sanitary freezer, but product will not be permitted to move through this area until the area is brought back into compliance.  was immediately notified of the findings.  Establishment SSOP records #11 addressing sanitation of walls in the packing area state .[newline]9CFR416.2(b)(2) states in part…walls, floors, and ceilings must be cleaned and sanitized as necessary to prevent adulteration of product or creation of instanitary conditions.  9CFR416.4(b) states..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 adulteratio of product.

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.

416.4(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: 416.4(b)

Citation: While conducting operational sanitation at 7:35 observed the cutting board in , what is identified as the cutting room -to have blood residue along the bottom of the cutting board 2 inches wide from incomplete cleaning of the prior day`s operation,management notified.No product involved. Your SSOP states that [redacted].

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: 03C02
Violation: 417.5(a)(3)

Citation: While reviewing the records for CCP 1B in the cutting room- recent entries revealed that no times were entered for monitoring, the same person that monitored also did the verification,and times of 6:55 on 7/12and 7/15 follow by 6:40 on 7/22 entered by the person doing verification give the appearance that operations are being conducted outside scheduled hours of operation. Management notified.Reg states that the est.shall maintain records documenting the monitoring of CCP`s and there critical limits,including the actual times,temperatures or other quantifiable values.

Regulation:

417.5(a)(3) Records documenting the monitoring of CCP’s and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment’s HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter production lot. Each of these records shall include the date the record was made.

Code: 03G01
Violation: 417.5(a)(3)

Citation: While performing a records review for the production of Bologna on Monday October 3rd , 2011 the following noncompliance was noted. For CCP 4B water cooker the records show only one temperature was recorded for the days’ production lot. The HACCP plan for [redacted] CCP 4B is as follows: ” [redacted]” There is no indication that the three temperatures will be averaged or that just the highest or lowest will be recorded, so the expectation is that three temperatures will be recorded for that CCP. This represents a failure of 9 CFR 417.5(a)(3). It should be noted that the one temperature that was recorded was within the critical limit.

Regulation:

417.5(a)(3) Records documenting the monitoring of CCP’s and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment’s HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter production lot. Each of these records shall include the date the record was made.

Code: 01C02
Violation: 416.16(a)

Citation: While performing a 01C02 the following noncompliance was found. The operational section of the weekly SSOP record was not filled out for Friday November 18, 2011. The Croghan Meat Market SSOP for Operational Section states ” “This represents a noncompliance with 9 CFR 416.16(a) which states [redacted]” Each official establishment shall maintain daily records sufficient to document the implementation and MONITORING of the Sanitation SOP’s. The establishment employee(s) specified in the Sanitation SOP’s as being responsible for the monitoring of the procedures specified in the Sanitation SOP’s shall authenticate these records with his or her initials and the date.”

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: 04B04
Violation: 442.4

Citation: While performing general labeling verification the following noncompliance was noted. The following scales have do not valid certification of accuracy: The tabletop scale in the spice room, The floor scale in the corner of the kill floor ,The floor scale in the packaging area near the Cryovac machine The Lewis County Department of Weight & Measures certification on the above listed scales expired in April 2011. This is a failure of 9 CFR 442.4(b) which states in part ” The operator of each official establishment shall display on or near each scale a valid certification of the scale’s accuracy from a state or local government’s weight and measures authority.”

Regulation:

442.4(b) The operator of each official establishment shall display on or near each scale a valid certification of the scale’s accuracy from a State or local government’s weights and measures authority or from a State registered or licensed scale repair firm or person, or shall have alternative documented procedures showing that the scale has been tested for accuracy in accordance with the requirements of NIST Handbook 44.

Code: 04C02
Violation: 313.16

Citation: At approximately 8:45am this morning, I witnessed the following non-compliance. While waiting behind a wall while a cow was going to be shot in the knockbox, there were two gunshots approximately 4 or 5 seconds apart. I ([redacted] SPHV) had attempted to move to a window in the door leading to the slaughter room after the first shot. I was doing this to confirm that the first shot had been successful in rendering the cow unconscious. Mr. requested that I remain behind the wall because they were going to administer a second gunshot. The second gunshot occurred during this conversation. I immediately observed the cow after the second gunshot and she was completely unconscious. I later inspected the skull and saw that bothshots had penetrated and were administered in the correct stunning/shooting location. I spoke to Mr. and explained that under Federal regulations, an animal is required to be rendered insensible/unconscious after a single shot, and that IPP including inspectors and veterinarians need to be able to verify that. By not being allowed to witness the cow after the first shot had been administered, I was unable to determine if this regulation had been met. As the second shot took place immediately, and I was able to determine that the cow was unconscious immediately after the second shot, I did not need to take any regulatory control action. I explained to Mr. that in the future we need to be able to verify insensibility with a single gunshot or captive bolt stun.

Regulation:

313.16(a) Utilization of firearms, required effect; handling. (1) The firearms shall be employed in the delivery of a bullet or projectile into the animal in accordance with this section so as to produce immediate unconsciousness in the animal by a single shot before it is shackled, hoisted, thrown, cast, or cut. The animal shall be shot in such a manner that they will be rendered unconscious with a minimum of excitement and discomfort.

Code: 03B02
Violation: 417.2(c)(5), 417.2(c)(7), 417.4(a)

Citation: While performing a review of the E.Coli 0157:H7 sampling on March 9, 2012, the following noncompliances were found. The Raw Non Intact HACCP plan does not indicate any E.Coli 0157:H7 testing is done for inhouse trim, [redacted] informed IPP that all trim goes for cooking but this needs to be specified in the plan. It must either be specified in the HACCP plan that it goes for cooking only or it must be tested for E. Coli 0157:H7 per 10,010.1.The Croghan Meat Market Raw Non Intact HACCP plan specifies on page 7, [redacted]. All the laboratory testing results made available do not show any testing of ground product for E. Coli 0157:H7 during all of 2011. These are a failure of 9 CFR 417.4, validation, verification and reassesment of the HACCP plan. Failure to address E. Coli 0157:H7 could result in adulterated product entering commerce.

Regulation:

417.2(c)(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;

417.2(c)(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.

417.4(a) Every establishment shall validate the HACCP plan’s adequacy in controlling the food safety hazards identified during the hazard analysis, and shall verify that the plan is being effectively implemented.

Code: 03C02
Violation: 417.2(c)(4), 417.2(c)(7)

Citation: While performing a review of The Croghan Meat Market Raw Not Ground HACCP Plan on March 12, 2012, the following noncompliance was found. The Prerequisite E. Coli Testing Program states that “[redacted] .” The supporting documentation for the Hazard Analysis consists of correspondence between EIAO officer and Dr. PhD. The correspondence states the following: Coliform/E.Coli (non-meat and Meat samples) Method has been validated by AOAC ( Official Method 988.19) per our conversation. Based on the protocol provided and the AOAC validated method, the method would be acceptable to FSIS for detection and enumeration of E. Coli and coliforms in sponge samples. E. Coli 0157:H7 for Meat Companies Ensure the company is testing [redacted] for a total of [redacted] Both a positive and negative control should be run concurrently with the sample during analysis.The method would be acceptable to FSIS for detecting E. coli 0157:H7 in ground beef and trim samples. The samples that Croghan Meat Market submits as part of its Prerequisite E. Coli Testing Program consist of sponge samples. This is a noncompliance as the supporting document specifies [redacted] for detection of E. Coli 0157:H7. This is a failure of 9 CFR 417.2.

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;

417.2(c)(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.

Code: 03B02
Violation: 417.2(c)

Citation: While reviewing the Hazard Analysis for the Raw Ground HACCP Plan for the Croghan Meat Market on March 23, 2012, the following noncompliance was found. On page 5 of the Hazard Analysis for the Raw Ground HACCP Plan the Croghan Meat Market states . However the Croghan Meat Market has failed to develop a CCP to address the E. Coli 0157:H7 hazard that is reasonably likely to occur. This represents a failure of 9 CFR 417.2(c) which states in part ” List the critical control points for each of the identified food safety hazards”. A CCP is designed to control a food safety hazard that has been determined to be reasonably likely to occur in its’ hazard analysis. A prerequisite program can not control a food safety hazard that has been identified by the establishment as reasonably likely to occur.

Regulation:

417.2(c)(2) List the critical control points for each of the identified food safety hazards, including, as appropriate: 

Code: 03C02
Violation:  417.2(c)

Citation: While reviewing the Hazard Analysis for the Raw Not Ground HACCP Plan for the Croghan Meat market on March 23, 2012 the following noncompliance was identified. On page 5 of the Hazard Analysis for the Raw Not Ground HACCP Plan , the Croghan Meat Market states [redacted]. However the Croghan Meat Market has failed to develop a CCP to address the E. Coli 0157: H7 hazard that is reasonably likely to occur. This represents a failure of 9 CFR 417.2(c) which states in part ” List the critical control points for each of the identified food safety hazards.” A CCP is designed to control a food safety hazard that has been determined to be reasonably likely to occur in its’ hazard analysis. A prerequisite program can not control a food safety hazard that has been identified by the establishment as reasonably likely to occur.

Regulation:

417.2(c)(2) List the critical control points for each of the identified food safety hazards, including, as appropriate.

Code: 03B02
Violation: 417.5(a)(1)

Citation: The Croghan Meat Market Raw Ground and Raw Not Ground Hazard Analysis states that [redacted]. The Croghan Meat Market prerequisite testing program for E.Coli 0157:H7 states that [redacted]d. Lab testing results from [redacted] the show that the Croghan Meat Market submits a “[redacted] for all E.Coli 0157:H7 samples, never a .  When I asked , manager of the Croghan Meat Market, for supporting documentation for the “sponge sample” as a valid method for detection of E. Coli 0157:H7 she provided me with correspondence between FSIS EIAO [redacted] and FSIS Microbiologist , PhD.  In this document it clearly states that for sampling of E.Coli 0157:H7, the meat companies must submit a 65gm or 375gm size sample.  A “sponge sample” is never mentioned. While reviewing the 2011 lab results for the Croghan Meat Market E.Coli 0157:H7 prerequisite testing program for beef and veal it should be noted that the March 3, 2011 sample is identified as [redacted], not beef or veal.  The June 1, 2011 sample is identified as [redacted], no mention of species or cut.  The August 1, 2011 sample is identified as [redacted], no mention of species or cut.  In 2011 there were three lab samples submitted for [redacted] product, January 3, 2011, July 18, 2011, and November 1, 2011.  When I asked , manager of Croghan Meat Market, if all of the product received from [redacted] went to the production of cooked product she said yes.  If all of the [redacted] product received at Croghan Meat Market went to the production of cooked product it received full lethality at the cooking  step  per Appendix A and should not be tested by the Croghan Meat Market E.Coli 0157:H7 prerequisite program as it   never entered the Raw Ground and Raw Not Ground HACCP processing categories. The lab sampling method that is not AOAC/FSIS approved and the incorrect selection of products to sample are a failure of 9 CFR 417.5(a)(1) which states ” The establishment shall maintain the following records documenting the establishment’s HACCP plan including the written hazard analysis prescribed in 417.2(a) of this part including all supporting documentation.”

Regulation:

417.5(a)(1) The establishment shall maintain the following records documenting the establishment’s HACCP plan: (1) The written hazard analysis prescribed in §417.2(a) of this part, including all supporting documentation

Code: 03C02
Violation: 417.2(b), 417.2(e)

Citation: While  inspecting the Croghan Meat Market retail freezer,  the following noncompliance was identified.   The  Croghan Meat Market retail freezer contains cryovacced packages of Chicken Split Fryers with a production date of 05/07/12 and Chicken Thighs with a production date of 11/25/11. While examining the  Croghan Meat Market Hazard Analysis  and HACCP Plan for Raw, Not Ground, CCP 1B is described  as the temperature of product prior to processing.   A review of the Croghan Meat Market Raw, Not Ground  CCP 1B log for 05/07/2012 and 11/25/2011 shows that a temperature for chicken prior to processing was not taken on either day.  This is a failure of 9 CFR 417.2(b)(1) and 9 CFR 417.2(e).

Regulation:

417.2(b) The HACCP plan. (1) Every establishment shall develop and implement a written HACCP plan covering each product produced by that establishment whenever a hazard analysis reveals one or more food safety hazards that are reasonably likely to occur, based on the hazard analysis conducted in accordance with paragraph (a) of this section, including products in the following processing categories:

417.2(e) Pursuant to 21 U.S.C. 456, 463, 608, and 621, the failure of an establishment to develop and implement a HACCP plan that complies with this section, or to operate in accordance with the requirements of this part, may render the products produced under those conditions adulterated.

Code: 04B04
Violation: 317.4

Citation: On June 13th the Croghan Meat Market freezer contained the following improperly labeled items: 3 one pound packages of frozen Jerked Chicken, 13 one pound packages of frozen Jerked Pork, 17 single steak packages of frozen seasoned steaks, 3 whole rib packages of frozen Ribs.  All of the above listed products were marked with a generic label.  This is a failure of 9 CFR 317.4(a) which requires multi ingredient products to have a sketch approved label.  , Croghan Meat Market manager, was verbally informed of this noncompliance at approximately 12:20 PM during the weekly meeting. I  observed as all of the improperly labeled products were removed from the Croghan Meat Market freezer by at approximately 12:45 PM.

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, accompanied 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: 03J02
Violation:  417.4(a)(2)(i)

Citation: While performing a slaughter HACCP records review task on 3/15/12 at approximately 1000 hours I noticed a noncompliance with the record keeping: there are no records that document the calibration of process monitoring instruments (in line thermometer) on the slaughter floor, this is CCP#1(CCP#1 is also the CCP for [redacted]). I brought this to Mr. attention and he stated that it had been a while since he had calibrated this thermometer and recorded the results and has no records stating the last time this was conducted. On 2/22/12 during the slaughter process I monitored CCP#1 with my new thermometer and the temperature met and was greater the critical limit and coincided with the in line thermometer that is used for CCP#1.While further reviewing the HACCP plan and prerequisite program on 3/16/12 I also noticed that it does not state the frequency in which the calibration of the process monitoring instruments is to be conducted, however Mr. does have records showing that he calibrates his other process monitoring instruments monthly.

Regulation:

417.4(a)(2)(i) Ongoing verification activities. Ongoing verification activities include, but are not limited to: The calibration of process-monitoring instruments;

Code: 01C01
Violation:  416.12(c)

Citation: While preforming a SSOP operational record review task on Tuesday, January 17, 2012 at approximately 1400 I noticed a non-compliance with the pre-operation, operational, and slaughter SSOP record keeping forms. I noticed that the processing pre-operational and processing operational forms did not list the following equipment/utensils that are used in the processing area, [redacted]). After I noticed these not on the processing pre-operational and operational forms I reviewed the slaughter pre-operational and slaughter operational forms and found that the slaughter pre-operational and slaughter operational forms did not list the following equipment/utensils that are used in the slaughter process, [redacted]. I brought this to Mr. attention and he said that they would fix the record keeping non-compliance

Regulation:

416.12(c) Procedures in the Sanitation SOP’s that are to be conducted prior to operations shall be identified as such, and shall address, at a minimum, the cleaning of food contact surfaces of facilities, equipment, and utensils.

Code: 01D01
Violation:  416.2(d)

Citation: While I was conducting a SPS verification in the walk-in cooler on September 27,2011 at approximately at 1110 am I noticed that there was condensation on the carcass hanging rails in the walk-in cooler. There was no product hanging directly under the condensation and no product was adulterated by the condensation. I informed Mr. of my findings and he immediately took corrective action by wiping the rails down to clear off the condensation.

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.

Code: 03B02
Violation:  417.2(a)(1), 417.2(a)(2), 417.5(a)(1)

Citation: ” The introduction of spices into the grinding step was not included in the hazard analysis or flow chart. The above mentioned noncompliance are not in compliance with the requirements of 9 CFR 417.2(a)(1) and 417.2(a)(2). Product Verification Testing The contracted lab is currently conducting the testing for Escherichia coli O157H:7. Based on the findings during the CFSA the establishment did not provide documents with supportable assurances that the current testing method, frequencies, collection site, and aseptic techniques used would be sufficient to detect Escherichia coli O157H:7 if present at low levels. This is not in compliance with 9 CFR 417.5(a)(1). [redacted] All product intended for grinding is [redacted]. However, the trimming of the boxed product was not included in the hazard analysis or flow chart. ” The hazard analysis and flow chart for the Raw Ground Plan did not correspond to the process in the establishment. [redacted], are produced. It cannot be determined if all hazards reasonably likely to occur were addressed because all steps are not incorporated into both the hazard analysis and flow chart. Past Similar NRs – Previous Ineffective Plant Actions: Additional changes still needed NR: 4-2010 dated 12/10/2010

Regulation:

417.2(a)(1) Hazard analysis. Every official establishment shall conduct, or have conducted for it, a hazard analysis to determine the food safety hazards reasonably likely to occur in the production process and identify the preventive measures the establishment can apply to control those hazards. The hazard analysis shall include food safety hazards that can occur before, during, and after entry into the establishment. A food safety hazard that is reasonably likely to occur is one for which a prudent establishment would establish controls because it historically has occurred, or because there is a reasonable possibility that it will occur in the  particular type of product being processed, in the absence of those controls.

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

417.5(a)(1) The written hazard analysis prescribed in §417.2(a) of this part, including all supporting documentation;

Code: 03C02
Violation:  417.2(a)(1)

Citation: The raw not ground plan does not address the trim that is generated from the process. These steps are not included in the hazard analysis or flow chart and so are not in compliance with the requirements of 9 CFR 417.2(a)(1) and 417.2(a)(2). The Raw Not Ground plan does not address the trim that is generated from the process. This product is then used in your Raw Ground (03B) process.

Regulation:

417.2(a)(1) Hazard analysis. Every official establishment shall conduct, or have conducted for it, a hazard analysis to determine the food safety hazards reasonably likely to occur in the production process and identify the preventive measures the establishment can apply to control those hazards. The hazard analysis shall include food safety hazards that can occur before, during, and after entry into the establishment. A food safety hazard that is reasonably likely to occur is one for which a prudent establishment would establish controls because it historically has occurred, or because there is a reasonable possibility that it will occur in the particular type of product being processed, in the absence of those controls.

Code: 03J02
Violation:  310.25(a), 417.2(b)

Citation: The establishment provided the [redacted]; this document describes [redacted]. The supporting documentation provides [redacted]. The establishment uses a critical limit of [redacted]F in their plan. However, review of the records for the past 6 months indicates the temperatures were all recorded below [redacted]F at CCP2. The supporting documentation does not support the decisions the establishment made in their plan regarding the chilling step and is noncompliant with 417.5(a)(1). The single HACCP plan and flow chart for slaughter includes beef/sheep/goats, and swine. It is not clear from the plan which steps are used in the processing of each individual species, and so does not comply with 9 CFR 417.2(b)(2).

Regulation:

310.25(a) Criteria for verifying process control; E. coli testing. (1) Each official establishment that slaughters livestock must test for Escherichia coli Biotype 1 (E.coli) Establishments that slaughter more than one type of livestock or both livestock and poultry, shall test the type of livestock or poultry slaughtered in the greatest number. The establishment shall:

417.2(b)(2) A single HACCP plan may encompass multiple products within a single processing category identified in this paragraph, if the food safety hazards, critical control points, critical limits, and procedures required to be identified and performed in paragraph (c) of this section are essentially the same, provided that any required features of the plan that are unique to a specific product are clearly delineated in the plan and are observed in practice.

Code: 03B02
Violation:  417.2(a)(1)

Citation: On this date at 1330 Dr. and I reviewed and discussed with Mr. the following noncompliance in his 03B HACCP plan: the Hazard Analysis for Raw, Ground (03B) does not address E. coli 0157:H7 in beef received for grinding, there is no supportive documentation that supports your testing frequency for ground product at . FSIS Guidelines recommends quarterly testing for plants that produce less than 1000 lbs of ground beef per day. . This is to notify you both orally and writing with this NR.

Regulation:

417.2(a)(1) Hazard analysis. Every official establishment shall conduct, or have conducted for it, a hazard analysis to determine the food safety hazards reasonably likely to occur in the production process and identify the preventive measures the establishment can apply to control those hazards. The hazard analysis shall include food safety hazards that can occur before, during, and after entry into the establishment. A food safety hazard that is reasonably likely to occur is one for which a prudent establishment would establish controls because it historically has occurred, or because there is a reasonable possibility that it will occur in the particular type of product being processed, in the absence of those controls.

Code: 06D01
Violation: 416.2(b)(3)

Citation: While performing unscheduled PBIS procedure 06D01( Random review of the Establishment facility using the Sanitation Performance Standards) at 08:00, the following SPS Noncompliance was observed. While observing the screen door that is part of the sliding door and behind the solid wood man door on the kill floor, I noticed an 1/2 inch gap at the bottom where the door meets the sill. The wood man door seals tightly when you close it, but the screen door does not. I showed Mr. this and he observed the gap. This has the potential to lead to an insanitary condition. The provisions of 9CFR 416.2(b)(3) of the Meat & Poultry Regulations have not been met. There have been no similar Noncompliance Records observed in the past 3 months. Mr. has been notified verbally and in writing with this Noncompliance Record.

Regulation:

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: 04C02
Violation: 313.1, 313.2

Citation: HATS Category III: Water availability and Feed Availability On 11/09/2011 at approximately 0820 hours while performing a DVMS humane handling assessment I observed that the pigs in two holding pens did not have access to water.   There were water tubs in each pen but the tubs were empty of water.  IIC stated the pigs had water when she performed antemortem inspection approximately 10 minutes earlier.  The pigs in the pens did not appear to be dehydrated and were bright, alert, and responsive.    This fails to meet the regulatory requirements prescribed in 9 CFR 313.2(e) which requires water to be available to livestock at all time.  Plant owner, Jim Mest was verbally notified of the noncompliance and was informed a noncompliance record would be written.  Immediate action was taken by Sanitation Foreman,  to fill the water tubs.  9 CFR 313.1 Livestock pens, driveways and ramps On 11/09/2011 at approximately 0850 hours while performing a DVMS humane handling assessment I observed the following noncompliance.  The bottom of the lower metal panel of front wall in the knockbox had rolled away from the wall.  The bottom edge of this metal panel was protruding into the front of the knock box.  No animals were present in the knock box at the time the noncompliance was found.  This fails to meet the regulatory requirement prescribed in 9 CFR 313.1 which requires pens to be free from protruding sharp metal of any kind.  Plant owner Jim Mest was verbally notified of the noncompliance and and was informed a noncompliance record would be written.  The knockbox was rejected with tag #B28351961.  Sanitation foreman and Plant owner Jim Mest then repaired the protruding metal sheet by affixing a wooden plywood sheet to the front lower wall of the knock box.  Reject tag #B28351961 was then removed at approximately 0920 hours and knock box was released for slaughter.      

Regulation:

313.1 (a) Livestock pens, driveways and ramps shall be maintained in good repair. They shall be free from sharp or protruding objects which may, in the opinion of the inspector, cause injury or pain to the animals. Loose boards, splintered or broken planking, and unnecessary openings where the head, feet, or legs of an animal may be injured shall be repaired.

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.

NOTICE of SUSPENSION HELD in ABEYANCE:

This letter confirms verbal notification to you on April 17, 2013, at 1630 by Dr. Larry Davis, Deputy District Manager (DDM), Philadelphia District Office, of our decision to place the Notice of Suspension (NOS), issued to your firm on April 16, 2013, in abeyance. FSIS is providing you with this Notice of Suspension Held in Abeyance based on your establishment’s proposed corrective actions and preventative measures. FSIS determined that the suspension action will be placed in abeyance and the assignment of inspection will resume, pending FSIS verification of the adequacy of your humane handling program in achieving regulatory compliance. FSIS will be verifying your actions to ensure that your establishment effectively implements the proffered corrective actions and preventative measures. This letter provides you with the chronology of events and conclusions, including your responsibility.

On April 16, 2013, after we were informed of an egregious humane handling incident at your establishment, FSIS issued a Notice of Suspension to withhold the marks of inspection and suspend the assignment of inspectors for your slaughter operation. This action was initiated, in accordance with Title 9 of the Code of Federal Regulation (9 CFR) Part 500.3(b), after FSIS determined that your establishment failed to handle animals humanely, in volation of the Federal Meat Inspection Act (FMIA) [21 U.S.C 603] and 9 CFR 313.2.

In response to the suspension, you submitted corrective actions and preventive measures on April 16, 2013 via e-mail. FSIS requested further clarification to your proposed actions and you then submitted  further corrective actions on April 17, 2013. FSIS carefully reviewed your submissions. Based on your complete submission of proffered corrective actions and preventative measures dated April 17, 2013, we placed the suspension in abeyance and allowed inspection operations to resume. The suspension action will remain in abeyance pending FSIS verification that your proposed corrective and preventice measures were implemented and effective in ensuring future regulatory compliance and preventing inhumane treatment of animals.

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NOTICE of SUSPENSION:

This letter confirms verbal notification by Dr. Larry Davis, Deputy District Manager (DDM), to Mr. [redacted] at 11:45 AM, on April 16, 2013, of the Food Safety and Inspection Service’s (FSIS) decision to suspend the assignment of inspectors for slaughter operations at your establishment #901M, Eklund Processing located in Stamford, NY. FSIS determined that your establishment has failed to handle animals humanely, resulting in the commission of an egregious act. Your establishment is not in compliance with Title 9 of the Code of Federal Regulation (9 CFR) Parts 313.2(a). We are taking this action in accordance the Federal Meat Inspection Act (FMIA) [21 U.S.C 603] and the Rules of Practice in 9 CFR Part 500.3(b).

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NOTICE of REINSTATEMENT of SUSPENSION:

This letter confirims verbal notification by Dr. Larry Davis, Deputy District Manager (DDM), to Mr. [redacted] at 11:15 am, on March 22, 2013, of the Food Safety and Inspection Service’s (FSIS) decision to reinstate the suspension of the assignment of inspectors for slaughter operations at your establishment has failed to handle animals humanely, resulting in the commission of an egregious act. Your establishment is not in compliance with Title 9 of the Code of Federal Regulations (9 CFR) Parts 313.2(f), 313.15(a)(1) and (3), and 313.15(b)(1)(iii) and (iv). We are taking this action in accordance the Federal Meat Inspection Act (FMIA) [21 U.S.C 603 et seq.], and the Rules of Practice in 9 CFR Part 500.3(b).

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NOTICE of SUSPENSION:

This letter confirms Dr. Roger Murphy’s, Deputy District Manager (DDM), verbal notification to Mr. [redacted] at 10:30 AM, on March 12, 2013, of the Food Safety and Inspection Service (FSIS) decision to suspend the assignment of inspectors for slaughter operations at your establishment #17965M, Gold Medal Packing located in Rome, NY. FSIS determined that your establishment has failed to handle animals humanely, resulting in the commission of an egregious act. Your establishment is not in compliance with Title 9 of the Code of Federal Regulation (9 CFR) Parts 313.2 (f), 313.15(a)(1) and (3), and 313.15(b)(1)(iii) abd (iv). We are taking this action in accordance the Federal Meat Inspection Act (FMIA) 21 U.S.C 603, and the Rules of Practice in (9 CFR) Part 500.3(b).

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Code: 01D01
Violation:  416.1

Citation: On June 20, 2012  at 12:15, when Dr. went out to do her dispositions, there was plastic bags with grease on them on the floor, in the retained area. The hand sink where she washes her hands had used paper towels wadded up in the drain.This creates unsanitary conditions which is a non compliance to 9 CFR 416.1.

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: 03C02
Violation:  304.3(c), 310.22(a)(1), 310.22(e)(1), 310.22(g)(2), 417.2(c)(5), 417.2(c)(7), 417.2(c)(7), 417.2(d), 417.2(e)

Citation: On June 20, 2012, I was reviewing Gold Medal”s new processing steps  in HACCP Plan for incoming beef over 30 months of age. The following non compliance is in the receiving step for beef from New York Custom in the newly addressed  V. Hazard Analysis in HACCP Plan  for Raw, Not Ground Products in Tact.In Gold Medal’s HACCP Plan for [redacted]   is in place, but it only addresses beef under the age of 30 months.  The establishment does not define how they are going to lot or test the beef carcasses ( over 30 months of age received from New York Custom Processors) for E. coli 0157:H7. At first, stated that they didn’t need testing because NYC does the testing. said that they would be testing each lot.[newline]Two bins of boneless trimmings were tagged with US Retained tag 39320082 and 3920083. A pallet with 18 boxes containing 2 boxes of Beef Tenderloin, 4 boxes of Beef Knuckles, 7 boxes of Beef Top Round and 5 boxes of Ribeye was retained with US Retained tag # 39320084. and were informed of the situation.

Regulation:

304.3(c) Before producing new product for distribution in commerce, an establishment shall have conducted a hazard analysis and developed a HACCP plan applicable to that product in accordance with § 417.2 of this chapter. During a period not to exceed 90 days after the date the new product is produced for distribution in commerce, the establishment shall validate its HACCP plan, in accordance with § 417.4 of this chapter.

310.22(a)(1) The brain, skull, eyes, trigeminal ganglia, spinal cord, vertebral column (excluding the vertebrae of the tail, the transverse processes of the thoracic and lumbar vertebrae, and the wings of the sacrum), and dorsal root ganglia from cattle 30 months of age and older and

 310.22(e)(1) Establishments that slaughter cattle and establishments that process the carcasses or parts of cattle must develop, implement, and maintain written procedures for the removal, segregation, and disposition of specified risk materials. These procedures must address potential contamination of edible materials with specified risk materials before, during, and after entry into the establishment. Establishments must incorporate their procedures for the removal, segregation, and disposition of specified risk materials into their HACCP plans or Sanitation SOPs or other prerequisite programs.

310.22(g)(2) Ensures that the carcasses or parts are accompanied by documentation that clearly states that the carcasses or parts contain vertebral columns from cattle that were 30 months of age and older at the time of slaughter;

417.2(c)(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

417.2(c)(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.

417.2(d)(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.

417.2(e) Pursuant to 21 U.S.C. 456, 463, 608, and 621, the failure of an establishment to develop and implement a HACCP plan that complies with this section, or to operate in accordance with the requirements of this part, may render the products produced under those conditions adulterated.

Code: 01C02
Violation:  416.4(a)

Citation: On June 5, 2012, while Dr was doing dispositions, she noticed the gauge on the steam for viscera table was not [redacted]  or above. At 12;15 pm the gauge read 75 degrees. nbsp;was notified. The steam boiler was off and employees had to reset it. The line was stopped and locked until the steam gauge read [redacted]. In Gold Medal’s HACCP Plan for Operational Sanitary procedures for slaughtering states ” [redacted].” A reading of 75 degrees is a failure to follow their HACCP Plan. This is a non compliance with 9 CFR 416.4(a).  No Product was adulterated or contaminated.

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.

Code: 03J02
Violation:  309.1

Citation: On May 16, 2012, Gold Medal employee’s  hung 52 bob calves without ante mortem inspection. This is a non copmliance to (CFR 309.1. Normally, On the first ante mortem check, gets up all the animals in Pens 14( A, B, C, D, E –depending-), pen 1 and pen 12. On May 18,2012, was getting up the calves. He asked me to check Pens 14 (A, B, C, D, E). They were the only pens that I checked  at 6:00 am.   read off what the Pen Card said as he handed them to me. While I was watching move the bobs around, I was standing next to in the walkway in the corner by pen 14 A and pen 12 was behind me. I did turn my head to see what was in there, but did not go into the pen to get them up nor did he give me the pen card to pen 12. When I went out to do ante mortem at approximately 7:35-7:40 am, pen Employees asked me to do ante mortem on calves. I asked them who’s calves they were in the pen before the ramp told me it was pen 12. I said that I did not do ante mortem on pen 12. stated that I did , that I should check my cards. I told him that I did not check them and the only pen cards Gave me were 14a, 14b, 14c,14d, and 14e. said he did not have the card when he looked so he thought that they were checked. I asked to see the cards had. The pen 12 card was among the cards that took out of his pocket, which is where they are always kept until employee hands them to me. should have known that He did not go into pen 12 which is in the back corner, away from all the other pens. thought that maybe got them up when he was taking care of the dead and non ambulatory calves. I did not see in pen 12 when I did first ante mortem.  Apparently the card was stuck to another one and did not see it and the assumed that pen 12 was checked. I had stop hanging.  I immediately informed   and of the situation. I stopped the slaughter line and had lock the line. I immediately informed   and of the situation. I went into office and informed Dr of the situation. Dr. informed to inform the higher up plant management. IPP counted the bob calves already slaughtered and we allowed them to go through the slaughter process. We tagged 52 carcasses with US Retained tags B39280116,  B39280201 through B39280232 and tag #s B39280267 through B39280283, B39280285 and B39280286. A lug of tongues was retained with tag# B39280264. A lug of hearts was retained with US Retain tag # B39280262. A lug of gullets was retained with tag # B39280266.  A container of rennaunts was retained with tag # B39280265.  All retained carcasses and parts were condemned and denatured with Dr. and I present on Fri, May 25, 2012.

Regulation:

309.1(a) All livestock offered for slaughter in an official establishment shall be examined and inspected on the day of and before slaughter unless, because of unusual circumstances, prior arrangements acceptable to the Administrator have been made in specific cases by the circuit supervisor for such examination and inspection to be made on a different day before slaughter.

Code: 04B04
Violation:  316.9

Citation: On May 24, while observing incoming shipments at [redacted], I noticed that the formula fed veal just unloaded from Gold Medal had illegible markings.  I observed that there was not one mark of inspection that you could read. The marks were just a blue drippy smear. I knew that the carcasses came from Gold Medal and that they were inspected, but just blue smears on carcasses. Normally, Gold Medal restamps before the carcasses leave the plant. On May 25,  2012, I looked at Gold Medal’s Pre-shipment Review Record.  In the space for the edible product properly labeled, it was checked with a check mark by In the space for product stamped, it was marked ok, by nbsp;I informed of the non compliance of  9 CFR 316.9. No product was adulterated.

Regulation:

316.9(a) Each carcass which has been inspected and passed in an official establishment shall be marked at the time of inspection with the official inspection legend containing the number of the official establishment.

Code: 03J02
Violation:  310.2

Citation: Regulations under 9 CFR 310.2 require maintenance of carcass identitiy throughout post mortem inspection. [newline] 9 CFR 310.2 (a) states” The head, tail, tongue……….shall be handled in such a manner as to identify them with the rest of the carcass and as being derived from the particular animal involved, untiil the post-mortem examination of the carcass and parts thereof has been completed.  Such handling shall include the retention of ear tags, backtags, implants, and other identifying devices affixed to the animal, in such a way to relate them to the carcass until the post-mortem examination has been completed.”  [newline]9 CFR 310.2 (b)(1)(i) states “The official State-Federal Department backtag on any carcass shall: Be removed from the hide of the animal by an establishment employee and placed in a clear plastic bag.  The bag containing the tag shall be affixed to the corresponding carcass. [newline]9 CFR 310.2 (b)(2)(i) states “Brucellosis and tuberculosis ear tags, herd identification ear tags, sales tags, ear bangles, and similar identification devices shall be removed from the animal’s hide or ear by an establishment employee and shall be placed in a clear plastic bag and affixed to the corresponding carcass.[newline]9 CFR 310.2(b)(3) states “In cases where both types of devices described in paragraphs (b)(1) and (2) of this section are present on the same animal, both types may be placed in the same plastic bag or in two separate bags.”[newline] 9 CFR 310.2 (b)(4) states “The circuit supervisor may allow the use of any alternate method proposed by the operator of an official establishment for the handling the type of devices described in paragraph (b)(2) of this section if such alternate method would provide a ready means of identifying a specific carcass with the corresponding devices by a Program inspector  during the post-mortem inspection”[newline]9 CFR 310.2 (b)(5) (i) states “ The official State-Federal Department backtags will be collected by a Program Inspector and used to obtain traceback information necessary for proprer disposition of the animal or carcass and otherwise handled according to instructions issued to inspectors.”[newline]At Gold Medal Packing, Est. 17965 [redacted]. We have requested that all forms of identication on each calf be transferred completely to the computerized tag.  The computerized tag does not contain the retain tag number because it is applied prior to inspection. [redacted]; This brings all the information together to maintain traceability.  This information is particularly important with condemned carcasses because the computerized tag is no longer available to FSIS employees once a carcass is gone.  The “Daily Retain Record” after condemnation is the only source for traceability for these carcasses. For this reason it is very important that the “Daily Retain Record” is accurate. More recently we requested that all forms of animal identification be removed from carcasses retained for pathology or residue testing, and placed in a clear plastic bag and be affixed to the carcass.  This is because merely

Regulation:

310.2(a) The head, tail, tongue, thymus gland, and all viscera of each slaughtered animal, and all blood and other parts of such animal to be used in the preparation of meat food products or medical products, shall be handled in such a manner as to identify them with the rest of the carcass and as being derived from the particular animal involved, until the post-mortem examination of the carcass and parts thereof has been completed. Such handling shall include the retention of ear tags, backtags, implants, and other identifying devices affixed to the animal, in such a way to relate them to the carcass until the post-mortem examination has been completed.

Code: 04B04
Violation:  317.1

Citation: On May 14, 2012, while checking on a retained carcass, I noticed four pallets with boxes of unlabeled  product. I immediately tagged the pallets with the following US Retained tags; B39280289, B39280290, B39280291 and B39281292. I notified of the situation. explained to me that he could not print the labels because he did not have the code for the computer. He stated that he would have to wait for to give him the code or to print the labels. was not present at the establishment at that time. The retain tags were removed at 9:00 am on May 15, 2012, at which time they were properly  labeled.

Regulation:

317.1(a) No official inspection legend or other official mark which has been previously used shall be used again for the identification of any product, except as provided for in paragraph (b) of this section.

Code: 01D01
Violation:  325.11(e)

Citation: On May 11, 2012, I asked  if I could see their permit for Disposal of Inedible and/or Condemned Denatured Material From Federal Establishments in New York State. I looked through the folder that he gave me. The most recent permit that I found was dated July 19, 2010 and expired on July 19,2011. The permit is renewable every year. Gold Medal Needs permission to remove inedible and/or condemned denatured material from their establishment to be in accordance Section 14.12, of the United States Department of Meat  and Poultry Manual.The last date on the copy of [redacted] license number was dated Jan 1, 2012 to December 31, 2010. This number is renewable every year. Gold Medal Needs to ask for a new copy of their new Disposal Plant License.No product is adulterated. was notified that the inedible permit is overdue, as well as copy of [redacted].

Regulation:

325.11(e) Except for inedible rendered animal fats and lungs or lung lobes, inedible products (including condemned products only if condemned for causes specified in § 314.11 of this subchapter) which were prepared at any official establishment, or at any State inspected establishment in any State not listed in § 331.2 of this subchapter, and which have the physical characteristics of a product fit for human food, may be transported from an official establishment or in commerce, without denaturing as required by this subchapter, if the following conditions are met:

Code: 03C02
Violation: 417.4(a)(2)(i), 417.4(a)(2)(iii)

Citation: On May 10, 2012, while looking through records, I noticed that a thermometer calibration was missing on the week of May 15th  through May 21st of 2012. I informed that there was no calibration in the Thermometer Calibration Log for 5/15-5/21.  It was most likely the week that she was at  . The employee filling in her spot wasn’t aware or didn’t know that they had to do it. Gold Medal’s  HACCP plan for Raw Intact  on page 15 under ongoing verification procedures & frequency  it states ” [redacted] “

Regulation:

417.4(a)(2)(i) The calibration of process-monitoring instruments

417.4(a)(2)(iii) The review of records generated and maintained in accordance with § 417.5(a)(3) of this part.

Code: 01C01
Violation:  416.13(c)

Citation: On May 10, 2012 while looking at records for Enterobacteriacae for the month of April. I noticed there was no test results for the week of April the ninth through the thirteenth. There were no results for the week of  April the twenty third through the twenty seventh. In Gold Medal’s HACCP  Plan [redacted]. was informed of the missing dates. Two missed weeks of 6 spot sponge test is a failure in the plants monitoring system. No product was aldulterated.

Regulation:

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

Code: 04C02
Violation:  313.2

Citation: On May 4, 2012, while watching employees at Gold Medal Packing, Est. 17965 unload calves with Dr. , District Veterinary Medical Specialist, Albany District, a  non-compliance was observed.  Calves were being unloaded from a double-deck trailer.  A plant employee was stunning two non-ambulatory disabled calves on the lower deck of the trailer towards the front.  Above and in front of this area, just behind the tractor cab there was a shelf that contained some more calves. This shelf was approximately 5-6 feet above the lower deck.  On the shelf there is a door which keeps the calves contained in the shelf area.  While the plant employee was stunning the two animals, this door became slightly ajar, and a calf slipped out and dropped to the lower deck.  Neither Dr. nor I actually observed the calf falling, however I counted 2 non-ambulatory calves just moments before on the lower deck, and then there were three calves.  In addition, both Dr. and I heard a thud.  The calf that fell did not appear to be injured and jumped to its feet shortly thereafter. When we mentioned this to the plant employee who was doing the unloading, he mentioned that when the door/ramp from the upper shelf is dropped down, their are no side-rails or guard preventing the calves from falling off.  He said calves on a few rare occasions have fallen before, and he has voiced a complaint about this. This incident is a non-compliance of  9 CFR 313.2(a) which states “Driving of livestock from the unloading ramps to the holding pens and from the holding pens to the stunnig area shall be done with a minimum of excitement and discomfort to the animals.” The lack of guards or side-rails on unloading ramps that results in animals falling from significant heights could result in injury in those animals.

Regulation:

313.2(a) Driving of livestock from the unloading ramps to the holding pens and from the holding pens to the stunning area shall be done with a minimum of excitement and discomfort to the animals. Livestock shall not be forced to move faster than a normal walking speed.

Code: 04C02
Violation:  313.1

Citation: While doing ante mortem in the pens on May 4, 2012, I noticed that the drain in Pen 14 C had a hole in it. The maintenance man, immediately placed a medal cover plate on top of the drain.  The plastic cris cross drain has a hole in it, about 2 ” in diamiter. Pen 14 C is the pen that leads directly into the ramp for the bob calves to enter into the conveyor to the stunning area. So every calf would be passing by that drain with the hole in it. There is the possibility that a calf or any other animal  might step into that hole or even just slip and fall. If the animal gets hurt, that would be an egregious act. The medal plate, that the maintenance man put on to cover the hole, could be kicked or slide off. There needs to be something more permanent there that does not slide or move so that there is no chance that an animal could get caught in it or hurt.Dr noticed that in Pen 6 B  and Pen 8, there are drain holes ( about 3″) without no covers at all. Pen 8 is only used for dead carcasses. Pen 6 B the drain hole is right where the gate swings open for Pen 6 C. The lambs that were in Pen 6 C had to walk right past that drain hole. Therefore, there is the possibility that an animal would step right into the hole. If an animal gets hurt that would be an egregious humane handling issue that would lead to a suspension of inspection.  was informed of the situation. Pen employees and Maintenance employee was also notified of the situation.

Regulation:

313.1(a) Livestock pens, driveways and ramps shall be maintained in good repair. They shall be free from sharp or protruding objects which may, in the opinion of the inspector, cause injury or pain to the animals. Loose boards, splintered or broken planking, and unnecessary openings where the head, feet, or legs of an animal may be injured shall be repaired.

Code: 03J02
Violation: 417.5(a)(1)

Citation: On April 27, 2012 at 5:50 am I was watching animals being stunned. I noticed that the bovine on the conveyor had very long legs. It was a larger size than calf and also had a bag with udders. I looked at the dentation and it was definitely over 30 months. I informed  the line Inspector that it was over 30 months. I applied yellow retain tag B 39 280140 to the carcass. I notified kill floor supervisor of the situation. During post mortem inspection, noticed that two more carcasses were over thirty months. He applied yellow retain tags B 39 280176 and  B 39 280613 to the carcasses. Dr. SPHV) checked the dentition on the three carcasses. Carcass with tag B 39 280140 was definitively over three years. The carcass with tag B 39 280613 had two full sets of incisors and one of a third set.  The carcass with the tag B 39 280176 had two full sets of incisors. Gold Medal’s HACCP Plan has [redacted]. They have a prerequisite program to control SRMs. The prerequisite program for SRM states under 2. Scope,  [redacted].” The prerequisite program for SRMs states under 3. Responsibility, ” [redacted] .” Gold Medal Packing  has a HACCP Plan for veal not beef. Gold Medal does not have supporting documentation on the age of the carcasses that were retained.Dr. and I, had a meeting with and . all present.  Dr. spoke with Dr. and discussed the situation.  It was discussed that Gold Medal Packing could apply with the Albany District to change Gold Medal’s Grant of Inspection to include inspection for heifers and steers. It was discussed that Gold Medal Packing would also need to address the Hazard Analysis to assess the risk of E.coli O157H7  in these older animals. The fact that these older animals have probably eaten more grain could increase the chance of E. coli O157H7 shedding in the manure.

Regulation:

417.5(a)(1) The written hazard analysis prescribed in § 417.2(a) of this part, including all supporting documentation

Code: 04B04
Violation:  317.1

Citation: On April 25, 2012, upon entering the offal cooler, I noticed two shelves contained unlabeled meat. There was 7 bags of frozen vacuum packed meat on the top shelf. There was 5 bags of frozen vacuum packed meat on the second shelf. I immediately applied US Retained tags B 39 280120 and B 39 280121, respectively. I immediately went to the plants main office and informed and of the situation.  had immediately label the product in question. No product was adulterated .

Regulation:

317.1(a) When, in an official establishment, any inspected and passed product is placed in any receptacle or covering constituting an immediate container, there shall be affixed to such container a label as described in § 317.2 except that the following do not have to bear such a label.

Code: 01D02
Violation:  310.18

Citation: On April 24, 2012, while doing a cooler check, I noticed 9 hog heads on 2 tree hooks had  hair on them. They were scalded heads saved from the previous days slaughter. The heads had excessive hair on them. I applied tags B39280146 and B39280139. One tag for each tree hook. I informedd of the situation. had employees immediately trim the hogs heads. I reinspected the hog heads and removed the retain tags.

Regulation:

310.18(a) Carcasses, organs, and other parts shall be handled in a sanitary manner to prevent contamination with fecal material, urine, bile, hair, dirt, or foreign matter; however, if contamination occurs, it shall be promptly removed in a manner satisfactory to the inspector.

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

Citation: On April 20, 2012, after Dr. finding of grease and contamination on carcasses in the cooler on a previous day, I checked the railing. Standing on the inspection stand and looking up, I noticed that the blue rail has flaking rust and spots of grease that could fall on carcass, possibly causing contamination. As I was walking off the kill floor, looking up there was a glob of grease about the size of a quarter on the rail ,where it turns before the scale. I informed of the situation and pointed it out to her. She stated that they would take care of it over the weekend. Dr did a cooler check on thursday April 19th and said that the carcasses looked good.

Regulation:

416.1 Each official establishment must be operated and maintained in a manner sufficient to prevent the creation of insanitary conditions and to ensure that product is not adulterated.

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

Code: 01D02
Violation:  310.18

Citation: On 4/17/12 at approx. 12:44 am while on the slaughter floor I observed 4 formula fed veal with areas of fecal contamination ranging in size from 1 1/2″ by 2″  to 2 1/2″ by 5″ on the rump area. I informed and of this sanitary dressing failure. The next day at approx. 7:30 am while in the cooler Dr. observed fecal and/or hair on bob calf carcasses slaughtered 4/17/12. He observed this on 11 legs, two pelvic areas and 2 briskets on 15 carcasses. He informed of these dressing failures and tagged the rails containing the carcasses from 4/17/12 with retained tags #B39280135 and B39280137. The formula fed calves were trimmed on the line and the bob calf carcasses were reprocessed by and released by Dr. . Sanitary dressing failures could result in carcasses with harmful bacteria entering commerce.

Regulation:

310.18(a) Carcasses, organs, and other parts shall be handled in a sanitary manner to prevent contamination with fecal material, urine, bile, hair, dirt, or foreign matter; however, if contamination occurs, it shall be promptly removed in a manner satisfactory to the inspector.

Code: 01D02
Violation: 310.18

Citation: On April 6, 2012, Dr. noticed that  8 veal heads( from the previous days kill in the Cooler off of the kill floor )had hide and hair on them. US Retained tag # B 36 736594 was applied to the tree hook. was notified of the noncompliance. The heads were trimmed and rechecked. After trimming the retain tag was removed.

Regulation:

310.18(a) Carcasses, organs, and other parts shall be handled in a sanitary manner to prevent contamination with fecal material, urine, bile, hair, dirt, or foreign matter; however, if contamination occurs, it shall be promptly removed in a manner satisfactory to the inspector.

Code: 04C02
Violation:  313.1

Citation: While observing 6 Market Hogs being stunned with Dr. at approximately 10:15am at Gold Medal Packing Est. 17965 found the following non-compliance.  Four hogs being moved into the stun box slipped on their hind legs just before stunning and one hog slipped on all fours moving into the stun box. The reason for this is that the floor of the stun box is hard plastic which is not conducive to being slip resistant. The 6 hogs being moved into the box did not appear to be under stress and no vocalization was heard.

Regulation:

313.1(b) Floors of livestock pens, ramps, and driveways shall be constructed and maintained so as to provide good footing for livestock. Slip resistant or waffled floor surfaces, cleated ramps and the use of sand, as appropriate, during winter months are examples of acceptable conctruction and maintenance.

Code: 01C01
Violation: 416.16(a)

Citation: On this day, March 29, 2012  at approximately 9:45 am , I went to check the Maintenance Post-Operational Equipment Checklist for the primary air gun, secondary air gun, and the hand held captive bolt gun. The maintenance checklist was for the guns was done on 3/27/2012  and on 3/28/2012. I observed take the primary air gun and the hand held gun apart and put them back together and fire them on 3/27/2012 but I did not watch him record the results.The checks were made but there was no initials or signature on either day. On the verification  plan it states [redacted]. No initials is a violation of  CFR 416.16 . was notified of the situation.

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: 01D01
Violation:  416.1, 416.3(c)

Citation: While touring the facilities on 03/29/2012 at approximately 1:00 pm found the following Non-Compliance in the Inedible room. Two gray Gondola’s with hides in them had the words ” Export Division” on two of the four sides,  but no where on the sides did the Gondolas have any words to identify these receptacles as Inedible to identify their permitted use. The two Gondolas were tagged with the following US Rejected tags #B36736587 and #B36736591 respectively. Also a blue barrel half full of hides with the words hooks on it, also didn’t have any words to identify its intended use. This barrel was tagged with US Reject tag #B39280175. was informed of the Non-Compliance.

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(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: 04B04
Violation: 317.1

Citation: On this day 3/19/2012 at 6:15 am, I noticed a pallet with ten boxes on it with no labels at all. I immediately applied retain tag #B39 280182 to the pallet. was notified of the noncompliance and he immediately labeled the boxes. They were pork primals packaged on Friday on 3/16/2012.Containers with no labels is noncompliance with CFR 317.1. No product was adulterated.

Regulation:

317.1(a)(1) Wrappings of dressed carcasses and primal parts in an unprocessed state, bearing the official inspection legend, if such wrappings are intended solely to protect the product against soiling or excessive drying during transportation or storage, and the wrappings bear no information except company brand names, trade marks, or code numbers which do not include any information required by § 317.2;

Code: 03J02
Violation:  417.5(a)(2)

Citation: While reviewing the HACCP Plan for Slaughter (Lamb, Goat, and Veal) at Gold Medal Packing, Inc. Est 17965 found the following Non-Compliance. The Plant has at their [redacted] step and at the step at as the [redacted] upper critical limit. [redacted] This is the upper limit USDA FSIS has set as the limit for suitability. A Memorandum Of Interview JRF4508032908G was written by Dr. VMD SVMO dated 03/08/2012 advising Est. 17965 that their written Slaughter HACCP Plan had [redacted] and needed to change it to [redacted]. As of this NR the in [redacted] the HACCP Plan has not been changed.

Regulation:

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

Code: 01B02
Violation:  416.13(c)

Citation: While performing Pre-Operational inspection at Gold Medal Packing Inc. at approximately 5:45am found the following Non-Compliance. The band saw in the boning room used to cut bob veal bones was found with meat and fat residue up in the blade guard where the blade goes through and underneath the guard. (HACCP Coordinator) was informed of the non-compliance. The blade guard was cleaned immediately and I reinpected it, then released for production. The following Non-compliance is the failure to follow part 416.13 (c) of the regulations.

Regulation:

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

Code: 01B02
Violation: 416.13(c)

Citation: While performing pre-operational inspection at Gold Medal Packing,Est. 17965, found the following non-compliances at approximately 6:55 am. The Offal Room was found with both food contact and non-food contact non-compliances. All the trays that hold product had dried meat and fat residue adhered to all areas of the trays. The frames of all the food product trays had dried meat and blood adhered to them. The walls of the offal room had small specs of blood adhered to them. The drip pans underneath the cooling units had black mold adhered to them. HACCP Coordinator, was informed of the non-compliances in the Offal room and the entrance doors were tagged with the following tags, US Rejected NoB39766626 and NoB39766627.The Offal room was reinspected at approximately 9:20am and released. The Wash Cabinet was found with hair and meat particles on the rail above where the carcasses come through and are washed. The area in question was approximately 6 feet long above the rail. Also the metal hinge at the entrance of the wash cabinet had meat particles adhered to it. HACCP Coordinator, was informed of the non-compliance and the wash cabinet was tagged with US Reject tag NoB39766649. At approximately 7:25am the wash cabinet was reinspected and released.

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)

Citation: At 1145 I observed the temperature dial on the moving viscera table indicated that water being applied to clean theunit was approximately 120 degrees Fahrenheit. The facility was operating as normal during this period, with livers, hearts, tongues and other viscera which were later destined for food being placed onto the table. This is in violation of 9CFR 416.4(a) and the establishment’s own operating SSOP which states on page 4 of 8 “[redacted] .” I rejected the line with US Reject Tag # B20517880 and informed Kill Floor Manager of this non-compliance orally.Mr. was shown this non-compliance visually. FI then informed me that the inspector’s station knife dip was not hot or steaming, suggesting that there may be a systemic problem with the steam/boiler system. Mr. repaired the steam supply and proposed waiting until the temperature rose above [redacted] Fahrenheit on the dial leading to the viscera table. After a several minute wait to ensure a stable temperature over [redacted] Fahrenheit the regulatory control action was relinquished and production allowed to resume as normal. A similar Non-compliance record was issued on 2/23/2012 under NR#JRF3308023023N. The establishment’s further planned action of “We will watch the table more closely for the next week” was not implemented or ineffective at preventing further reoccurrence. As always you have the absolute right to appeal.

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.

Code: 01C02
Violation:  416.4(a)

Citation: On Feb 21, 2011 at 6:37 and again at 7:15 I stopped the line because the pans on the evisceration table were coming up with blood residue spots some as wide as 3 inches. I notified HACCP )and (kill floor manager) of the situation. No product was affected or adulterated. and adjusted the steam and water valves so that the evisceration pans were coming up clean.

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.

Code: 03J02
Violation:  417.5(a)(1)

Citation: On 02/14/2012 a bob veal was retained for pathology with US Retain #61663091. The animal was condemned by SPHV Dr. for septicemia. A KIS test was performed on the calf and the KIS test was positive on 02/15/2012. The calf number was E568 from [redacted]. The true buyer/seller of this calf is from [redacted]. had a previous violation back in 12/07/2011 and should have been held for testing by the plant according to Gold Medals (Est. 17965) Residue Prerequisite Program on 02/14/2012. I reviewed the Plants affidavits and [redacted] had an updated affidavit signed on 01/10/2012 signifying that he would not ship any calves with drugs. Also the Plant had as a T1 violator on their Violator Log. This represents that the animal can be received into the Plant but should have been held and tested by the Plant. The following Non-Compliance is a failure to follow 417.5 (a) (1).

Regulation:

417.5(a)(1) The written hazard analysis prescribed in §417.2(a) of this part, including all supporting documentation;

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

Citation: On Feb 13, 2011 at approximately 12:15 while on the inspection stand waiting for the formula fed veal to come around, I noticed something on the beam above the station where they split carcasses and spray with proxyaceticacid there was something up there. I asked one of the employees and kill floor manager what was up there. They said it look like a scrap of veal meat. They got a steel rod that they use to put hooks on rail and knocked it down. It fell to the floor. It was a wing off of a bird it was plain to see that it had feathers on it. I immediately showed it to Dr. and Dr. Somehow it got into the building and was on the overhead rail where carcasses pass through all day long. This is a non compliance to CFR 416.2(b)(3). The floors, walls and ceilings must be constructed to prevent the entrance of vermin into the building. was notified of this non compliance. No Product was affected or adulterated at this time.[newline][newline][newline][newline]Update; on Feb 15, 2011 at approximatelyI noticed that up in the venilation fan you can see part of a bird, looks like the other wing flapping as the fan blows on it. I pointed this out to _ and _. _ said he would tell the maintance man about it so he could check it out.

Regulation:

416.2(a) 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.

Code: 03J02
Violation:  417.7

Citation: At 1330 I conducted a Slaughter HACCP procedure with SVMO [redacted] I reviewed the Gold Medal Slaughter HACCP Plan and its pre-requsite programs.We read supporting Slaughter HACCP plan, the “[redacted]” was reassessed this month and changes made to sections 5.2a. Sections 5.1.b3 & 5.2b3 had been deleted. The author listed for the program was “[redacted].” Mr. signature was the only one on the signature page. A review of the training logs in the HACCP binderrevealed HACCP course diplomas for Ms. and other members of management. No information for Mr. HACCP training was listed. A meeting with myself, Mr. and SVMO [redacted] was held. Mr. was shown the training section of the binder. CSI [redacted] asked Mr. in the presence of SVMO [redacted] whether or not he had ever been certified in the 7 HACCP Principles. Mr. stated “No.” This is non-compliance with 9CFR 417.7. Mr. was informed of this non-compliance orally and in writing with this report. He was advised that he had the right to appeal and that any appeal could be handled through SVMO [redacted] since my time as a relief CSI ends today. As always you have the right to appeal.

Regulation:

417.7(b) The individual performing the functions listed in paragraph (a) of this section shall have successfully completed a course of instruction in the application of the seven HACCP principles to meat or poultry product processing, including a segment on the development of a HACCP plan for a specific product and on record review.

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

Citation: At 0720 I conducted a routine Operational Sanitation Procedure. I entered the hot carcass cooler and noticed two storage bins labeled edible. These were being used to hold spreaders andother metal implements. The bins were stained on the interior with debris of a variety of colorsand at least one shaving composed of an unknown solidforeign material approximately half an inch in length was seen at the bottom ofthe top bin. It appeared as if these bins had not been cleaned in some time. As these bins were labeled edible they should not have been used for equipment storage, and their presence in the carcass cooler/storage/processing area raised the possibility of an employee later using them for product transport or storage which would adulterate product. This is non-compliance with 9CFR 416.1, 416.4(d) and416.4(a).US Reject tags B20518275 and B21138592 were applied to the bins. Ms. HACCP Coordinator, was shown this non-compliance visually and then informed of it orally and in writing with this report. Ms. proposed corrective action of immediately removing them from product handling areas, having the equipment stored in a sanitary manner and having the bins cleaned before being returned to use.As always you have the right to appeal.

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: 01D01
Violation:  325.11(e)

Citation: On Feb 3, 2011 at 8:10 am ,I preceded to the shipping area to look at shipping records. In the shipping room I noticed Three pallets of boxes that had no labels on them. The inspection number was crossed out on the bullet on the boxes. The boxes were boxes normally used for veal carcass or veal fore quarter, but it wasn’t checked off which one. I applied U.S.Retain tags B39 766644, B39 76645, and B39 76647 to the pallets. I informed and of the situation. informed me that they were all hides. made a sign that said HIDES and put one on each pallet. There was nothing on any of the boxes that stated INEDIBLE. The U.S. Inspected and passed by the Dept of Agriculture part of the bullet was not blacked out or crossed out which would lead you to believe that what was in the boxes was inspected and passed. According to CFR 325.11(3) when transported from an official establishment or in commerce under this paragraph (e) the outside container of such inedible products shall be conspicuously marked words “Inedible –Not intended for Human Food” in letters not less than 2 inches high.

Regulation:

325.11(e) Except for inedible rendered animal fats and lungs or lung lobes, inedible products (including condemned products only if condemned for causes specified in §314.11 of this subchapter) which were prepared at any official establishment, or at any State inspected establishment in any State not listed in §331.2 of this subchapter, and which have the physical characteristics of a product fit for human food, may be transported from an official establishment or in commerce, without denaturing as required by this subchapter, if the following conditions are met:

Code: 03J02
Violation:  417.5(a)(1)

Citation: On 02/03/2012 during slaughter at Gold Medal Packing (Est. 17965) a bovine (cattle) was presented for post-mortem inspection in the afternoon. I Inspector performed my post-mortem inspection and discovered by observing the teeth (dentition) that the animal had two sets of adult teeth that would indicate that the animal is over thirty months of age. To verify my findings Dr. the SPHV here at Gold Medal Packing looked at the same head and confirmed the age. Gold Medal’s HACCP Plan [redacted]. The prerequisite plan states [redacted]. The bovine passed inspection but because the animal was received into the Plant for slaughter the Plant failed to follow the prerequisite program that Gold Medal Packing (Est. 17965) wrote. The animal was US Retained with tag number B39766657 and [redacted] (HACCP Coordinator) was informed of the Non-Compliance.

Regulation:

417.5(a)(1) The written hazard analysis prescribed in §417.2(a) of this part, including all supporting documentation;

Code: 01B02
Violation:  416.13(c)

Citation: While performing Pre-Operational Inspection in the coolers at Est. 17965 Gold Medal Packing found the following Non-Compliance at approximately 5:45am. The green swinging cooler doors coming into the boning room had fat residue adhered to the side that Bob Calves would be pushed through. The doors involved the area in question was approximately 2 ft by 2 ft. Both white swinging doors coming out of the chill cooler had blood, grease and black residue on the sides where the product, Calves, would be pushed through. (HACCP Coordinator) was informed of the doors and that the areas in question would be tagged with US Rejected tag #39766652.

Regulation:

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

Code: 04B01
Violation:  317.8

Citation: On Jan 27,2011 while completing a product standard task at approximately 1:35 pm, I noticed an opened box that was labeled veal diamonds. Inside the box was three vacuumed packed packages. One package was labeled part D which was approximately 20 lbs. One package was labeled part tongues which was approximately 7 lbs. And the last package was labeled loin which was approximately 4 lbs. [newline]I applied retain tag number B 39 766673 to the box. [newline]I notified the plant manager immediately.[newline]No product was adulterer. The product was just improperly labeled.

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: 03J02
Violation:  417.2(c)(4)

Citation: While observing the wash cabinet where the carcasses are washed and sprayed, observed the carcasses not being sprayed with [redacted] from the knee to the top of the hock at approximately 6:50 am.[newline][newline]The line was stopped and tagged with US Retained B38439581 and [redacted] (HACCP Coordinator) informed. The nozzles were replaced immediately and after the nozzles were replaced the carcassess were being sprayed properly and the line released. [newline]Before the line was stopped 10 carcasses had already passed the spraying area without proper application and was informed of the carcasses. She immediately re-sprayed the carcasses with [redacted].[newline]The Plant failed to monitor the application of their [redacted] according to CCP 3B of the Slaughter HACCP Plan.

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;

Code: 01B02
Violation:  416.13(c)

Citation: While performing Pre-Operational Inspection at Gold Medal Packing Est. 17965 at approximately 5:35am found the following Non-Compliance.[newline] [newline]The wash cabinet where product is washed and then sprayed with acid, the ceiling and surrounding area was found with the following. [newline]1. The ceiling had multiple specs of fat/meat particles adhered to it just above where the product is washed. [newline]2. The beam above the chain where the product is washed had dirt and hair adhered to it below where the product is washed.[newline] 3. The rail where the hooks travel with product where dirty along where the product is washed. [newline][newline]The wash cabinet was US Rejected with NO.B38439574 and (HACCP Coordinator) informed of the Non-Compliance.

Regulation:

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

Code: 03J02
Violation:  309.16, 417.2(c)(5), 417.2(c)(6), 417.3(a)(3), 417.5(a)(1)

Citation: On Nov 8, 2011, Gold Medal slaughtered a bob veal calf brought by [redacted] The establishment tagged it as 1445 [redacted] The sample was sent to [redacted] on Dec 1, 2011 because an in plant residue test was positive. On Dec 14, 2011 the Lab confirmed that the sample was [redacted] Inspection personal asked plant for owner information again and the plants response was that[redacted] stated that the number 1445 is not their bill. So the true producer is unknown. Gold Medals HACCP Plan Residue Control Prerequisite Program on page 6 under 5.1b1. states [redacted]. The establishment does not have the supporting documentation to support their HACCP plan. Unidentified livestock can not be matched to a known violator on the Violator List if it is unidentified. Unidentified livestock is banned from slaughter until a producer is identified. Establishment has a failure in record keeping and failure to take corrective actions.

Regulation:

309.16(a) Except as provided by paragraph (d) of this section, livestock suspected of having been treated with or exposed to any substance that may impart a biological residue which would make the edible tissues unfit for human food or otherwise adulterated shall be handled in compliance with the provisions of this paragraph. They shall be identified at official establishments as ‘‘U.S. Condemned.’’ These livestock may be held under the custody of a Program employee, or other official designated by the Administrator, until metabolic processes have reduced the residue sufficiently to make the tissues fit for human food and otherwise not adulterated. When the required time has elapsed, the livestock, if returned for slaughter, must be re-examined on ante-mortem inspection. To aid in determining the amount of residue present in the tissues, officials of the Program may permit the slaughter of any such livestock for the purpose of collecting tissues for analysis for the residue. Such analysis may include the use of inplant screening procedures designed to detect the presence of antimicrobial residues in any species of livestock.

417.2(c)(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;

417.2(c)(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.

417.3(a)(3) Measures to prevent recurrence are established;

417.5(a)(1) The written hazard analysis prescribed in §417.2(a) of this part, including all supporting documentation;

Code: 01C02
Violation:  416.13(c)

Citation: On this day from approximately 9:30 through 10:00 AM whioe performing dispositions, I noticed that the temperature gauge for the viscera table read between 140 through 150 degrees F. The SSOP states ” .” This could be a potential food safety hazard, because the the pans which contain heads and tongues appear not be sanitized adequately. 9 CFR 416.13 (c) states: c) Each official establishment shall monitor daily the implementation of the procedures in the Sanitation SOP’s HACCP Coordinator was notified.

Regulation:

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

Code: 06D01
Violation:  416.3(b)

Citation: While doing animal dispositions in the morning at approximately 10:00 am, Dr noticed that the round gear wheel on the end of the evisceration table was exposed and is rusty. No tags were applied because it is not a food contact area. Equipment should be maintained to keep it in good working condition( lack of greased gear makes it rusty and squeaky). was notified.

Regulation:

416.3(b) Equipment and utensils must not be constructed, located, or operated in a manner that prevents FSIS inspection program employees from inspecting the equipment or utensils to determine whether they are in sanitary condition.

Code: 03J01
Violation:  417.2(c)(4), 417.4(a)(2)(ii)

Citation: On 10/24/2011 at 2:30pm while inspecting hog carcasses at postmortem inspection area I noticed fecal material in the crotch area on several carcasses. I mentioned this to Kill floor manager, I noticed they were bunging the hogs on the bed before they were burnt, scrubbed and washed. He said they couldn’t bung them on the rail because of the hooks they were using made it difficult. At 3:45 pm I placed retained tags B 38 43905 and B 38 439606 on the first and last scalded hogs and retained all the scalded hogs because of fecal matter in the crotch. was notified of the situation.

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;

417.4(a)(2)(ii) Direct observations of monitoring activities and corrective actions;

Code: 01C02
Violation:  416.14

Citation: On this day, while I was I was in cooler 3 sorting through carcasses held for residue testing, I noticed 4 carcasses with grease on the hind legs. The carcasses were identified as 612 (tagged by HACCP), 318 (tagged by HACCP), 23KV6365, and 994, and were retained with retain tags B39766485, B39766484, B39766488, and B39766481, respectively.Carcass 318 also had hair that had not been removed. 9 CFR 416.4(d) states “Product must be protected from adulteration during processing, handling, storage, loading and unloading at and during transportation from official establishments.” These carcasses were adulterated. , HACCP coordinator, and were contacted.

Regulation:

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: 06D01
Violation:  416.1, 416.2(d)

Citation: On this day 8/1/11 at 12:30pm, while in the hide cooler, I noticed that the compressor in the middle by the paper towel dispenser was dripping like it was raining. The drops were hitting the shelf and spattering all over on boxes and plastic bags. I also noticed that there was ice on three units and they were all compensating and dripping. There was no product involved but the condensation and dripping and splattering all over the place creates an unsanitary condition. This is a violation of 9 CFR 416.1 and 416.2(d). Past Similar NRs – Previous Ineffective Plant Actions: failure to maintain sanitary conditions NR: 32-2011 dated 6/30/2011

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(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.

Code: 03J01
Violation:  417.3(a)(3)

Citation: On this day , while reviewing records, Dr. noticed that on Fabrication HACCP Records that on the last three Fridays temperatures were exceeding the critical limits. On 6/17/11 Primals [redacted], veal trim [redacted] and veal bones [redacted]. A corrective action was made but not a preventive measure, which is a violation of 9 CFR 417.3(a)(3). On 6/24/11 temperatures were on veal bones [redacted], sub primal [redacted] and trim [redacted]. A corrective action and a preventive measure were both stated for that day. Again on 7/1/11 the temperatures exceeded critical limits again (veal trim [redacted] and veal bones [redacted]) with no corrective and no preventive measure which is a violation of 9CFR 417.3(a)(3). Plants actions have failed from preventing a reoccurrence.

Regulation:

417.3(a)(3) Measures to prevent recurrence are established;

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

Citation: On this day at 6:10 am, while checking the coolers for condensation I noticed that the well saw located in cooler #3 had dried on meat particles from the previous days operations. I applied retain tag # B 39 182205 to the well saw. was notified. Plant failed to monitor the cleaning of equipment used for processing which is a violation of 9 CFR 416.4(a) Past Similar NRs – Previous Ineffective Plant Actions: failure to prevent sanitary conditions and sanitary equipment NR: 19-2011 dated 4/4/2011; NR: 2-2011 dated 1/21/2011

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.

416.3(b) Equipment and utensils must not be constructed, located, or operated in a manner that prevents FSIS inspection program employees from inspecting the equipment or utensils to determine whether they are in sanitary condition.

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: 04B01
Violation:  317.8

Citation: On Monday, June 27, 2011, 15 ovine were slaughtered at Gold Medal Packing that were labeled as “lambs” on the pen card. The load of “lambs” was accompanied by a letter from the farm of origin stating that they were 12 months of age or younger. The line inspector, questioned this and held 7 heads for veterinary inspection. I examined these heads at a later time and determined that they were derived from older sheep. These heads were also held for examination by an APHIS technician for scrapies sampling. We collectively determined by examining the dentition that these 7 heads came from sheep 4-5+ years of age. The associated sheep were custom-killed by Gold Medal for another meat packing establishment. The sale of these sheep was between the farm of origin and the other meat-packing plant. Gold Packing was essentially the go-between. Gold Medal shipped these sheep out to the other establishment , and the Bill of Lading that accompanied the shipment (#001342) had 15 “lambs” listed as part of the shipment. This is mislabeling or misrepresentation of the product being shipped. Furthermore, the plant kill sheets listed these animals as lambs. This is a record-keeping violation according to 9 CFR 320.1(b)(i). was contacted.

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: 06D01
Violation:  416.1, 416.2(d)

Citation: On this day at 1;30 pm, while in the hide cooler Dr. noticed that the compressor was dripping water and it is going all over the place creating an unsanitary condition. There is no product involved but the dripping condensation is a violation to 9 CFR 416.1 and 416.2(d). Plant management is responsible for maintaining sanitary conditions. Past Similar NRs – Previous Ineffective Plant Actions: plants failure to maintain sanitary conditions NR: 4-2011 dated 1/21/2011

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(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.

Code: 03C01
Violation:  417.2(c)(4)

Citation: 03C01-monitoring The Boneless Veal Disposition record for the May 27, 2011 was filled out even though there was no E. coli O157:H7 test results for the sample since the lab discarded it. The establishment failed to perform their monitoring procedures which states, “[redacted] ” This is a violation of 9 CFR 417.2(c)(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;

Code: 03C01
Violation:  417.4(a)(2)(ii)

Citation: 03C01-verification The Antimicrobial Intervention Records from May 31 to June 24, 2011 were reviewed. The records show that [redacted] was done at a minimum of [redacted] except for the week of June 6-10, 2011. The records show that direct observation of the [redacted] application was performed at least once week as described in the Raw, Not ground HACCP plans except for the week of June 20 to June 24, 2011. These are violations of 9 CFR 417.4(a)(2)(ii).

Regulation:

417.4(a)(2)(ii) Direct observations of monitoring activities and corrective actions;

Code: 03C01
Violation:  417.2(c)(4)

Citation: 03C01 (monitoring and preshipment review?) o The Boneless Veal Disposition Records from April 25 to May 27, 2011were reviewed. The records show that [redacted] except for May 20, 2011. For the May 20th production lot, the establishment failed to perform their monitoring procedures which states, ” [redacted].” This is a violation of 9 CFR 417.2(c)(4). o I reviewed the Boneless Veal Disposition Record from April 25 to May 24, 2011. The preshipment review was not signed for the May 4th or May 20th production date. The product was shipped; this is a violation of 9 CFR 417.5(c).

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;

Code: 03C01
Violation:  417.3(a)(3)

Citation: 03C01 (corrective action) On April 27, 2011, the establishment took corrective actions when the critical limit () for the veal subprimal cuts, veal primal cuts, boneless trim and veal bones exceeded at the afternoon monitoring (approximately 12 pm). The corrective actions included, “During afternoon monitoring, temperatures were all above the critical limit. All product were put into cooler until temperatures were within critical limits. All product temperature was brought under critical limit. [Preventive measures] Temperatures are monitored with calibrated thermometers and data loggers. Product was immediately put into freezer and preshipment was not signed until it was brought under control. The corrective actions do not give adequate preventive measures. The statement, “Temperatures are monitored with calibrated thermometers and data loggers.” does not explain how it will prevent the product temperature from increasing above the critical limit. This is a violation of 9 CFR 417.3(a)(3).

Regulation:

417.3(a)(3) Measures to prevent recurrence are established;

Code: 03J01
Violation:  417.2(c)(6)

Citation: 03J01- recordkeeping A review of the documents for the Residue Control Program showed that the establishment failed to completely implement and document their program. The following deficiencies were noted. The establishment did not identify all calves from suppliers with previous violations. o On May 6, 2011, one calf from [redacted] (tag #11) was not identified on the Disposition Log and was not tested. Also one calf from [redacted] (tag #13) was not identified on Disposition Log and was not tested. o On May 10, 2011, a calf ( tag #179) from [redacted] was not identified. o On May 13, 2011, a calf from [redacted] (tag #227) was identified on disposition log and FS IS tested but not recorded on violator test log. o On May 13, 2011, on the disposition log, a calf from [redacted] (tag #332) was identified as a calf from [redacted], tested by FSIS but not recorded on violator test log. o On May 20, 2011, [redacted], a calf (tag #X761) from [redacted] was not identified. ” The Violator Test Log does not have documentation for the test performed on calves from on 5/27/2011. This log is used to track the testing status of a violator.

Regulation:

417.2(c)(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.

Code: 03J01
Violation:  417.4(a)(2)(ii)

Citation: The Antimicrobial Intervention Logs from April 25 to May 27, 2011 were reviewed. The direct observation of the titration monitoring procedure was performed weekly as described in the Slaughter HACCP plan except for the following weeks: May 2-6 and May 23-27, 2011. This is a violation of 9 CFR 417.4(a)(2)(ii)

Regulation:

417.4(a)(2)(ii) Direct observations of monitoring activities and corrective actions;

Code: 03C02
Violation:  417.4(a)(2)(ii)

Citation: On this day as part of an 03C02, I reviewed the records for the HACCP plan for Raw Not Ground (Intact) . CCP 1B is the “[redacted]”. For the monitoring procedure for this CCP “[redacted] .” For the verification procedure “[redacted] . 9 CFR 417.4(a)(2)(i)(ii)(iii) states “Ongoing verification activites include but are not limited to: The calibration of process-monitoring instruments;direct observation of monitoring activities and corrective actions; and the review of records generated and maintained in accordance with 417.5(a)(3).” The “direct observation of monitoring activities and activities” means that one person does the monitoring procedures and one person does the verification procedure, especially in a larger plant such as Gold Medal Packing where there are plenty of employees. On May 16 a review of records showed that verified and monitored the application of [redacted] to intact veal. This a verification non-compliance.

Regulation:

417.4(a)(2)(ii) Direct observations of monitoring activities and corrective actions;

Code: 03J01
Violation:  417.5(a)(1)

Citation: On this day I reviewed producer information from April 11 through April 22, 2010, that gets faxed from the calf buyers prior to slaughter. The plant reviews this information for producers that have had previous violations and makes dispositions according to the prerequisite program for residues. The residue program in place at the time stated ” [redacted].” The program also states “[redacted] “” On April 12, two calves (#F843, #F846) were obtained from [redacted] through the [redacted] Sale. [redacted] had not signed an affidavit, and this producer had two violations on 7/27/2010 (580769) and on 2/22/2011 (574882). These animals were slaughtered and not plant-condemned. This was NOT IN COMPLIANCE with the residue program.. On April 15, a calf (#27) was purchased through the [redacted] sale from [redacted]. This owner had two violations on 6/18/2010 (579146) and 6/22/2010 (579161). [redacted] had not signed an affidavit. There is no evidence or documentation that suggests that this calf was plant-condemned. This was NOT IN COMPLIANCE with the residue program. On April 20, two calves (#N572, N571) were purchased from [redacted] through the [redacted] sale. This owner had a previous violation on 10/20/2010 (580185) and had not signed an affidavit. There was no evidence that these calves were plant-condemned. This was NOT IN COMPLIANCE with the residue program in place. On April 22, one calf (T795) was purchased from [redacted] through the [redacted] sale. [redacted] is a repeat violator that had violations on 2/4/2010 (514487) and 11/12/2009 (512028). This producer had signed an affidavit. The calf should have been separated out for FSIS testing. The calf was slaughtered without prior testing. This was NOT IN COMPLIANCE with the current residue program. On April 22, one calf (#245) was purchased from [redacted] through the [redacted] sale. [redacted] is the owner of [redacted]. [redacted] residue history (2 violations) is noted above. [redacted] had not signed an affidavit. This animal was slaughtered and not plant-condemned. This was NOT IN COMPLIANCE with the residue program. On April 22, brought in one calf (#607) owned by [redacted]. [redacted] has had two violations on 1/26/2010 (514469) and 3/10/2010 (515954). [redacted] had signed an affidavit. This animal was slaughtered without prior testing. This was NOT IN COMPLIANCE with the residue program. On April 22, brought in a calf (P419) owned by [redacted]. This owner had two previous violations on 8/20/2010 (580047, 580048) and had signed an affidavit. This animal was slaughtered without prior testing. This was NOT IN COMPLIANCE with the residue program. I relayed this monitoring non-compliance to [redacted] Human Resource Director, who is now in charge of the residue program.

Regulation:

417.5(a)(1) The written hazard analysis prescribed in §417.2(a) of this part, including all supporting documentation;

Code: 03C02
Violation:  417.4(a)(2)(ii)

Citation: During the review of records for CCP 1B, Antimicrobial treatment for the raw, not ground intact and furthered processed HACCP plans, the following noncompliance’s were noted. The Antimicrobial Intervention Record from March 14 to April 2011 were reviewed. The records show that then direct observations of the titration was done at a minimum of at least once a week except for the following weeks: March 28-April 1 and11-15. The records show that direct observation of the application was performed at least once a week as described in the Raw, Not Ground HACCP plans except for the following weeks: March 21-25, March 28-April 1, April 4-8,and April 11-15. These are violations of 9 CFR 417.4(a)(2)(ii).

Regulation:

417.4(a)(2)(ii) Direct observations of monitoring activities and corrective actions;

Code: 03C02
Violation:  417.3(a)(1)

Citation: On 11 April 2011 Fabrication HACCP Record, the temperature of the veal sub primal cut at 12:00 pm was F. This temperature exceeds the critical limit of F. The establishment signed the preshipment review and did not take corrective actions. This is a violation of 9CFR417.3(a)(1)

Regulation:

417.3(a)(1) The cause of the deviation is identified and eliminated;

Code: 04B04
Violation:  312.2, 317.1

Citation: On this day, April 20, 2011 at @:2:20 pm, while walking through the coolers, I noticed a gray lug in cooler #3 with approximately 40 lbs of unidentified meat with no label or identification on it. I immediately tagged it with tag # B 30 436430 because the lug was not labeled edible also Dr. found four other grey lugs with no edible label on them, these were retained.. I then notified of the situation. This is a food safety issue because the product has no identification, not the species, or the cut, and not a lot number. Past Similar NRs – Previous Ineffective Plant Actions: failure to put proper labels on products NR: 17-2011 dated 3/16/2011; NR: 16-2011 dated 3/15/2011; NR: 1-2011 dated 1/7/2011; NR: 64-2010 dated 12/29/2010

Regulation:

312.2(a) The official inspection legend required by part 316 of this subchapter to be applied to inspected and passed carcasses and parts of carcasses of cattle, sheep, swine and goats, meat food products in animal casings, and other products as approved by the Administrator, shall be in the appropriate form as hereinafter specified:

317.1(a) When, in an official establishment, any inspected and passed product is placed in any receptacle or covering constituting an immediate container, there shall be affixed to such container a label as described in §317.2 except that the following do not have to bear such a label.

USDA Inspection Report: 8 Apr 2011

Code: 03J01
Violation:  417.5(a)(1)

Citation: On this day I reviewed a copy of the Gold Medal Packing’s Residue Notification Log.[redacted] . These lists are reviewed in the morning prior to the commencement of slaughter operations. While reviewing the list I counted 12 entries missing. There were also an additional 7 that need to be added, but information for these was provided during the past week. The 13 missing owners are: [redacted]. This is a recordkeeping violation since the plant failed to keep their Residue Notification Log up-to-date. HACCP Coordinator and Human Resources Director were notified of this violation. (b)(6)

Regulation:

417.5(a)(1) The written hazard analysis prescribed in §417.2(a) of this part, including all supporting documentation;

Code: 03J01
Violation:  417.5(a)(2)

Citation: On this day 4/7/2011, while looking over the receiving sheets for calves brought in for slaughter from 3/29/2011-4/6/07, I noticed that calves were listed from buyers that have not completed the acknowledgment letter(GMP Residue Policy Notification for Buyers). In Gold Medal’s Residue Control Prerequisite Program on page 2 section 5.1–Prevention and Residue Findings in the second paragraph it states “[redacted].” On 3/29/11 calves were slaughtered from [redacted], [redacted], and [redacted] On 3/30/11 calves were slaughtered from [redacted] On 4/1/11 calves were slaughtered from [redacted] and [redacted] (who is not on the list). On 4/5/11 calves from [redacted] were slaughtered. On 4/6/11 calves from [redacted] and [redacted] were slaughtered. As Of this date 4/7/11, on Gold Medal’s Livestock Buyers Log [redacted], [redacted], [redacted], [redacted], and [redacted] have not returned an affidavit. was notified of noncompliance. Past Similar NRs – Previous Ineffective Plant Actions: record keeping NR: 18-2011 dated 3/25/2011; NR: 15-2011 dated 3/11/2011; NR: 12-2011 dated 3/9/2011; NR: 9-2011 dated 2/21/2011; NR: 7-2011 dated 2/1/2011; NR: 5-2011 dated 2/1/2011; NR: 63-2010 dated 12/29/2010; NR: 62-2010 dated 12/28/2010; NR: 58-2010 dated 12/7/2010; NR: 57-2010 dated 12/7/2010

Regulation:

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

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

Citation: On this day @ 8;30am, I noticed an employee coming out of the cooler carrying a dirty greasy [redacted] reciprocating saw, which he had just used to cut 20 pork carcasses into primal cuts and had boxed them all. IIC immediately applied the following retain tags to the four pallets; B 30 436506, B 30 436514, B 30 436515 and B 30 436520. I notified of the situation of using a dirty greasy [redacted] from the maintenance department to cut pork into primal cuts, potentially contaminating the primal cuts. IIC supervised as all the boxes were opened and all the pork primals were trimmed and brought back to an acceptable condition and repackaged. Using a dirty greasy [redacted] creates an insanitary condition and the potential to contaminate the product which is a violation of 9CFR 416.4(a),(b), and (c). Past Similar NRs – Previous Ineffective Plant Actions: failure to prevent sanitary conditions and sanitary equipment NR: 2-2011 dated 1/21/2011; NR: 65-2010 dated 12/30/2010; NR: 62-2010 dated 12/28/2010; NR: 52-2010 dated 11/9/2010; NR: 50-2010 dated 11/5/2010

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

Code: 03J01
Violation:  417.5(a)(1)

Citation: As part of Gold Medal Packing’s prerequisite program for residues, faxed lists from calf buyers are reviewed prior to slaughter to identify calves from single violators and repeat violators.Calves from violators re either tested or condemned according to the written program, The program states:”[redacted] ” Furthermore it states: ” [redacted].”On this day, upon reviewing the faxed buyers lists from 2/28/2011 through 3/11/11to see if calves from single and repeat residue violators were pulled out appropriately the following non-compliances were found: On March 1, 2011, 2 calves from [redacted], tag # 315 and 314, from [redacted] was not dentified and pulled. [redacted] is a single violator that had a violation on 9/10/2010 (580075). They have submitted an affidavit and were suppposed to be tested. On March 2, 2011, 1 calf from [redacted], tag # 217 from [redacted] (9/15/10) was not identified and pulled. [redacted] had a violation on 9/15/2010 (580088). On March 8, 2011, 1 calf from [redacted], tag #1448 from whio had a previous violation on 11/10/2010 (574681) was not identified and pulled. On March 8, 2011, 1 calf from [redacted] Sale, tag #V226, who had a previous violation on 10/29/10 (574652) was not identified and pulled. On March 9, 2011, 1 calf from [redacted] tag # 365 from [redacted] was not identified and pulled. On March 10, 2011, 1 calf from [redacted], tag # 7392 from [redacted] was not identified and pulled. This owner had a single violation on 11/4/2010 (574670). On March 11, 2011, 1 calf from [redacted] with tag #221from who had a previous violation on 12/10/10 (574759) was not identified and pulled. This a monitoring non-compliance and failure to follow the prerequisite program for residues. HACCP coordinator, was notified

Regulation:

417.5(a)(1) The written hazard analysis prescribed in §417.2(a) of this part, including all supporting documentation;

Code: 03J01
Violation:  417.5(a)(2)

Citation: On this day, while looking over the receiving sheet for calves brought in for slaughter, noticed that calves were listed from Buyers that have not completed the acknowledgment letter(GMP Residue Policy Notification for Buyers). In Gold Medal’s Residue Control Perquisite Program on page 2 in section 5.1-Prevention and Residue Findings in the second paragraph it states ” [redacted] ” On this day calves were received from buyers [redacted]. On Gold Medal’s Livestock Buyer Log , and have not returned an affidavit and and are not on the buyers log. and were notified of the noncompliance. Past Similar NRs – Previous Ineffective Plant Actions: recordkeeping failure NR: 15-2011 dated 3/11/2011; NR: 12-2011 dated 3/9/2011; NR: 9-2011 dated 2/21/2011; NR: 7-2011 dated 2/1/2011; NR: 5-2011 dated 2/1/2011; NR: 63-2010 dated 12/29/2010; NR: 62-2010 dated 12/28/2010; NR: 58-2010 dated 12/7/2010; NR: 57-2010 dated 12/7/2010; NR: 51-2010 dated 11/4/2010

Regulation:

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

Code: 04B04
Violation:  316.9

Citation: On March 16, at 7;00 am, while making sure the unidentified product from previous day was all properly labeled, I noticed that the bob calves that were retained with blue retained tags for kis test were stamped with the mark of inspection. I notified and cut off all the marks of inspection. US Inspected and Passed marks of inspection can not be applied to US Retained Product until the product has been released to the plant and the retained tag removed by inspection personal. This was not a food safety issue as the product is still under USDA control.

Regulation:

316.9(b) Except as provided otherwise in §316.8, each primal part of a carcass and each liver, beef tongue, and beef heart which has been inspected and passed shall be marked with the official inspection legend containing the number of the official establishment before it leaves the establishment in which it is first inspected and passed, and each such inspected and passed product shall be marked with the official inspection legend containing the number of the official establishment where it was last prepared. Additional official marks of inspection may be applied to products as desired to meet local conditions. Primal parts are the wholesale cuts of carcasses as customarily distributed to retailers. The round, flank, loin, rib, plate, brisket, chuck, and shank are primal parts of beef carcasses. Veal, mutton, and goat primal parts are the leg; flank, loin, rack, breast, and shoulder. The ham, belly, loin, shoulder, and jowl are pork primal parts. Equine primal parts are the round, flank, loin, rib, plate, brisket, chuck, and shank.

Code: 04B04
Violation:  317.1, 317.2(b), 317.2(c)

Citation: On March 15, 2011 at 1:30 pm, while doing a walk through the coolers, I noticed that there was 4 pallets containing a total of 66 boxes of unidentified product. I immediately tagged the four pallets with the following tags; B 30 436536, B 30 436537, B 30 436538 and B 30 436539. I notified that there was 4 pallets of unidentified product. They contained primal cuts of pork which were processed on the previous day. was also notified and the proper labels were applied. CFR 317.1(a) states that “When , in an official establishment, any inspected and passed product is placed in any receptacle or covering constituting an immediate container, there shall be affixed to such container a label described in CFR 317.2. Past Similar NRs – Previous Ineffective Plant Actions: plant employees are failing to label product before it goes in the cooler NR: 1-2011 dated 1/7/2011; NR: 64-2010 dated 12/29/2010; NR: 45-2010 dated 9/29/2010

Regulation:

317.1(a) When, in an official establishment, any inspected and passed product is placed in any receptacle or covering constituting an immediate container, there shall be affixed to such container a label as described in §317.2 except that the following do not have to bear such a label.

317.2(b) Any word, statement, or other information required by this part to appear on the label must be prominently placed thereon with such conspicuousness (as compared with other words, statements, designs, or devices, in the labeling) and in such terms as to render it likely to be read and understood by the ordinary individual under customary conditions of purchase and use. In order to meet this requirement, such information must appear on the principal display panel except as otherwise permitted in this part. Except as provided in §317.7, all words, statements, and other information required by or under authority of the Act to appear on the label or labeling shall apppear thereon in the English language: Provided, however, That in the case of products distributed solely in Puerto Rico, Spanish may be substituted for English for all printed matter except the USDA inspection legend.

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:

Code: 03J01
Violation:  417.5(a)(1)

Citation: The prerequisite program for residues at Gold Medal Packing, Est. 17965 requires that [redacted]. . When we receive violative results from the FSIS Lab, we supply the plant with those results and an attached copy of owner information (if the plant has previously provided us with owner information). I reviewed the plant’s “USDA Testing” notebook to look for copies of Residue Violation Notices sent to single violators.Typically the Notices are attached to the copy of owner information and LEARN results. Upon reviewing the notebook, the following owners did not appear to have received letters: [redacted] In some cases the owner paper and violative results were present in the notebook, but there was no attached Residue Notification Letter. In other cases there was no documentation for the samples whatsoever. If by chance we did not provide the plant with a copy of LEARN results, which is not very likely, the plant received notification of these violatives through MOIs, and plant meetings. Furthermore, I have given the plant a copy of my residue Excel spreadsheet several times which contains producers, date of violations, actual drug residue.. By one process or another the plant has been informed of these violations. During my review of the records, I noticed that there were also some repeat violators that did not receive a Residue Violation Notice for each violation but had received at least one Residue Violation Notice and a Repeat Violator Letter at some point. I spoke to about the missing owner papers to make sure I exhausted all possible records to find the letters. I gave a copy of the LEARN results with attrached owner information for each of these producers. I also gave her an MOI with a summary of these violators. Past Similar NRs – Previous Ineffective Plant Actions: Recordkeeping failure NR: 12-2011 dated 3/9/2011; NR: 9-2011 dated 2/21/2011; NR: 5-2011 dated 2/1/2011; NR: 63-2010 dated 12/29/2010; NR: 57-2010 dated 12/7/2010; NR: 51-2010 dated 11/4/2010

Regulation:

417.5(a)(1) The written hazard analysis prescribed in §417.2(a) of this part, including all supporting documentation;

Code: 04B04
Violation:  316.6

Citation: On March 11 2011, at 7:00am, Dr. tagged the hog carcasses in the cooler # 4, with retained tag numbers B 30 436550 and B 30 436554. She noticed that all the federal legends stamps were illegible and that you couldn’t read an establishment number on any of them. They were stamped but not legible. CFR 316.6 states ” that products are not to be removed from an official establishment unless marked in accordance with the regulation. was informed and carcasses were restamped.

Regulation:

316.6 No person shall remove or cause to be removed from an official establishment any products which the regulations in this subchapter require to be marked in any way unless they are clearly and legibly marked in compliance with such regulations.

Code: 01C02
Violation:  416.16(a)

Citation: On March 10, 2011 while reviewing shipping records I noticed that there was no records of the hog carcasses that were shipped out on March 9, 2011. I notified and that there was no records of the hogs being shipped to [redacted]. This is a violation of 320.1 which requires records to be kept. Also noted on the shipping records there is no identification of the product shipped. It states the temperature of product but does state what the product was, such as veal or pork or lamb which also is a violation of product identification. said that he would inform who records the information on shipping.

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: 03J01
Violation:  417.5(a)(1)

Citation: On this day I composed an NR as part of an 03J01 because we have 33 lab submission forms for residue testing for which the plant has not provided owner information. When we have KIS positive samples and need to submit tissue to the FSIS Midwestern laboratory, we provide the plant with all the necessary information, i.e. slaughter date, retain tag #, sale tag #, and sale of origin so that we can acquire owner name and address pertaining to those samples. In addition, I periodically write a Memorandum of Interview (MOI) with a summary of all the missing owner information. I wrote an MOI that included most of these samples in January 2011. Despite these efforts we still do not have owner information. The date these samples were taken range from November 12, 2010 through December 28, 2010. They were all bob veal samples. The sample numbers are 574690, 574695, 574696, 574709, 574711,574719, 574724, 574725, 574726, 574740, 574774, 574775, 574777, 574779, 574780, 574782, 574783, 574784, 574795, 574797, 574799, 574800, 574802,574803, 574804, 574805, 574806, 574809, 574811, 574816, 574819, 574820, 574821. We have already received results from the laboratory for these samples. Plant employees did not give us owner information because they did not have the information. This is in violation of 9 CFR 320.1(b)(iv),which states a required record is ” (iv) The name and address of the buyer of livestock or article sold by such person, and the name and address of the seller of livestock or articles purchased by such person;” Furthermore, the prerequisite program for residues at Gold Medal Packing requires that [redacted]. Without owner information, plant employees cannot effectively implement the prerequisite program. When FSIS employees have owner information, this provides an additional way to determine if the plant has been purchasing calves from previous violators and making the appropriate plant dispositions. Past Similar NRs – Previous Ineffective Plant Actions: Failure to provide owner information NR: 9-2011 dated 2/21/2011; NR: 5-2011 dated 2/1/2011; NR: 63-2010 dated 12/29/2010; NR: 57-2010 dated 12/7/2010; NR: 51-2010 dated 11/4/2010

Regulation:

417.5(a)(1) The written hazard analysis prescribed in §417.2(a) of this part, including all supporting documentation;

Code: 06D01
Violation:  416.1, 416.4(d)

Citation: On March 7, 2011 at 2:30 pm while performing inspection on the line, while slaughtering lambs, I noticed on the last few lambs, the person who trims the necks wasn’t trimming the weasand out that was left inside the cavity. I asked who was going to trim the necks and he said he would take care of it. I pointed out and showed and that the weasand was still inside and that the opening in the body cavity at the neck needs to be opened up. When the slaughter was done I went into the cooler off of the kill floor and checked the lamb carcasses. Some of the carcasses still had the weasand inside. Some of the cavities were filled with water and fatty tissue (from washing them), because with the brisket not being split and the neck opening plugged it has no where to go. I immediately tagged the four rails of lamb carcasses with retained tags B 30 436573, B 30 436583, B 30 436582 and B39 766385. I informed of the situation. This is a failure in sanitation operarational dressing procedures.

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

Code: 03J01
Violation:  417.5(a)(1)

Citation: On 2/25 while reviewing the residue prerequisite program records I saw failed to provide the owners of the calves they delivered on 2/23/2011,2/24/2011 and 2/25/2011 and the plant slaughtered the animals anyway. The plants prerequisite program states that [redacted]. had no signed an affidavit as of 2/25. The plant has not followed it prerequisite program as required by 417.5(a)(1). I informed of this none compliance. Failure to address residue by following the residue prerequisite program will result in residue entering commerce. Past Similar NRs – Previous Ineffective Plant Actions: failure to follow prerequisite program NR: 9-2011 dated 2/21/2011; NR: 5-2011 dated 2/1/2011

Regulation:

417.5(a)(1) The written hazard analysis prescribed in §417.2(a) of this part, including all supporting documentation;

Code: 04B01
Violation:  318.1(a), 318.1(i)

Citation: In the morning while checking the cooler for condensation inspector found three boxes of ground beef and 3 boxes of beef cuts from [redacted] processors in the cooler. Talking with and reviewing the HACCP plan determined that the plant didn’t address receipt of product other than their own product being returned. Reg 318.1(a,i) require that only inspected product enter an establishment and that all information necessary for determining the origin and processing of a product be maintained. As a corrective action [redacted] has modified the shipping documents to be for either shipping or receiving. Included information on incoming product is company, temperature and sanitation of vehicle, random temperature of product, package integrity, odor presence and inspection legend present. The following people were trained in the use of the document for receiving [redacted] and [redacted].

Regulation:

318.1(a) Except as otherwise provided in paragraphs (g) and (h) of this section or §318.12, no product shall be brought into an official establishment unless it has been prepared only in an official establishment and previously inspected and passed by a Program employee, and is identified by an official inspection legend as so inspected and passed. Notwithstanding the foregoing provisions of this subparagraph, product imported in accordance with part 327 of this subchapter and not prepared in the United States outside an official establishment, may enter any official establishment subject in other respects to the same restrictions as apply to domestic product. Products received in an official establishment during the Program employees absence shall be identified and maintained in a manner acceptable to such employee. Product entering any official establishment shall not be used or prepared thereat until it has been reinspected in accordance with §318.2. Any product originally prepared at any official establishment may not be returned into any part of such establishment, except the receiving area approved under §318.3, until it has been reinspected by the inspector.

318.1(i) The operator of the official establishment shall furnish such information as is necessary to determine the origin of any product or other article entering the official establishment. Such information shall include, but is not limited to, the name and address of the seller or supplier, transportation company, agent, or broker involved in the sale or delivery of the product or article in question.

Code: 03J01
Violation:  417.5(a)(1)

Citation: On this day I reviewed the Residue Notification Log [redacted]. To assess progress on the Residue Notification Log, I compared the log to a violator’s spreadsheet that we keep on the FSIS computers. I used February 1, 2010 as the start date. There are 6 violators in the log that had violations prior to this date, so I assumed violators after that date were all included in the log. It is important to keep data back this far to identify if someone becomes a repeat violator within a year’s time. The Residue Notification Log fell short of being up-to-date.The Residue Notification Log contained [redacted] entries, whereas the spreadsheet contained [redacted] entries. The entries included were somewhat hit or miss – i.e. it was not just the most recent violators that were missing from the log, but owners with violations that occurred throughout the year. While some of the discrepancy can be accounted for by the fact that not all violations for each violatior are included in the log as a separate entry in all cases (e.g. [redacted] entered once, two violations, [redacted] entered three times, 4 violations; [redacted] two entries, two violations; [redacted] one entry, 2 violations) much of it is due to owners missing from the log all together – e.g.[redacted]. (violation 12/7/2010), [redacted] (violation 11/12/2010), [redacted] (violation, 11/18/2010), [redacted] (violation 10/7/2010), [redacted] (violation 10/5/2010) not to be confused with [redacted] which is on the list, [redacted] (violation 9/21/2010), to name a few. Seven of the entries in the Residue Notification Log were single violators that were entered more than once. These owners were [redacted], [redacted], [redacted], [redacted], [redacted], [redacted], [redacted], Of some concern is that multiple repeat violators, specifically [redacted], [redacted], [redacted], [redacted], [redacted], [redacted], and are missing from the Residue Notification Log. While the plant employees use additional information when reviewing the faxed lists, this Log is a component of the prerequisite program for residues and should be kept up-to-date. Failure to keep this up-to-date is a recordkeeping non-compliance. Past Similar NRs – Previous Ineffective Plant Actions: Failure to completely implement residue program NR: 5-2011 dated 2/1/2011; NR: 63-2010 dated 12/29/2010; NR: 57-2010 dated 12/7/2010; NR: 51-2010 dated 11/4/2010

Regulation:

417.5(a)(1) The written hazard analysis prescribed in §417.2(a) of this part, including all supporting documentation;

Code: 03J01
Violation:  417.5(a)(1)

Citation: The prerequisite program for residues at Gold Medal Packing requires that [redacted]. According to the prerequisite program for residues at Gold medal, [redacted].. Upon reviewing the last 4 weeks (1/172011 through 2/18/2011) of faxed lists I noticed the following non-compliances with the residue program in this area: On 1/18, Gold Medal Packing purchased 3 calves from [redacted] (H626, H627 and H628), through the sale. This producer had a previous violation (Sample # 574763) on 12/10/2010 that was reported on LEARN 1/4/2011. He also had violations on 3/30/2010 and 8/7/2009, so he is certainly a producer with whom the plant should be familiar.The plant did not separate these 3 calves out for intensified residue testing. On 1/28, the plant purchased 2 calves, X758 and X759 from through the sale. This producer had a previous violation on 12/10/2010 that was reported on LEARN on 1/6/2011. These calves were not pulled out for intensified residue testing. On 1/28/2011, Gold Medal Packing purchased 2 calves, #255 and # 254 from [redacted] through the sale. [redacted] had a previous violation on 9/10/2010 (Sample # 580075). These 2 calves were not pulled for intensified residue testing. On 2/1/2011, the plant pulled out 2 calves for intensified residue testing from [redacted]. This owner had two previous violations on 12/10/2010 (574763, reported on LEARN on 1/4/2011), and 3/30/2010 (515993). This owner is a repeat violator. The plant should not be purchasing calves from this owner for 12 months, with the stipulation that the owner has signed a Drug Free Residue Affidavit. On 2/1/2011, the plant purchased a calf from [redacted] with ID numbers of 4535 and 4536. This producer had a previous violation on 11/17/2010 (574701), reported on 12/7/2010. The owner has not sent back a Drug Residue Free Affidavit, and the plant did not identify these calves for intensified testing. On 2/4/2011, the plant slaughtered calf Z776 purchased from [redacted]. had a previous violation on 12/16/2010 (574792). This violation was reported on 1/25/2011. This owner did not sign a Drug-Free Residue Affidavit. On 2/8/2011, the plant slaughtered 7 calves from [redacted]. had a previous violation on 9/10/2011 (580075). These calves were identified as 477, 486, 485, 475, 480, 478, and 479. There is no indication that these calves were pulled for intensified residue testing.[redacted] has not signed and returned a Drug-Free Residue Affidavit. These are monitoring non-compliances of the plant’s residue program. The plant failed to monitor the faxed lists from the sales appropriately for single and repeat violators

Regulation:

417.5(a)(1) The written hazard analysis prescribed in §417.2(a) of this part, including all supporting documentation;

Code: 03J01
Violation:  417.5(b)

Citation: There was a recordkeeping deficiency with the 23 December, 2010 Antimicrobial Intervention Record, there was no times recorded for the second monitoring of the application for CCP 1B,CCP 3B, and CCP 5B of the slaughter HACCP plan. This is a violation of 9 CFR 417.5(b). was notified.

Regulation:

417.5(b) Each entry on a record maintained under the HACCP plan shall be made at the time the specific event occurs and include the date and time recorded, and shall be signed or initialed by the establishment employee making the entry.

Code: 03C01
Violation:  417.4(a)(2)(ii)

Citation: The Antimicrobial Intervention Record for the week of January 17 to 21 shows that a direct observation of the titration for the raw not ground was not performed. This is a violation of their HACCP plan which states that . This is a violation of 9 CFR 417.4(a)(2)(ii). HACCP Manager was notified.

Regulation:

417.4(a)(2)(ii)  Direct observations of monitoring activities and corrective actions;

Code: 03J01
Violation:  417.5(a)(1)

Citation: On this day as part of an 03J01, I reviewed the Residue Notification Log at Gold Medal Packing, Establishment 17965. [redacted]. The log’s purpose is [redacted]. The log includes information such as [redacted]. [redacted]. After comparing the spreadsheet of violatives which I maintain for determining FSIS KIS testing rate to the plant’s Notification Log, I concluded that only 48 out of a possible 200 violations were on the list. Furthermore, several single residue violators, including for e.g. [redacted], [redacted], and [redacted] were on the list twice. As an aside, I also noticed there was no column for violation date on the log. This date is important information for determining which calves, based on violation date, to pull out for intensified residue testing based . Failure to complete this log is a record-keeping violation of the prerequisite program for residues, which would fall under 417.5(a)(1). was notified of this violation Past Similar NRs – Previous Ineffective Plant Actions: Failure to completely implement prerequisite program for residues NR: 63-2010 dated 12/29/2010; NR: 62-2010 dated 12/28/2010; NR: 58-2010 dated 12/7/2010; NR: 57-2010 dated 12/7/2010; NR: 51-2010 dated 11/4/2010; NR: 44-2010 dated 9/13/2010; NR: 43-2010 dated 9/7/2010; NR: 42-2010 dated 9/7/2010; NR: 30-2010 dated 8/11/2010

Regulation:

417.5(a)(1) The written hazard analysis prescribed in §417.2(a) of this part, including all supporting documentation;

Code: 06D01
Violation:  416.2(d)

Citation: On Jan 21, 2010 at 12:05 while observing doing her Six Spot Test on the kill floor, I noticed that the ventilation shaft near the employees with the air knives was dripping several drops of water. No product was affected. This is a violation of 416.2(d). Plant management is responsible for maintaining sanitary conditions. and were notified. Past Similar NRs – Previous Ineffective Plant Actions: maintence NR: 46-2010 dated 9/30/2010

Regulation:

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.

Code: 04B04
Violation:  441.1

Citation: On Jan 21,2010 at 0913 hour Dr noticed that while the plant went on break, a pre-evisceration [redacted] sprayer was continuously saturating one particular calf. A plant employee tried to shut the sprayer off but couldn’t find the switch. Dr. placed retain tag # B39766286 on the saturated calf. Company break is 15 minutes long. was notified that the calf was retained and why. At 11:25 Dr noticed that another calf had been saturated with the [redacted] in the same spot (pre-evisceration [redacted] wash). The plant lunch time is a half hour long. the carcasses were saturated and were a bleached white color. The carcasses have the potential for possible water retention, which would be a violation of 9 CFR 441.10 ( no written protocol). The end product must not retain water from the antimicrobial application. Any treatment such as antimicrobial treatments should be described in the protocol. An establishment does not have to maintain a protocol on file if the data or information that clearly demonstrates that its products do not maintain water as a result of the process, e.g., spraying meat with antimicrobial agents where the end product does not retain water from the antimicrobial application FSSIS Directive 6700.1 and 6700.1 Amend 1.

Regulation:

441.10(a) Raw livestock and poultry carcasses and parts will not be permitted to retain water resulting from post- evisceration processing unless the establishment preparing those carcasses and parts demonstrates to FSIS, with data collected in accordance with a written protocol, that any water retained in the carcasses or parts is an unavoidable consequence of the process used to meet applicable food safety requirements.

Code: 01C02
Violation:  416.13(c), 416.5(a)

Citation: On this Jan 21, 2010 at approximately 1045 am, while Dr. was working with the online inspector, she noticed that the trimmer was not washing his hands or sterilizing his knife. Dr. notified the kill floor manager. At 1130 am I went out on the kill floor to observe the trimmer that is right next to the online inspector. The trimmer was not dipping his knife in sterilizer and was not washing his hands. I went and observed other workers on the line. The employee that is right after the transfer station dehiding legs and the employee taking off the heads both waited till after they did 3 or 4 calves before they washed their hands and dipped their knives. I notified , the kill floor manager, what I had observed and he corrected the problem immediately. The Operational Sanitation HACCP Plan on page 4 of 8 under SSOP Line h states ” [redacted].” In the same plan, line b states ” [redacted].” This is a failure of the plant to monitor the implementation of sanitation regulation 416.13(c) and failure of employee hygiene regulation 416.5(a). Past Similar NRs – Previous Ineffective Plant Actions: failure to follow sanitary dressing as stated in their HACCP Plan NR: 52-2010 dated 11/9/2010; NR: 50-2010 dated 11/5/2010

Regulation:

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

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.

Code: 04B04
Violation:  317.1, 317.2(b), 317.2(c)

Citation: Jan 7, 2010 at approximately 1540 hour, while placing untested residue samples in the offal cooler, I noticed that there was seven shelves with unlabeled product on them. The boxes of retained carcasses that I had released the day before were spread out on the shelves thawing but there was no labels on any of them to identify the product. The boxes that they were in were already trashed, so there is no identification telling what lot the carcasses were from. The employees from the boning room had already gone home for the day and the room was being cleaned. I retained the shelves with retained tag B39766318 on the rack with the bottom two shelves with unidentified product and retain tag B39766319 to the rack containing five shelves of unidentified product. I notified notified plant manager said that he would label them. I stated to that even though he put a boneless veal label on the product, he doesn’t have record of the previous lots that the carcasses came from. This also brings up that Gold Medal does not have a tempering step in either the HACCP Plan For Raw, Not Ground Products(Further Processed) or the HACCP Plan For Raw Not Ground(boneless veal for non-intact purposes). Violation of 9 CFR 417.2(a)(2). Gold Medal’s Further Processed flow chart does not account for frozen retained carcasses just refrigerated carcasses. What is the process exactly. Violation of 9 CFR 417-2(a)(1). Carcasses being thawed are from multiple slaughter and boning days. Past Similar NRs – Previous Ineffective Plant Actions: The HACCP designee and plant employees failed to label products that go into the cooler before the day’s shift was over NR: 64-2010 dated 12/29/2010; NR: 45-2010 dated 9/29/2010; NR: 22-2010 dated 7/21/2010

Regulation:

317.1(a) When, in an official establishment, any inspected and passed product is placed in any receptacle or covering constituting an immediate container, there shall be affixed to such container a label as described in §317.2 except that the following do not have to bear such a label.

317.2(b) Any word, statement, or other information required by this part to appear on the label must be prominently placed thereon with such conspicuousness (as compared with other words, statements, designs, or devices, in the labeling) and in such terms as to render it likely to be read and understood by the ordinary individual under customary conditions of purchase and use. In order to meet this requirement, such information must appear on the principal display panel except as otherwise permitted in this part. Except as provided in §317.7, all words, statements, and other information required by or under authority of the Act to appear on the label or labeling shall app pear thereon in the English language: Provided, however, That in the case of products distributed solely in Puerto Rico, Spanish may be substituted for English for all printed matter except the USDA inspection legend.

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:

Code: 01C02
Violation:  416.12(d), 416.13(b), 416.13(c)

Citation: On this day at approximately 12:30 PM as part of an 01C02 I did a walk-through of the coolers at Gold Medal Packing to observe them for the presence of condensation. Condensation has been a problem in the recent past. and is one of the parameters being monitored under the plant’s current verification plan. As a corrective action the plant is supposed to [redacted].The SSOP under Operational Sanitation states “[redacted]” The last cooler check was done at 6:00 AM during pre-op . I went through coolers 4, 3, and 2 initially, and they looked great. The ceilings and rails were nice and dry. There was absolutely no condensation observed. I went through cooler 1 last . In cooler 1, one of the evaporators was iced-up and dripping condensation. In addition, the rails and beams nearby were dripping condensation. To further complicate matters, the fans on the evaporator were aerosolizing the condensate, saturating or sprinkling (depending on proximity to evaporator) carcasses on the two rails nearby. Sixty-seven carcasses were tagged, and moved to rails away from the evaporator until an acceptable corrective action could be made. The drip pan, fan blades and the fins on the evaporator were examined. They were extremely clean. and were made aware of the situation.

Regulation:

416.12(d) The Sanitation SOP’s shall specify the frequency with which each procedure in the Sanitation SOP’s is to be conducted and identify the establishment employee(s) responsible for the implementation and maintenance of such procedure(s).

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.

Code: 04B04
Violation:  317.1, 317.2(b), 317.2(c)

Citation: On Dec 29,2010 at 1503 hour, while performing verification on cheek meat, I noticed that in the offal cooler there was 5 shelves in the corner that had 2 bags on each shelf with unidentified product. I notified who was cleaning the processing room at that time. I applied yellow retain tag # B 38593325 to the shelving unit. When I left at 1715 hour there was still no labels that identified the product. On the morning of Dec 30 when I went into the offal cooler at 0600 hour to get the Kis Samples, there was still no labels applied to identify the product. CFR 317.19(a) states that ” When , in an official establishment, any inspected and passed product is placed in any receptacle or covering constituting an immediate container, there shall be affixed to such container a label as described in CFR 317.2. Past Similar NRs – Previous Ineffective Plant Actions: Plant employees are not labeling containers before they go into the coolers as stated in the plants corrective actions in the previous Nr’s NR: 45-2010 dated 9/29/2010; NR: 22-2010 dated 7/21/2010

Regulation:

317.1(a) When, in an official establishment, any inspected and passed product is placed in any receptacle or covering constituting an immediate container, there shall be affixed to such container a label as described in §317.2 except that the following do not have to bear such a label.

317.2(b) Any word, statement, or other information required by this part to appear on the label must be prominently placed thereon with such conspicuousness (as compared with other words, statements, designs, or devices, in the labeling) and in such terms as to render it likely to be read and understood by the ordinary individual under customary conditions of purchase and use. In order to meet this requirement, such information must appear on the principal display panel except as otherwise permitted in this part. Except as provided in §317.7, all words, statements, and other information required by or under authority of the Act to appear on the label or labeling shall app pear thereon in the English language: Provided, however, That in the case of products distributed solely in Puerto Rico, Spanish may be substituted for English for all printed matter except the USDA inspection legend.

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:

Code: 01C02
Violation:  416.13(c), 416.16(a)

Citation: On Dec 29,2010 at 0538 when CSI completed ante-mortem on bob calves in pen 7A and 7B, pen foreman gave CSI the pen card to pen 1 and told CSI that I , CSI had already preformed ante-mortem on pen 1. CSI came into the inspection office and told me what had said. I informed CSI that I did not perform ante-mortem on pen 1. I preformed ante-mortem on kill chute A, kill chute B, center pen, and pen 2. At that point when we realized that pen 1 was not checked for ante-mortem. Pen 1 were hung before pen 2. The 29 bob calves from pen 1 was already hung and were proceeding on the rail to the inspection station without having ante-mortem preformed on them. Dr. informed of the situation and that the 29 bob calves would have to be condemned without inspection personal performing ante-mortem on them. said that he was going to appeal that decision. The 29 carcasses and parts with (with the exception of the viscera) are all retained with yellow retained tags as follows; 29 carcasses retained with tag #’s B39766203 – B39766331, 29 heads with tag # B38593321, 29 tongues with tag # B39766202, and 29 rennet’s with tag # bB39766201. All carcasses and parts remain under FSIS control. No similar NR’s have been written.

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.

Code: 03J01
Violation:  417.5(a)(1)

Citation: As part of the prerequise program for residues at Gold Medal Packing, [redacted]. Since last January 1st there have been roughly 200 producers with residue violations at Gold Medal. Of these 200 producers, only 48 are listed on the residue violation log. Furthermore, some of these 48 owners are listed twice. This log has been designed partly in response to a recent Food Safety Assessment that was conducted.. Failure to list all residue violators on this log is a recordkeeping violation. was made aware of non-compliance Past Similar NRs – Previous Ineffective Plant Actions: Recordkeeping/Corrective actions NR: 62-2010 dated 12/28/2010; NR: 58-2010 dated 12/7/2010; NR: 57-2010 dated 12/7/2010; NR: 51-2010 dated 11/4/2010; NR: 44-2010 dated 9/13/2010; NR: 43-2010 dated 9/7/2010; NR: 42-2010 dated 9/7/2010; NR: 30-2010 dated 8/11/2010; NR: 17-2010 dated 7/9/2010

Regulation:

417.5(a)(1) The written hazard analysis prescribed in §417.2(a) of this part, including all supporting documentation;

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

Citation: Dec 28,2010 at 9:50 am while DR. was doing dispositions she noticed that the gauge for the viscera table was at 70 degrees and it should read [redacted] degrees. Kill floor manager was notified and he adjusted it to [redacted] degrees. In Gold Medal’s HACCP Plan for Operational Sanitary procedures for slaughtering states ” [redacted].” A reading of 70 degrees is a failure to follow their HACCP Plan. It is a noncompliance to regulation 416.4(a) which states “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. It is also a noncompliance of 416.4(d) which states “Product must be protected from adulteration during processing, handling, storage, loading at and during transportion from official establishments.” No product was adulterated or contaminated.

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: 03J01
Violation:  417.5(a)(1)

Citation: Under the recent revisions in the prerequisite program for residues at Gold Medal Packing, [redacted]. In the previous version of the prerequisite program for residues, [redacted]. Under the new version of the prerequisite program for residues at Gold Medal Packing [redacted]. On this day I reviewed the invoices that came in with the truckloads of calves to be slaughtered for the day. Two of the invoices contained calves from previous violators/repeat violators. The [redacted] invoice came in with [redacted] bob veal from [redacted]. This farm had a single violation on 7/27/2010. The [redacted] invoice also listed [redacted] calves from [redacted]. This farm had two previous violations on 9/28/2010 and 11/16/2010 [redacted]. In addition, an invoice from a [redacted] sale in listed [redacted] bob veal from [redacted]. This farm had two violations on 6/18/2010 and 6/22/2010. Calves from these owners were not separated and tested, or refused according to the residue program All of the information concerning violatives had been previously conveyed to the plant via MOIs, LEARN results attached to owner information and a copy of an FSIS-generated spreadsheet that contained all pertinent information on residue violations. This is a failure to address residues prior to slaughter. [redacted] in the HACCP plan because [redacted]. Past Similar NRs – Previous Ineffective Plant Actions: Failure to review records to pinpoint problem producers. NR: 58-2010 dated 12/7/2010; NR: 57-2010 dated 12/7/2010; NR: 51-2010 dated 11/4/2010; NR: 44-2010 dated 9/13/2010; NR: 43-2010 dated 9/7/2010; NR: 42-2010 dated 9/7/2010; NR: 30-2010 dated 8/11/2010; NR: 17-2010 dated 7/9/2010

Regulation:

417.5(a)(1) The written hazard analysis prescribed in §417.2(a) of this part, including all supporting documentation;

Code: 03J01
Violation:  417.5(c)

Citation: During the 60 day visit by Dr at Gold Medal Packing Co Inc Est 17965M , it was noted on 25 November 2010 the pre-shipment review was signed at 10:30 am and the last monitoring activity took place at 11:00 am, also noted on 17 December 2010 the pre-shipment review was signed at 10:10 am and the last monitoring activity took place at 4:45 pm. These are violations of 9 CFR 417.5(c). HACCP QC Manager was notified at the meeting held this date.

Regulation:

417.5(c) Prior to shipping product, the establishment shall review the records associated with the production of that product, documented in accordance with this section, to ensure completeness, including the determination that all critical limits were met and, if appropriate, corrective actions were taken, including the proper disposition of product. Where practicable, this review shall be conducted, dated, and signed by an individual who did not produce the record(s), preferably by someone trained in accordance with §417.7 of this part, or the responsible establishment official.

Code: 01B01
Violation:  416.13(a)

Citation: During a 60 day visit by Dr at Gold Medal Packing Co Inc Est 17965M, it was noted that the establishment failed to perform all of their preoperational sanitation procedures. The establishment did not perform the [redacted] food contact surfaces Enterobacteriaceae testing once for November 2010. This is a violation of CFR 416.13(a). HACCP QC Manager was notified at the meeting held this date.

Regulation:

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

Code: 05A02
Violation:  310.25(a)

Citation: Acording to the Verification and Validation Plan pertaining to Generic E.coli Sampling Program for the week of 29 November 2010 thru 03 December 2010 as required, verify the establishment is swabbing [redacted]. Approximately, as reported, [redacted] veal were killed and 5 E.coli swab tests were taken, required is E.coli swab tests. This is a violation of 310.25(a). HACCP Manager notified of this violation.

Regulation:

310.25(a) Criteria for verifying process control; E. coli testing. (1) Each official establishment that slaughters livestock must test for Escherichia coli Biotype 1 (E.coli) Establishments that slaughter more than one type of livestock or both livestock and poultry, shall test the type of livestock or poultry slaughtered in the greatest number. The establishment shall:

Code: 03J01
Violation:  417.5(a)(1)

Citation: On this day I reviewed the residue samples collected and corresponding owner papers at Gold Medal Packing, Establishment 17965. In Gold Medal Packing’s prerequisite program for residues, it states “[redacted].” This step was added to the prerequisite program for residues at the beginning of October. Since the step was added, Gold Medal has not received any Drug Residue Free Affidavits from producers, yet has purchased calves from 3 repeat violators. These violators are [redacted]- animal purchased on 10/26/2010, previous violatives occurred on 7/2/2010 and 7/30/2010,[redacted] – calf purchased on 11/3/2010, previous violatives were on 8/18/2010 and 6/30/2010, and [redacted] animal slaughtered on 11/9, credited with two violatives on 5/14/2010 and 7/20/2010. This is clearly a failure on the plant’s part to implement the residue program as written and more specifically a failure to perform their corrective action for repeat violators. was notified.

Regulation:

417.5(a)(1) Every official establishment shall conduct, or have conducted for it, a hazard analysis to determine the food safety hazards reasonably likely to occur in the production process and identify the preventive measures the establishment can apply to control those hazards. The hazard analysis shall include food safety hazards that can occur before, during, and after entry into the establishment. A food safety hazard that is reasonably likely to occur is one for which a prudent establishment would establish controls because it historically has occurred, or because there is a reasonable possibility that it will occur in the particular type of product being processed, in the absence of those controls.

Code: 03J01
Violation:  417.5(a)(2), 417.5(e)(2)

Citation: Gold Medal Packing performs a verification and validation of process control procedures/sanitary dressing which involves [redacted]. Tests run on the swabs include an aerobic plate count and Enterobacteriaceae test. On 3 December 2010 test results pertaining to the verification and validation of PCP/sanitary dressing procedures were requested from Records were requested for October and November 2010 . Results could not be provided by management for bob veal for the first week in October and the third and forth weeks of November. Formula Fed Veal records were not available for October and November. On Monday 6 December 2010 the request was made for the missing records. Management provided records for the forth week of November for bob veal and records for November for Formula Fed Veal. Results still missing are for the first week in October and the third week of November for bob veal and for October for Formula-Fed veal.. Regulation 417.5{e}{2} USDA FSIS requires that records are available within 24 hours of the request .

Regulation:

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

417.5(e)(2) 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.

Code: 03J01
Violation:  417.5(a)(2)

Citation: On this day, while going over residue reports from bob veal, I reviewed reports which are awaiting owner/producer identification that are filed away in a separate place. Eight sample reports have been set aside for some quite time. The samples are #579131 sampled on 6/11/10, #579186 sampled on 6/24/10, #580760 sampled on 7/23/10, #580027 sampled on 8/11/10, #580033 sampled on 8/13/10, #580037 sampled on 8/17/10, #580067 sampled on 9/9/10, and #580110 sampled on 9/22/10. Producer information is considered supporting documentation according to 9 CFR 417.5 (a)(2), because producer information is crucial to successfully implementing the prerequisite plant for residues at Gold Medal Packing. Additionally, bob veal are tested for residues at Gold Medal in accordance with 9 CFR 310.21. Producer identification is an important component of the testing program described in this regulation, because “all subsequent calves from the same producer which has previously sold or delivered to official establishments any carcass that was condemned because of drug residues must be tested according to this paragraph until five consecutive animals test completely free of animal drug residues” Without producer information this would not be possible. Furthermore, according to 9 CFR 320.1(b)(iv), “the name and address of the buyer of livestock or articles sold by such person, and the name and address of the seller of livestock or articles purchased by such person” is a record required to be kept by the plant.. was notified quite a while ago about the missing information and she has made efforts to get this information from the truckers and auction barns, but she has been unsuccessful. This non-compliance is not a direct food safety hazard, but the absence of producer information reduces the plant’s control over the level of violative residues entering the plant.

Regulation:

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

Code: 01C01
Violation:  416.13(b)

Citation: On 17/18 November 2010 Dr reviewed the records for testing, the establishment did not perform any testing during operations to verify operational sanitation as written in the SSOP. This is a violation of 9CFR 416.13(b). Plant management and were notified of this violation at the exit meeting on 18 November 2010.

Regulation:

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

Code: 03C01
Violation:  417.4(a)(2)(ii)

Citation: On 17/18 November 2010 Dr reviewed the records that show that direct observation of the application was only performed for the monitoring activity of the slaughter HACCP plan CCP and the establishment failed to perform the direct observation of the monitoring of CCP 1B of the Raw, Not Ground (intact and further processed) HACCP plans. This is a violation of 9CFR 417.4(a)(2)(ii). Plant management and were notified of this violation at the exit meeting on 18 November.

Regulation:

417.4(a)(2)(ii) Direct observations of monitoring activities and corrective actions;

Code: 03C01
Violation:  417.2(c)(4)

Citation: On 17/18 November 2010 Dr reviewed the Antimicrobial Intervention Record monitoring the [redacted] application that occurred prior to the start of operations and there was no product on the Lazy Susan to monitor on the following days: October 12,13,14,15, and November 1,3,4,and 12. This is a violation of 9 CFR 417.2(c)(4). The Fabrication HACCP Records were reviewed and records show that on 5 November 2010 there was no pm monitoring activity. This is a violation of 9 CFR 417.2(c)(4). Plant management plus were notified of these violations at the exit meeting on 18 November 2010.

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;

Code: 03J01
Violation:  417.4(a)(2)(ii), 417.5(a)(3)

Citation: At approximately 7:10 am I did a carcass check on swine carcasses in cooler 4 that were slaughtered the previous day. Due to the previous history of fecal matter in the pelvic area. I observed that the skinned pigs were fine, but the scalded carcasses had fecal matter in the pelvic area. This is a failure of the Zero Tolerence CCP in the HACCP plan for Pork Slaughter.The critical limit for CCP 1 in the HACCP Plan for Pork Slaughter is that “[redacted].” To accomplish this [redacted]. Noting that it was only on the scaulded pigs, I talked with and kill floor supervisor and asked their procedures on bunging the scalded pigs. Employees were bunging before the pig is being burnt, scrubbed and washed, which allows direct contamination to the exposed pelvic area. This is a failure of the Zero Tolernce CCP to prevent fecal matter which is a potential source of the biological hazard, E coli 0157:H7. and kill floor Supervisor were informed of the non-compliance. Scalded carcasses were retained with tag # B 20 434702. Past Similar NRs – Previous Ineffective Plant Actions: The failure of sanitary dressing procedures and monitoring of the Zero Tolerance CCP NR: 49-2010 dated 10/26/2010

Regulation:

417.4(a)(2)(ii) Direct observations of monitoring activities and corrective actions;

417.5(a)(3) Records documenting the monitoring of CCP’s and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment’s HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter production lot. Each of these records shall include the date the record was made.

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

Citation: On this day at approximately 0900 hours Dr and I on a routine walk thru noted in Cooler #4(NewCooler) noticed dripping condensation onto swine carcasses. A Retained Tag # B20434673 was applied. It was noted that a HACCP Rejected tag was attached to the cooler because of frost on the refrigeration units, however product remained in the cooler. was informed. Past Similar NRs – Previous Ineffective Plant Actions: Not observed on one of four condensation checks. NR: 50-2010 dated 11/5/2010; NR: 34-2010 dated 8/17/2010

Regulation:

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.

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

Citation: On this day at 7:15 AM while doing dispositions at the disposition rail I observed the trays on the viscera table as they were coming up from the sanitizing cycle underneath the table. I noticed that quite a few of the pans were coming up with dried blood on them (60%), particularly on the right side of the tray. I did not observe any fecal material. Since hearts are on these trays, cross-contamination between condemned and passed carcass tissue could be a potential problem. The plant was cited for this same problem in an NR on 11/05. On that day there was also dried blood and tissue on the trays due to failure of a pump which increases pressure of the water coming out of the nozzles that clean the trays.. The immediate corrective action on that day was to have an employee stand at the end of the table and spray off the blood and tissue from the pans. I was told the long term corrective action was to change the pump. The plant used the immediate corrective action of hosing off the pans yesterday, 11/04. Today, on 11/05, the plant is no longer using the immediate corrective action of cleaning off the pans with a hose, but the pump has not been replaced. 416.4(a) states “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 conditionsand adulteration of product. 416.4(d) states “Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments. Past Similar NRs – Previous Ineffective Plant Actions: Failure to use immediate corrective action until long term solution is implemented NR: 50-2010 dated 11/5/2010

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

Citation: On this day at 10:30 AM while performing dispositions at the disposition rail I checked the moving viscera table. I noticed a small to moderate amount of blood remaining on the trays after they went through the sanitizing cycle. I counted trays and estimated that 80% of them came through the cycle containing blood. .Since hearts are on these trays cross-contamination could be a potential problem, although most of the blood was confined to one side of the pans. I notified HACCP coordinator. 416.4(a) states “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 adulteration of product. 416.4 (d) states “Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

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: 03J01
Violation:  417.5(a)(1)

Citation: On this day I reviewed the records for the Prerequisite Program for Residues with HACCP coordinator. This program has recently been ammended to better address residue issues in bob veal. One added preventative measure is that owners of all KIS positive animals will be notfied of the test results and be made aware that follow-up testing will be conducted at the USDA’s Midwestern Laboratory. Plant management is made aware of the KIS positive tests on a daily basis by FSIS employees in the plant. In reviewing the records I found no documentation that KIS positive letters had been sent out. Somewhat in the plant’s defense, there will always be owners that will not get these letters because sale barns sometimes don’t provide owner information until after results come back from the Midwestern laboratory. At that point it is senseless to send out a KIS positive letter. A second new preventative measure is that a letter entitled “GMP Residue Policy Notification for Buyers” will be sent out to all buyers that instructs them to use the FSIS Repeat Violator List. Knowledge obtained from this list will either help them to avoid purchasing calves from repeat violators or at least notify Gold Medal Packing when they have purchased a calf from a repeat violator. It states in the Residue program that “[redacted] .” While reviewing the records there is sufficient evidence that all of the buyers have received a letter. However, letters were sent out to 29 buyers, and only 3 have been signed and returned. Gold Medal is continuing to purchase animals from the other 26 buyers. Gold Medal Packing is to maintain a Buyer Log which contains a list of the buyers, when letters were sent, and when acknowledgement of the letter was returned. To date, a buyer log has not been set up with all this pertinent information. Past Similar NRs – Previous Ineffective Plant Actions: Ineffective Prerequisite Program for Residues NR: 44-2010 dated 9/13/2010; NR: 43-2010 dated 9/7/2010; NR: 42-2010 dated 9/7/2010; NR: 30-2010 dated 8/11/2010; NR: 17-2010 dated 7/9/2010; NR: 19-2010 dated 6/29/2010

Regulation:

417.5(a)(1) ) The written hazard analysis prescribed in §417.2(a) of this part, including all supporting documentation;

Code: 03J01
Violation:  417.4(a)(2)(ii), 417.5(a)(3)

Citation: n this day at approximately 11 AM I went into the south (#3) cooler where swine carcasses processed the day before were being stored. I examined them for hair and fecal material. Of the [redacted] pigs slaughtered approximately 20% of them had small amounts of fecal material in the pelvic canal. This is a failure of the Zero Tolerance CCP in the HACCP plan for Pork Slaughter. The critical limit for CCP 1B in the HACCP Plan for Pork Slaughter is that there will be “[redacted]” To accomplish this, the ” [redacted]”. Furthermore, [redacted]. Verification of swine carcasses was done on that day. Although the particular carcasses observed with fecal material may not have been amongst 2 carcasses checked during monitoring and 1 carcass checked during the verification procedure that day, this is still a failure of the zero tolerance CCP to prevent fecal material which is a potential source of the biological hazard, E coli 0157:H7. was notified of the non-compliance. A plant employee examined and trimmed all the carcasses.

Regulation:

417.4(a)(2)(ii) – (2) Ongoing verification activities. Ongoing verification activities include, but are not limited to: (ii) Direct observations of monitoring activities and corrective actions;

417.5(a)(3) Records documenting the monitoring of CCP’s and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment’s HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter production lot. Each of these records shall include the date the record was made.

Code: 03J01
Violation:  417.3(a)(1)

Citation: This date following a verification plan for Gold Medal Packing, Inc, Establishment # 17965 M, it was noted that the concentration critical limits was performed at plus/minus 0430 hours and verified plus/minus at this time. As per SVMO and FLS, verification cannot be performed prior to hours of operation. At plus/minus 1345 hours, I observed HACCP Asst. testing the concentration in the processing department. Several tests were performed with results ranging from ppm to ppm. These tests were taken over a period of 30 minutes time. During the time when the concentrations were found to be inadequate, employees in the processing room continued to bone out the carcasses, and spray and cryovac the meat. A Retained Tag # B20434553 was applied to veal product processed this date because the plant did not cease operations while the situation was being assessed.. HACCP Asst, HACCP Manager, and VP were notified. Adjustments were made to the delivery system and several more tests were performed resulting in readings ofppm to ppm. The adjustment that the plant made was to bring in the hose out of the offal room which runs off a different pump. Production Records were obtained from for product produced on 20 October 2010. Product was “run back thru” the system receiving the correct ppm spray finishing at 1630 The failure of the three sprayers to spray a correct concentration in the processing room is a failure of their HACCP Plan. Reference several previous NRs.

Regulation:

417.3(a)(1) – (a)The written HACCP plan shall identify the corrective action to be followed in response to a deviation from a critical limit. The HACCP plan shall describe the corrective action to be taken, and assign responsibility for taking corrective action, to ensure: (1) The cause of the deviation is identified and eliminated;

Code: 01B02
Violation:  416.13(c), 416.2(d)

Citation: This date at approximately 0600 hours, performing pre-operational inspection, noted in the Number 2 Cooler was dripping liquid onto a hook with three veal carcasses. A Rejected/Retained Tag Number B20434543 was applied to the area and the veal carcasses. VP, Processing Foreman, and HACCP Trainee were all notified. Reference previous NRs Numbers 0046-2010, 0026-2010, 0023-2010, and 0021-2010.

Regulation:

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.

Code: 06D01
Violation:  416.2(d)

Citation: This date at approximately 0730 hours, I and Dr performing a IPPS review, noted beaded condensation in the New Cooler. No product was in the cooler. A Rejected tag # B20434509 was applied. Processing Foreman was notified. Reference several previous NRs including NR # 0026-2010-15670, 0023-2010, and 0021-2010.

Regulation:

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.

Code: 04B04
Violation:  317.1, 317.2(b), 317.2(c)

Citation: This date at approximately 0600 hours, performing pre-operation inspection, noted in the offal cooler were three racks of product that were not identified. Retained tag # B20434511 was applied. In the south cooler three white lugs of product were not identified. Retained tag # B20434512 was applied. HACCP Asst. was notified. This is a labeling non-compliance with USDA Regs, reference 317.1, 317.2(b) and 317.2(c). Reference previous related NR # 0032-2009-15217.

Regulation:

317.1(a) When, in an official establishment, any inspected and passed product is placed in any receptacle or covering constituting an immediate container, there shall be affixed to such container a label as described in §317.2 except that the following do not have to bear such a label.

317.2(b) Folders and similar coverings made of paper or similar materials, whether or not they completely enclose the product and which bear any written, printed, or graphic matter, shall bear all features required on a label for an immediate container.

317.2(c) No covering or other container which bears or is to bear a label shall be filled, in whole or in part, except with product which has been inspected and passed in compliance with the regulations in this subchapter, which is not adulterated and which is strictly in accordance with the statements on the label. No such container shall be filled, in whole or in part, and no label shall be affixed thereto, except under supervision of a Program employee.

Code: 03J01
Violation:  310.22(b), 310.22(e)(4)(i)

Citation: During a review of the SRM records at Gold Medal Packing, it was noted that multiple entries were omitted. Review of the SRM removal records indicated that no entries were recorded for three days, 8, 9, and 10 September 2010. This is a recordkeeping non-compliance. was notified. Actual SRM removal is observed by USDA inspectors prior to boning or shipping FF Veal heads. Bob Veal heads, Non-FF Veal heads and all distal ileum are condemned by the plant. Reference previous NR Number 0042-2010-15670. Past Similar NRs – Previous Ineffective Plant Actions: Not recording SRM records. NR: 42-2010 dated 9/7/2010

Regulation:

310.22(b) Specified risk materials are inedible and prohibited for use as human food.

310.22(e)(4)(i) Establishments that slaughter cattle and establishments that process the carcasses or parts of cattle must maintain daily records sufficient to document the implementation and monitoring of the procedures for the removal, segregation, and disposition of the materials listed in paragraph (a) of this section, and any corrective actions taken.

Code: 03J01
Violation:  417.5(a)(1), 417.5(a)(2), 417.5(a)(3), 417.5(c)

Citation: While reviewing HACCP records during nthe FSA the following violations were noted. Incomplete records for the Metal Inclusion Prevention Prerequisite Program indicates that it is not being followed. Checks for the metal prior to operations were not conducted consistently for all included. The plant failed to have all letters of guarantee from the suppliers of packaging materials as written in the shipping and receiving program, to demonstrate hazards are addressed for packaging materials. You have not provided documentation for the selection and efficacy of the lower critical limit of ppm in the further processed plan. Review of your preshipment review records from May 6, 2010, to July 16, 2010 demonstrated inconsistent execution of the activities. The dates of the preshipment reviews correspond with the date that your firm receives the lab results, and may not accurately reflect the date the preshipment review for the Boneless Veal Product disposition CCP was completed. However, there are seven preshipment reviews that occur on a Sunday, and four on Saturdays excluding the holiday weekend, which indicate they were not completed the date the record was filled out. These are in violation of 417.5(a)(1),(2), (3) and 417.5(c)

Regulation:

417.5(a)(1) The written hazard analysis prescribed in §417.2(a) of this part, including all supporting documentation;

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

417.5(a)(3) Records documenting the monitoring of CCP’s and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment’s HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter production lot. Each of these records shall include the date the record was made.

417.5(c) Prior to shipping product, the establishment shall review the records associated with the production of that product, documented in accordance with this section, to ensure completeness, including the determination that all critical limits were met and, if appropriate, corrective actions were taken, including the proper disposition of product. Where practicable, this review shall be conducted, dated, and signed by an individual who did not produce the record(s), preferably by someone trained in accordance with §417.7 of this part, or the responsible establishment official.

Code: 03J01
Violation:  310.22(b), 310.22(e)(4)(i)

Citation: During the FSA at Gold Medal Packing while checking the SRM records it was noted that multiple entries were omitted. Review of the SRM Removal Records revealed the following SRM recordkeeping non-compliances were not in accordance with >20% of the time: Actual SRM removal is observed by USDA inspectors prior to boning or shipping of the FF heads. Bob heads, “Grasser” heads and all distal ileum are condemned by the plant. ” The number of animals documented on the records did not account for all animals with SRMs slaughtered on 5/6, 5/7, 5/13, 5/14, 6/2, 6/15, 6/16, 6/23, 7/15, 7/19, and 7/22. The records did not accurately reflect the number of heads that were disposed on days Formula-Fed Calves were slaughtered. Your plant sells the heads intact, after the removal of all tonsillar material, but would still document them as having been thrown out on the record (4) Recordkeeping requirements. (i) Establishments that slaughter cattle and establishments that process the carcasses or parts of cattle must maintain daily records sufficient to document the implementation and monitoring of the procedures for the removal, segregation, and disposition of the materials

Regulation:

310.22(b) Specified risk materials are inedible and prohibited for use as human food.

310.22(e)(4)(i) Establishments that slaughter cattle and establishments that process the carcasses or parts of cattle must maintain daily records sufficient to document the implementation and monitoring of the procedures for the removal, segregation, and disposition of the materials listed in paragraph (a) of this section, and any corrective actions taken.

Code: 06D01
Violation:  416.2(a)

Citation: During the FSA while a walk around of Gold Medal Packing was being conducted the below potential hazard was noted. The facility failed to prevent the potential breeding ground and harborage for flies and other insects by only partially covering the pit on the left side of the facility, which collects the wastewater from the processing room and the kill floors. This is a violation of 416.2(a), which states, (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

Regulation:

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.

Code: 01B02
Violation:  416.13(c)

Citation: On this date at approximately 0530 hours, I noted while performing pre-operational inspection, the veal head rack on the kill floor was splashed with dried blood in several spots. A Rejected Tag Number B20434405 was applied to the veal head rack. was notified of the rejected veal head rack. Reference previous similar NR’s, Numbers 20100010, 20100012, 20100013, 20100022, and 20100039.

Regulation:

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

Code: 01B02
Violation:  416.13(c)

Citation: On this date at approximately 0600 hours, I noted while performing pre-operational inspection, two inedible chutes on the kill floor with several blood splashes on both of them. A Rejected Tag Number B20434403 was applied to both of the inedible chutes. was notified of the rejected chutes. Reference previous similar NR’s, Numbers 20100010, 20100012, 20100013, and 20100022.

Regulation:

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

Code: 01B02
Violation:  416.13(c)

Citation: On this date at approximately 0600 hours, performing pre-operation inspection, I noted in the “New” Cooler on most of the overhead beams, beaded condensation. Carcasses in the cooler were not involved. A Rejected Tag Number B20434363 was applied to the Cooler. HACCP/QC Manager was notified. Reference previous NR’s Numbers 34-2010,26-2010,23-2010, and 21-2010.

Regulation:

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

Code: 03J01
Violation:  417.2(c)(4)

Citation: This date at approximately 1000 hours, Dr and I observed both and HACCP QC Manager, test the concentration of the [redacted] at both delivery points on the kill floor several times, recording the results that varied from [redacted] ppm to [redacted] ppm. Variety Meats were recorded at [redacted] ppm. The Cooler was recorded at [redacted] ppm. The Boning Room was recorded at [redacted] ppm and [redacted] ppm. The purpose of the spray is to address E Coli 0157H7 In the HACCP Plan for Raw, Not Ground Products it states in part under corrective actions ” [redacted]. The failure of the [redacted] sprayers to spray a correct concentration is a failure of their HACCP Plan and a failure to take corrective actions. Two Rejected Tags were applied, one to the [redacted] Pump on the kill floor, B20434396 and one to the [redacted] Pump in the Processing Room, B20434397. Two Retained Tags were applied, one to the veal in the Chill Cooler, B20434399 and one to all other veal product in the Processing Room and other Coolers. Reference to other NR’s Numbers 0032-2010-15543, 0025-2010-15670 and 0024-2010-15670. HACCP Coor dinator was present and was notified.

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;

Code: 03J02
Violation:  417.2(a)(1), 417.5(a)(1)

Citation: On this day while reviewing LEARN results from 8/20/2010, it became apparent that there is now a producer with FIVE residue violations at Gold Medal Packing.[redacted] has had 5 reported residue violations in the nearly three month period spanning from mid-May through the end of July. The 5 violations occurred on 5/18/2010 (497530, Neomycin, Oxytetracycline in the kidney), 5/28/2010 (579106, Neomycin in the kidney), 6/11/2010 (579126, Neomycin in the Kidney), and 2 violations on 7/27/2010 (580766, 580770, Neomycin in the kidney). Residues at Gold Medal Packing are addressed in a prerequisite program, therefore [redacted] in the HACCP plan for Veal, Lamb, and Goat Slaughter. The prerequisite program [redacted]. With the recurrence and number of repeat violators, it is clear that residues ARE a hazard likely to occur, and the prerequisite program is NOT addressing this hazard. The recurrence of residue violations in veal carcasses is in violation of 417.2(a)(1) which states that ” Every official establishment shall conduct, or have conducted for it, a hazard analysis to determine the food safety hazards reasonably likely to occur in the production process and identify the preventive measures the establishment can apply to control these hazards.” This establishment is not identifying residues as a hazard likely to occur, and clearly is not identifying the appropriate preventive measures to apply to control residues. Furthermore, the presence of violative drug residues in multiple veal carcasses is not in accordance with 9 CFR 318.20, which states that “Animal drug residues are permitted …..if such drug residues are within tolerance levels approved by the Food and Drug Administration”. The carcasses identified with violative drug residues are not a food safety hazard because they are disposed of in accordance with Directive 10,800.1 and 10,220.3. However at the current time [redacted]% of all bob veal slaughtered at Gold Medal are being tested for residues. This means that [redacted]% of the bob veal are not being tested. Without a doubt some of these latter carcasses are adulterated with drug residues, they are entering commerce, and therefore are a potential food safety hazard HACCP coordinator was made aware of this producer with a fifth violation, and has been made aware of all the other violations as they have been reported. Past Similar NRs – Previous Ineffective Plant Actions: Failure of corrective actions to prevent calves with residues from entering the plant NR: 36-2010 dated 8/20/2010; NR: 29-2010 dated 08/11/2010 NR: 19-2010 dated 06/29/2010 NR: 17-2010 dated 07/09/2010 NR: 10-2010 dated 05/06/2010 NR: 6-2010 dated 3/11/2010

Regulation:

417.2(a)(1) Every official establishment shall conduct, or have conducted for it, a hazard analysis to determine the food safety hazards reasonably likely to occur in the production process and identify the preventive measures the establishment can apply to control those hazards. The hazard analysis shall include food safety hazards that can occur before, during, and after entry into the establishment. A food safety hazard that is reasonably likely to occur is one for which a prudent establishment would establish controls because it historically has occurred, or because there is a reasonable possibility that it will occur in the particular type of product being processed, in the absence of those controls.

417.5(a)(1) The written hazard analysis prescribed in §417.2(a) of this part, including all supporting documentation;

Code: 03J02
Violation:  417.2(a)(1), 417.5(a)(1)

Citation: On this day while reviewing reports on LEARN for residue tests of bob veal, it became apparent that Gold Medal Packing has for a second time a fourth violation from one producer. In this case the producer is [redacted]. The most recent violation is Sample 580770 (Neomycin – Kidney), which was taken on 07/27/2010. The previous 3 violations were Sample #579126 (6/11/2010, Neomycin – Kidney), Sample # 579106 (5/28/2010, Neomycin – Kidney) , and Sample # 497530 (5/18/2010, Neomycin,Oxytet – Kidney). Residues at Gold Medal Packing are addressed in a prerequisite program, therefore [redacted] in the HACCP plan for Veal, Lamb, and Goat Slaughter. The prerequisite program [redacted]. With the recurrence and number of repeat violators, it is clear that residues ARE a hazard likely to occur, and the prerequisite program is NOT addressing this hazard. The recurrence of residue violations in veal carcasses is in violation of 417.2(a)(1) which states that ” Every official establishment shall conduct, or have conducted for it, a hazard analysis to determine the food safety hazards reasonably likely to occur in the production process and identify the preventive measures the establishment can apply to control these hazards.” This establishment is not identifying residues as a hazard likely to occur, and clearly is not identifying the appropriate preventive measures to apply to control residues. Furthermore, the presence of violative drug residues in multiple veal carcasses is not in accordance with 9 CFR 318.20, which states that “Animal drug residues are permitted …..if such drug residues are within tolerance levels approved by the Food and Drug Administration”. The carcasses identified with violative drug residues are not a food safety hazard because they are disposed of in accordance with Directive 10,800.1 and 10,220.3. However at the current time [redacted]% of all bob veal slaughtered at Gold Medal are being tested for residues. This means that [redacted]% of the bob veal are not being tested. Without a doubt some of these latter carcasses are adulterated with drug residues, they are entering commerce, and therefore are a potential food safety hazard HACCP coordinator was made aware of the producer with a fourth violation, and has been made aware of all the other violations as they have been reported. Past Similar NRs – Previous Ineffective Plant Actions: Failure to make appropriate corrective actions NR: 6-2010 dated 3/11/2010 NR: 10-2010, dated 05/06/2010 NR: 19-2010, dated 06/29/2010 NR’ 17-2010 dated 07/09/2010 NR: 29-6010 dated 08/11/2010

Regulation:

417.2(a)(1) Every official establishment shall conduct, or have conducted for it, a hazard analysis to determine the food safety hazards reasonably likely to occur in the production process and identify the preventive measures the establishment can apply to control those hazards. The hazard analysis shall include food safety hazards that can occur before, during, and after entry into the establishment. A food safety hazard that is reasonably likely to occur is one for which a prudent establishment would establish controls because it historically has occurred, or because there is a reasonable possibility that it will occur in the particular type of product being processed, in the absence of those controls.

417.5(a)(1) The written hazard analysis prescribed in §417.2(a) of this part, including all supporting documentation;

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

Citation: On this date at approximately 1145 hours during a tour of the facility by both the EIAO and FSIS Inspector they came upon the Chill Cooler, right off the Kill floor they observed dripping condensation off the ceiling and then the cooling fans were spreading the condensation onto 2 carcasses already retained for KIS test sampling. the 2 bob veal carcasses were tagged US Retained with tag #B20 434355. was shown the non-compliance with 9 CFR 416.13(b), 416.13(c) and 416.2(d). Review of plant’s SSOP shows a Ventilation SPS Prerequisite program and it states, “[redacted].” Review of plant records had no mention of any condensation issues. Past Similar NRs – Previous Ineffective Plant Actions: employee that sets up room told to check ceiling and rails throughout the day. Reference similar previous NR 26-2010 dated 7/22/2010, NR 23-2010 dated 7/20/2010, NR 21-2010 dated 7/14/2010

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.

416.2(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.

Code: 06D01
Violation:  416.2(b)(4)

Citation: On this date at approximately 1000 hours I was touring the Boning room when I saw hearts, livers and lungs in blue colored plastic tubs marked “EDIBLE” and “INEDIBLE” sitting on a portable rack. Being that lungs are an inedible item I showed the non-compliance with 9 CFR 416.2(b)(4) to both _ and _ .No further regulatory action was required because the tubs were all emptied to the rendering and then the lugs were all sent to the maintenance shop to have “INEDIBLE” printed on them. Past Similar NRs – Previous Ineffective Plant Actions: Reminded employees and cleaning crew that blue tubs are for EDIBLE in the boning room. The grey tubs are for the kill floor NR: 4-2010 dated 2/23/2010

Regulation:

416.2(b)(4) Rooms or compartments in which edible product is processed, handled, or stored must be separate and distinct from rooms or compartments in which inedible product is processed, handled, or stored, to the extent necessary to prevent product adulteration and the creation of insanitary conditions.

Code: 03J02
Violation:  417.5(a)(3)

Citation: On this date at approximately 1200 hours I was reviewing all the records generated for the Slaughter HACCP Plan for the week of 8/8/10 to 8/13/10 and the two following recordkeeping noncompliance’s with 9 CFR 417.5(a)(3) were noted and shown to QC Manager: First under CCP 1B, 3B, 5B for the spraying of anti-microbial interventions under monitoring it states, [redacted],” but upon review of the completed records the concentration of the anti-microbial agent was not tested prior to use per the written monitoring procedure for the days records were reviewed. The first testing of the concentration of the anti-microbial agent was noted at different times in the morning each day. Then under CCP 4B, for the days records were reviewed, I found no results to tell whether the operation (monitoring step) was being conducted during each day per the cheek meat monitoring written procedure which states, ” [redacted],” or CCP 4 was not monitored because the process was not performed that particular day.

Regulation:

417.5(a)(3) Records documenting the monitoring of CCP’s and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment’s HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter production lot. Each of these records shall include the date the record was made.

Code: 06D01
Violation:  416.1, 416.4(b)

Citation: On this date at approximately 0600 hours while performing pre-operational inspection I found the following Sanitation Performance Standards (SPS) non-compliances in the Boning Room: On the under side of the boning table frame there was dry meat/fat pieces and product residues from the previous day’s operations. On the under side of the conveyor shut leading to the lazy susan there was also dry meat/fat particles from the previous day’s operations. and were shown the non-compliances with 9 CFR 416.1 and 416.4(b).

Regulation:

416.1 Each official establishment must be operated and maintained in a manner sufficient to prevent the creation of insanitary conditions and to ensure that product is not adulterated.

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

Code: 03J01
Violation:  417.5(a)(2)

Citation: On this day, while going over residue reports from bob veal, I reviewed reports which are awaiting owner/producer identification that are filed away in a separate place. Three sample reports have been set aside for some quite time. The samples are #515930, collected on 2/26/2010, #515960, collected on 3/11/2010, and #515971, taken on 3/18/2010. Producer information is considered supporting documentation according to 9 CFR 417.5 (a)(2), because producer information is crucial to successfully implementing the prerequisite plant for residues at Gold Medal Packing. Additionally, bob veal are tested for residues at Gold Medal in accordance with 9 CFR 310.21. Producer identification is an important component of the testing program described in this regulation, because “all subsequent calves from the same producer which has previously sold or delivered to official establishments any carcass that was condemned because of drug residues must be tested according to this paragraph until five consecutive animals test completely free of animal drug residues” Without producer information this would not be possible. Furthermore, according to 9 CFR 320.1(b)(iv), “the name and address of the buyer of livestock or articles sold by such person, and the name and address of the seller of livestock or articles purchased by such person” is a record required to be kept by the plant.. was notified quite a while ago about the missing information and she has made efforts to get this information from the truckers and auction barns, but she has been unsuccessful. This non-compliance is not a direct food safety hazard, but the absence of producer information reduces the plant’s control over the level of violative residues entering the plant.

Regulation:

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

Code: 03J01
Violation:  318.20, 417.2(a)(1), 417.5(a)(1)

Citation: On this day while reviewing reports from residue testing of bob veal, it became apparent that Gold Medal Packing now has a fourth violation from one producer, . The most recent violation is Sample #580686 (Neomycin – Kidney), which was taken on 7/13/2010. The previous 3 violations were Sample #579153 (6/18/2010, Neomycin – kidney), Sample # 497483 (4/27/2010, Neomycin – Kidney) , and Sample # 515923 (2/23/2010, Flunixin – Liver). In addition to this producer with four violations, there are also 3 producers with 3 residue violations( [redacted] ), and 9 producers with 2 residue violations each. Residues at Gold Medal Packing are addressed in a prerequisite program, therefore in the HACCP plan for Veal, Lamb, and Goat Slaughter. The prerequisite program addresses residues by [redacted]. With the recurrence and number of repeat violators, it is clear that residues ARE a hazard likely to occur, and the prerequisite program is NOT addressing this hazard. The recurrence of residue violations in veal carcasses is in violation of 417.2(a)(1) which states that “[redacted]” Every official establishment shall conduct, or have conducted for it, a hazard analysis to determine the food safety hazards reasonably likely to occur in the production process and identify the preventive measures the establishment can apply to control these hazards.” This establishment is not identifying residues as a hazard likely to occur, and clearly is not identifying the appropriate preventive measures to apply to control residues. Furthermore, the presence of violative drug residues in multiple veal carcasses is not in accordance with 9 CFR 318.20, which states that “Animal drug residues are permitted …..if such drug residues are within tolerance levels approved by the Food and Drug Administration”. The carcasses identified with violative drug residues are not a food safety hazard because they are disposed of in accordance with Directive 10,800.1 and 10,220.3. However at the current time [redacted]% of all bob veal slaughtered at Gold Medal are being tested for residues. This means that [redacted]% of the bob veal are not being tested. Without a doubt some of these latter carcasses are adulterated with drug residues, they are entering commerce, and therefore are a potential food safety hazard HACCP coordinator was made aware of the producer with a fourth violation, and has been made aware of all the other violations as they have been reported. Past Similar NRs – Previous Ineffective Plant Actions: Ineffective prerequisite program for residues NR: 24-2010 dated 7/21/2010 Past Similar NRs – Previous Ineffective Plant Actions: Ineffective prerequisite program for drug residues and ineffective changes made upon reassessment of HACCP plan NR: 24-2010 dated 7/21/2010

Regulation:

318.20 Animal drug residues are permitted in meat and meat food products if such residues are from drugs which have been approved by the Food and Drug Administration and any such drug residues are within tolerance levels approved by the Food and Drug Administration, unless otherwise determined by the Administrator and listed herein.

417.2(a)(1) Every official establishment shall conduct, or have conducted for it, a hazard analysis to determine the food safety hazards reasonably likely to occur in the production process and identify the preventive measures the establishment can apply to control those hazards. The hazard analysis shall include food safety hazards that can occur before, during, and after entry into the establishment. A food safety hazard that is reasonably likely to occur is one for which a prudent establishment would establish controls because it historically has occurred, or because there is a reasonable possibility that it will occur in the particular type of product being processed, in the absence of those controls.

417.5(a)(1) The written hazard analysis prescribed in §417.2(a) of this part, including all supporting documentation;

Code: 04B04
Violation:  317.8

Citation: At 0610 hours this date, performing a pre operational inspection in the East Cooler, noted were 7 boxes and 1 bag of product marked “pig”. A pig was not found in each container. All other labeling requirements were present, this is not a food safety issue. This is not accurate labeling per 317.8. A US Retained tag NO B38541651 was applied to the product. HACCP Coordinator was informed.

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: 04B04
Violation:  316.9

Citation: On a walk thru at approximately 0900 hours on 23 July 2010, noted in the Center and South Coolers, bob veal carcasses with US Inspected and Passed marks of Inspection had been applied to bob veal carcasses that also had US Blue Retained Tags. US Inspected and Passed marks of inspection and US Retained Tags both are not allowed on the same carcass at the same time, reference 316.9. HACCP Coordinator was informed. This was not a food safety issue, as the product was under USDA control and disposition was made [redacted].

Regulation:

316.9(b) Inspected and passed sausage and other products, in casings or in link form, of the smaller varieties, shall bear one or more official inspection legends and one or more lists of ingredients in accordance with part 317 of this subchapter on each kilogram (2.205 lbs.) of product, except where such products leave the official establishment completely enclosed in properly labeled immediate containers having a capacity of 5 kilograms (11.025 lbs.) or less and containing a single kind of product: Provided, That such products in properly labeled closed containers exceeding 5 kilograms (11.025 lbs.) capacity, when shipped to another official establishment for further processing or to a governmental agency, need only have the official inspection legend and list of ingredients shown twice throughout the contents of the container. When such products are shipped to another official establishment for further processing, the inspector in charge at the point of origin shall identify the shipment to the inspector in charge at destination by means of Form MP 408–1.

Code: 06D01
Violation:  416.2(d)

Citation: On this day EIAO Dr and EIAO while doing a walk thru of the chill cooler, noted beaded condensation on the ceiling in front of the refrigeration unit on the south end of the cooler. Condensation may result in direct contamination to the hanging veal carcasses if dripping occurs, no product was contaminated. In the Sanitation Standard Operating Procedures, Section V Operational Sanitation, 1i1 states [redacted], C . 1i3 states,  [redacted]. These two seem to list two different corrective actions. Section VI. Operational Sanitation-Corrective Actions states  [redacted]. Corrective actions (as per 416.15), including  [redacted]; are recorded on the respective SSOP Records. HACCP Coordinator was notified and corrective action was taken, condensation was removed and area :blocked off” for use. Reference similar previous NR No 0021-2010-15670 dated 14 July 2010 and NR No 0023-2010-15670 dated 20 July 2010.

Regulation:

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.

Code: 03C01
Violation:  417.4(a)(2)(ii)

Citation: On this day EIAO Dr and EIAO while doing a walk thru of the processing department noted that the [redacted] spray was not operating at the end of the processing table over the lazy susan with veal product on the table. The purpose of the [redacted] spray is to address E Coli 0157H7. In the HACCP Plan for Raw, Not Ground Products (Further Processing) CCP 1B, under Hazard, Ongoing Verification Procedures and Frequency, under 417.4(a)(2)(11)which states, “Once per day, one direct observation of the antimicrobial treatment CCP for the Raw HACCP Process categories and corrective actions, if taken, will be performed by a quality control. The HACCP manager or designee will record results of this verification activity on the Antimicrobial Intervention Record (GMP-HACCP-Form-003). The non operating nozzle not operating resulted in the product in the lazy Susan not being properly sprayed with spray. Under corrective actions on CCP 1B it states “[redacted].” The failure of the sprayer is a indication of failure to take corrective action. This is a food safety hazard, but there is a spray after this CCP that are not CCPs. HACCP Coordinator was notified and corrective action was taken, the spray was turned on.

Regulation:

417.4(a)(2)(ii) Direct observations of monitoring activities and corrective actions;

Code: 03J01
Violation:  417.2(c)(4), 417.3(a)(1), 417.3(a)(2)

Citation: On this day Dr EIAO and EIAO while doing a walk thru of the kill floor, noted that the pre evisceration cabinet was not operating properly. There are three sets of nozzles in the cabinet and the bottom set was not operating and was turned off, so the veal carcasses were not sprayed completely. The purpose of the cabinet is to provide spray to address E Coli 0157H7. In the HACCP plan for veal, lamb and goat slaughter it states in CCP 1B “[redacted] ” The non operating nozzles resulted in the carcasses not being completely covered with the [redacted] spray. It was also noted that when a space was on the line between the veal carcasses they were not being sprayed properly due to the electric eye not operating properly. Under corrective actions on CCP 1B it states “[redacted]” The failure of the [redacted] sprayer is a indication of failure to take corrective action. This is a food safety hazard ,but there are two or three [redacted] sprays that are not CCPs, after this [redacted] spray depending on final disposition of product. HACCP Coordinator was notified and immediate corrective action was taken, the bottom set of nozzles were turned on.

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;

417.3(a)(1) Every official establishment shall conduct, or have conducted for it, a hazard analysis to determine the food safety hazards reasonably likely to occur in the production process and identify the preventive measures the establishment can apply to control those hazards. The hazard analysis shall include food safety hazards that can occur before, during, and after entry into the establishment. A food safety hazard that is reasonably likely to occur is one for which a prudent establishment would establish controls because it historically has occurred, or because there is a reasonable possibility that it will occur in the particular type of product being processed, in the absence of those controls.

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

Code: 04B04
Violation:  317.1, 317.2(b), 317.2(c)

Citation: On this day at approximately 1530 hours while walking through the offal cooler to put residue samples away, I noticed three trays of bob veal hearts and three trays of tongues that were unlabeled. These organs were from today’s production, and all processing and kill floor employees had left for the day. Typically a label is placed on these trays by the end of the production day, but at that hour it was unlikely that they would be labeled. Retain tags were placed on the trays of hearts (B20434995, B20434963, and B20434993), and on the trays of tongues (B20434992, B20434994, and B20434993). HAACP coordinator was contacted. This observation was part of an unscheduled 04B04. Failure to label the hearts and tongues is a non-compliance with 9 CFR 317.1, 317.2(b), and 317.2(c)

Regulation:

317.1(a) When, in an official establishment, any inspected and passed product is placed in any receptacle or covering constituting an immediate container, there shall be affixed to such container a label as described in §317.2 except that the following do not have to bear such a label.

317.2(b) Any word, statement, or other information required by this part to appear on the label must be prominently placed thereon with such conspicuousness (as compared with other words, statements, designs, or devices, in the labeling) and in such terms as to render it likely to be read and understood by the ordinary individual under customary conditions of purchase and use. In order to meet this requirement, such information must appear on the principal display panel except as otherwise permitted in this part. Except as provided in §317.7, all words, statements, and other information required by or under authority of the Act to appear on the label or labeling shall appear thereon in the English language: Provided, however, That in the case of products distributed solely in Puerto Rico, Spanish may be substituted for English for all printed matter except the USDA inspection legend.

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:

Code: 06D01
Violation:  416.2(d)

Citation: At Est 17965M Gold Medal Packing, at approximately 0545AM with EIAO Dr EIAO and HACCP Coordinator, performing a 01BO2 on the processing department, beaded condensation was noted on the ceiling area and rails at the south end of the department. Dripping water was also noted from the ventilation shaft at the east side of the department. No product was affected. In the Sanitation Standard Operating Procedures, Section V Operational Sanitation, 1i1 states, [redacted]. 1i3 states,  [redacted]. These two seem to list two different corrective actions. Section VI. Operational Sanitation-Corrective Actions states  [redacted]. Corrective actions (as per 416.15), including  [redacted]; are recorded on the respective SSOP Records. A USDA Rejected Tag # B20434376 was applied. This is a violation of CFR 416.2(d). HACCP coordinator applied a HACCP Reject Tag and “blocked off” the ventilation shaft area. Reference similar previous NR No 0021-2010-15670 dated 14 July 2010.

Regulation:

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.

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

Citation: At Est 17965M Gold Medal Packing, at approximately 0530 AM with EIAO Dr EIAO and HACCP Coordinator, performing a 01BO2 on the kill floor, blood was noted on the head rack. A USDA Rejected tag # B20434380 was attached and HACCP Coordinator was notified. On the cutting board on the S/S table at the south end of the kill floor several black specks were noted. A USDA Rejected tag # B20434379 was attached and was notified. This is a violation of CFR 416.4(a). Reference Sanitation Standard Operating Procedures lll Pre-Operational Sanitation-Processing Equipment and Facility Sanitation .B.1. Production Departments (Daily, before each use) Clean affected equipment, floors, and walls according to the General Equipment and Facility Sanitation SOPs, and IV Pre-Operational Sanitation- Corrective Actions which states, [redacted]. In accordance with 416.15(b), Corrective actions include procedures to insure appropriate disposition of product that may be contaminated, restore sanitary conditions, and prevent the Recurrence of direct contamination of products.

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.

Code: 06D01
Violation:  416.2(d)

Citation: At Est 17965M Gold Medal Packing, at approximately 0910 AM on a “walk tru” during a FSA with Dr , EIAO HACCP, and IIC, beaded condensation was noted on the ceiling of the Chill Cooler. No product involved, HACCP Coordinator was informed, product was moved from area and stops were placed on rails to prevent possible contamination, supervised by In the Inedible Cooler dripping condensation and running water from the refrigeration unit overhead was noted, contaminating tubs of inedible rennet’s retained on a previous NR and condemned. HACCP Coordinator corrected after this product was removed and disposed of. Regulations state ventilation must be sufficient to prevent condensation which may result in possible contamination.

Regulation:

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.

Code: 03J02
Violation:  310.2, 310.3

Citation: On this day at approximately 9:30 AM while performing daily dispositions, I was presented with a bob veal carcass that had obvious signs of polyarthritis and septicemia. At the time of postmortem examination, all parts associated with this carcass were accounted for except for the abomasum. Abomasums are typically harvested from bobs at Gold Medal Packing and sold for their rennet content. Stomachs that are removed for this purpose must be from calves that have been inspected and passed. This particular carcass was retained for pathology and did not pass inspection. Furthermore the fact that the stomach was missing is in violation of 9 CFR 310..2 and 310.3 which explain that all body parts should remain with a carcass until post-mortem examination is complete. The abomasum from this condemned carcass was missing and was mixed in with 1 of 6 lugs of abomasums from carcasses that had passed inspection during the morning’s production.. The lugs were located in the hide cooler and were retained with Retain Tags B20434959 and B20434960 while plant management ws notified. I spoke with HAACP coordinator and made her aware of the situation. Since the lug in which the condemned aomasum was located could not possibly have been identified, made the decision to discard and denature the 6 lugs of calf stomachs. Past Similar NRs – Previous Ineffective Plant Actions: Failure to ensure that all carcass parts remain together until post-mortem examination is complete. NR: 9-2010 dated 4/30/2010

Regulation:

310.2(a) The head, tail, tongue, thymus gland, and all viscera of each slaughtered animal, and all blood and other parts of such animal to be used in the preparation of meat food products or medical products, shall be handled in such a manner as to identify them with the rest of the carcass and as being derived from the particular animal involved, until the post-mortem examination of the carcass and parts thereof has been completed. Such handling shall include the retention of ear tags, backtags, implants, and other identifying devices affixed to the animal, in such a way to relate them to the carcass until the post-mortem examination has been completed.

310.3 Each carcass, including all detached organs and other parts, in which any lesion or other condition is found that might render the meat or any part unfit for food purposes, or otherwise adulterated, and which for that reason would require a subsequent inspection, shall be retained by the Program employee at the time of inspection. The identity of every such retained carcass, detached organ, or other part shall be maintained until the final inspection has been completed. Retained carcasses shall not be washed or trimmed unless authorized by the Program employee.

Code: 06D01
Violation:  314.3

Citation: On multiple occasions I have asked the employee in the antemortem pens who is responsible for denaturing the dead calves, to come and get an FSIS employee in the office so we can observe that procedure each day. If we are out in the pens making observations on humane handling or performing antemortem, then the employee obviously does not need to come and get one of us. Our observations of denaturing have been hit or miss because we have been unaware of when this procedure was being done.The denaturant is kept in a plastic milk jug by a desk in the antemortem pens. As part of an ongoing 06D01, I made note of the denaturant level in this container on the afternoon of June 30th.July There have been 3 slaughter days since that observation – July 1st, July 2nd and July 12th. The level of denaturant in the container remained the same. Furthermore, the needle on the end of the syringe typically used was bent in exactly the same fashion on July 2nd and July 12th. The bend in the needle rendered it useless. Clearly the dead calves had been loaded onto a truck without being denatured for several days. This is in viollation of 9 CFR 314.3, which states that (a) Carcasses, parts of carcasses, and other products condemned at an official establishment that has no facilities for tanking shall except as provided in paragraph (b) of this section or elsewhere in this part, be destroyed in the presence of an inspector by incineration, or denatured with crude carbolic acid, or cresylic disinfectant, or a formula consisting of one part FD&C No. 3 green coloring, 40 parts water, 40 parts liquid detergent, and 40 parts oil of citronella or any other proprietary material approved by the administrator in specific cases. When such product is to be denatured, it shall be freely slashed before the denaturing agent is applied, except that, in the case od dead animals that have not been dressed, the denaturant be applied by injection. The denaturant must be deposited in all portions of the carcass or product to the extent necessary to preclude its use for food purposes.

Regulation:

314.3(a) Carcasses, parts of carcasses, and other products condemned at an official establishment which has no facilities for tanking shall, except as provided in paragraph (b) of this section or elsewhere in this part, be destroyed in the presence of an inspector by incineration, or denatured with crude carbolic acid, or cresylic disinfectant, or a formula consisting of one part FD&C No. 3 green coloring, 40 parts water, 40 parts liquid detergent, and 40 parts oil of citronella or any other proprietary material approved by the Administrator in specific cases. When such product is to be denatured, it shall be freely slashed before the denaturing agent is applied, except that, in the case of dead animals that have not been dressed, the denaturant may be applied by injection. The denaturant must be deposited in all portions of the carcass or product to the extent necessary to preclude its use for food purposes.

Code: 03J01
Violation:  417.2(a)(1), 417.5(a)(1)

Citation: On this day while reviewing residue recordsas part of an 03J01, it became evident that two same source suppliers that ship bob veal to Gold Medal Packing now have three residue violations each. These producers are and . Residues are addressed in a prerequisite program. For repeat violators, the plan states that “[redacted] “. Previously, the prerequisite program stated that “[redacted].” This wording change was made on 6/25/2010, which incidentally in the cases of both suppliers was after the second violation but before the third. This new approach to residue violators by way of wording, has turned out to be an ineffective method for preventing calves with residues from entering the plant. According to 9 CFR 417.2 (a) Hazard analysis. (1) Every official establishment shall conduct, or have conducted for it, a hazard analysis to determine the food safety hazards reasonably likely to occur in the production process and identify the preventative measures the establishment can apply to control these hazards. The hazard analysis shall include food safety hazards that can occur before, during and after entry into the establishment. A food safety hazard that is reasonably likely to occur is one for which a prudent establishment would establish controls because it historically has occurred, or because there ia a reasonable possibility that it will occur in the particular type of product being processed in ther absence of these controls. Past Similar NRs – Previous Ineffective Plant Actions: Failure of corrective action for residue viuolations NR: 19-2010 dated 6/29/2010

Regulation:

417.2(a)(1) Every official establishment shall conduct, or have conducted for it, a hazard analysis to determine the food safety hazards reasonably likely to occur in the production process and identify the preventive measures the establishment can apply to control those hazards. The hazard analysis shall include food safety hazards that can occur before, during, and after entry into the establishment. A food safety hazard that is reasonably likely to occur is one for which a prudent establishment would establish controls because it historically has occurred, or because there is a reasonable possibility that it will occur in the particular type of product being processed, in the absence of those controls.

417.5(a)(1) The written hazard analysis prescribed in §417.2(a) of this part, including all supporting documentation;

Code: 03J01
Violation:  417.5(a)(1)

Citation: On this day while reviewing our residue results as part of an 03J02, I found residue laboratory submission forms that contained the names of 4 same source suppliers that have had 2 prior residue violations each, at Gold Medal Packing Est. 17965. Residues are addressed in a prerequisite program. According to the prerequisite program, “[redacted]. However in the HAACP plan for slaughter of veal lamb and goats, under Step 6-Reception, where Residues (Growth Hormone) and Residues are addressed, it states that “[redacted]”. had residue violations on 11/12/2009 (Sample# 512028) and 2/4/2010 (Sample# 514487). An additional animal purchased from this producer was sampled on 6/4/2010. had residue violations on 2/23/2010 (Sample# 515923) and 4/27/2010 (Sample# 497483). An additional animal was sampled on 6/18/2010 (Sample# 579133).[redacted] had residue violations on 12/29/2009 (Sample# 514391) and 5/14/2010 (Sample# 497528). Additional calves were sampled from this source on 6/22/2010 (Sample# 579168) and 6/18/2010 (Sample# 579155, 579149) and 6/15/2010 (Sample# 579138). had residue violations on 5/18/2010 (Sample# 497530) and 5/28/2010 (579106). An animal from this farm was sampled on 6/11/2010 (Sample# 579126).. While it is not against regulations to purchase a third calf from a producer that has had two violations (see Notice 03-10), the fact that calves from same source suppliers have entered the facility is not consistent with the HAACP plan as written. Furthermore, the fact that calves have been repeatedly purchased from same source suppliers may be an indication that the residue program in place is not effective. HAACP coordinator has been made aware of these findings.

Regulation:

417.5(a)(1) The written hazard analysis prescribed in §417.2(a) of this part, including all supporting documentation;

Code: 01D01
Violation: 416.1, 416.2(b)(1), 416.2(b)(2), 416.2(d)

Citation: On Thursday, June 21, 2012, around 12:00pm, while walking through the main holding cooler at Establishment 21554M Grizzly’s Custom Cutting, the following noncompliance was observed:
Mr. [redacted] was in the process of mopping condensation/liquid from the ceiling of the main holding cooler. He was addressing the area over the 2nd rail from the processing room, about one quarter of the way from the front of the cooler. As he pressed on the seam to soak up a drop of liquid, several more droplets formed on either side of the mop head. He was able to catch them before they dripped onto the 4 swine carcasses that were underneath. At that point, he moved the 4 swine carcasses from under the area and mopped up additional newly accumulated liquid. As he pushed the mop onto the plastic ceiling tile, additional droplets formed along the seam. Mr. [redacted] left the cooler and I, along with CSI [redacted] remained and observed droplets accumulate and drip to the floor at an approximate rate of 1 drip every 3 seconds. Thorough inspection of the rest of the holding cooler revealed no other areas of liquid accumulation along seams or on overhead structures. Thorough review of the 4 swine carcasses that were under the affected area revealed no evidence of contamination from dripping liquid. Regulatory Control Action was taken: the second rail from the processing room was rejected with tag number B41007167. The above is in noncompliance with 9CFR 416.1, 416.2(d), and 416.2(b)(1-2).
Mr. [redacted] plant owner/manager, and Ms. [redacted] plant manager, were notified by CSI [redacted] of the above noncompliances.
Upon review of past NRs, 3 previous noncompliances with the similar cause were identified: NR GUM5510065313 (6/13/12) was documented for liquid dripping from seams of the ceiling in the main holding cooler during a severe rainstorm; NRs GUM5810060514 (6/14/12) and GUM5909055630 (5/30/12) were documented for liquid accumulation on and around the cooling unit in the main holding cooler. Further planned actions of repairing the roof, draining and drying the cooler ceiling, retraining employees, and creating a condensation monitoring record were ineffective in preventing recurrence of the noncompliances.
Mr. [redacted] was informed that this noncompliance record will be linked to previous noncompliances of similar cause and that continued failure to meet regulatory requirements can lead to enforcement actions described in 9CRF 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(b)(1) Construction. Establishment buildings, including their structures, rooms, and compartments must be of sound construction, be kept in good repair, and be of sufficient size to allow for processing, handling, and storage of product in a manner that does not result in product adulteration or the creation of insanitary conditions.

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

416.2(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: 01D01
Violation: 416.2(a)

Citation: At 0900 on 20 June 2012, while on the kill floor, Dr [redacted] reached down and opened the mouse trap located in the hallway next to the door. There was a badly decomposed mouse and maggots inside the trap . The Slaughter SSOP report for 20 June was checked off by [redacted] as being acceptable. Mr [redacted] said that he did not realize that there was a trap located there. [redacted] was immedatly notified of the situation.
This is in non compliance with 416.1 and 416.2 a.
Review of past Non Compliance records indicated that NR GUM5909055630 showed the same root cause. The further planned action was to increase monitoring, which will be checked weekly. This was ineffective in preventing reoccurence of the non compliance. Mr. [redacted] was informed that failure to meet regulatory requirements can lead to enforcement actions described in 9CFR 500.4.

Regulation:

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.

Code: 01D01
Violation: 416.1, 416.2(b)(1), 416.2(b)(2), 416.2(d), 416.4(d)

Citation: At 1500, on 13 June 2012, after returning from Est. 04684 EIAO [redacted] informed me,CSI [redacted] that there were 2 beads of condensation on the chilling unit in the main holding cooler over unprotected quarter carcasses. I went out to the holding cooler and verified that there were in fact, 2 beads of condensation on the drip pan. I notified Est. personal [redacted] and pointed it out to him. He said he was going to get a towel and wipe it off, but was sidetracked when gave him another task. Periodically I went back into the cooler to see if the beads of condensation were removed, or if they had dripped onto exposed product. Finally, at 1630 I inspected the beads and they were still there. At that time I notified [redacted] and he wiped them down with a towel. No product contamination was involved. [newline]The Establishment has a written SOP procedure in place addressing SPS issues, to include [redacted]. The Raw SSOP report from 13 June 2012 shows that condensation was monitored and acceptable. This in non compliance with 9CFR 416.1, 416.2d, 416.4d,416.13b and c. I applied Tags to all 3 doors, ( B41007168, B41007174, and B41007169), rejecting the holding cooler.[newline]A review of documented past Non compliances showed that on 30 May2012 , NR GUM5909055630 stated that condensation was dripping onto one beef carcass in the holding cooler. Response to the NR was: The condensation was removed from the ceiling and the affected beef carcass was trimmed immediately. [newline]The Establishment response failed to correct the non compliance and prevent a reoccurence. Continued failure to meet regulatory requirements can lead to enforcement actions 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(b)(1) Construction. Establishment buildings, including their structures, rooms, and compartments must be of sound construction, be kept in good repair, and be of sufficient size to allow for processing, handling, and storage of product in a manner that does not result in product adulteration or the creation of insanitary conditions.

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

416.2(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(b), 416.13(c), 416.14, 416.2(b)(1), 416.2(b)(2), 416.2(d), 416.4(d)

Citation: At 1600,12 June 2012 EIAO [redacted] came into the inspection office and notified me, CSI [redacted] that water was leaking through the main holding cooler ceiling , dripping onto several beef quarters. I went to the holding cooler and confirmed that the ceiling was leaking thru half of the seams in the ceiling closest to the cutting room. I immediately notified [redacted] of the situation, and two of his personnel moved the carcasses out from the affected area and trimmed all affected product . I then reinspected the quarter carcasses and had the Est. personnel move them to the blast cooler. I sugested that Mr. [redacted] put a plastic shroud over the rest of the carcasses that were not in the affected area, and he said he would. At 0800 on 13 June 2012 I went into the main holding cooler to inspect the area and all product in the non-affected area, and saw no deficiencies, but there was no plastic shroud covering the remaining carcasses. US Retain Tags B41007175, B41007176, and B41007177 were placed on all rails affected by the leaking ceiling, and Mr. [redacted] was notified. All livers and tongues affected were disposed of.[newline]The Establishment has a written SOP procedure in place addressing SPS issues, to include [redacted]. The Raw SSOP report record indicates condensation was monitored and is acceptable. This is in non compliance with 9CFR 416.1, 416.2d, 416.4d, 416.13b and c.A review of past 3 months documented non-compliances did not reveal similar causes.

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.

416.14 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.

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

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

416.2(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: 06B02
Violation: 416.1, 416.3(a), 416.4(a)

Citation: On May 31, 2012, at approximately 0730 while Mr. [redacted] EIAO was performing a Review & Observation of the establishment performing pre-operational procedures, the following noncompliances were observed. • Meat particles were found on the blades of the cuber in the raw meat cutting room. U.S. Rejected B37778747 • Rust was found on the bolts and a blade was chipped in the mixer located in the process/smoked area. U.S. Rejected B3778749. • The bacon slicer in the process/smoke area had residue from previous operations. U.S. Rejected B3778748. • Residue from previous operations was found on the lower part of the supports of the grinder guard located in the process/smoke area. U.S. Rejected B3778750. • Meat particles were observed in the throat of the [redacted] stuffer in the process/smoke area. U.S. Rejected B20437382. Inspection operations were not being conducted in the areas where the equipment was found to be unsanitary. However, the establishment was conducting retail operations and had released the equipment for inspection. Mr. [redacted] was verbally notified of the noncompliances. A review of noncompliance records documented the previous 3 months did not reveal any similar in nature.

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(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: 01D01
Violation: 416.1, 416.2(a), 416.2(b)(1), 416.2(b)(3), 416.2(d)

Citation: On May 29, 2012, from approximately 0930-1100 during the Comprehensive Food Safety Assessment (CFSA) at Grizzly’s Custom Cutting Est., Dr. [redacted] SVMO, Mr. [redacted] Relief Inspector and Mr. [redacted] EIAO started the initial tour of the facility. During the tour we observed the following unsanitary conditions inside the official premises of the facility. 1)Evidence of live pest (flies) on the walls of the chill cooler, and numerous dead pests (flies) on the chill cooler floor. 2) Beaded, dripping liquid falling from an overhead cooling unit directly onto a beef carcass hind quarter. This beef carcass was U.S. Retained B20437377. Mr. [redacted] Owner present at the time, retrieved a knife and immediately began trimming the affected area where the liquid had dripped. 3)One live pest (fly) on a beef hind leg hanging in the cooler. Mr. [redacted] was present at the time an immediately removed this fly off the carcass leg, trimmed the affected area and said that he would address the other flies in this cooler but that he had not had a chance to remove or clean this area because of the Memorial Day holiday. Later in the day observation of the cooler again revealed flies in the cooler. The flies were observed on two beef hindquarters. Mr. [redacted] was informed of the noncompliance and the two hindquarters were U.S. Retained B3778765 and B3778770. 4) Gap under the main entrance. Entering the main entrance leads directly into the retail store, the front area of the employee room, and the raw meat cutting room. However, there is no other door that closes to prevent entry of pest leading from the main entrance, into these areas. In addition, the dry storage area, adjacent to the raw meat cutting room has numerous live small moth-like insects on the wall above the coats and boxes in this area. No live pest were observed on product in the raw meat cutting room. Mr. [redacted] left during a tour of the outside official premises; however we observed the following unsanitary conditions. 1)Evidence of rodent droppings on a burlap cloth located in the attic above the smoke house. There is unused equipment, boxes and other items stored in a manner that prevent a complete inspection of this area. U.S. Rejected B3778760 2) Evidence of rodent droppings in the box storage room. There are two entry points (holes) in the box storage room along the bottom edge and along the ceiling. Boxes and pallets were also stored up against the walls preventing inspection of the entire parameter of the room. U.S. Rejected B20437412.Expansion of the inspection revealed no other evidence of rodent droppings in the rest of the inside facility including the production areas, spice room, cooler, freezer, the slaughter floor, dry storage area for the retail, retail areas, and shipping/receiving area. Mr. [redacted] returned afterwards and explained that these boxes in the box room are used for boxing finished product. We informed Mr. [redacted] of the conditions in the attic area as well and returned to show him however, the door was locked, and Mr. [redacted] explained that he did not know who locked the door and we were not able to gain re-entry into this area. A review of previously documented noncompliance records did reveal one documented similar in nature on 03/21/12. The plant managements response to the similar noncompliance record stated “Will fix hole and clean up box room and upstairs storage”. The establishments response failed to maintain the areas to prevent unsanitary conditions from reoccuring.

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

416.2(b)(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.

416.2(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(c)

Citation: At approximately 0815 after receiving verbal clearance from establishment personnel that the slaughter department was released for USDA inspection the following pre-operational sanitation noncompliances were observed.

1) The carcass splitting saw had fat on the blade and blade guide.
2) The head rack contained fat and dry blood.
3) The offal pan had fat and was greasy to the touch on the outer edges of the pan. These areas are food contact surfaces which resulted in U.S. Rejected Tag #B20439589 being applied to the equipment. After reviewing the Slaughter SSOP Report (GCC-SSOP-FORM-001) which was completed at 0800, it was determined that all equipment was found acceptable by establishment personnel.

Mr. [redacted] was verbally notified of the noncompliances. A review of noncompliance records documented the previous 3 months did not reveal any similar in nature.

Regulation:

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

Code: 03G02
Violation: 417.5(a)(3)

Citation: While reviewing HACCP records in the Ready to eat processing room at approximately 1100 the following noncompliance was observed.
On 04/27/2012 the establishment cooked Mild Italian Sausage which achieved a final cook temperature of [redacted] F at 1425 according to Smoked Products HACCP Report (GCC-HACCP-FORM-007). The product met CCP 1B (Smoke/Cook) according to Appendix A as stated in the HACCP Master Plan (GCC-HACCP-008) for the Fully Cooked, Not Shelf Stable products. After the lethality temperature is achieved the product is chilled according to Appendix B. The following chilling procedure (CCP 2B) is attached to HACCP Master Plan (GCC-HACCP-008) for the Fully Cooked, Not Shelf Stable products. [redacted]. As previously stated in the noncompliance record CCP 1B was met at 1425 and the establishment did take a temperature at 1442 which showed the product to be at a temperature of [redacted] degrees F. While this is not the critical limit of [redacted] degrees F it is reasonable to conclude the product achieved to meet the first time/temperature requirement that [redacted].
The noncompliance occurred when the establishment failed to document on the Smoked Products HACCP Report any additional time and temperature values to assure as required in the Master HACCP Plan. The record review of CCP 1B and CCP 2B was conducted at 1625 on 04/27/2012 by Mr. [redacted] and the results were documented as “OK”. Mr. [redacted] was verbally notified of the noncompliance and that I would be placing U.S. Retained Tag# B20437417 on the 63.4 lbs of Cooked Mild Italian Sausage produced on 04/27/2012.
A review of noncompliance records documented the previous 3 months did not reveal any similar in nature concerning the Fully Cooked, Not Shelf Stable HACCP process.

Regulation:

417.5(a)(3) Records documenting the monitoring of CCP’s and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment’s HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter production lot. Each of these records shall include the date the record was made.

Code: 03J02
Violation: 417.4(a), 417.5(a)(1), 417.5(a)(2)

Citation: When reviewing the establishments Certificate of Analysis from [redacted] dated 04/23/2012, the following noncompliances were observed. On 04/16/2012 the establishment collected a quarterly swab sample of a beef carcass which was analyzed on 04/17/1012 for E.coli 0157:H7 utilizing [redacted]. The result was reported as [redacted] per swab.
When reviewing the E.coli 0157:H7 Verification program it states [redacted]. It further states [redacted]. [redacted] is approved for raw beef products. The establishment failed to provide documentation to support the method used to analyze the swab. Failure to provide this support questions the validity and sensitivity of the sample method to detect the pathogen if present. Furthermore, [redacted]. Because of this noncompliance the effectiveness of the Anti-microbial agent applied to the beef carcasses at CCP 2B cannot be supported.
A review of noncompliances documented the previous 3 months indicated a similar noncompliance documented on 04/03/12. The establishment did not provide a response to the linked noncompliance record as of 04/26/12. A new sample was collected but the same noncompliaces still exist.

Regulation:

417.4(a) Every establishment shall validate the HACCP plan’s adequacy in controlling the food safety hazards identified during the hazard analysis, and shall verify that the plan is being effectively implemented.

417.5(a)(1) The establishment shall maintain the following records documenting the establishment’s HACCP plan: The written hazard analysis prescribed in § 417.2(a) of this part, including all supporting documentation;

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

Code: 03B02
Violation: 417.4(a)(2)(iii), 417.5(a)(1), 417.5(a)(2)

Citation: When reviewing the establishments Certificate of Analysis from [redacted]dated 04/23/2012, the following noncompliances were observed.
On 04/16/2012 the establishment collected a quarterly trim sample from Beef Chuck which was analyzed on 04/17/1012 for E.coli 0157:H7 utilizing AOAC method 2000.14. The result was reported as [redacted] per 25 grams. When reviewing the Beef Products (E.coli 0157:H7) section of the establishments prerequisite program for Receiving and Returns the following procedures are described. The product is sampled [redacted]. The program also states [redacted]. It further states [redacted].
The establishments laboratory failed to follow the instructions provided by the establishment to analyze 375 grams instead of 25 grams. The 25 gram sample size is not equal to USDA methods, which calls into question the sensitivity of the test to be able to detect the pathogen if present. Furthmore, the prerequisite program sampling is used to verify the effectiveness of the suppliers Continuing Letters of Guarantee. These letters are required by the establishment to assure the supplying establishment has CCPs in place to reduce or eliminate E.coli 0157:H7 to undetectable levels prior to entering the establishment.
This noncompliance calls into question the decisions in the Hazard Analysis that [redacted].
On 04/16/2012 the establishment collected a quarterly ground beef sample which was analyzed on 04/17/2012 for E.coli 0157:H7 utilizing [redacted]. The result was reported as [redacted] per 25 grams. The E.coli 0157:H7 Verification program states [redacted]. It further states [redacted]. It further states
The establishments laboratory failed to follow the instructions provided by the establishment to analyze 375 grams instead of 25 grams. The 25 gram sample size is not equal to USDA methods, which calls into question the sensitivity of the test to be able to detect the pathogen if present. Furthermore, as stated in the hazard analysis [redacted].
This noncompliance calls into question the decisions in the Hazard Analysis that [redacted].
A review of previously documented noncompliance records in the last 3 months indicated a similar noncompliance documented on 04/03/12. The establishment did not provide a response to the noncompliance record as of 04/26/12. New samples were collected but the same noncompliances still exist. Mr. [redacted] was verbally notified of the noncompliances.

Regulation:

417.4(a)(2)(iii) Ongoing verification activities. Ongoing verification activities include, but are not limited to: (i) The calibration of process-monitoring instruments; The review of records generated and maintained in accordance with § 417.5(a)(3) of this part.

417.5(a)(1) The establishment shall maintain the following records documenting the establishment’s HACCP plan: The written hazard analysis prescribed in § 417.2(a) of this part, including all supporting documentation;

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

Code: 03J02
Violation: 417.4(a)(2)(iii), 417.5(a)(1), 417.5(a)(2)

Citation: On April 2, 2012, while reviewing the results for the E coli O157:H7 first quarter samples and the establishments associated written prerequisite programs and HACCP plans during an unscheduled Slaughter HACCP Implementation Task at Establishment 21554M Grizzlys Custom Cutting, the following noncompliances were observed: First, the quarterly beef carcass swab for E coli O157:H7 that was submitted on 3/15/12 was tested by the lab for Generic E coli. When asked about this, Mr. stated that the lab ran the wrong test and informed FSIS that he would re-submit the sample for the correct testing. He submitted a second sample on 3/30/12. Mr. Informed FSIS on 4/6/12 that the lab said that the sample was but he did not have a report because the fax machine was out of ink. On 4/9/12 Mr. provided FSIS a report that showed a sample date of 3/30/12 and a date received of 4/2/12. Therefore, because the sample was not shipped overnight as per the plants program and supporting documentation, Mr. is unable to support the integrity of the sample at the time it arrived at the lab on 4/2/12, and the results are not supportable. Therefore, the plant failed to produce a valid sample result for the first quarter of 2012 (January 1-March 31). The plants written prerequisite program for E coli O157:H7 Verification (GCC-PRP-005, page 2-3) states that . . This is in noncompliance with 9CFR 417.4(a)(2) ongoing validation. Second, the Sample Submission form sent to the lab had conflicting dates: The (Date Submitted) section was documented by the establishment as 3/13/12, but the (Sample ID/Collection Date) in the sample information section for all samples (qt ground E coli, qt chuck IBP, and qt spong E coli) was changed by the establishment to 3/15/12 prior to submission. The final lab report states . The plant is unable to provide records to support the collection dates and that the samples were shipped overnight, and therefore the viability of the samples. The is used as support that , and therefore the decisions made in the HA are not supportable. This is in noncompliance with 9CFR 417.5(a)(1,2) recordkeeping. Third, the plant does not have a system in place for source traceability for any of the E coli samples (carcass swab, N60 chuck trim, ground beef) and there is no documentation of the product implicated by each sample. There is no documentation of the carcass which was sampled (owner name, slaughter date, or other identification) or the source/origin/supplier for the ground sample. The chuck trim sample (N60) states IBP, but no other information lot/package/pack date/volume implicated by sample lot is documented for traceability. The written E coli O157:H7 Verification Prerequisite Program (GCC-PRP-005) does not contain support or documentation of what the sampled lot represents i.e. there is no specified definition of a lot. The plants written program references the Grinding Raw Material and Formulation Reco

Regulation:

417.4(a)(2)(iii) Ongoing verification activities. Ongoing verification activities include, but are not limited to: The review of records generated and maintained in accordance with § 417.5(a)(3) of this part.

417.5(a)(1) The establishment shall maintain the following records documenting the establishment’s HACCP plan: (1) The written hazard analysis prescribed in § 417.2(a) of this part, including all supporting documentation

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

Code: 03G02
Violation: 417.5(a)(1), 430.4(b)(2), 430.4(c)(2), 430.4(c)(5)

Citation: On March 29-30, 2012, while reviewing the results for the Listeria species first quarter sample and the establishments written Listeria Sampling program in the SSOP for an unscheduled Fully Cooked Not Shelf Stable Task at Establishment 21554M Grizzlys Custom Cutting, the following noncompliances were observed:

First, the date of collection on the establishments Listeria Sampling Report (GCC-FORM-010 Rev1) was 3/13/12. However, the Sample Submission form sent to the lab had conflicting dates: The (Date Submitted) section was documented by the establishment as 3/13/12, but the (Sample ID/Collection Date) in the sample information section was changed by the establishment to 3/15/12 prior to submission. The final lab report states a (Date and Time Sampled) as 3/15/12. According to page 7 of the written SSOP program: [redacted] The discrepancy in the dates on the forms fails to support that the samples were submitted overnight, and therefore brings into question the viability of the sample, and therefore the validity of the results. This is in noncompliance with 9CFR 416.13(b), 416.14, 430.4(c)(2), and 430.4(c)(5).

Second, the Listeria Sampling Report (GCC-FORM-010 Rev1) has a pre-printed list of equipment (vac packer, pack off table, scale, scale table, red lugs, vac bags, vinyl gloves, saw, bacon slicer). Review of the past 3 years of records showed that this list has been the same for all samples collected. When asked about this, Mr. [redacted], the RTE employee who routinely collects the samples, stated that he randomly selects a numbered chip which corresponds to one of the pieces of equipment listed on the Listeria Sampling Report to determine which site to sample for the quarter. Mr. [redacted] confirmed that the list of eligible sample locations is not altered based on production, but is the same list each quarter. This is inconsistent with the protocol on page 6 of the SSOP, which states: [redacted] This is a failure of the plant to implement their written procedures. Using this preprinted list could result in: a) sampling equipment that is not in use at the time, and more importantly, b) potential exclusion of food contact surfaces that are routinely used from the random sampling program (carts, trays, knives, packaging materials, tables in the packing room, scissors, etc). This is in noncompliance with 9CFR 416.13(b), 416.14, 430.4(b)(2)(iii)(A), 430.4(b)(2)(iii)(D), and 430.4(c)(5).

Third, it was observed that the time of collection on the Listeria Sampling Report was 7:40am. This is prior to the start of operations for the establishment. Upon review of the past 3 years records, sampling times have consistently been documented as prior to the start of operations. When asked, Mr. [redacted] confirmed that he has consistently collected the Listeria samples prior to the start of operations. He also confirmed that samples are collected whether the plant will be producing any RTE product that day or not. This is inconsistent with the protocol on page 6 of the SSOP, which states: [redacted] This is in noncompliance with 9CFR 416.13(b) and 430.4(b)(2)

Regulation:

417.5(a)(1) The establishment shall maintain the following records documenting the establishment’s HACCP plan: The written hazard analysis prescribed in § 417.2(a) of this part, including all supporting documentation;

430.4(b)(2) In order to maintain the sanitary conditions necessary to meet this requirement, an establishment producing post-lethality exposed RTE product must comply with the requirements included in one of the three following alternatives: Alternative 2. Use of either a postlethality treatment (which may be an antimicrobial agent) that reduces or eliminates microorganisms on the product or an antimicrobial agent or process that suppresses or limits growth of L. monocytogenes. If an establishment chooses this alternative:

430.4(c)(2) For all three alternatives in paragraph (b): Sanitation measures for controlling L. monocytogenes and procedures for antimicrobial agents or processes that suppress or limit the growth of the pathogen may be incorporated either in the establishment’s HACCP plan or in its Sanitation SOP or other prerequisite program. When these control procedures are incorporated into the Sanitation SOP or prerequisite program, and not as a CCP in the HACCP plan, the establishment must have documentation that supports the decision in its hazard analysis that L. monocytogenes is not a hazard that is reasonably likely to occur.

430.4(c)(5) If L. monocytogenes control measures are included in the Sanitation SOP, the effectiveness of the measures must be evaluated in accordance with § 416.14.

Code: 03F02
Violation: 310.22(e)(1), 417.2(a)(1), 417.5(a)(1)

Citation: On Monday April 2, 2012, while reviewing Hazard Analyses for the recordkeeping component of an unscheduled Heat Treated Shelf Stable Task at Establishment 21554M Grizzlys Custom Cutting, the following noncompliance was observed:

In 4 of the establishments Hazard Analyses, [redacted]. The relevant HACCP plans are: GCC-HACCP-008 (Fully Cooked Not Shelf Stable Hots and Sausage), GCC-HACCP-010 (Heat Treated Shelf Stable Jerky), GCC-HACCP-011 (Heat Treated Shelf Stable Snack Sticks), and GCC-HACCP-007 Heat Treated Shelf Stable Bar Sausage. The plant has a written SRM Prerequisite Program (GCC-PRP-002), but this program [redacted]. The plant does not address the potential contamination with SRM before, during, and after entry into the establishment for HT-SS and FC-NSS products as there are no written control procedures designed to either (1) prohibit the entry into the establishment of bone-in beef from cattle 30 months of age and older, or (2) ensure that such product is handled in an appropriate manner if it is permitted to enter the establishment. This is in noncompliance with 9CFR 310.22(e)(1) for SRM control, 9CFR 417.2(a)(1) for hazard identification in the Hazard Analysis and 417.5(a)(1) for supporting documentation.

Mr. [redacted] was informed of the above noncompliances.

Review of past noncompliances did not reveal any of similar cause.

Regulation:

310.22(e)(1) Procedures for the removal, segregation, and disposition of specified risk materials. Establishments that slaughter cattle and establishments that process the carcasses or parts of cattle must develop, implement, and maintain written procedures for the removal, segregation, and disposition of specified risk materials. These procedures must address potential contamination of edible materials with specified risk materials before, during, and after entry into the establishment. Establishments must incorporate their procedures for the removal, segregation, and disposition of specified risk materials into their HACCP plans or Sanitation SOPs or other prerequisite programs.

417.2(a)(1) Hazard analysis. Every official establishment shall conduct, or have conducted for it, a hazard analysis to determine the food safety hazards reasonably likely to occur in the production process and identify the preventive measures the establishment can apply to control those hazards. The hazard analysis shall include food safety hazards that can occur before, during, and after entry into the establishment. A food safety hazard that is reasonably likely to occur is one for which a prudent establishment would establish controls because it historically has occurred, or because there is a reasonable possibility that it will occur in the particular type of product being processed, in the absence of those controls.

417.5(a)(1) The establishment shall maintain the following records documenting the establishment’s HACCP plan: The written hazard analysis prescribed in § 417.2(a) of this part, including all supporting documentation;

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

Citation: At approx: 0830 hours while performing a SPS-06D01, verification inspection I observed the following NonCompliance. There is a hole in the siding near the unloading dock off the kill floor at the bottom of the overhead door jam on the right hand side. The approximate size was four inches by four inches. That would allow the entrance of vermin. I immediately told plant owner Mr. [redacted] about the hole, he told me to show him which I did. Mr. [redacted] told me he would fix it right away. There is a double door between the unloading dock and the kill floor, so no reject tag was issued at this time. There was no evidence of any rodent activity at this time. The above is in noncompliance with regulation 416.2(a) & 416.2(b)(3). Further I observed clutter on the walk way of the over head storage area above the RTE processing room. I was not able to inspect the area because I could not walk down the walk way there is no passage way. Also the Box room off the raw processing room has a cluttered walk way and inspection can not inspect the store room because there is no passageway. The above is in NonCompliance with Regulation 416.2(a). Mr. [redacted] told me he will have it straightened up to allow inspection of the areas mentioned. No reject tags issued at this time. Plant owner Mr. [redacted] was informed of the above noncompliances. Review of past NonCompliance did not show any with same cause in the past three months.

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.

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

Citation: On December 2, 2011, while performing an unscheduled SPS Verification Task – review of water potability requirements, the following noncompliance was observed:

The establishment does not have a current water potability certificate on file. The last water certification test was performed on March 28, 2011 – over 8 months ago. According to 9CFR 416.2(g)(1), a plant who uses a private well for its water supply must have documentation certifying the potability of the water supply that has been renewed at least semi-annually (i.e. every 6 months).

On October 27, 2011, CSI [redacted] requested the certificate from Plant Owner [redacted] Mr. [redacted] told CSI [redacted] that he had submitted the sample and would provide the results to FSIS as soon as he received them. However, no results have been provided to FSIS since that discussion.

Today, I asked Mr. [redacted] if he had received the results of the sample submitted around 10/27, and he stated that he did not and that he submitted a new sample within the last week. I informed Mr. [redacted] that this is in noncompliance with 9CFR 416.2(g)(1), and that because he does not have a current certificate, he is unable to support that the plant’s water supply is safe for use in a food processing environment (i.e. not contaminated and/or a potential food safety risk).

The plant is currently processing venison and retail. I informed Mr. [redacted] that he would have to provide a current certificate before inspected slaughter and processing could resume. He stated he would have the results available to FSIS by the beginning of next week (12/5-7/11).

Review of past noncompliances does not reveal any of similar cause.

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(g)(1) Water supply and water, ice, and solution reuse. A supply of running water that complies with the National Primary Drinking Water regulations (40 CFR part 141), at a suitable temperature and under pressure as needed, must be provided in all areas where required (for processing product, for cleaning rooms and equipment, utensils, and packaging materials, for employee sanitary facilities, etc.). If an establishment uses a municipal water supply, it must make available to FSIS, upon request, a water report, issued under the authority of the State or local health agency, certifying or attesting to the potability of the water supply. If an establishment uses a private well for its water supply, it must make available to FSIS, upon request, documentation certifying the potability of the water supply that has been renewed at least semi-annually.

Code: 03J02
Violation: 417.3(a)(1), 417.3(a)(3), 417.4(a)(2)(ii), 417.4(a)(2)(iii), 417.5(a)(3), 417.5(b)

Citation: At approximately 1500 on November, 2- 2011, while performing an unscheduled Slaughter HACCP procedure, the following noncompliance was observed:

On the Lamb/Swine Slaughter Report form for 11/01/11, there was no record of a Direct Observation for CCP-1B – Zero Tolerance. GCC-HACCP-003 p. 10 of 12 states that the plant will “ [redacted].” Further there was no Record Review perform for that slaughter record dated 11/1/11.The Plants HACCP plan states that [redacted]. on pg 11of 12 GCC-HACCP-003. Further more there was no record of Carcass Chill Monitoring for the lamb and swine carcasses slaughtered the same day 11/01/11. GCC-PRG-008 Carcass Chilling Prerequisite Program states that “ [redacted] .” I observed the storage chill log for 11/1/11 and all cold storage units were within range, so no product was retained. The above is in noncompliance with 9CFR 417.4(a) (2) (ii) – Direct Observations of monitoring activities and 417.5(a) (3) – Record keeping of CCPs and ongoing verification procedures and results.The above is also in NonCompliance with 417.3(a)(3),& 417.3(a)(1), &417.5(b).

I notified Kill Floor Manager [redacted] who explained , he had not recorded his findings at the time because he was to busy to document the record. I then notified Plant Owner [redacted] of this Noncompliance’s. Mr. [redacted] stated that [redacted] his employee was in charge of doing the paper work. He would check with him.

Mr. [redacted] came to the inspection office and told me that he completed the missing information on the Slaughter forms. He also state he found the Carcass Chill log.He said they were in the pile. I told him I looked through the plie and it was not there, If he just fill one out today it would demonstrate the carcass were cold, but in fact the documentation was not done in a timely manner. Further all HACCP records must be made available to inspection personal. Why would yesterday record be some were other than on top of the clip board and I looked through the records on the clip board and it was not there at the time of my inspection review. I told him the plant was going to receive a NonCompliance for repeatedly not performing the required procedures for record documentation.. The daily Direct Observation & Record Review and the Carcass Chill log were not document correctly and in the time frame. The HACCP plan states [redacted]Further when I reviewed the slaughter forms they were not done or completed.

Review of past noncompliance’s showed; that NR- GUM3512093628, documented on 9/28/11 for incomplete slaughter HACCP records and Prerequisite Program records. Also, NR- GUM0309101824/1 documented on 10/24/11. The Plants responses and Further planned actions included having a meeting with all employees to review how to perform HACCP monitoring, CCPs, Record Reviews, and other slaughter record. Further NR-GUM0309101824/1 plant response state’s Mr. [redacted] will reviewing the HACCP Plans and prerequisite programs with [redacted] Based on the above noncompliance, these further planned actions were ineffective to prevent recurrence of the noncompliance,or the plants further planed actions were not performed.

Mr. [redacted] was informed that the current noncompliance have been linked to the previous noncompliance and that the furthe

Regulation:

417.3(a)(1) The written HACCP plan shall identify the corrective action to be followed in response to a deviation from a critical limit. The HACCP plan shall describe the corrective action to be taken, and assign responsibility for taking corrective action, to ensure: The cause of the deviation is identified and eliminated;

417.3(a)(3) Measures to prevent recurrence are established;

417.4(a)(2)(ii) Ongoing verification activities. Ongoing verification activities include, but are not limited to: Direct observations of monitoring activities and corrective actions

417.4(a)(2)(iii) The review of records generated and maintained in accordance with § 417.5(a)(3) of this part.

417.5(a)(3) Records documenting the monitoring of CCP’s and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment’s HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter production lot. Each of these records shall include the date the record was made.

417.5(b) Each entry on a record maintained under the HACCP plan shall be made at the time the specific event occurs and include the date and time recorded, and shall be signed or initialed by the establishment employee making the entry.

Code: 03J02
Violation: 417.4(a)(2)(ii), 417.5(a)(3), 417.5(b)

Citation: At approximately 0900 on October 24, 2011, while performing an unscheduled Slaughter HACCP procedure, the following noncompliance was observed:

On the Lamb/Swine Slaughter Report for 10/21/11, there was no record of a Direct Observation for CCP-1B – Zero Tolerance. GCC-HACCP-003 p. 10 of 12 states that [redacted].” There was also no record of Carcass Chill Monitoring for the lamb and swine carcasses slaughtered Friday, 10/21/11. GCC-PRG-008 Carcass Chilling Prerequisite Program states that “[redacted] ” This is in noncompliance with 9CFR 416.4(a)(2)(11) – Direct Observations of monitoring activities and 417.5(a)(3) – Recordkeeping of CCPs and ongoing verification procedures and results.

I notified Kill Floor Manager [redacted] who explained that he had performed the direct observation on one swine carcass and one lamb carcass, but he had not recorded his findings at the time because he was unsure which to document. He had consulted other employees on the requirements, but failed to record any results at the time. Mr. [redacted] also stated that he did not work on Saturday, so he was not responsible for taking the 24 hour carcass temperatures and recording the results for the Prerequisite Program. I observed Mr. [redacted] then take temperatures on the largest swine from the 10/21/11 kill, and results were acceptable at that time. I also observed Mr. [redacted] document his findings from the Direct Observation on the Slaughter Report and make a note to document the reason the DO was not documented at the time it was performed.

I then notified Plant Owner [redacted] of these noncompliances and he reviewed the requirements of CCP-1B and direct observation with Mr. [redacted] Regarding the Carcass Chill Program, Mr. [redacted] stated that the employees who worked on Saturday were not aware of the need to take and record the carcass temperatures.

LINKED NR: Review of past noncompliances showed NR GUM3512093628, documented on 9/28/11 for incomplete slaughter HACCP records and Prequisite Program records. Further planned actions included having a meeting with all employees to review how to perform HACCP monitoring, CCPs, Record Reviews, and other slaughter records. Based on the above noncompliances, these further planned actions were ineffective to prevent recurrence of the noncompliance.

Mr. [redacted] was informed that the current noncompliances have been linked to the previous noncompliances and that the further planned actions were ineffective in preventing the noncompliance from recurring. He was also informed that continued failure to meet regulatory requirements supports an enforcement action under the Rules of Practice.

Regulation:

417.4(a)(2)(ii) Ongoing verification activities. Ongoing verification activities include, but are not limited to: Direct observations of monitoring activities and corrective actions;

417.5(a)(3) Records documenting the monitoring of CCP’s and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment’s HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter production lot. Each of these records shall include the date the record was made.

417.5(b) Each entry on a record maintained under the HACCP plan shall be made at the time the specific event occurs and include the date and time recorded, and shall be signed or initialed by the establishment employee making the entry.

Code: 03J02
Violation: 417.4(a)(2)(ii), 417.4(a)(2)(iii), 417.5(a)(3), 417.5(b), 417.5(c)

Citation: At approximately 1500 hours, at Estab 21554, while performing a Slaughter HACCP task, I observed the following Noncompliance’s with the slaughter records regarding the plants Slaughter HACCP Plan (GCC-HACCP-001 pg 1-15).

The Wash Report Form GCC-HACCP-005 containing CCP2 was incomplete. There was no direct observation recorded for 09/26/11.
There also was no record review performed for records dated 09/26/11.

Further, the Carcass Chill Report Form GCC-PRG-003 for animals killed 9/26/11 was not [redacted] as outlined in the Carcass Chill Prerequisite Program (GCC-PRG-008 pg 1-2). The initial carcass hot temperatures were recorded, but there were no carcass chill temperatures recorded within 24 hours to verify carcasses were adequately chilled.

I notified slaughter employee [redacted] and he immediately went to the holding cooler and took the chill temperatures on the largest carcass listed on the slaughter form weighing 1100 lbs.. The temperatures were [redacted] (surface), [redacted] (round), and [redacted] (chuck) at approximately 3:00pm. The initial temperatures were recorded at 11:45 am. the previous day. The Establishment prerequisite program states that [redacted].

Further, the Pre-shipment Review was signed on the Slaughter Zero Tolerance form GCC-HACCP-004 for date 09/26/11 even though the reports listed above were incomplete and ongoing verification procedures were not performed.

No regulatory control action was taken at this time because CCPs were under control and temperature verification indicated that product was not compromised.

The above are in noncompliance with 9CFR 417.4(a) (2) (ii), 417.4(a) (2) (iii), 417.5(a) (3), 417.5(b), and 417.5(c).

Review of past noncompliance did not show any with the same cause in the past 3 months.

Management Mr.[redacted] Establishment owner was notified of the above NonCompliance.

Regulation:

417.4(a)(2)(ii) Ongoing verification activities. Ongoing verification activities include, but are not limited to: Direct observations of monitoring activities and corrective actions;

417.4(a)(2)(iii) The review of records generated and maintained in accordance with § 417.5(a)(3) of this part.

417.5(a)(3) Records documenting the monitoring of CCP’s and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment’s HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter production lot. Each of these records shall include the date the record was made.

417.5(b) Each entry on a record maintained under the HACCP plan shall be made at the time the specific event occurs and include the date and time recorded, and shall be signed or initialed by the establishment employee making the entry.

417.5(c) Prior to shipping product, the establishment shall review the records associated with the production of that product, documented in accordance with this section, to ensure completeness, including the determination that all critical limits were met and, if appropriate, corrective actions were taken, including the proper disposition of product. Where practicable, this review shall be conducted, dated, and signed by an individual who did not produce the record(s), preferably by someone trained in accordance with § 417.7 of this part, or the responsible establishment official.

Code: 1.00E+01
Violation: 310.25(a)

Citation: At 1530 hours on August 1, 2011, while performing a Generic E-coli Verification Procedure, I observed the following noncompliance.

The Establishment has not collected and/or reported at least one Generic E-coli sample per-week since the first full week of June. Results are available for the first 4 samples taken 6/7, 6/14, 6/21, and 6/28. There are no results for weeks 5-9. The plant’s Generic E. coli Prerequisite Program (GCC-PRG-003) states that “[redacted].” Further, the establishment has not charted the most recent 13 results on a graph or process control chart. Plant management was made aware of this noncompliance and stated they would contact the lab to obtain the results. These issues are in noncompliance with 9CFR 310.25(a)(1)(i), 310(a)(1)(iii), 310.25(a)(2)(v)(A) and 310.25(a)(4).

Upon further inspection of the results by SPHV [redacted] it was determined that the plant is not following their written procedures. The Plant’s Generic E. coli program (GCC-PRG-003) states that “ [redacted].” According to plant records, samples taken 6/7, 6/14, and 6/21 were shipped on 6/21 and arrived at the lab on 6/22. Further, at the time of arrival, samples were [redacted] degrees Celsius, which is [redacted] degrees above the recommended [redacted] degrees Celsius. When asked, plant management stated they batched the samples to save money and were not aware of the effect it would have on the validity of the samples, and that they did not have support for the change in procedure. This is in noncompliance with 9 CFR 310(a)(1)(i) and 310.25(a)(2)(i).

Generic E coli performance standards are designed to verify the effectiveness of sanitation and process control in slaughter facilities.

The above noncompliances indicate failure to support that the process is under control.

Review of past noncompliances did not show any with similar cause.

Regulation:

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

310.25(a)(2)(i) Sampling requirements. Written procedures. Each establishment shall prepare written specimen collection procedures which shall identify employees designated to collect samples, and shall address location(s) of sampling, how sampling randomness is achieved, and handling of the sample to ensure sample integrity. The written procedure shall be made available to FSIS upon request.

Code: 03J02
Violation: 417.2(c)(7), 417.4(a)(2)(iii)

Citation: At 1500 hours,While performing a Slaughter HACCP Inspection procedure. I observed the following NonCompliance with the establishment’s prerequisite program for quarterly sampling of E-coli 0157:H7, on-going verification.

The Establishment has not performed its quarterly Beef swab sample for E-coli 0157:H7. The last test results made available to inspection was 3/31/11, which was [redacted] The Establishment prerequisite program GCC-PRP-005 pg 2-5 states that .[redacted] The establishment missed ,or did not show a record for the second quarter sample verification that E-coli 0157:H7 is under control in the establishment slaughter HACCP system.

The above is in noncompliance with Reg 417. (a)(2) & 417.2(c)(7) &417.4(a)(2)(iii).
The above noncompliance was shown to plant management.Plant management stated that they sent out the samples but have not recieved any results.

Review of past noncompliance did not show any with the same cause in the past three months.

Regulation:

417.2(c)(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.

417.4(a)(2)(iii) Ongoing verification activities. Ongoing verification activities include, but are not limited to: The review of records generated and maintained in accordance with § 417.5(a)(3) of this part.

Code: 06D01
Violation: 417.4(a)(2)(ii), 417.4(a)(3), 416.2(d)

Citation: While perform a scheduled 06D01 Other Inspection Requirement/ Facilities and Equipment Standard Inspection I observed the following NonCompliance in the Main Holding Cooler. There was large amounts of dripping condensation in the main holding cooler hallway that leads to the RTE processing room the ceiling was covered in water droplets from one end to the other. I took regulatory control action with US. Reject tag B41007084 . I place the tag at the entrance to the hall way so that no open product would be allowed down the hall way. At the time here was no open product in the hallway at the time of my observation, so no product was effected at this time. I informed plant Management QC. [redacted] of the Noncompliance. Mr. [redacted] immediately had an employee wipe down the cooler hallway ceiling. Review of past noncompliance did not show any with same cause in the past 3 months. There was no record of the condensation problem on the SPS or SSOP forms from that day. The Establishments written SPS GCC-SPS-002 pg 002 pg 2,3 state’s that [redacted]. The above noncompliance is in noncompliance with Regulation 416.2(d).

Regulation:

417.4(a)(2)(ii) Ongoing verification activities. Ongoing verification activities include, but are not limited to: Direct observations of monitoring activities and corrective actions;

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

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: 03C02
Violation: 310.22(e)(4)(i)

Citation: While conducting the FSA (Food Safety Assessment) from 07/26/10 through 09/21/10, the following Non-compliances were observed for ISP 03C02 by EIAO Dr. [redacted] The SRM Program (PRG-002 pg 2,3) states that . In actual practice, Dr. [redacted] observed that cutting room personnel are recording “30 months of age and older cattle were boned at the end of the day,” but specific identifying information of the carcasses is not listed. Therefore the SRM removal could not be verified. This is noncompliant with 9 CFR 310.22 (e) (4) (i). The SRM Program is referenced in all 3 Slaughter 03J HACCP Plans, the 03B raw ground HACCP plan, and the 03C raw not ground HACCP plan. Further, Dr. [redacted] talked with Mr. [redacted] (QC/HACCP manager) and he explained to her that [redacted]. This practice is not documented in the SRM program and individual cattle identifications are not recorded at fabrication, so SRM removal in the boning room cannot be verified from observation of the records, which is noncompliance with 9 CFR 310.22 (e) (4) (i) and 303.1 (b) (1). Review of past Non-compliance did not show any with the same cause in the past 3 months.

Regulation:

310.22(e)(4)(i) Recordkeeping requirements. Establishments that slaughter cattle and establishments that process the carcasses or parts of cattle must maintain daily records sufficient to document the implementation and monitoring of the procedures for the removal, segregation, and disposition of the materials listed in paragraph (a) of this section, and any corrective actions taken.

Code: 03F02
Violation: 417.5(a)(1), 417.5(a)(2)

Citation: While conducting the FSA (Food Safety Assessment) from 07/26/10 through 09/21/10, the following Non-compliances were observed for ISP 03F02 by EIAO Dr. [redacted] The firm has no support for the frequency of direct observation of monitoring or record review for CCP-1B or CCP-2B (HACCP-011 Pg 9-11). This is noncompliant with 9 CFR 417.5 (a) (2). The firm does not have adequate supporting documentation for CCP 1B (direct acidification) in the beef snack stick process (HACCP-011 Pg 9 & 11). They are using the “[redacted]” to support [redacted] and [redacted] to support [redacted], however, neither of these documents contains information to support that their process for producing the snack sticks will inhibit the growth of Listeria monocytogenes after the initial thermal process. The typical water activity of beef snack sticks is around 0.92-0.95, and a product with this Aw and a pH of 5.0-5.3 typically meets the criteria for an antimicrobial process that effectively inhibits Listeria monocytogenes. Even though this firm’s process for acidification brings the pH to below 4.5, they still need documentation that measuring the pH without also having data about the Aw can be supported scientifically, or data needs to be collected about the Aw of the product. This is noncompliant with 9 CFR 417.5 (a) (1). Review of past Non-compliances did not show any with same cause in the past 3 months.

Regulation:

417.5(a)(1) The establishment shall maintain the following records documenting the establishment’s HACCP plan: The written hazard analysis prescribed in § 417.2(a) of this part, including all supporting documentation;

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

Code: 03G02
Violation: 417.2(c)(4), 417.5(a)(2)

Citation: While conducting the FSA (Food Safety Assessment) from 07/26/10 through 09/21/10, the following Non-compliances were observed for ISP 03G02 by EIAO Dr. [redacted] The CCP-2B for cooling (HACCP-008 Pg 10,11& HACCP-009 Pg 10,11) lists the monitoring procedure as [redacted]. The firm does not use a data logger to monitor cooling temperatures, therefore, in order to make sure they are meeting their critical limits of, [redacted] the monitoring procedure should list a frequency for checking the product temperature manually. This is noncompliant with 9 CFR 417.2 (c)(4). The firm has no support for the frequency of direct observation of monitoring or record review for CCP-2B in HACCP-008 Pg 10,11 & HACCP- 009 Pg 10,11. This is noncompliant with 9 CFR 417.5 (a) (2). Review of past Non-Compliances did not show any with same cause in the past 3 months.

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;

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

Code: 03H02
Violation: 417.2(c)(4), 417.5(a)(2)

Citation: While conducting the FSA (Food Safety Assessment) from 07/26/10 through 09/21/10, the following Non-compliances were observed for ISP 03H02 by EIAO Dr. [redacted] The CCP for chilling (CCP 1B-HACCP-006, Pg 8,9) lists [redacted]. The firm does not use a data logger to monitor chilling temperatures, therefore, in order to make sure they are meeting their critical limits of [redacted], the monitoring procedure should list a frequency for checking the product temperature manually. This is noncompliance with 9 CFR 417.2 (c) (4). They have no support for just manually checking a cooling temperature for each smokehouse of product. The firm has no support for the selection of their monitoring or verification frequencies (CCP1-B Chilling HACCP-006 Pg 8,9). This is noncompliance with 9 CFR 417.5 (a) (2). Review of past Noncompliance did not show any with same cause in the past 3 months.

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;

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

Code: 03B02
Violation: 417.5(a)(2)

Citation: While conducting the FSA (Food Safety Assessment) from 07/26/10 through 09/21/10, the following Non-compliances were observed for ISP 03B02 by EIAO Dr. [redacted] The firm did not provide adequate supporting documentation for the critical limit selected for CCP 1B, monitoring frequencies, or verification frequencies ( HACCP-005, Pg12,13- temp monitoring in freezer) in accordance with 9 CFR 417.5 (a)(2). Review of past Non-compliance did not show any with same cause past 3 months.

Regulation:

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

Code: 03C02
Violation: 417.5(a)(2)

Citation: While conducting the FSA (Food Safety Assessment) from 07/26/10 through 09/21/10, the following Non-compliances were observed for ISP 03C02 by EIAO Dr. [redacted] The firm did not provide adequate supporting documentation for the critical limit selected for CCP 1B, monitoring frequencies, or verification frequencies, (HACCP-004 pg 10,11) in accordance with 9 CFR 417.5 (a) (2). Review of past Non-compliance did not show any with same cause in the past 3 months.

Regulation:

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

Code: 03J02
Violation: 417.2(a)(2), 417.5(a)(2)

Citation: While conducting the FSA (Food Safety Assessment) from 07/26/10 through 09/21/10, the following Non-compliances were observed for ISP 03J02 by EIAO Dr. [redacted] In the flow diagram for the beef/veal slaughter plan, the flow diagram (HACCP-001 Pg 4) lists [redacted]. In her observations of slaughter operations ,she found that . In addition, step 7 – “” should read “” only, as the plant switched to using a rifle to stun cattle in 2006 and no longer bone out the heads. This is noncompliant with 9 CFR 417.2(a) (2) The establishment’s hazard analysis . This is noncompliant with 417.2(a) All 3 of the Slaughter HACCP plans had no supporting documentation for the selection of the monitoring and verification frequencies and the establishment does not have support for the procedure they use for the carcass spray application (CCP 2B). This is noncompliant with 9 CFR 417.5 (a) (2). Review of past Non-compliances did not show any with same cause in past 3 months.

Regulation:

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

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

Code: 06D01
Violation: 416.1, 416.4(a), 416.4(b)

Citation: At approx; 0830 hours I observed the following noncompliance while performing an unscheduled 06D01 Other Inspection Requirements / Facilities and Equipment Standard. In the kill floor dressing area I observed that The carcass roller hooks are rusty and greasy. Further there is no segregation between the clean roller hooks and the dirty ones. I took regulatory control action with reject tag No. B41007150. Management was notified of the above noncompliance. I informed them that the roller hooks needed to be cleaned before use. They cleaned the hooks for use that day and separated them from the Dirty ones. The above is in noncompliance with 416.1;416.4(a);416.4(b). No product was involved at this time. Review of past noncompliance’s did not show any with same cause in past three months.

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.

416.4(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: 03C02
Violation: 417.4(a)(2)(ii), 417.5(a)(3)

Citation: At approx:10:00 hours while performing a PBIS HACCP/ Raw Not Ground Inspection Procedure I observed the following Noncompliance. There was no record of a Direct Observation for the week of, 08/02/10. The Plants HACCP plan states on GCC-HACCP-004 page 10, [redacted]. I Informed Plant management of the noncompliance. Mr. [redacted] told me that it was performed but they forgot to record it. The above is in noncompliance with 417.4(a)(2)(ii) & 417.5 (b). Review of past noncompliance’s for past 3 months did not show any with same cause. This document serves as written notification that your failure to comply with regulatory requirements could result in additional regulatory or administrative action.

Regulation:

417.4(a)(2)(ii) Ongoing verification activities. Ongoing verification activities include, but are not limited to: Direct observations of monitoring activities and corrective actions;

417.5(a)(3) Records documenting the monitoring of CCP’s and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment’s HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter production lot. Each of these records shall include the date the record was made.

Code: 04C02
Violation: 313.2

Citation: At approx. 0810 hours while performing PBIS 04C02 Humane Handling and Anti-mortem inspection I and inspector [redacted] observes the following noncompliance. Pen No.3 had one Holstein Steer in it. There was no water available to this animal the water trough was empty . Pens 2 had one swine , there was water available to it. Pen 4 had one beef animal it also had water available to it. Pen 5 had one beef animal in it and it had water available to it. I rejected pen 3 with reject tag No 41007158. I rejected the Nock box with reject tag no B41007152. Management Kill Forman was informed of noncompliance above. Kill floor Forman immediately watered the animal in pen 3. Reject tag no. B41007152 was removed from Nock Box. The above is in noncompliance with 313.2(e). Review of Noncompliance for the past 3 months did not show any with same cause. This document serves as written notification that your failure to comply with regulatory requirements could result in additional regulatory or administrative action.

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: 03J02
Violation: 417.5(a)(3)

Citation: On Friday 7/30/10, while performing the records review portion of an unscheduled 03J02 procedure (Slaughter HACCP verification) the following non-compliance was discovered: According to FSIS Slaughter Inspector [redacted] on Monday 7/26/10, at approximately 1200 hours, he observed the slaughter trimmer, [redacted] mix a second batch of [redacted], which was then used throughout the afternoon. The plant was slaughtering a large volume of market swine that day (a total of swine were slaughtered), necessitating the second batch. According to the HACCP plan (GCC-HACCP-003 P.11 of 12), ” [redacted].” Upon reviewing the Carcass Antimicrobial Report, the weights and temperature of “Batch 1” are recorded correctly. However, there is no record of the weights or temperature of the second batch of [redacted] that was mixed up at 1200 as the HACCP plan requires. This is in noncompliance with 9CFR 417.5(a)(3) – records documenting the monitoring of CCPs and CLs. All other slaughter CCPs and records are complete for that day. No regulatory action was taken based on the fact that plant history supports adequate mixing and application of the [redacted] – there have been no documented deviations at this CCP. Kill floor manager was [redacted] notified of this noncompliance and stated he will discuss it with the slaughter staff. Review of the past 3 months NR’s shows none of the same cause.

Regulation:

417.5(a)(3) Records documenting the monitoring of CCP’s and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment’s HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter production lot. Each of these records shall include the date the record was made.

Code: 01C02
Violation: 416.14, 416.2(d), 416.4(d)

Citation: At approx: 1400 hours while performing 01C02, SSOP/ Operational Sanitation Inspection I observed the following Noncompliance. In the Main Holding cooler there was condensation dripping from the cooling unit onto two beef carcass quarters. I took regulatory control action with retain tag No.B41007112 on the beef quarters and rejected the carcass rail with tag No. B41007159. Plant management was informed of the above noncompliance. The beef carcass quarters were moved to a different rail away from the problem area. Further, the two beef carcass quarters involved were trimmed and retain tag No.B41007112 was removed. I checked the daily SSOP record for 7/23/10 and there was no mention of the above noncompliance at the time the noncompliance was observed. Plant management stated the problem with the drip pan would be fixed ASAP. The above is in noncompliance with regulation 416.14,416.2(d),416.4(d). Review of past noncompliance’s did not show any in past three months with same cause. This document serves as written notification that your failure to comply with regulatory requirements could result in additional regulatory or administrative action.

Regulation:

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.

416.2(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: 06D01
Violation: 416.1, 416.2(b)(1), 416.4(d)

Citation: At approx. 1520 hours while performing and unscheduled PBIS 06D01,Other Inspection Requirements / Facilities and Equipment Standard and Verify Sanitation Performance Standards Inspection. I observed the following Noncompliance in the Main Holding Cooler. The ceiling above the second rail switch from the processing room is dripping water when it rains outside. It has been determined that there is a leak in the roof. The rail was Rejected with reject tag No B41007118. There was no product involved at this time. Plant management was told of the above noncompliance. Plant management told inspection that the leak will be fixed ASAP or by Thursday 7/15/10 after the weather clears. The above is in Noncompliance with Regulation 416.1,416.2(b)(1) and 416.4(d). Review of past Noncompliance’s did not show any with the same cause in the past three months. This document serves as written notification that your failure to comply with 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(b)(1) Construction. 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(d) Product must be protected from adulteration during processing, handling, storage, loading, and unloading at and during transportation from official establishments.

Code: 06D01
Violation: 310.18, 416.1, 416.3(b), 416.4(d), 416.2(a)

Citation: At approximately 1520 hours while performing and unscheduled 06D01 Other Inspection Requirements / Facilities and Equipment Standard Verify Performance Standards Inspection I observed the following noncompliance. There is high weeds between the Gov. Office production office ,RTE processing room and the Entrance to the Tool maintenance room. There is also various clutter which includes old light fixtures wood blocks a rail switch a tail gate a sheet of sheet metal, small animal cages, bags of pop cans along the or near to the entrance door to the slaughter dressing room and the slaughter dressing room/inedible room and unloading dock. There is high grass between the animal holding pens and the storeroom and retail store. The box store room near the back of the retail store and closest to the slaughter room is cluttered and can’t be inspected because of various clutter. This box store room was rejected with reject tag No.B41007110. The Box store room in front of the retail store is also cluttered with box’s and can’t be inspected. I rejected this store room with reject tag No.B41007123. The above is in noncompliance with regulation 416.2(a) Outside Premises. Plant Management Miss [redacted] was told of the above noncompliance. Review of past noncompliance did not show any with the same cause in the past 3 months. This document serves as written notification that your failure to comply with regulatory requirements could result in additional regulatory or administrative action. The box room’s were released after they were straighten up and could be inspected. Reject tags No.B41007110,No.B41007123 were removed.

Regulation:

310.18(a) Carcasses, organs, and other parts shall be handled in a sanitary manner to prevent contamination with fecal material, urine, bile, hair, dirt, or foreign matter; however, if contamination occurs, it shall be promptly removed in a manner satisfactory to the inspector.

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(b) Equipment and utensils must not be constructed, located, or operated in a manner that prevents FSIS inspection program employees from inspecting the equipment or utensils to determine whether they are in sanitary condition.

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(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.

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

Citation: At approximately 0800, after given verbal permission to perform a pre-operational inspection from [redacted] I began my inspection. Upon inspecting the patty machine it was seen that several pieces of fat and meat were on the protective guard on the top of the machine. This is a non-compliance with 9 CFR 416.4(a). Continuing my inspection of the patty machine it was seen that there was a film of fat on the part that moves that cup that forms the patty. This is a non-compliance with 9 CFR 416.4(b). [redacted] was immediately shown these non-compliances. No tag was used since this machine was immediately take out of service by the establishment and cleaned and sanitized in my presents. After a re-inspection, the machine was released for production. Further inspection of the processing room revealed no other non-compliances. A review of the last three months of NRs revealed no similar non-compliances. This document serves as written notification that failure to comply with regulatory requirements may result in further regulatory or administrative actions.

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(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: 06D01
Violation: 416.2(a)

Citation: On this date while performing a scheduled 06D01, at 0900 hrs., the following was noted: -The grounds surrounding the building are in a degree of overgrowth thus providing possible harborage for pests and rodents. Mr. was notified of this deficiency. He was also informed that this document serves as written notification that failure to comply with regulatory requirements could result in additional regulatory or administrative actions. Past Similar NRs – Previous Ineffective Plant Actions: Outside sanitatiion NR: 9-2010 dated 5/11/2010; NR: 7-2010 dated 5/3/2010; NR: 6-2010 dated 4/15/2010; NR: 3-2010 dated 3/16/2010

Regulation:

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.

Code: 01B02
Violation: 416.3(c)

Citation: On this date while performing a scheduled 01B02 pre-operational inspection after the plant had a chance to perform theirs, the following was noted: – One inedible barrel placed in the middle processing room and one on the kill floor were not properly labeled as inedible. Because operations had not yet started the barrels were replaced and properly labeled for future use. No product was noted in the barrels. Mr. was notified of this deficiency at approximately 0705hrs. He was also informed that this document serves as written notification that failure to comply with regulatory requirements could result in additional regulatory or administrative actions. Past Similar NRs – Previous Ineffective Plant Actions: Inedible NR: 10-2010 dated 5/12/2010

Regulation:

416.3(c) Receptacles used for storing inedible material must be of such material and construction that their use will not result in the adulteration of any edible product or in the creation of insanitary conditions. Such receptacles must not be used for storing any edible product and must bear conspicuous and distinctive marking to identify permitted uses.

Code: 06D01
Violation: 314.7, 416.4(b)

Citation: On this date while performing my 01B02 scheduled task and after the plant performed their preoperational check, the following was noted: 1- The underside of each of the processing tables has noted build up of debris. No food contact was noted at this time. Mr. , plant manager, was notified of this deficiency at approx 0715hrs. He was also informed that this document serves as written notification that failure to comply with regulatory requirements could result in additional regulatory or administrative actions. Past Similar NRs – Previous Ineffective Plant Actions: sanitation NR: 13-2010 dated 7/20/2010; NR: 10-2010 dated 5/12/20

Regulation:

314.7 Carcasses of livestock which have been condemned on ante-mortem inspection shall not be taken through rooms or compartments in which an edible product is prepared, handled, or stored.

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: 03J02
Violation: 310.18, 417.2(c)(4)

Citation: At approximately 1430 hours while conducting the review and observation component of an unscheduled 03J02 procedure task subsequent the establishments verbal and noted acceptable result of Monitoring and Verification (Direct Observation) at CCP#1S (Final Wash) for Zero Tolerance I observed the following; while observing the same 5 swine carcasses previously monitored by establishment management which was verified through direct observation at the final rail for zero tolerance I observed one swine carcass with loose tan fecal smear with identifiable grain materials within the hip bone along the tail bone and one swine carcass with an approximate 1/8″ X 1/4″ brown fecal matter adhered to the inside ham portion (right hind leg). The establishment Slaughter HACCP plan for Swine signed and dated 1/6/10, page 12, CCP#1S states: “[quote redacted] ” and page 16, CCP#1S states: “[quote redacted] “. HACCP/QC Manager, immediately notified verbally of the non-compliance. This is a failure of 9CFR 417.2(c)(4) and 9CFR 310.18(a). This document serves as written notification that your failure to comply with regulatory requirement(s) could result in additional regulatory or administrative action.

Regulation:

310.18 (a) Carcasses, organs, and other parts shall be handled in a sanitary manner to prevent contamination with fecal material, urine, bile, hair, dirt, or foreign matter; however, if contamination occurs, it shall be promptly removed in a manner satisfactory to the inspector. (b) Brains, cheek meat, and head trimmings from animals stunned by lead, sponge iron, or frangible bullets shall not be saved for use as human food but shall be handled as described in §314.1 or §314.3 of this subchapter.

417.2(c)(4) Hazard Analysis and HACCP Plan.  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: 06D01
Violation: 416.1, 416.2(b)(1), 416.2(d), 416.4(b)

Citation: At approximately 1310 hours, while conducting a scheduled 01C02 procedure task I observed the following: Kill Floor: -An unknown black/gray matter on both the exposed surfaces of the glass board and painted walls and ceiling surfaces throughout the room. -Peeling paint on the overhead I-beam directly above the dehairing machine adjacent to the scalder. -Rust on the bottom surface of the overhead I-beam directly above product and employee traffic areas and swine presentation tables. Chill Box: -Beaded condensate on the surface of the ceiling directly above the first rail storing exposed goat carcasses. -Rust/ rust stains on the surface of the ceiling at the front of the refrigeration unit on the left side and the first meat rail. HACCP/QC Manager, immediately notified verbally of the non-compliance. This is a failure to meet 9CFR 416.1; 9CFR 416.2(b)(1); 9CFR 416.4(b) and 9CFR 416.2(d). This document serves as written notification that your failure to comply with regulatory requirement(s) 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(b)(1) Construction. Establishment buildings, including their structures, rooms, and compartments must be of sound construction, be kept in good repair, and be of sufficient size to allow for processing, handling, and storage of product in a manner that does not result in product adulteration or the creation of insanitary conditions.

416.2(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.

Code: 03J01
Violation: 417.2(a)(1), 417.2(a)(2)

Citation: At approximately 0700 hours, I observed the following in the Kill Floor; an establishment employee, apply an Antimicrobial Spray to the surface of a Swine carcass after the Final Wash step and prior to the Chill Box step. While conducting the recordkeeping component of a scheduled 03J01 procedure task and reviewing the establishments Swine HACCP plan, I noted that the establishment has not incorporated this step (Antimicrobial Spray) into the process flow chart and has not conducted or had conducted for it a hazard analysis for this process step. QC/Manager removed the Antimicrobial Spray immediately after verbal notification and established control of the spray. The establishments Swine HACCP plan last signed and dated 1/6/10. This is a failure to meet 9CFR 417.2(a)(1) and 9CFR 417.2(a)(2). This document serves as written notification that your failure to comply with regulatory requirement(s) could result in additional regulatory or administrative action.

Regulation:

417.2(a)(1) Hazard analysis. Every official establishment shall conduct, or have conducted for it, a hazard analysis to determine the food safety hazards reasonably likely to occur in the production process and identify the preventive measures the establishment can apply to control those hazards. The hazard analysis shall include food safety hazards that can occur before, during, and after entry into the establishment. A food safety hazard that is reasonably likely to occur is one for which a prudent establishment would establish controls because it historically has occurred, or because there is a reasonable possibility that it will occur in the particular type of product being processed, in the absence of those controls.

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

Code: 03B02
Violation: 417.2(a)(2)

Citation: At approximately 0830 hours, while performing the recordkeeping component of a scheduled 03B02 procedure task I observed the following; the establishment’s process flow chart for Raw Ground products does not depict the actual flow process as observed during the production of Raw Ground products (ground beef/pork, sausage products and patty products). There are no connecting factors from the ” step to the “” step or from the “” to “” step; there are no connecting factors from the ” ” step to the ” step; no connecting factors from the “” step to the “” step. The establishment Raw Ground HACCP plan last signed and dated 1/6/10. HACCP/QC Manager, immediately notified verbally of the non-compliance. This is a failure to meet 9CFR 417.2(a)(2). This document serves as written notification that your failure to comply with regulatory requirement(s) could result in additional regulatory or administrative action.

Regulation:

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

Code: 06D01
Violation: 416.1, 416.4(b)

Citation: At approximately 0800 hours it was observed the establishment had conducted it’s pre-operational inspection of the facility. I then conducted a scheduled pre-operational inspection of the facility. The top on the stainless steel table was observed to have product residue from the previous day operation. Mr. was informed of my findings and took immediate corrective action to address the situation. Two supports for a shelf under the scale on the kill floor were beginning to show signs of rust. This a failure to comply with regulations 9 CFR 416.1 and 416.4(b)

Regulation:

416.1 Each official establishment must be operated and maintained in a manner sufficient to prevent the creation of insanitary conditions and to ensure that product is not adulterated.

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

Code: 06D01
Violation: 416.2(b)(2)

Citation: On this date at approximately 0900hrs. while performing a scheduled 06D02 inspection the following was noted: – Outside on the loading deck the rail is pitted with rust and rail dust. No product contact noted. – Outside on the loading dock the chiller box floor is in need of cleaning. No product contact. – Outside on the loading dock over the chill box leaks allowing water through around the chill box was noted. No product contact noted. – Outside next to the chill box on the North side of the loading dock is where the offal cans are located and are in close proximity to the chill box resulting in potential pest contamination. Mr. was notified of these deficiencies at approximately 0930hrs. He was also informed that this document serves as written notification that failure to comply with regulatory requirements could result in additional regulatory or administrative actions.

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: 06D01
Violation: 416.4(b)

Citation: On this date while performing a scheduled 01B02 pre-operational inspection, after the plant had the opportunity to perform theirs, the following was noted: – Several clumps of hair were noted on the lower portion of the derailing machine from yesterdays kill. This is not a product contact area but need to be cleaned and sanitized. – Several small are of dried blood were noted around the blood pit from yesterdays kill. Mr. was notified of these discrepancies and he took immediate action prior to the start of kill. He was also informed that this document serves as written notification that failure to comply with regulatory requirements could result in additional regulatory or administrative actions. Past Similar NRs – Previous Ineffective Plant Actions: Sanitation NR: 14-2010 dated 8/10/2010; NR: 13-2010 dated 7/20/2010; NR: 10-2010 dated 5/12/2010

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: 06D01
Violation: 416.2(a)

Citation: On this date while performing a scheduled 06D01 task the following was noted: – Several area in the parking areas are pitted and holding standing water, several in close proximity to the facility. This facilitates a potential problem for contamination and needs to be dealt with. Area noted were the Back of the building by the pens, the west of the building by the outside refer and storage trailer and by the front area of the loading dock. Mr. was notified of this deficiency at approximately 1135 hrs. He was also informed that this document serves as written notification that failure to comply with regulatory requirements could result in additional regulatory or administrative actions. Past Similar NRs – Previous Ineffective Plant Actions: SPS NR: 12-2010 dated 7/19/2010; NR: 9-2010 dated 5/11/2010; NR: 7-2010 dated 5/3/2010

Regulation:

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.

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

Citation: At approximately 0705 hours while conducting a scheduled 01B02 procedure task subsequent the establishments verbal and noted acceptable pre-operational procedure I observed the following: Kill Floor- -Meat particles, fat scraps, residue and hair on the hilt, handle and product contact surface of four knife blades and the inside surface of employee’s knife scabbard in direct contact with the knife blades. Four knives and scabbard rejected with US Rejected tag #B 30 649392. -Clumps of hair and hair adhered to the non-product contact surface of the rubber beater paddles, surfaces of the inside lower frame and the bottom surfaces of the pivoting cradle of the Dehairing Machine. Dehairing Machine rejected with US Rejected tag #B 30 649393. Processing/ Packing Room: -Smearing black unknown material on the product contact surface of the boning board of the Boning Table beside the Grinding Machine. Boning Table rejected with US Rejected Tag 30 649394. -Rust/ rust stains on the cutting board supports and table frame of two boning tables in the Processing Room and one boning table in the Packing Room. – One knife with meat particles on the contact surface of the blade and hilt and one knife with fat residue on the handle. Knives rejected with US Rejected tag #B 30 649394. -Dried blood and meat residue on the Vacuum Machine heating element and on the inside non-contact surface area of the lid across from the heating element directly above finished packaged products stationed in the Packing Room. -Fat residue/ residuals on the inside surface of the lower wheel housing behind the lower wheel of the Band-Saw stationed in the Processing Room. This is a failure to meet: 9CFR 416.1; 9CFR 416.4(a), 9CFR 416.4(b), 9CFR 416.13(c). I verbally notified , Production Supervisor immediately of the non-compliances. The establishments SSOP plan signed and dated 1/8/10, page 2, Pre-Operational Sanitation section “[quote redacted]” states: ” [quote redacted]” and section titles “[quote redacted]” states: “[quote redacted] “. This document serves as written notification that your failure to comply with regulatory requirement(s) could result in additional regulatory or administrative action. Past Similar NRs – Previous Ineffective Plant Actions: No preventative measure documented at this time. NR: 21-2010 dated 10/19/2010

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(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: 03J02
Violation: 417.2(a)(1), 417.2(a)(2), 417.2(c), 417.2(c)(4), 417.2(c)(7)

Citation: At approximately 1300 hours while conducting the recordkeeping component of a scheduled 03J02 procedure task I observed the following while reviewing the establishments HACCP plan for Pork, Sheep, Goat Slaughter; there is no identifying step for Shipping/ Distribution in the flow chart and the establishment has not conducted or has not had conducted for it a hazard analysis for this specific step of the process. There are no connecting factors in the flow chart from the [redacted] step of the process to the [redacted] step as reflected in the establishments actual flow process. In the establishments HACCP Plan on page 11, the establishment has not identified the amount of carcasses that will be [redacted]. The establishments Pork, Sheep, Goat Slaughter HACCP plan was last reassessed and signed on 9/15/10. In the establishments Beef Slaughter Program, Hot Water Spray and Antimicrobial Spray are identified as CCP #2 on the HACCP Plan page. The establishment has failed to identify the Monitoring Frequency as well as Verification Frequency for the Hot Water Spray on the HACCP Plan sheet on page 13. The establishments Beef Slaughter HACCP plan was last reassessed and signed on 1/10/10. This is a failure to meet: 9CFR 417.2(a)(1); 9CFR 417.2(a)(2); 9CFR 417.2(c)(4) and 9CFR 417.2(c)(7). I verbally notified HACCP/ QC Manager immediately of the non-compliances. This document serves as written notification that your failure to comply with regulatory requirement(s) could result in additional administrative or regulatory action.

Regulation:

417.2(a)(1) Hazard analysis. Every official establishment shall conduct, or have conducted for it, a hazard analysis to determine the food safety hazards reasonably likely to occur in the production process and identify the preventive measures the establishment can apply to control those hazards. The hazard analysis shall include food safety hazards that can occur before, during, and after entry into the establishment. A food safety hazard that is reasonably likely to occur is one for which a prudent establishment would establish controls because it historically has occurred, or because there is a reasonable possibility that it will occur in the particular type of product being processed, in the absence of those controls.

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

417.2(c) The contents of the HACCP plan. The HACCP plan shall, at a minimum:

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;

417.2(c)(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.

Code: 03G02
Violation: 417.4(a)(3), 417.5(a)(1), 417.5(a)(2), 430.4(b)(3)

Citation: At approximately 1340 hours while conducting the recordkeeping component of an unscheduled 03G02 procedure task I observed the following while reviewing the establishments Fully Cooked, Not Shelf Stable HACCP plan; the establishment has not identified potential Biological Hazards (Listeria Monocytogenes (Lm), Clostridium Perfrigens) at any step of the process in the Hazard Analysis on pages 3, 4 or 5 for their Fully Cooked, Not Shelf Stable products. The establishment has identified Sleeves, Hands, Gloves, Aprons and Lugs as a potential hazard and has identified Unsanitary Conditions as the Biological Hazard at the Slice/Split step of the process but does not identify the potential Biological hazard of Lm/ Listeria Species under the Potential Hazard section of the Hazard Analysis on page 1. The Preventive Measures outlined on page 1 in the Hazard Analysis for the Slice/ Split step states “[quote redacted] “. Review of the establishment’s supporting documentation, Protocol for Processing and Packaging Fully Cooked-Not Shelf Stable Products does not address/ identify all potential areas of direct product contact as identified in the Hazard Analysis or in the actual production process such as aprons, gloves, hands, sleeves and trays. The establishment has determined that no CCP’s are necessary for their Fully Cooked, Not Shelf Stable program in their Hazard Analysis and has Justified their decision by stating “[quote redacted]” Raw, Not Ground) programs. On 9/15/10 the establishment had reassessed and implemented a new 03B and 03C program and thus has changed the location of their CCP from [redacted] no longer  supports the control or justification for the decisions made as stated in their Hazard Analysis and no reassessment has been conducted due to the changes that could affect the hazard analysis or alter the HACCP plan. The establishments Fully Cooked, Not Shelf Stable program was last reassessed and signed on 10/7/09. This is a failure to meet: 9CFR 417.5(a)(1), 9CFR 417.5(a)(2); 9CFR 417.4(a)(3) and 9CFR 430.4(b)(3). I verbally informed HACCP/ QC Manager, immediately of the non-compliances. This document serves as written notification that your failure to comply with regulatory requirement(s) could result in additional administrative or regulatory action.

Regulation:

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

417.5(a) The establishment shall maintain the following records documenting the establishment’s HACCP plan:
(1) The written hazard analysis prescribed in §417.2(a) of this part, including all supporting documentation;

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

430.4(b) In order to maintain the sanitary conditions necessary to meet this requirement, an establishment producing post-lethality exposed RTE product must comply with the requirements included in one of the three following alternatives:
(3) Alternative 3. Use of sanitation measures only.

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

Citation: At approximately 0700 hours while conducting a scheduled 01B02 procedure task subsequent the establishments verbal and noted acceptable pre-operational procedure documented on the SSOP Inspection Form I observed the following: Kill Floor- -Meat/ fat scraps, residue and hair on the handle and product contact surface of three knife blades and the inside surface of employee’s knife scabbard in direct contact with the knife blades. Three knives and scabbard rejected with US Rejected tag#B 10 396185. -Clumps of hair and hair adhered to the product conduct surface of the rubber beater paddle metal tips and non-product contact surface of the rubber beater paddles, surfaces of the inside lower frame and the bottom surfaces of the pivoting cradle of the Dehairing Machine. Dehairing Machine rejected with US Rejected tag#B 10 396185. -Rust stains and black unknown material on the product contact surface of the Splitting Saw blade and guide, and dried product residue on the motor housing. Splitting Saw rejected with US Rejected tag#B 10 396185. -Product residue and hair on the underside frame supports and frame of the stainless steel singing table adjacent to the scalder. Processing/ Packing Room: -Rust stains on the product contact surface of the grinder auger and dried meat residuals and ingredient pieces affixed to the product contact surfaces of the auger housing (grinder head) grooves. Grinder parts rejected with US Rejected tag#B 10 396198. – Fat scraps/particles and product residue on the inside contact surface and outside non-product contact surface of the gray edible lugs. Twenty Six lugs rejected with US Rejected tag#B 10 396198. -Dried product residue on the exposed surfaces of the grinder power cords directly above the boning table and the band saw power cords. This is a failure to meet: 9CFR 416.1; 9CFR 416.4(a), 9CFR 416.4(b), 9CFR 416.13(c). , Production Supervisor verbally notified immediately of the non-compliances. The establishments SSOP plan signed and dated 1/8/10, page 2, Pre-Operational Sanitation section “[quote redacted]” states: “[quote redacted]” and section titles “[quote redacted]” states: “[quote redacted]” . This document serves as written notification that your failure to comply with regulatory requirement(s) could result in additional regulatory or administrative action. Past Similar NRs – Previous Ineffective Plant Actions: Employees retrained on cleaning. NR: 25-2010 dated 11/3/2010

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(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: 06D01
Violation: 416.4(b)

Citation: On this date, the following was noted after the plant performed their Pre-operational inspection: – Kill floor drains had noted fat buildup from previous kill. 5-6 particles an inch a piece noted. – Middle processing room also had noted fat and material buildup in those drains. 8-10 inch long pieces were noted. Mr. was notified of these deficiencies at 0810 hrs. and he was also informed that this document serves as written notification that failure to comply with regulatory requirements could result in additional regulatory or administrative actions. Drains were immediately cleaned and sanitized. Past Similar NRs – Previous Ineffective Plant Actions: sanitation NR: 28-2010 dated 11/11/2010; NR: 25-2010 dated 11/3/2010

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: 06D01
Violation: 416.3(a)

Citation: On this date, while performing a scheduled task, 01B02, after the plant had a chance to perform their own pre-operational inspection the following was noted: – In the middle processing room the underside of the meat cutting table on the Northwest side of the room was noted having meat debris particles from previous day. Approximately 3 cluster areas found about 2-3 cm in diameter! Mr. was notified and immediatlely have an employee flip, clean and sanitixe the underside and then the topside of said table. He was also informed that this document serves as written notification that failure to comply with regulatory requirements could result in additional regulatory or administrative actions. Past Similar NRs – Previous Ineffective Plant Actions: Sanitation NR: 28-2010 dated 11/11/2010; NR: 25-2010 dated 11/3/2010

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.

Code: 06D01
Violation: 416.2(b)(1), 416.2(b)(2)

Citation: On this date while performing an unscheduled 06D01 task the following was noted: – Frost build up around the bottom of the indoor freezer door prohibiting it from opening. – Boxed product, while not directly on the floor, was not elevated enough to prevent possible contamination. – Air curtains which separate the offal room from the kill floor had significant build up and were not cleaned and sanitized. – Inedible barrels not cleaned properly prior to startup. Immediate action taken by employees, cleaned barrels brought in immediately, soiled ones removed for cleaning. – Rust on conduit over the inspection area on the kill floor. – On the kill floor, the railed table adjacent to the scalder has plastic/rubber covering on the bars in between the legs with openings that allow for water penetration and possible buildup thus creating a possible bacterial environment. Mr. was notified of these deficiencies and took immediate actions to correct. He was also informed that this document serves as written notification that failure to comply with regulatory requirements could result in additional regulatory or administrative actions. Past Similar NRs – Previous Ineffective Plant Actions: sanitation NR: 1-2011 dated 1/18/2011

Regulation:

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

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

Code: 04B04
Violation: 319.141

Citation: On this date while performing a scheduled 04B04 inspection task the following was noted: – In the large chill box product was noted in several bins without labeling. This product was for further processing into sausages as relayed to me by the processing room manager. It was in the refer box to remain chilled prior to heading to the stuffing machine. Product was retained using a U.S. Retained tag No. B 10396197. Product is to be reworked and properly labeled throughout the further processing steps. Mr. was notified of the deficiency and he was also informed that this document serves as written notification that failure to comply with regulatory requirements could result in additional regulatory or administrative actions.

Regulation:

319.141 ‘‘Fresh Pork Sausage’’ is sausage prepared with fresh pork or frozen pork or both, but not including pork byproducts, and may contain Mechanically Separated (Species) in accordance with §319.6, and may be seasoned with condimental substances as permitted under part 318 of this subchapter. The finished product shall not contain more than 50 percent fat. To facilitate chopping or mixing, water or ice may be used in an amount not to exceed 3 percent of the total ingredients used. [35 FR 15597, Oct. 3, 1970, as amended at 43 FR 26424, June 20, 1978; 47 FR 28257, 28258, June 29, 1982]

Code: 06D01
Violation: 416.2(a)

Citation: On this date, while performing the scheduled task 6D01 the following was noted: – Exterior overgrowth of the grass and weeds surrounding the plant on the east and south sides exceeds the height of what is appropriate to prevent harborage of pests and rodents. Mr. was notified of this non compliance at approx. 1210 hrs. He was also informed that this document serves as written notification that failure to comply with regulatory requirements could result in additional regulatory or administrative actions.

Regulation:

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.

Code: 06D01
Violation: 416.2(b)(1)

Citation: On this date, while performing the 06D01 scheduled task, the following was noted – The retail cooler door, in the middle processing room, on the East side of the room, was in disarray. The lower portion of the door was falling apart and is need of fixing. No food product contact was noted and Mr. was notified of this non-compliance at approximately 0945 hours. Mr. was also informed that this document serves as written notification that failure to comply with regulatory requirements could result in additional regulatory or administrative actions. Past Similar NRs – Previous Ineffective Plant Actions: Sanitation NR: 3-2011 dated 4/19/2011

Regulation:

416.2(b)(1) Construction. 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: 06D01
Violation: 416.2(b)(2)

Citation: On this date, while performing a scheduled 06D01 task, the following was noted – While checking the loading docks, off of the middle processing room, on the West side of the building, it was noted that the area was cluttered, in disarray and in disrepair. This area could become a sanitation problem. Some areas of concern is that water has built up in the rubber tire bumpers, there is a dirt and debris build up on the floor and some build up on the outside walls and outside of cooler doors, which are not in use currently. No food contact was noted at this time. Mr. was notified of this non-compliance at approximately 1000hrs. He was also informed that this document serves as written notification that failure to comply with regulatory requirements could result in additional regulatory or administrative actions. Past Similar NRs – Previous Ineffective Plant Actions: SPS NR: 5-2011 dated 7/13/2011

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: 06D01
Violation: 416.2(b)(1), 416.2(b)(2)

Citation: On this date while performing the scheduled 06D01 task at 0930hrs, the following was noted: – Entrance and exit openings to the offal room, molding in disrepair, coming off the corners, bottom needs repair due to exposed wall covering. – Conduits on the kill floor peeling and flaking, no product contact noted. – Covering to chill box door, on the kill floor starting to exhibit cracks and hinges starting to exhibit the beginnings of rusting process. no product contact noted. Mr. was notified of these discrepancies. He was also informed that this document serves as written notification that failure to comply with regulatory requirements could result in additional regulatory or administrative actions. Past Similar NRs – Previous Ineffective Plant Actions: Facilities NR: 6-2011 dated 9/12/2011; NR: 3-2011 dated 4/19/2011

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.

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: 01B01
Violation: 416.13(a), 416.13(c)

Citation: On this date while performing Pre-op inspection of the plant after the plant had the opportunity to perform its own, the following was noted:[newline] – Grinder #1 located in the middle processing room, when inspected I found several particles of meat from the previous days processing, 3 pieces about 2-3 mm in size. [newline]- In the front processing room located on the S/S table in the Eastern part of the room, particles of spices and possible rust dust were found behind the radio, this was not a product contact area. [newline]Both non-compliances were addressed immediately by the processing manager. Mr. was notified of these deficiencies and he was also informed that this document serves as written notification that failure to comply with regulatory requirements could result in additional regulatory or administrative actions.

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.

Code: 03J02
Violation: 417.2(c)(4), 417.5(a)(1), 417.5(a)(3), 417.5(b)

Citation: As an outcome of a Food Safety Assement the following deviations were found: [newline]Slaughter [newline]- For each entry on the “[quote redacted] and “[quote redacted] monitoring and verification records, the plant identifies species and date. However, for multiple monitoring results only one time is recorded for each monitoring activity. Each entry on a record shall be made at the time the specific event occurred in accordance with 9 CFR 417.5 (b). [newline]- For the [redacted] spray intervention on beef the establishment is recording the word “acceptable;” however, this does not meet 9 CFR 417.5 (a) (3) as the quantifiable observations or values must be documented. o The HACCP plant does not describe an actual critical limit for CCP 2B, as it lists that “[quote redacted] .” This is a noncompliance with 9 CFR 417.2 (c) (3). Review of the SOP found that it outlines the critical limit as “[quote redacted] .” [newline]- The establishment’s pre-requisite program for swabbing cattle carcasses for E. coli O157:H7 outlines that [quote redacted] The establishment performed testing concentrated from July to December, but cannot support this frequency because they slaughter cattle all year. They must verify the effectiveness of their interventions on an ongoing basis. This is a noncompliance with 9 CFR 417.4 (a) and 9 CFR 417.5 (a) (1). – The establishment harvests the heart, liver, and tongue. The HACCP plan outlines [redacted], but does not list the frequency of monitoring the application of [redacted] to the variety meats. This is a noncompliance with 417.2 (c) (4), which requires the plant to list the procedures and frequencies that will be used to monitor each CCP. The establishment is not documenting the monitoring results or verification activities for the variety meats. This is a noncompliance with9 CFR 417.5 (a) (3), which requires that records document the monitoring of the CCPs and their critical limits. [newline]- The pH of [redacted] is monitored as a prerequisite program. The control limit of the pH is 2.5 to 3. [redacted] to detect the pH control limit of 2.5 to 3. This does not meet the regulatory requirements of 9 CFR 417.5(a)(1). [newline]- For CCP 2B, the hazard analysis outlines that [redacted] . I observed on October 21, 2011, that five animals are monitored by plant management at different times, but that only one time was written down for all five monitoring activities. This is a noncompliances with 9 CFR 417.5 (b), as each entry on the record must be made at the time it occurred.

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;

417.5(a)(1) The establishment shall maintain the following records documenting the establishment’s HACCP plan: (1) The written hazard analysis prescribed in §417.2(a) of this part, including all supporting documentation;

417.5(a)(3) Records documenting the monitoring of CCP’s and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment’s HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter production lot. Each of these records shall include the date the record was made.

417.5(b) Each entry on a record maintained under the HACCP plan shall be made at the time the specific event occurs and include the date and time recorded, and shall be signed or initialed by the establishment employee making the entry.

Code: 01C01
Violation: 416.12(a)

Citation: As a outcome of the Food Safety Assement the following deviations were found: [newline]Sanitation SSOP [newline]o The establishment does not have documentation to support that cotton gloves are maintained in a sanitary condition during production to prevent the cross contamination or adulteration of product. This is a noncompliance with 9 CFR 416.4 (a) and 416.12 (a).

Regulation:

416.12(a) The Sanitation SOP’s shall describe all procedures an official establishment will conduct daily, before and during operations, sufficient to prevent direct contamination or adulteration of product(s).

Code: 01D01
Violation: 416.1

Citation: As a outcome of the Food Safety Assement the following deviations were found: [newline]SPS[newline] – On November 03, 2011, I toured the dry storage warehouse and an upstairs storage room. I observed large amounts of debris such a dirt, dust, and mud in the corners of the floor in these rooms. There is also clutter on the floor such as tools, old equipment, extension cords, etc. that block access to inspection along the corners and wall junctions; these areas must be maintained so that it does not interfere with inspection by FSIS personnel and the clutter creates a possible harborage point. In addition, one of the exterior cooler was observed to have a door seal peeling off, which may facilitate the entry of vermin or pests. This is a noncompliance with 9 CFR 416.2 (a). [newline]- The rails on the kill floor have a buildup of either condensation or grease that was pooling at a turning point in the rail, however, no dripping was observed. The rails, in cooler holding hog carcasses, had buildup of flaking rust and/or grease on the top of the rail. The goat cooler had some dust buildup on top of the rail. However, no product contamination was observed. An I-beam above the rails was covered in duct tape which may prevent thorough cleaning. The ceiling had a buildup of dust and dirt. This is a noncompliance with 9 CFR 416.4 (b). [newline]- The freezer has a buildup of ice below the cooling unit on the floor and around the door and the ice in front of the door contains frozen meat particles. The cooler leading from the kill floor had visible condensation near the cooling unit The rails on the kill floor had condensation present, however, no product contamination was noted. This is a noncompliance with 9 CFR 416.2 (d), as the establishment must have a ventilation system that is adequate to control vapor and condensation to prevent the creation of an insanitary condition of product adulteration. [newline]- The cooler and freezer doors throughout the establishment are in disrepair, with corrosion or cracking fiberglass. Exterior coolers do not seal tightly and one was observed to have the seal peeling off. Ice accumulation was observed on the ceiling and floor of the freezer. Establishment buildings, including their structures, rooms, and compartments must be of sound construction, be kept in good repaired, and be of sufficient size to allow for processing, handling, and storage of product in manner that does not result in product adulteration of the creation of insanitary conditions. In regards to the condition of the rails, floors, and ceilings, the establishment is not in compliance with 9 CFR 416.2 (b) (1) and 416.2 (b) (2).

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

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

Code: 03C02
Violation: 417.2(c)(4), 417.5(a)(1), 417.5(a)(2)

Citation: As a outcome of the Food Safety Assement the following deviations were found: [newline]03C HACCP [newline]- The establishment’s hazard analysis identifies pathogen presence as likely to occur in the process but the HACCP system is designed around preventing pathogen growth, not presence. While the hazard analysis outlines both presence and growth as likely to occur, there are no preventive measures or controls outlined to address presence and the establishment does not indentify why presence is an actual hazard in their system. The establishment does not have a HACCP plan or critical control points to address pathogen presence. This is with a noncompliance with 9 CFR 417.2 (a), 417.2 (b), and 417.2 (c) (2). [newline]- The establishments “SOP for [quote redacted] ” outlines that  [redacted], however, the establishment does not have a reference thermometer. In addition, the SOP does not outline a scientific, regulatory, or technical reference to support the thermometer calibration procedures as written. These deviations are a noncompliance with 9 CFR 417.5 (a) (2). [newline]- The establishment’s hazard analysis identifies that [redacted]. The establishment uses  [redacted] to prevent this hazard and lists that  [redacted]. Review of the monitoring records revealed that product temperature is only being monitored in the AM, but production occurs all day. The establishment cannot support the frequency of monitoring each lot, as they are only measuring temperatures in the AM. This is a noncompliance 9 CFR 417.5 (a) (1).

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;

417.5(a)(1) The establishment shall maintain the following records documenting the establishment’s HACCP plan: (1) The written hazard analysis prescribed in §417.2(a) of this part, including all supporting documentation;

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

Code: 03B02
Violation: 417.4(a)(2)(i), 417.5(a)(1)

Citation: As a outcome of athe Food Safety Assement the following deviations were found:[newline]03B HACCP [newline]- The establishment’s hazard analysis identifies pathogen presence as likely to occur in the process but the HACCP system is designed around preventing pathogen growth, not presence. While the hazard analysis outlines both presence and growth as likely to occur, there are no preventive measures or controls outlined to address presence and the establishment does not indentify why presence is an actual hazard in their system. The establishment does not have a HACCP plan or critical control points to address pathogen presence. This is with a noncompliance with 9 CFR 417.2 (a), 417.2 (b), and 417.2 (c) (2). [newline]- Review of the establishments raw ground products found that the intended use as “cooked by consumer,” and sells the product retail and wholesale. The establishment cannot support the decision in the hazard analysis regarding consumer cooking practices, because they have not provided support for the statement “product is labeled to instruct consumers to fully cook product (and thereby kill pathogens).” This is a noncompliance with 9 CFR 417.5 (a) (1) and 417.2(a) (1). [newline]- The establishments receiving SOP outlines that “[quote redacted] ” and that “ [quote redacted]” However, the establishment has not been  [information redacted] specified in the SOP, a noncompliance with 9 CFR 417.5 (a) (1). [newline]- The establishment’s pre-requisite program for sampling finished ground beef for E. coli O157:H7 outlines that [information redacted]. The establishment performed testing concentrated in the warm months but cannot support its frequency of performing E. coli O157:H7 verification testing in the “[quote redacted]” and ,[quote redacted]” because they grind beef year round. They must verify the effectiveness of their interventions on an ongoing basis. This is a noncompliance with 9 CFR 417.4 (a) and 9 CFR 417.5 (a) (1). [newline]- The establishments “SOP for Calibration of Thermometers” outlines that  [information redacted], however, the establishment does not have a reference thermometer. In addition, the SOP does not outline a scientific, regulatory, or technical reference to support the [information redacted] procedures as written. These deviations are a noncompliance with 9 CFR 417.5 (a) (2).

Regulation:

417.4(a)(2)(i) Ongoing verification activities include, but are not limited to: The calibration of process-monitoring instruments;

417.5(a)(1) The establishment shall maintain the following records documenting the establishment’s HACCP plan: The written hazard analysis prescribed in §417.2(a) of this part, including all supporting documentation;

Code: 03H02
Violation: 417.5(a)(1), 417.5(a)(2)

Citation: As a outcome of the Food Safety Assessment the following deviations were noted: [newline]03H HACCP [newline]- The establishment’s hazard analysis identifies pathogen presence as likely to occur in the process but the HACCP system is designed around preventing pathogen growth, not presence. While the hazard analysis outlines both presence and growth as likely to occur, there are no preventive measures or controls outlined to addressed presence and the establishment does not indentify why presence is an actual hazard in their system. The establishment does not have a HACCP plan or critical control points to address pathogen presence. This is with a noncompliance with 9 CFR 417.2 (a), 417.2 (b), and 417.2 (c) (2). [newline]- The establishment’s SOP describes that [information redacted]. The establishment has not been recording temperature of the whole bacon received. The establishment must follow the SOP as designed to support the decisions made in the hazard analysis in accordance with 9 CFR 417.5 (a) (1).[newline] – The establishments “SOP for [information redacted]” outlines that [information redacted], however, the establishment does not have a reference thermometer. In addition, the SOP does not outline a scientific, regulatory, or technical reference to support the [information redacted] procedures as written. These deviations are a noncompliance with 9 CFR 417.5 (a) (2). [newline]- The establishment’s hazard analysis identifies that [information redacted]. The establishment uses [information redacted] to prevent this hazard and lists that [information redacted]. Review of the monitoring records revealed that product temperature is only being monitored in the AM, but production occurs all day. The establishment cannot support the frequency of monitoring each lot, as they are only measuring temperatures in the AM. This is a noncompliance 9 CFR 417.5 (a) (1).

Regulation:

417.5(a)(1) The establishment shall maintain the following records documenting the establishment’s HACCP plan: The written hazard analysis prescribed in §417.2(a) of this part, including all supporting documentation;

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

Code: 04B04
Violation: 317.2(f)(1), 317.8(a)

Citation: At approximately 0920 hours, while performing a scheduled SSOP Operational Review and Observation task, observed the following in the Processing Cooler. An employee introduce a pre-measured package of dry seasonings and  potable water into the grinding/mixing machine with ground pork during the formulation of Breakfast Sausage. [newline]A review of the labels affixed to the finished products in the Processing Cooler, fail  to  declare water used during the formulation of Breakfast Sausage product within the ingredients statement of the label. [newline]One case, containing 20 lbs. of Breakfast Sausage retained with US Retained tag# B 19 929037.[newline]Plant Manager, immediately notified verbally of the non-compliance.[newline]This is a failure to meet 9 CFR 317.8(a)  and 9 CFR 317.2(f)(1).

Regulation:

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

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

Citation: At approximately 06:45 while performing review and observation for pre-operational sanitation in live kill area observed the following non-compliance. Four metal racks used for hanging Ducks coming out of wash cabinet in kill area observed dirty with fat and blood residue on top hooks of metal racks from previous days operation These metal racks are a food contact surfaces . Metal racks immediately rejected with U.S. Reject tag # B39443328 and Production Supervisor verbally informed of non-compliance and 9CFR 416.1, 416.4(a) and 416.13(c) and failure to carry out written procedures outlined in establishments SSOP. Plants SSOP records observed for days pre-operation did not reflect FSIS Inpsector’s findings.Metal Racks washed and sanitized prior to start of operations.U.S Reject Tag removed by FSIS Inspector.

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.

416.13(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: 03C02
Violation: 381.66(b)

Citation: At approximately 1310 hours, while verifying internal product temperature of poultry during further processing and packaging operations observed the following in the Packing Room prior to the location of the establishments CCP #3B, Refrigerated Storage. Upon request, Production Supervisor, inserted the probe of a calibrated digital thermometer internally into a duck leg, placed within an immediate container (plastic bag) at the Cry-O-Vac Machine. The thermometer reading revealed the internal product temperature to be [redacted] exceeding 55 F, the maximum temperature product may rise to internally as set forth in 9 CFR 381.66(b)(1).  Additional random temperatures taken from twenty-five cases of fully labeled and boxed duck legs staged adjacent the Cry-O-Vac Machine within the Packing Room, revealed further products exceeding 55 F, with a maximum temperature of [redacted] observed.  The establishment, at this time has no records available on file supporting the temperatures of products used during further processing and packaging operations, and operates in accordance with 9CFR 381.66(b)(1) . Production Supervisor, initiated immediate corrective action(s) following verbal notification and the observation of the non-compliance.  This is a failure to meet 9 CFR 381.66(b)(1) and 9CFR 416.1.

Regulation:

381.66(b)(1) All poultry that is slaughtered and eviscerated in the official establishment shall be chilled immediately after processing so that the internal temperature is reduced to 40 °F. or less, as provided in paragraph (b)(2) of this section unless such poultry is to be frozen or cooked immediately at the official establishment. Eviscerated poultry to be shipped from the establishment in packaged form shall be maintained at 40 °F. or less, except that during further processing and packaging operations, the internal temperature may rise to a maximum of 55 °F.: Provided, That immediately after packaging, the poultry is placed under refrigeration at a temperature that will promptly lower the internal temperature of the product to 40 °F. or less, or the poultry is placed in a freezer. Poultry which is to be held at the plant in packaged form in excess of 24 hours shall be held in a room at a temperature of 36 °F. or less.

Code: 01D01
Violation:  416.1, 416.2(e)(1), 416.2(g)(1)

Citation: At approximately 0920 hours, while performing on-line inspection duties at the Mechanical Evisceration Table in the Evisceration Room observed the following; pressure to the potable water lines, and chlorinated water lines dropped which provided a trickle of water at the Final Wash Station (CCP# 2B), and the Liver Station. The chlorinated water from the wash hose at the Final Wash Station, and wall mounted spray nozzle at the Liver Station did not provide sufficient amounts of water too thoroughly wash the carcasses and livers of organic matter, and contaminates. On-line hand wash sprayers, table mounted sprayers, hand wash sink, and hoses for equipment cleaning affected providing a little to no water. [newline]Further observation of the establishment, including the Large Kill Room, Processing Room, Small Kill Room, and Packing Room all affected by the decreased water pressure where little to no water was provided at carcass wash, equipment cleaning, and hand wash areas. [newline]Management did not initiate or take corrective action(s) prior to, or following verbal notification of the non-compliance.[newline]Operations ceased in the Large and Small Kill Rooms, Evisceration Room, and Packing Room and the establishment rejected with US Rejected tag# B40198850. [newline]Production Supervisor, immediately notified verbally of the non-compliance.[newline]This is a failure to meet 9CFR 416.1, 9CFR 416.2(e) and 9CFR 416.2(g)(1).

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)(1) Carry sufficient quantities of water to required locations throughout the establishment

416.2(g)(1) A supply of running water that complies with the National Primary Drinking Water regulations (40 CFR part 141), at a suitable temperature and under pressure as needed, must be provided in all areas where required (for processing product, for cleaning rooms and equipment, utensils, and packaging materials, for employee sanitary facilities, etc.). If an establishment uses a municipal water supply, it must make available to FSIS, upon request, a water report, issued under the authority of the State or local health agency, certifying or attesting to the potability of the water supply. If an establishment uses a private well for its water supply, it must make available to FSIS, upon request, documentation certifying the potability of the water supply that has been renewed at least semi-annually.

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

Citation: At approximately 0648 hours, while performing a scheduled Pre-op Review and Observation task subsequent the establishments verbal and noted acceptable pre-operational sanitation procedure observed the following:[newline]Large Kill Room:[newline]-Meat and fat particulates, approximately 1/8″ in their greatest size, blood smears/ bloodstains and potions of feathers on the non-direct product contact surfaces of seven random shackles on the Wash Line shackles.[newline]-Fat residue, and fat scraps affixed to the non-product contact surfaces of the inside frame, inner lip around the frame openings, and the backside of the inner-mounted spray bars to the Wash Cabinet at the end of the Wash Line.[newline]Evisceration Room:[newline]- A 12″ X 5″ area of splattered blood, and meat scraps on the underside, non-product contact surface of the Boning/ Wash Table stationed along the Southwest wall adjacent the Mechanical Evisceration Table. [newline]Production Supervisor, immediately notified verbally of the non-compliances.[newline]This is a failure to comply with 9CFR 416.1, and 9CFR 416.4(b).

Regulation:

416.1 Each official establishment must be operated and maintained in a manner sufficient to prevent the creation of insanitary conditions and to ensure that product is not adulterated.

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

Code: 01D01
Violation:  416.1, 416.2(c)

Citation: On April 25,2012.at approximately 1240 hours,while performing a schedule routine SPS verification task of the facility,[newline]Observed the following in Cooler#1:A Non-Operable set of lights on the Northeast side of the Cooler creating inadequate[newline]lighting within the Northeast section of the cooler,hindering the inspection of the sanitary conditions,product conditions,and verification of product.[newline]The Northeast section of Cooler#1 is rejected with US Rejected tag#B4019721[newline]Production Supervisor, immediately notify vebally of the non-compliances.[newline]This is a failure to meet 9CFR416(c) and 9CFR416.1[newline]This document serves as written notification that failure to comply with regulatory requirements[newline]Could result in additional or administrative action(s).

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(c) 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.

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

Citation: At approximately 0648 hours, observed the following while performing the review and observation, and recordkeeping, verification activities, of a scheduled routine Pre-Op SSOP Review and Observation task prior to the start of operations, and subsequent the establishments verbal and noted acceptable pre-operational inspection:[newline][newline]Processing Room:[newline] -Numerous meat and fat particles/ scraps, approximately 1/8″ to 7/16″ in size, and bloodstains on the direct product contact surfaces of an edible stainless steel rolling tank, and direct product contact surfaces of two 12″ x 12″ plastic cutting board squares. The stainless steel rolling tanks situated next to the Entrance / Exit door for Cooler #2 and the cutting boards positioned on the stainless steel table set along the Southeast wall beside the Entrance/ Exit door to Cooler #2. Cutting boards and stainless steel tank rejected with US Rejected tag#B40198847. [newline] -Product residue, bloodstains and ingesta affixed to the underside, non-product contact surface of the grates and inside frame surfaces of the wash table stationed along the Northeast wall next to the ice machines.[newline]Evisceration Room:[newline] -Six meat scraps, approximately 3/16″ to 1/4″ in size, and splattered bloodstains on the inside direct product contact surfaces of an edible stainless steel rolling tank, positioned between the mechanical evisceration table and the processing tables. Edible stainless steel rolling tank rejected with US Rejected tag#B40198848. [newline] -Meat particles and ingesta embedded between the non-product contact surfaces of the plastic guide and stainless frame of both sides, atop the length of the mechanical eviscerations table. [newline] Production Supervisor, immediately notified verbally of the non-compliances. [newline] The establishments SSOP Plan signed and dated 10/20/09, page 1, section I. Pre-operational Sanitation, sub-section A. Equipment Cleaning, part 2. Monitoring and Recordkeeping states: “[redacted].[newline] This is a failure to meet 9CFR 416.1, 9CFR 416.13(c), 9CFR 416.4(a), and 9CFR 416.4(b).[newline] [newline] 

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.

416.13(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: 01D01
Violation:  416.1, 416.2(b)(2), 416.4(b)

Citation: Today at approximately 0710 hours, I observed the following: (1) Dark brown greasy residues at a shackle track above the poultry scalding tank located inside the slaughter room. (2) Thick dust at surfaces around the ventilation fans in the slaughter room and in the evisceration room. (3) Dust also found at the surface of a ceiling tile located above the ventilation fan in the evisceration room. QC manager was notified and shown of the noncompliance listed above. Manager said that the noncompliance areas will be cleaned after the operation is finished today.

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.

Code: 01D01
Violation:  416.1, 416.2(a), 416.2(b)(1), 416.2(c)

Citation: At approximately 1230 hours, while performing a scheduled Directed SPS Verification Task of the facility, observed the following In Freezer #2. Frost suspended approximately 3″ inch in its greatest length, throughout the entire surface of the ceiling directly over finished products in packaged form. Packages (plastic immediate containers) and boxes (shippers/ immediate containers) have evidence of frost and ice on their surfaces. No product contamination observed at this time. [newline][newline]Boxed products stocked along the South wall, are broken allowing stored individually sealed packages to spill from the boxes in a manner of disarray onto the tops and in between used boxes (shippers) and pallets. Finished products stored in manner interfering with inspection of products and the freezer premises. Metal screws observed scattered across the tops of three boxes upon entering the freezer on the right side. No contamination of product observed at this time.[newline][newline]Inadequate lighting within the freezer, hindering the inspection of the sanitary conditions, product conditions, and verification of finished product labeling. [newline][newline]Freezer #2 rejected with US Rejected tag# B40198792.[newline][newline]Production Supervisor, immediately notified verbally of the non-compliances.[newline][newline]This is a failure to meet 9CFR 416.1, 9CFR 416.2(a)(2), 9CFR 416.2(b)(1) and 9CFR 416.2(c).

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

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

416.2(c) 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.

Code: 03J02
Violation:  417.5(b)

Citation: On 03/04/12 at approximately 1215 hours, while reviewing the establishments Slaughter HACCP Record, CCP# 2B, Fecal Contamination Check and Chlorine Monitoring Form, dated 03/04/12 while performing the recordkeeping, and review and observation, verification activity, of a Directed Slaughter HACCP task, observed the following. No documented performances of a direct observation for the Fecal Contamination Check and Chlorine Monitoring, and no documented performance of a record review for CCP# 2B. [newline][newline]Today, 03/05/12 at 1310 hours, while reviewing the Slaughter HACCP record, CCP# 2B, Fecal Contamination Check and Chlorine Monitoring Form, dated 03/04/12 while performing the recordkeeping, verification activity, of a Routine Slaughter HACCP task, observed the following. Documented direct observations for the Fecal Contamination Check and Chlorine Monitoring performance, at 1010 and 1015 hours, respectively; and a documented record review performance, at 1205 hours for CCP# 2B. [newline][newline]The HACCP Record for CCP# 2B did not contain the documented direct observations and record review performed on 03/04/12, at the time the event occurred.[newline][newline]The establishments Slaughter HACCP plan signed and dated 01/20/11, Section 4. Critical Limits, Monitoring, and Corrective Actions, pages 2 and 3, under Verification Procedures states: “[redacted] “; “[redacted] “, and “[redacted]”. [newline][newline]Production Supervisor, stated that corrective actions taken immediately, but were failed to be recorded.[newline][newline]This is a failure to meet 9 CFR 417.5(b).

Regulation:

417.5(b) Each entry on a record maintained under the HACCP plan shall be made at the time the specific event occurs and include the date and time recorded, and shall be signed or initialed by the establishment employee making the entry.

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

Citation: At approximately 0650 hours, observed the following while performing the review and observation, and recordkeeping, verification activities, of a scheduled routine Pre-Op SSOP Review and Observation task prior to the start of operations, and subsequent the establishments verbal and noted acceptable pre-operational inspection. In the Processing Room, numerous meat and fat particles/ scraps, approximately 1/8″ to 7/16″ in size, and dried bloodstains on the direct product contact surface of the stainless steel tabletop stationed along the Northeast wall beside the Entrance/ Exit door. Table rejected with US Rejected tag# B40198781. Dried product residue, and bloodstains affixed to the underside, non-product contact surface of the grates in close proximity to the drain holes of the Washing Table stationed along the Northeast wall next to the Ice Machines. In the Large Kill Room, scattered meat and fat particles on the exposed surfaces of the power cord to Picking Machine #1, spanning from the machine to the ceiling. [newline][newline][newline][newline]Production Supervisor, immediately notified verbally of the non-compliances. [newline][newline][newline][newline]The establishments SSOP Plan signed and dated 10/20/09, page 1, section I. Pre-operational Sanitation, sub-section A. Equipment Cleaning, part 2. Monitoring and Recordkeeping states: “[redacted]. [newline][newline][newline][newline]This is a failure to meet 9CFR 416.1, 9CFR 416.13(c), 9CFR 416.4(a), and 9CFR 416.4(b).

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.

416.13(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: 01D01
Violation:  416.1, 416.2(e)(2), 416.2(e)(4)

Citation: At approximately 1345 hours, while performing the review and observation, verification activity of a scheduled routine Operational SSOP review and observation task, observed the following. A 2′ X 4′ area of pooling wastewater, murky in color containing suspended and non-suspended organic matter, that is approximately 1 1/2″ in depth, between the Mechanical Evisceration Table and the Processing/ Wash Table stationed along the Southeast wall adjacent the Exit door to the Inedible area at the end of the floor drain. The trench style floor drain that runs along and is adjacent to the Southeast wall is blocked, allowing stagnant waste water to accumulate, approximately 1″ to 2 1/2″ at its maximum depth, containing floating organic waste, and is in direct connection with the pooling wastewater. The area of pooling wastewater and the blocked floor drain area are in an employee, and raw exposed product traffic area.[newline][newline]In the Packing Room, at approximately 1355 hours, observed a 4′ X 6′ area of pooled stagnant blood and water, approximately 3/4″ in depth directly in front of and below the [redacted] Packing Machine, an employee, and raw exposed product traffic area. [newline][newline]Production Supervisor, immediately notified verbally of the non-compliances. [newline][newline]This is a failure to meet 9CFR 416.1, 9CFR 416.2(e)(2), and 9CFR 416.2(e)(4).[newline][newline]

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)(2) Properly convey sewage and liquid disposable waste from the establishment;

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: 03J02
Violation:  417.2(c)(7), 417.4(a)(2)(ii), 417.5(a)(3)

Citation: At approximately 0940 hours, while performing both recordkeeping, and review and observation, verification activities, of a routine Slaughter HACCP task, observed the following while reviewing the establishments Slaughter HACCP Records for CCP# 2B, Fecal Contamination Check and Chlorine Monitoring Form, dated 02/12/12. No documented performance of a direct observation for Fecal Contamination Check, and Chlorine Monitoring (CCP# 2B) during the evisceration of small ducks, from the start of operations to 0855 hours, the completion timeof the evisceration of small ducks. [newline][newline]The establishment’s records review, verification activity performed at 0855 hours, with noted acceptable findings.[newline][newline]The establishments Slaughter HACCP plan for small ducks signed and dated 01/20/11, page 17, under Verification Procedures states: [redacted] & . In addition, “ [redacted] ”. [newline][newline]Production Supervisor, verbally notified immediately of the non-compliance.[newline][newline]This is a failure to meet 9CFR 417.2(c)(7), 9 CFR 417.5(a)(3) and 9 CFR 417.4(a)(2)(ii).

Regulation:

417.2(c)(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.

417.4(a)(2)(ii) Direct observations of monitoring activities and corrective actions

417.5(a)(3) Records documenting the monitoring of CCP’s and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment’s HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter production lot. Each of these records shall include the date the record was made.

Code: 03J02
Violation:  417.2(c)(4)

Citation: At approximately 1235 hours, at the time of reviewing the establishment’s Slaughter HACCP Record, CCP #2B, Fecal Contamination Check and Chlorine Monitoring Form, dated 02/05/12 while performing the recordkeeping, verification activity, of a routine Slaughter HACCP task, observed the following. The initial monitoring for chlorine concentration documented as performed at 0600 hours with a concentration of [redacted] prior to the start of the evisceration process. The performance of the second chlorine concentration documented as performed at 0840 hours with a concentration of [redacted]. The day’s evisceration process concluded at 0925 hours, and at which time the establishment performed the verification procedure, records review, noting acceptable findings. [newline][newline]The monitoring of the subsequent chlorine concentration monitoring exceeded two hours from the performance of the initial monitoring prior to start-up. [newline][newline]The establishments Slaughter HACCP plan signed and dated 01/20/11, section 4. Critical Limits, Monitoring, and Corrective Actions, page 2, under Monitoring Procedures/ Frequency Person Responsible states: “[redacted] “. [newline][newline]Production Supervisor, immediately notified verbally of the non-compliance. [newline][newline]This is a failure to meet 9 CFR 47.2(c)(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;

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

Citation: At approximately 0655 hours, observed the following while performing the review and observation, and recordkeeping, verification activities, of a scheduled routine Pre-Op SSOP Review and Observation task prior to the start of operations, and subsequent the establishments verbal and noted acceptable pre-operational inspection. In the Evisceration Room unknown thread-like material, green in color, affixed to two plastic cones, and fraying plastic pieces on the direct product contact surface of the tabletop processing cone stands stationed on the processing table along the West wall adjacent the hand-wash sink. Processing cone stands rejected with US Rejected tag# B40 198719. The electrical control box posted on the West wall above the processing table has a black unknown substance on the bottom-exposed surface, directly above the processing table, and on the plastic electrical conduit pipes and junction box exiting the control box. In the Large Kill Room, rested along the Northeast wall adjacent the two picking machines, observed five dried feathers on the top section of the tabletop for Picker #1, a direct product contact surface, and dried feathers, meat particles and grease on the underside of the tabletop, a non-product contact surface. Picker #2 has product residue embedded within the pitted and uneven welds, along the square opening for the rotating rubber fingers on the tabletop, a product contact surface. Picker #1 and Picker #2 rejected with US Rejected tag# B40198717. The two power cords exiting the picking machines that extend to the ceiling have dried meat and fat particles, and dried feathers scattered on the exposed surfaces. In the Processing Room, two large plastic totes and one large plastic rolling bin used for edible products are unclean and have an unknown black matter, and grit/stone-like substance on the inside bottom surface, a direct product contact surface. Two large totes and one large rolling bin rejected with US Rejected tag#B40198718. Production Supervisor, immediately notified verbally of the non-compliances. The establishments SSOP Plan signed and dated 10/20/09, page 1, section I. Pre-operational Sanitation, sub-section A. Equipment Cleaning, part 2. Monitoring and Recordkeeping states: &[redacted]s ”. This is a failure to meet 9CFR 416.1, 9CFR 416.13(c), 9CFR 416.4(a), 9CFR 416.4(b) and 9CFR 416.3(a).

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.

416.13(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(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: 01D01
Violation:  416.1, 416.2(b)(2), 416.4(b)

Citation: At approximately 0650 hours, while performing a Directed Pre-op Review and Observation task subsequent the establishments verbal and noted acceptable pre-operational sanitation observed the following: [newline][newline]Large Kill Room: [newline]-Flaking and peeling paint throughout the North East wall alongside the picking machine and wash line. [newline][newline]-Various sized pieces of paint on the underside, non-product contact surface of the picking machines table-top, staged along and in contact with the North East wall. [newline][newline]-Rust on the outer exposed surfaces of the kill line and wash line drive wheels and overhead support beam. [newline][newline]Cooler #1: [newline]-Verdigris on the outside surface of the pipes exiting the rear of two overhead refrigeration units positioned along the South East wall in proximity to exposed carcasses. [newline][newline]Evisceration Room: [newline]-Verdigris on the outside surface of the pipes exiting the side of the overhead refrigeration unit, in proximity to exposed carcasses and product traffic area. [newline][newline]-Verdigris on the outside surface of the pipes exiting the side of the overhead refrigeration unit directly above the end of the mechanical evisceration table. [newline][newline]-Rust on exterior surface of the overhead refrigeration unit support bars, directly above the mechanical evisceration table. [newline][newline]Packing Room: [newline]-Meat particles and product residue on the non-product contact surface of the lid to the [redacted] machine adjacent the heating elements on each sealing side of the machine, and on both sides of two heating elements secured to the lid. [newline][newline]-Scattered meat particles on a 2’ x 2’ area of the ceiling surface and exterior surface of the light shield directly above the packing table and band-saw machine location (when operated). [newline][newline]Production Supervisor, immediately notified verbally of the non-compliances. [newline][newline]This is a failure to comply with: 9CFR 416.1, 9CFR 416.2(b)(2) and 9CFR 416.4(b).

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.

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

Citation: At approximately 0655 hours, observed the following in the Evisceration Room while performing the review and observation, and recordkeeping, verification activities, of a Directed Pre-Op SSOP Review and Observation task subsequent the establishments verbal and noted acceptable pre-operational inspection: [newline][newline]-Fat and meat particles affixed to the direct product contact surface of the plastic cutting boards, and dried product residue underside and inside exposed surfaces of the supporting frame for the cutting boards stationed adjacent the hand wash sink along the Southeast wall. Cutting/ processing table rejected with US Rejected tag# B40198720. [newline][newline]-Meat scraps along the outer lip of the large processing table’s backsplash, a non-product contact surface, and five pieces of fat approximately ¾” in their greatest dimension, within the hollow stainless steel assembly, a non-product contact surface, that runs the length of the table along the backsplash and drainage trough junction, directly behind the tabletop stainless steel slotted plates. The large processing tables positioned along the Southeast wall beside the cutting/ processing table. [newline][newline]-Meat and fat particles on the outside frame structure and on the underside surfaces of the cutting board supports bars of the staging/ processing table situated in the East corner. [newline][newline]Production Supervisor, immediately notified verbally of the non-compliances. [newline][newline]The establishments SSOP Plan signed and dated 10/20/09, page 1, section I. Pre-operational Sanitation, sub-section A. Equipment Cleaning, part 2. Monitoring and Recordkeeping states: “[redacted] ”. T[newline][newline]his is a failure to meet: 9CFR 416.1, 9CFR 416.13(c), 9CFR 416.4(a) and 9CFR 416.4(b).

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.

416.13(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: 01D01
Violation:  416.1, 416.4(b)

Citation: At approximately 0655 hours, while performing a Direct Pre-Op SSOP Review and Observation Task, subsequent the establishments verbal and noted acceptable pre-operational inspection the following observations were noted: [newline][newline]Evisceration Room: [newline]- Meat and fat particles, and product residue on the underside frame, a non-product contact surface of the processing table adjacent the hand wash sink along the East wall and the processing table along the North wall next to the entrance/ exit door to Cooler #1. [newline][newline]Processing/ Shipping Room: [newline]-Product residue and an unknown black material on the underside frame and support legs, non-product contact surfaces of the stainless steel topped processing tables stationed along the Northeast Wall between the entrance/ exit doors to the Evisceration Room and Cooler #4. [newline][newline]Packing Room: [newline]-Meat scraps affixed to the legs, under frame and components of the tabletop pan scale, and exposed rust on the lower frame below the scale pan, a non-product contact surface. [newline][newline]-Rust, and a black and white unknown spotted substance on the underside frame surfaces of the scale pan. [newline][newline]Production Supervisor, immediately notified verbally of the non-compliances. [newline][newline]This is a failure to meet: 9CFR 416.1 and 9CFR 416.4(b).

Regulation:

416.1 Each official establishment must be operated and maintained in a manner sufficient to prevent the creation of insanitary conditions and to ensure that product is not adulterated.

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

Code: 04B04
Violation:  381.129, 381.96

Citation: At approximately 1245 hours, while performing a Directed General Labeling task I observed the following on the storage rack in the Southeast corner next to the entrance/exit door to Cooler #4. Seven cases ready for shipment containing 42 individually labeled consumer sized packages of raw ready to cook 8oz Petite Duck Breasts (Lot# 308-11) do not bear an official poultry inspection legend on the finished product packages. The principal display panel, a cardboard sleeve securely affixed to the packages declares the establishments official establishment number (P-number) within an official meat inspection legend described in 9CFR 312.2(b)(1), and declares the animal raising claims “Antibiotic Free”, an un-approvable claim and “No Growth Stimulants”. The “No Growth Stimulants” claim is not followed by or do not address the qualifying disclaimer statement of “Federal regulations prohibit the use of hormones” as required.[newline][newline]Seven cases of 8 oz Petite Duck Breasts, approximately totaling 21lbs retained with US Retained tag# B40198713 in Cooler#4 and 4 cases, approximately 4,000 labels (cardboard sleeves) bearing a pre-printed meat inspection legend containing the establishments P-number and animal raising claims rejected with US Rejected tag#B40198712 in the Labeling Storage Room. [newline][newline]Production Supervisor, immediately notified verbally of the non-compliance and the actions taken. [newline][newline]This is a failure to meet: 9CFR 381.96 and 9CFR 381.129(a).

Regulation:

381.129(a) No poultry product subject to the Act shall have any false or misleading labeling or any container that is so made, formed, or filled as to be misleading. However, established trade names and other labeling and containers which are not false or misleading and which are approved by the Administrator in the regulations or in specific cases are permitted.

381.96 Except as otherwise provided in this subpart, the official inspection legend required to be used with respect to inspected and passed poultry products shall include wording as follows: ‘‘Inspected for wholesomeness by U.S. Department of Agriculture.’’ This wording shall be contained within a circle. The form and arrangement of such wording shall be exactly as indicated in the example in Figure 1, except that the appropriate official establishment number shall be shown, and if the establishment number appears elsewhere on the labeling material in the manner prescribed in § 381.123(b), it may be omitted from the inspection mark. The administrator may approve the use of abbreviations of such inspection mark; and such approved abbreviations shall have the same force and effect as the inspection mark. The official inspection legend, or the approved abbreviation thereof, shall be printed on consumer packages and other immediate containers of inspected and passed poultry products, or on labels to be securely affixed to such containers of such products and may be printed or stenciled thereon, but shall not be applied by rubber stamping. When applied by a stencil, the legend shall not be less than 4 inches in diameter. An official brand must be applied to inspected and passed carcasses and parts of ratites that are shipped unpacked.

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

Citation: At approximately 1215 hours while performing a routine Operational SSOP Review and Observation task, I observed the following in the Evisceration Room; a live active rodent on the portable duck storage rack in direct contact with un-eviscerated duck carcasses, and the product and non-product contact surfaces of the storage rack. The storage rack situated at the time of observance near the exit door leading to the Inedible storage area from the Evisceration Room. [redacted] Ducks from the affected storage rack from Cooler #5have completed evisceration and were in the process of evisceration on the mechanical evisceration table, and were in processing for various parts. Exposed duck parts were additionally present in the Processing/ Shipping Room on the wash table, next to the Ice Machine upon findings. [newline][newline]The Evisceration and Processing/Shipping Room are in direct connection with no physical separation or barrier, as well as being in direct connection with the Small Kill Room by the approximate 1” to 1 3/4” gap at the bottom of the door separating the rooms. [newline]No operations conducted on this day in the Small Kill Room. [newline]Approximately 50 lbs of duck liver, 160 lbs of duck breasts, 40 lbs of duck meat, 450 lbs of duck legs and 364 lbs (28 whole ducks) of un-eviscerated duck carcasses were exposed and unprotected in the Evisceration and Processing/ Shipping Room and were retained with US Retained tags # B39 718931, B40198714, B39 718927 and B39 7188929. [newline][newline]Operations in the Evisceration and Processing/ Shipping Room seized immediately at the time of findings. The Evisceration Room, Processing/ Shipping Room, Small Kill Room and Cooler #5 in their entirety rejected with US Rejected tag #B40198709 and #B40198710, respectively. [newline][newline]Immediately, the Production Supervisor, and Plant Manager, were notified verbally of the non-compliance and regulatory actions taken, respectively. [newline][newline]Further Inspections of the facility including the affected rooms and products, revealed no further evidence of rodent activity and additional physical separations from the affected areas are in place. [newline][newline]No vulnerabilities observed within the Evisceration and Processing/ Shipping Room, Small Kill Room and Cooler #5 permitting entrance of vermin or pests at this time, following the findings.[newline][newline]No exposed packaging materials are present or stored in the Evisceration and Processing/ Shipping Room. [newline][newline]The establishments SSOP records, form SSOP Form F1 reveals acceptable findings for operational sanitation inspection, noting the last acceptable check performance was 1205 hours. [newline][newline]The establishments SSOP plan signed and dated 10/11/08, page 2, under II. Operational Sanitation, Section 2. Monitoring and Recordkeeping states: [redacted]” and “ [redacted]”. [newline][newline]This is a failure to meet: 9CFR 416.13(c), 9CFR 416.1, 9CFR 416.

Regulation:

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

416.2(a) 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(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: 01D01
Violation:  416.1, 416.2(b)(1), 416.2(c), 416.2(h)(1), 416.4(b)

Citation: At approximately 1330 hours, while performing a routine SPS Verification inspection task of the establishment’s facility I observed the following: Employee Welfare Areas: – An approximate 3” x 4” hole in the West wall adjacent the lockers in the South end of the Men/Women’s locker room. -Inadequate lighting in the South end of the Men/ Women’s locker room, an area equipped with employee lockers, a bench and storage hooks. -Dust on the tops of the lockers throughout the locker room. -Trash and debris scattered on the floor and behind the lockers stationed along the West wall in the North end of the locker room. -The floor within the stall of the Men’s Bathrooms littered with used and unused toilet tissue and trash. Employee Lunch Room: -An approximate 5” x 10” hole in the middle of the North Wall adjacent the vending machine and an approximate 6” x 12” hole in the middle of the South Wall adjacent the vending machine. -Trash and debris scattered throughout the floor of the lunchroom, between and on the tops the vending machines, tables and refrigerators. Immediately, I notified Production Supervisor, verbally of the non-compliances. This is a failure to meet: 9CFR 416.1, 9CFR 416.2(b)(1), 9CFR 416.2(c), 9CFR 416.2(h)(1) and 9CFR 416.4(b).

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

416.2(c) 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.

416.2(h)(1) Dressing rooms, toilet rooms, and urinals must be sufficient in number, ample in size, conveniently located, and maintained in a sanitary condition and in good repair at all times to ensure cleanliness of all persons handling any product. They must be separate from the rooms and compartments in which products are processed, stored, or handled.

416.4(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:
Violation:  416.1, 416.2(b)(2), 416.4(b)

Citation: At approximately 0940 hours, while conducting the review and observation of a routine Operational SSOP procedure task I observed the following: [newline][newline]Cooler #1: [newline]-Unknown white substance on the exposed surfaces of the overhead refrigeration unit fan guards stationed along the East wall directly above exposed duck carcasses. [newline]-Black unknown material on the exposed surfaces of the East wall below the overhead refrigeration units, on the surface of the ceiling and along the ceiling wall juncture. [newline]-Rust on the surfaces of the electrical wire conduit supports, affixed to the ceiling and wall surfaces. [newline][newline]Evisceration Room: [newline]-Unknown spotted black substance on the outside exposed surface of the refrigeration unit directly above the end of the mechanical evisceration table, situated in approximately the center of the room. [newline][newline]Cooler #4: [newline]- Dust on the overhead refrigeration unit fan guards directly above finished products. [newline][newline]Packing Room: [newline]-Unknown black substance on the exposed ceiling surface and wall surfaces above and behind the finished product packing tables and cry-o-vac machine, along the East wall. [newline]-Dust in the fan guards of the overhead refrigeration units, directly above a finished product packing table. [newline][newline]Immediately, I notified Production Supervisor, verbally of the non-compliances. [newline][newline]This is a failure to meet: 9CFR 416.1, 9CFR 416.2(b)(2) and 9CFR 416.4(b).

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.

Code: 03J01
Violation:  417.2(c)(4)

Citation: At approximately 0745 hours, while performing the review and observation component of an unscheduled 03J01 procedure task I observed the following at CCP #2B (Carcass Wash). Of the 10 randomly selected whole duck carcasses on the processing table subsequent the Carcass Wash step, one whole duck carcass has an approximate 1/2″ X 2 1/2″ fecal smear in its greatest dimension on the outside lower portion of the abdominal flap (skin). The fecal smear observed is of a darkish green color that is consistent with a semi-solid material. The establishment records indicate that the monitoring and direct observation (verification) of CCP# 2B were not performed prior to or at the time of the findings. I immediately notified Production Supervisor, verbally of the non-compliance and at this time corrective actions were immediately initiated by the establishment, on the whole duck carcass. The establishments Slaughter HACCP plan signed and dated 01/20/11, Section 4: Critical Limits, Monitoring and Corrective Actions, page 2 under Critical Limits states: “[redacted]”, and under Monitoring Procedures/ Frequency states: “[redacted]” This is a failure to meet: 9CFR 417.2(c)(4) The 02 process will be performed.

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

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

Citation: At approximately 0700 hours, while performing a scheduled 01B02 procedure task prior to the start of operations and subsequent the establishments verbal and noted acceptable pre-operational inspection I observed the following; fat/ meat scraps and a greasy unknown substance on the direct product contact surfaces of two stainless steel table tops, including the exposed surface of the stainless steel backsplash affixed to the rear of the tables stationed on each side of the Machine along the East wall in the Packing Room. The stainless steel scale situated on the stainless steel table adjacent the Exit/ Entrance door is unclean with adhered fat particles and a greasy film material covering the exposed surface of the scale pan. Two stainless steel tables and one stainless steel scale rejected with US Rejected tag #B39718928. The establishments SSOP plan signed and dated 10/11/08, page 1 section I. Pre-operational Sanitation sub-part 2. Monitoring and Recordkeeping states: ” [redacted]”. I immediately notified Production Supervisor, verbally of the non-compliance. This is a failure to meet: 9CFR 416.13(c); 9CFR 416.4(a), 9CFR 416.4(b). Past Similar NRs – Previous Ineffective Plant Actions: Observe the saw immediately prior to use and correct any deficiencies as needed. NR: 33-2011 dated 8/17/2011

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(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: 06D02
Violation:  416.2(b)(2), 416.2(d), 416.4(b)

Citation: Today at approximately 0700 hours, I observed 2 broken ceiling mounted transparent light panel with yellowish dried stain at around the broken opening area of the panels located inside the large poultry slaughter room. And also, I observed many rust spots appearing along the shackle track located above the hot water tank inside the large poultry slaughter room. There were more rust sports appearing at the lower level section of the shackle track. Failure to meet the federal regulatory requirement of the 9 CFR 416.2(b)(2) which stated that 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. Failure to meet the federal regulatory requirement of the 9 CFR 416.4(b) which stated that non-food-contact surfaces of facilities, equipment 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. On the same day, at approximately 1000 hours I observed beaded condensation appearing at the ceiling tiles and at the bottom surfaces of the 2 cooling units located inside the evisceration room. No products were put below where the water beads were dripping. Therefore no tag was applied. Failure to meet the federal regulatory requirement of the 9 CFR 416.2(d) which stated that ventilation adequate to control condensation to the extent necessary to prevent adulteration of product and the creation of insanitary conditions must be provided. Plant manager Ms. was notified and shown of all the noncompliance areas immediately. Plant manager Ms. immediately called the plant mechanic to come to check all the noncompliance areas.

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 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.

Code: 06D02
Violation:  416.2(b)(2), 416.2(c), 416.4(b)

Citation: Today at approximately 0650 hours after Ms. told me that her Pre-Op procedure of today was finished and found all areas were acceptable, then I performed my inspection. I observed the followings: (1) The ceiling mounted light set and light fixture were partially covered with feathers and thick dust located at the live ducks holding area inside the “Small Slaughter Room”. Plus, 2 of 4 lights of the same set were not functioning. (2) Yellowish wet residue appearing on the entire top surface of the small ” ice making machine which was located against a raw exposed poultry products processing table inside the poultry processing/packing area. (3) Wet black particles, sands, were appearing on the top surface of the large “[redacted] ice making machine located next to the small “[redacted] ice making machine. (4) Greasy, oily, rusty surfaces appearing at the bottom side of the 2 raw poultry product processing tables located next to the back exit of the evisceration room. Plant manager Ms. was notified and shown of the noncompliance. Ms. said that she will find the plant’s Maintenon guy to fix the areas of noncompliance. -Failure to meet the federal regulatory requirement of the 9 CFR 416.2(b)(2) which stated that ceilings within the establishments must be cleaned and sanitized as necessary to prevent adulteration of product or the creation of insanitary conditions. -Failure to meet the federal regulatory requirement of the 9 CFR 416.2(c) which stated that lighting of good quality and sufficient intensity to ensure that sanitary conditions are maintained. -Failure to meet the federal regulatory requirement of the 9 CFR 416.4(b) which states: 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. Past Similar NRs – Previous Ineffective Plant Actions: The corrective action(s) indicated were not completed. NR: 30-2011 dated 8/15/2011

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(c) 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(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: At 0745 hours the following was observed in the packing room. One band saw used to cut frozen livers was unclean, product residue was observed on the upper fly wheel and rust was observed on the blade. This does not comply with Title 9 CFR 416.13(c). SSOP plan signed and dated 1/27/97 states ” Mrs. was shown the noncompliance and informed it was rejected from use, US Tag # B 17 234354. SSOP records indicated that all contact surfaces were found acceptable and documented as such Past Similar NRs – Previous Ineffective Plant Actions failed to prevent reoccurrence. NR: 31-2011 dated 8/15/2011

Regulation:

416.13(c) 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.

Code: 06D01
Violation:  416.1, 416.2(b)(2), 416.2(b)(3)

Citation: At approximately 0710 hours the following was observed in the dry storage (packing material) area: The area was littered and unclean with debris (e.g. plastic, garbage, wood from pallets). Area was rejected from use, US Tag # B 17 234354. In the packing material storage area, I observed a storage freezer that is constructed of wood (the outside of the cooler) which is porous material. Title 9 CFR 416.2(b)(2) states, “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.” The freezer cooler is not impervious to moisture; Mr. was informed of the noncompliance.

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.

416.2(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: 01B02
Violation:  416.13(c)

Citation: At 0710 hours the following was observed in the small duck kill room. Three scabbards were unclean, blood was observed in the inside surface which is in direct contact the knives blades. Three scabbards and 2 knives were rejected from use, US Tag # B 17 234360. This does not comply with Title 9 CFR 416.13(c). SSOP plan signed and dated 1/27/97 states ” Mrs. was shown the noncompliance. SSOP records indicated that all contact surfaces were found acceptable and documented as such.

Regulation:

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

Code: 06D02
Violation:  416.2(b)(2), 416.2(d)

Citation: At 0715 hours I observed beaded condensation on the frame of the doorway between the small duck slaughter area and the duck holding/staging area. This does not comply with Title 9 CFR 416.2(d). In the holding/staging area for the live ducks (small) the area was emanating a foul odor. Mr. was shown the above mentioned noncompliance and informed area was rejected US tag # B 17 234354. In the “small slaughter” live duck holding/staging area, I observed that the ceiling is constructed of wood which is porous material. Title 9 CFR 416.2(b)(2) states, “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.” The Ceiling is not impervious to moisture; Mr. was informed of the noncompliance.

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 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: 06D01
Violation:  416.2(b)(3)

Citation: At approximately 0830 hrs., I observed the following. In the Shipping area, while the two garage doors were closed, the bottoms were not flush to the ground. Their is an approximate 1/2 inch gap across the entire length of the door on the right side and an approximate 12″ section of the other. plant manager was informed. This is a noncompliance with Title 9CFR 416.2(b)(3) which requires walls, floors doors, ceilings, windows and other outside openings to be constructed and maintained to prevent the entrance of vermin, such as flies, rats, and mice.

Regulation:

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

Citation: At approximately 0645 hrs., and prior to the start of production subsequent plant managers preoperational inspection, I observed the following. In the evisceration room, on the conveyor, several boning boards are deeply scored and have visible brown stains in their crevices and a few along the surfaces of the exposed product contact zones. U.S. Reject tag No. B30440052 was applied. The Establishment’s SSOP plan, signed and dated, 10/20/09, on page 1, under Pre-operational Sanitation, states, ” [redacted] ” Mr. Operations Manager was immediately informed. This is in noncompliance with Title 9CFR 416.13(c) which requires each official establishment to monitor daily the implementation of the procedures of the SSOP’s. Title 9CFR 416.4(a) requires all food contact surfaces, including food contact surfaces of utensils and equipment to be cleaned and sanitized as frequently as necessary to prevent the creation of insanitary conditions and the adulteration of product. Past similar NR’s – Ineffective further planned actions stated, ” Supervision and management will observe to prevent reoccurrence and to provide additional training to clarify plant policies.” NR#23 -2011, dated 07/05/2011.

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: 06D01
Violation:  416.2(b)(3), 416.4(b)

Citation: Today at approximately 1230 hours, after I finished reviewing the plant’s facilities inspection result work sheet Form F-2 which showing all areas were marked “Acceptable” for today then I started to perform my facilities inspection for today. I observed the following: (1) I observed 4 dead flies laying inside a transparent light cover located inside the food product vacuum-pack packing room. No flies were observed flying or moving at anywhere inside the vacuum-pack packing room at the moment, but I observed an opening size about 1 1/2″x18″ which appeared to be a piece of rubber was missing located at the top of the flopping door entrance to this room. Plan manager was notified and shown. (2) I observed dust appearing on the 2 white color drainage pipes connecting to the 2 cooling units located inside the processing room with the ice making machine. Failure to meet the federal regulatory requirement of the 9 CFR 416.2(b)(3) stated that doors must be constructed and maintained to prevent the entrance of vermin, such as flies, rats and mice. Failure to meet the federal regulatory requirement of the 9 CFR 416.4(b) stated that 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.

Regulation:

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

Citation: Today at approximately 0800 hours, during the processing operating time, in the processing room where has the ice making machine, I observed one plant-worker picked up a contaminated raw duck leg from the ground and put it on the same table surface where the other clean food products were accumulated. I spent a minute to observe if anyone comes to perform the corrective action. One minute was gone and no one came to correct it. When I about to start issuing a USDA Rejected/Retained tag, the plant manager came by and asked me what had happened. I told her what I observed as what written above. She immediately asked one worker to remove that contaminated duck leg from that clean food contact table surface. The section on that table was contaminated was observed cleaned/sanitized. The entire immediate corrective action was observed to be performed satisfactory. No tag need to apply. Plant’s SSOP-Processing Operation section 2. Monitoring (a) states: [redacted]. Failure to comply with the federal regulatory requirement of the 9 CFR 416.13(c) which states: Each official establishment shall monitor daily the implementation of the procedure in the Sanitation SOP’s. Failure to comply with the federal regulatory requirement of the 9 CFR 416.4(a) which states: All food-contact surfaces, must be cleaned and sanitized as frequently as necessary to prevent the creation of insanitary conditions and the adulteration of product. This document serves as written notification that failure to comply with regulatory requirement(s) could result in additional regulatory or administrative action.

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: 06D01
Violation:  416.2(b)(3)

Citation: At 1330 hours on this date Inspector observed two sections of 1×6 boards located at the top section of the wall directly under the roof line that are bent and loose. This wall is adjacent to the employee parking lot. Birds were noticed nesting in the openings caused by the loose sections of boarding. At the present time this construction is not acceptable to exclude birds from entering the facility. No product is affected. Plant Manager will be notified upon receiving this non compliance report at 1400 hours on this date for facility meeting with USDA Inspector.

Regulation:

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: 06D01
Violation:  416.2(a)

Citation: Inspector noticed at 1215 hours today after leaving the evisceration department after evis duties and walking into the warehouse to see Plant Manager in the HACCP records office, that the means and resources used to control flies in the warehouse area is not effective at the present time. The two fly “zappers”, one located above the employee exit door to the hallway to exit the warehouse is not operational. The other “zapper” located hanging from the ceiling prior to entering the new shipping room has two ultra violet lights not functioning that are used to attract flying insects. No product is affected. Plant Manger will be notified this afternoon upon receiving this non-compliance report.

Regulation:

416.2(a) 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:  416.15(a)

Citation: During the production shift on the date 05/19/2011 at approximately 1130 hours production management stopped production to address the issue of dripping moisture from the cooling unit located above the back end of the evisceration table. The dripping moisture was confined to one location and was dripping from the area near the pipe/elbow connection. Maintenance was notified and plastic sheeting was positioned to catch dripping moisture and to prevent the product/evis table from becoming contaminated. Inspector let production resume after the table was sanitized [redacted]. as part of the 03J plan for CCP # 2B carcass wash. On the date 05/20/2011 at the mid point of a five hour evis period Production Management stopped evisceration because moisture started dripping from a location different from the location of the previous day on the same cooling unit. The evis table was sanitized [redacted]. No product was involved but as noted earlier CCP #2 was next in the processing sequence. A drip pan was installed to catch the moisture dripping from the cooling unit. Plant Manager was notified at 1300 hours on this date that the facility was not in compliance with 9CFR 416.15(a) for not being able to make appropriate improvements in the execution of the sanitation SOPs thus not being able to correctly eliminate the recurrence of dripping moisture above the evisceration table from the previous days production. No product was retained.

Regulation:

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: 06D01
Violation:  416.2(b)(1)

Citation: While performing pre-op inspection in the room at 0645 hours on this date Inspector noticed that when the cooler door is closed the guide rail and beam located below the guide rail exhibit peeling and flaking paint that is loose to the touch. The peeling paint is located midway on the guide rail with a length of approximately four inches. There was no product in the area at this time. Informed Plant Manager of the non compliance this morning after evisceration duties. There is a floor rail post which prevents product containers from being located directly below the peeling paint. This is a non compliance for building/facility repair as referenced in 416.2(b)(1).

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: 06D01
Violation:  416.3(c)

Citation: The requirements for 9CFR 416.3(c) are not being met for the red receptacles used for storing inedible material. The red receptacles are primarily used in the large bird slaughter room. The red receptacles do not bear conspicuous markings to identify its permitted use. Notified Operations Manager on this date. No product is involved.

Regulation:

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: 03C02
Violation:  417.5(a)(1), 417.5(a)(3)

Citation: During a review of the HACCP plan, 03C Raw Not Ground Process, it was determined that the HACCP form CCP 3B is used for slaughter and raw not ground processes. The records do not indicate the product name or identity that was monitored therefore it is difficult to discern if the slaughter CCP 3B or raw not ground CCP 3B was monitored for each specific event. Operations Manager notified on this date at 1300 hours. During a review of the HACCP plan and records , it was determined that the requirements of 9CFR 417.5(a)(1) are not being met adequately for Est. # 17966P 03C’s raw not ground process. The hazard analysis for process 03C indicates [redacted]. The establishment does not have records to support decisions made in this hazard analysis. Records are not maintained that document product temperature, length of processing time or room temperature to support the decision. Operations Manager notified on this date at 1300 hours.

Regulation:

417.5(a)(1) The written hazard analysis prescribed in § 417.2(a) of this part, including all supporting documentation

417.5(a)(3) Records documenting the monitoring of CCP’s and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment’s HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter production lot. Each of these records shall include the date the record was made.

Code: 03J02
Violation:  417.5(a)(3)

Citation: During review of the 03J slaughter HACCP plan and records , it was determined that the 03J Slaughter HACCP plan for Est. # 17966P does not meet the requirements as stated in 9 CFR 417.5(a)(3) under 417.5 records as noted in part 417 HACCP systems. There are two HACCP plans in the facility under the 03J slaughter process (foie gras and small ducks). Both plans use form 2B to monitor CCP 2. Each has a different frequency for monitoring. The processing records on form 2B do not indicate which HACCP plan or product is monitored at each event. Also noted during review of both HACCP processes (03J slaughter and 03C raw not ground) that both HACCP processes use the same HACCP records for CCP 3B titled HACCP Form 3B for Refrigerated Storage Control. The records do not document what type of product was monitored therefore it is difficult to discern if the slaughter CCP 3B or raw not ground CCP 3B was monitored at each event. Operations Manager notified on this date at 1300 hours for the record keeping non compliances.

Regulation:

417.5(a)(3) Records documenting the monitoring of CCP’s and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment’s HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter production lot. Each of these records shall include the date the record was made.

Code: 01B02
Violation:  416.3(a)

Citation: At pre-op inspection in the small bird kill room at 0630 hours on this date Inspector applied tag #s B40198703 and B401987704 to two slaughter cones on forward section of slaughter equipment thus rejecting the two tagged cones for operations until issues are corrected. The two cones have metal splits about 5-7 inches in length creating sharp points where the metal is split. The two cones at present are not constructed to facilitate thorough cleaning. Plant Manager notified verbally at 0635 hours on this date. No product is involved.

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.

Code: 06D01
Violation:  416.4(b)

Citation: Noted on this date at 1300 hours in the small bird kill room that the drainage for the wax break trough is poor. The trough does not slope adequately allowing for blood stained water to drain quickly. The outlet drain pipe for the trough is about 3 feet above floor level and the water draining from the trough does not go directly to a floor drain and helps create unsanitary pooling of water in the area that employees may walk through when performing their duties. Spoke with room supervisor and the excess water was squeeged as well as excess feathers on the floor area from the defeathering equipment. This helped alleviate the pooled water. Plant Manager will be notified upon receipt of this non compliance report. No product retained. No equipment tagged.

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: 06D01
Violation:  416.2(b)(3), 416.4(b)

Citation: On this date at 1230 hours Plant Manager was notified that the sliding door in the inedible room that opens to the outside has a large hole in the bottom left area and does not close completely at the floor junction that can allow the entrance of pests into the facility. This does not comply with 9CFR 416.2(b)(3). Also observed in the room adjacent to the live staging area in the large duck slaughter department that the area between the unloading ramp had debris, used gloves, and coffee cups discarded on the floor in the area. To the right of the outside entrance door there was a buildup of old wood construction materials, about 3 feet in length in the buffer zone area to the right of the door. This does not comply with 416.4(b) and 416.2(b)(3)

Regulation:

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: 01C02
Violation:  416.4(a)

Citation: At approximately 1300 hours on this date, FSIS Inspection Personnel observed an employee in the small bird slaughter room who was working at the “wax breaking” station use a knife for trimming excess wax from a poultry carcass. When the first carcass was finished the knife was put into the bottom of the trough which contained water, blood and other materials from slaughtered poultry carcasses. The trough is located directly below a series of hooks on which the waxed poultry are hung for ease of breaking wax and trimming. The trough collects the wax, excess water, blood etc dripping from the poultry carcasses and drains out to the floor drains. When the first carcass was transferred to the next station in the process the employee picked up the knife from the trough and continued to work on the second carcass in line. In this instance 416.4 was not being met. The knife was not sanitized after being placed into contaminated water for work on the second carcass. Plant Manager was notified of this infraction and all carcasses were sanitized with chlorinated water of 30 PPM to prevent contamination, the trough was cleared of plugged residue, standing water, all utensils(knives) were sanitized and PM had knife sheaths added to the frame of the unit for knife storage while carcasses are being transferred to the next station. Employees were addressed for proper sanitation procedures as required in the plant SSOP program.

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.

Code: 06D01
Violation:  416.2(a)

Citation: At 0945 hours this morning Inspector observed that the metal cages/racks used for storing plastic product coolers for product transport in the warehouse dry dock area also are being used to store miscellaneous items, in an unorderly fashion, especially on the top section of the storage cages/racks which makes it difficult and interferes with FSIS Inspection procedures. Items stored in the area include cardboard boxes, drapes/clothes as well as two truck spare tires without the rims. Sections of 416.2(a) are not being adheared to. Plant Manager was notified of the above condition and viewed the area with Inspector at 1100 hours.

Regulation:

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

Code: 06D01
Violation:  416.4(d)

Citation: At approximately 1200 hours on this date after finishing evisceration duties on the inspection table I was walking through the shipping preparation area to the USDA office and I noticed condensate dripping from the plastic elbow for the condensate drainage that is located below the first cooling unit hanging from the ceiling across from cooler #2. I spoke with the shipping foreman and he mentioned to me that the condensate had been dripping from the elbow earlier during the shift and he took precautions to instruct his employees not to stage packaged product/shipping containers under the unit. This area is located next to the area where raw product is trimmed/cut on occasion but no product was being trimmed at the time I was there. I spoke with Plant Manager at 1215 and we observed the elbow dripping condensate. A cause could not be determined but the situation is not in compliance with 9CFR 416.4(d) which states that” product must be protected from adulteration during processing, handling, storage, loading and unloading……”.

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: 06D01
Violation:  416.1, 416.2(d)

Citation: At approximately 0740 hours while performing an unscheduled 01C02 procedure task I observed the following; beaded condensate on the exposed surface of the ceiling above the loading end of the evisceration table directly above exposed duck carcasses and an employee traffic area; beaded condensate above duck carcasses and the boning tables across from the evisceration table stationed along the South wall. I verbally informed Production Supervisor, immediately of the non-compliance. This is a failure to meet: 9CFR 416.1; 9CFR 416.2(d). This document serves as written notification that your failure to comply with regulatory requirement(s) 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(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.

Code: 06D01
Violation:  416.3(a)

Citation: At 0650 hours while performing pre-operational inspection in the large bird kill room I noticed that the welds for the four square corners on the two rectangular openings located on the top of the removed cover for the number 2 defeathering machine were worn in sections and pitted/rusted in areas. A section of the frames outer edge was broken and still attached but slanted away about 3/4 inch. The equipment was sanitized the evening before and no evidence of attached particles (duck meat, skin, feather sections) was observed. The present construction condition of the cover needs to be addressed. No product is retained and I did not tag the equipment for the cover is not a direct product contact surface. Plant Manager was notified of the condition of the cover at 0700 this morning and will notify maintenance for a work order to repair the cover.

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.

Code:  06D01
Violation:  416.1

Citation: At 1230 hours on this date CSI made observations on doors/door frames throughout the facility and found the following items in six locations throughout the facility for non compliance to CFR 416.1 for not being maintained to requirements to support CFR 416.1 1) The upper section of the door frame for the doorway to the evis cooler from the kill room has damaged metal sheathing on the upper right area about 4-6 inches in circumference with some evidence of peeling paint and rust visible in other sections of the upper door frame. 2) The door frame on the inside of freezer #1 has exposed wood from new construction on the upper section and side sections of the frame. Also there is a narrow plastic strip in the center of the upper door frame which is split in sections. 3) The swinging doors and door frame for the door between the kill room and the evis room has one broken hinge on the lower left section of the frame. The door hinge covers are ragged and in unsanitary condition due to excess wear. Portions of the wood framing is cracked on the lower left section and the seals are broken/split in various locations. 4) The swinging door between the hallway and casing zone has split seals above the doors. 5) The swinging doors for the new shipping room still in construction for both ends of the room, 2 areas, have loose metal panels exposing the materials under the panels. Product passes through the door areas that is in process as well as finished packed/cased product. No product retained. No equipment tagged. Supervisor will be notified upon receipt of this non compliance report.

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: 06D01
Violation:  416.1

Citation: On this date FSIS Inspection Personal observed that the horizontal drain in the floor area observed upon entering cooler # 3 has a buildup of debris which can be described as excess dust, wood chips, misc. items as well as the circular drain located near the horizontal running drain which has a buildup of materials in the trap and around the floor area around the drain. Product stored in the cooler is finished/packed/cased product. No product is retained. Plant Manager notified upon receipt of this non compliance report.

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: 06D01
Violation:  416.4(b)

Citation: At 1215 hours on this date FSIS Inspector observed in the large slaughter room that three vertical 1×1.5 inch support metal angle iron sections for the support of the link chain conveyor system located near and above the stun bath have sections of flaking paint developing. The circular disc assembly for the 90 degree turn of the link chain conveyor located above the stun bath has sections of rust visible. No finished product is involved in this area. No product retained or equipment rejected. Plant Manager will be notified on this date upon receipt of this NR report.

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: 06D01
Violation:  416.2(c)

Citation: At 1130 this morning FSIS Inspector observed that empty constructed corrugated product containers are being stored in the new cooler/freezer unit that is under construction off the corrugated storage warehouse. Upon entering the unit it was observed that nothing could be observed because there are no lights working in the unit. Inspection understands that the unit is under construction but Inspection must ensure that sanitary conditions are maintained per 416.2(c) with adequate lighting. The concern is with the corrugated product containers that will contain product eventually. No finished/raw product is involved. Plant Manager notified at 1200 hours on this date.

Regulation:

416.2(c) 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.

Code: 06D01
Violation:  416.4(b)

Citation: At 1130 hours this morning FSIS Inspector spoke with Plant Manager about the build up ice on the under sides of the two cooling units located hanging from the ceiling in the cut up/packing room off the evisceration room. There was considerable frosting and ice visible on the undersides. Inspector looked at the sides of each unit and noted that there was frost buildup also on the defrosting plates?/grids? There was no cut up table located under the cooling unit as well as product being assembled for shipping under the other unit. PM had instructed personal to keep product away from under the units to avoid possible product contamination. Maintenance has been notified of this problem to check unit/defrost cycles. Parts of 416.4(b) are not being met for non food contact surfaces. No product is involved, no equipment/product retained.

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: 06D01
Violation:  416.2(a)

Citation: At 0655 hours on this date while walking through the warehouse facility Inspector noticed that there are no buffer zones maintained in the corrugated boxes warehouse area. Pallets of corrugated are stored right up to the wall which will interfere with Inspection activities for rodent and pest control in the warehouse. No product is involved. Mr. verbally notified at 0830 hours this morning and Supervisor to be notified upon receipt of this NR.

Regulation:

416.2(a) 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(b), 416.3(b), 416.4(b)

Citation: On wensday December 22 At approximately 0950 hours while performing scheduled PBIS task 01C02 and after the QA had preformed op-sanitation, and before establishment re-start operation from lunch brake. CSI observed multiple non-compliances.1) While verifying sanitary conditions in the area of the Freezer NO.1. I identified the following condition which is in violation of regulations contained in 9 CFR 416. On the East wall of the Freezer Storage Area there are a large condensate ice cycles hanging from the air conditioning unit in the back of this freezer. ice cycles about 3 feet’s long by 2 feet’s around, Upon reviewing of this company sanitation documents prepared for the day, these areas mentioned above were marked as acceptable. Also pallets and broken boxes lids blocks the freezer entrance, prevent the CSI from entering the area checking for rodent and other pests, ) In the Raw Product Storage Cooler NO. 2 there is condensation over the door frame upon entering this cooler, condensation droplets on the bottom of the air conditioning unit, and condensation forming on the ceiling in several other areas of this cooler. No direct product contamination was observed in either one of these storage areas. I immediately notified plant manager verbally and in writing of these non-compliances. The Plant manager was notified of the failure to meet regulatory requirements. (CFR.416.3)( b) (CFR.416.4)( b) (CFR.416.1) and states General rules, 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. plant manager immediately provided the following preventive measure and corrective action. I observed as the establishment implemented corrective actions by immediately talk to maintenance manager about the non-compliances, and maintenance manager immediately remove buildup ice cycles from freezer unite. The establishment’s monitoring/implementation was ineffective in preventing the insanitary conditions and the regulatory noncompliance. This is a repetitive noncompliance (NR) and therefore linked to NR: 0037-2010-13720 dated 09/09/2010: Past Similar NRs Previous Ineffective Plant Actions: procedures to prevent reoccurrence ineffective, The establishment’s SSOP monitoring failed to detect or prevent these deviations from Sanitary Standard Operating Procedure and thereby presented a risk of product adulteration. These types of noncompliance’s do not meet USDA Regulatory Requirements and this plants written SOP/Sanitation plan and the responsibilities of an approved TQC system. U.S.DA , I explained to, Plant manager that this is considered a non product contact surface. but These non-compliances if not detected could cause product adulteration or the creation of insanitary conditions if allowed to come into contact with product, and could pose a public health issue if product entered commerce. And Continue failure to meet regulatory requirements could result in further enforcement actions as described in 9 CFR Part 500- Rules of Practice.

Regulation:

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

416.3(b) Equipment and utensils must not be constructed, located, or operated in a manner that prevents FSIS inspection program employees from inspecting the equipment or utensils to determine whether they are in sanitary condition.

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), 416.13(c), 416.14, 416.4(b)

Citation: On Wednesday December 15 At approximately 1410 hours while performing scheduled PBIS task 01C02 and after the QA had preformed op-sanitation. the CSI observed multiple non-compliances.1) In the shipping department and cut department room, the CSI observed dock tape, paper empty boxes, and box lids on the floor, and on top of products, being allowed to accumulate throughout the department.2) evisceration room CSI observed multiple non-compliances. CSI observed, bloody water, feathers, Fats, throughout the department, No direct product contamination was observed in either one of these two departments. I immediately notified plant manager verbally and in writing of these non-compliances. The Plant manager was notified of the failure to meet regulatory requirements.416.13(b) (c) 416.14 (CFR.416.1) states General rules, 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. plant manager immediately provided the following preventive measure and corrective action. I observed as the establishment implemented corrective actions by by re-washing the evies area and scrubbed the evies table and walls with soap and properly cleaned and sanitized the equipment and all these non-compliances listed above. After sanitary conditions were restored I re-inspected the and found it acceptable, Plant manager giving instructions to the shipping and evisceration crew to be more observant when noncompliance found in op-sanitation area, These types of noncompliance’s do not meet USDA Regulatory Requirements and this plants written SOP/Sanitation plan and the responsibilities of an approved TQC system USDA reviewed the Establishments SOP Record for these areas. and all plant inspection checks were marked “A” for acceptable. These Records did not reflect the conditions observed by USDA during this Inspection. The establishment’s monitoring failed to detect or prevent these deviations from Sanitary Standard Operating Procedure and thereby presented a risk of product adulteration. U.S.D.A explained to plant manager immediately This is considered a product contact surface. But if not detected could cause product adulteration or the creation of insanitary conditions if allowed to come into contact with product, and could pose a public health issue if product enter commerce. The establishment’s monitoring/implementation was ineffective in preventing the insanitary conditions and the regulatory noncompliance. This is a repetitive noncompliance (NR) and therefore linked to NR: 0043-2010-13720 dated 12/07/2010: Past Similar NRs Previous Ineffective Plant Actions: procedures to prevent reoccurrence ineffective, Continue failure to meet regulatory requirements could result in further enforcement actions as described in 9 CFR Part 500- Rules of Practice.

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.

416.14 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.

416.4(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(a), 416.13(b), 416.13(c), 416.14, 416.15(a), 416.2(e), 416.4(a), 416.4(b)

Citation: On Monday December 07 At approximately 0646 hours while performing scheduled PBIS task 01B02 and after the QA had preformed pre-op sanitation and before the start of operations, the CSI observed multiple non-compliances.1) In the evisceration room the CSI observed unidentified black specks, blood, feathers, Fats, stains, Grease and foreign material found on evisceration table. 2) CSI observed In the evisceration room, back-flow conditions floor drainage blocked in all areas in evisceration room, 3) In the evisceration room the CSI observed unidentified black specks, blood, feathers, Fats, stains, Grease, rust and foreign material found on 2 large and 2 small medal bins weal’s, establishment uses those medals bins transferring product from evisceration room to coolers.CSI immediately took a corrective action by applying U.S. Rejected tag #B40198797 to evisceration department and CSI immediately notified the plant manager immediately verbally and in writing notified of these non-compliances. Plant manager immediately provided the following preventive measure and corrective action by removing the medal bulk bins from evisceration area to be scrub clean and sanitized. And wash, and sanitized evisceration table, and talk to maintenance manager about blocked drainage in evisceration room. Plant manager added more personal for daily clean-up, and giving instructions to clean-up crew to be more observant when noncompliance found in pre-up sanitation, After sanitary conditions were restored I re-inspected all the non-compliances listed above , and found it acceptable and U.S. Rejected tag were removed, these noncompliance that this is considered a product contact surface for evisceration table, and non product contact surface to medal bins weal’s, These non-compliances are a failure to meet USDA Regulatory Requirements, 9CFR416.4(a)(b) 416.2(e) 416.13(c) 416.14- 416.15(a)-416.3(a) 416.1 ).states: each official establishment must be operated and maintained in a manner sufficient to prevent the creation of unsanitary conditions and to ensure that product is not adulterated, The establishment’s monitoring/implementation was ineffective in preventing the insanitary conditions and the regulatory noncompliance. The establishment’s SSOP monitoring failed to detect or prevent these deviations from Sanitary Standard Operating Procedure and thereby presented a risk of product adulteration. This is a repetitive noncompliance (NR) and therefore linked to NR: 0028-2010-13720 dated 07/16/2010: Past Similar NRs Previous Ineffective Plant Actions: procedures to prevent reoccurrence ineffective, U.S.D.A explained to plant manager immediately This is considered a non- product contact surface. And a product contact surface. But if not detected could cause product adulteration or the creation of insanitary conditions if allowed to come into contact with product, and could pose a public health issue if product enter commerce. The plants further planned actions has not been effective in correcting the deficiencies. Continue failure to meet regulatory requirements could result in further enforcement actions as described in 9 CFR Part 500- Rules of Practice.

Regulation:

416.13(a) Each official establishment shall conduct the pre-operational procedures in the Sanitation

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.

416.14 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.

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

416.2(e) Plumbing systems must be installed and maintained to:

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: 01C02
Violation:  416.13(b), 416.14, 416.3(a), 416.4(a), 416.4(b)

Citation: FSIS operational inspection procedure 01C02 to assess compliance with sanitation requirements. At approximately 1115 hours while performing scheduled PBIS (operational sanitation) CSI observed multiple non-compliances, 1) packing room area, water about 3/4 inches in deferent location in packing room floor doing operation hour no product in this are at this time, plant employee in the area walking through the bloody and dirty water, immediately U.S.D.A. took a corrective action by immediately applied U.S. Rejected tag #NO B4198793 and notifying plant manager for failure to meet USDA Regulatory Requirements. 2) shipping an receiving area, trash and debris (plastic, paper, pieces of woods plastic pipes, boxes, being allowed to accumulate throughout the Receiving and shipping Dock Area outside of the shipping Cooler, 3) evisceration department area. CSI observed significant amounts of blood fat water skin all over the floor. After the QA had preformed operational sanitation after lunch brake. U.S.D.A. took a corrective action by stopping the operation from re-start and immediately notify plant manager for failure to meet USDA Regulatory Requirements. 4) Box room area. CSI observed empty broken boxes and paper knifes on top broken lids and other debris all over the box room area floor. Department, manager immediately verbally and in writing notified of these non-compliances. The Plant manager was notified of the failure to meet regulatory requirements. CFR( 416.13)b (416.14)c (416.3)a (416.4)a.b (CFR.416.1) states General rules, 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. The establishment’s monitoring/implementation was ineffective in preventing the insanitary conditions and the regulatory noncompliance. Plant management immediately. immediately provided the following preventive measure and corrective action by re-washing the evies area and scrubbed the evies table and walls with soap and properly cleaned and sanitized the equipment and all these non-compliances listed above. After sanitary conditions were restored I re-inspected all the non-compliances are listed above and found it acceptable and I released to establishment. These types of noncompliance’s do not meet USDA Regulatory Requirements and this plants written SOP/Sanitation plan and the responsibilities of an approved TQC system USDA reviewed the Establishments SOP Record for these areas and all plant inspection checks were marked “A” for acceptable. These Records did not reflect the conditions observed by USDA during this Inspection. The establishment’s monitoring failed to detect or prevent these deviations from Sanitary Standard Operating Procedure and thereby presented a risk of product adulteration. U.S.D.A inspector explained to plant manager that this is considered a none product contact surface. But if not detected these noncompliance’s could cause product adulteration or the creation of insanitary conditions if allowed to come into contact with product, and could pose a public health issue if product entered commerce. The plants further planned actions has not been effective in correcting the deficiencies. Continue failure to meet regulatory requirements could result in further enforcement actions as described in 9 CFR Part 500- Rules of Practice.

Regulation:

416.13(b) Each official establishment shall conduct all other procedures in the

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.

416.3(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(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(a), 416.3(a), 416.3(b), 416.4(a), 416.4(b), 416.5(b)

Citation: On Sunday October 31 At approximately 0647 hours while performing un-scheduled PBIS task 01B02 and after the QA had preformed pre-op sanitation and before the start of operations, the CSI observed multiple non-compliances.1) In the evisceration room the CSI observed unidentified black specks, blood, feathers, Fats, and stains, and foreign material found on 10 aprons ready to be use by plant employees, this non-compliances considered food-contact surfaces, CSI took corrective action by applied U.S. Rejected tag # B40198890 to all 10 aprons. Also CSI observed in same department unidentified black specks; blood, feathers, Fats, and stains, rusts, and foreign material all over Duck salvages rack from the previous day’s operation. 2) cut-up department CSI unidentified black specks, fats, blood, grease all over the ice machine, ice machine located between evisceration room and cut-up department. . I immediately notified the plant manager verbally and in writing of these non-compliances listed above. Plant manager were notified of the failure to meet regulatory requirements. For (CFR.416.1) states General rules, 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. And (CFR.416.3)(a) 416.3)b and (416.5) (b) and (416.13) (a) Plant manager immediately took corrective action by removing all old dirty aprons from plant employee and replace them for new aprons. And Plant manager immediately scrub clean and sanitized, ice machine, the same for Duck salvage rack scrub clean and sanitized, After sanitary conditions were restored I re-inspected all the non-compliances listed above, and found it acceptable and U.S. Rejected tag were removed, I explained to, Plant manager that this is considered a product contact surface in one department, and non product contact surface in the other departments. These non-compliances if not detected could cause product adulteration or the creation of insanitary conditions if allowed to come into contact with product, and could pose a public health issue if product entered commerce. These types of noncompliance’s do not meet USDA Regulatory Requirements and this plants written SOP/Sanitation plan and the responsibilities of an approved TQC system USDA reviewed the Establishments SOP Record for these areas and all plant inspection checks were marked “A” for acceptable. These Records did not reflect the conditions observed by USDA during this Inspection. The establishment’s monitoring failed to detect or prevent these deviations from Sanitary Standard Operating Procedure and thereby presented a risk of product adulteration. And Continue failure to meet regulatory requirements could result in further enforcement actions as described in 9 CFR Part 500- Rules of Practice.

Regulation:

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

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.

416.3(b) Equipment and utensils must not be constructed, located, or operated in a manner that prevents FSIS inspection program employees from inspecting the equipment or utensils to determine whether they are in sanitary condition.

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.

416.5(b) 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.

Code: 06D01
Violation:  416.1, 416.2(a), 416.2(b)(1), 416.2(b)(2), 416.2(b)(3)

Citation: At approximately 1125 hours CSI observed the following noncompliance’s while performing a routine walkthrough with the plant manager throughout the Establishment, I performed an unscheduled PBIS task 06D01.CSI observed multiple non compliances, 1) Freezer NO.1. I identified the following condition which is in violation of regulations contained in 9 CFR 416. On the East wall of the Freezer Storage Area there are broken concrete missing chipped or worn off, also a large condensate ice cycles hanging from the air conditioning unit in the back of this freezer. ice cycles was not removed sins the last noncompliance NR.10/08/2010, Upon review of this company’s sanitation documents prepared for the day, Also pallets and broken boxes lids blocks the freezer entrance, prevent the CSI from entering the area checking for rodent and other pests, 2) In the Raw Product Storage Cooler NO. 2 there is condensation over the door frame upon entering this cooler, condensation droplets on the bottom of the air conditioning unit, and condensation forming on the ceiling in several other areas of this cooler. No direct product contamination was observed in either one of these storage areas. 3) Walls between new cooler area and shipping manager room office CSI observed display of black & brown staining marks all over the area walls paint has white flaked, chipped or worn off. 3) evisceration room area, U.S.D.A observed non-compliances, swimming double door between evisceration area and big duck kill room area broken form the base and missing door seal all the way around has never bean repair sins the last 3 NR. And the same for the other 3 double swimming doors never bean replace or repaired, 4) upon entering small ducks kill room area CSI observed broken concrete louse or missing, concrete has bean repaired previous but planned actions has not been effective in correcting the deficiencies, 5) U.S.D.A office, CSI observed 3 live rodent on top U.S.D.A desk and rodent droppings several places in the U.S.D.A office floor/wall juncture behind the desk, I also observed 5 dead mouse on the glue board in the U.S.D.A office underneath the desk. I immediately notified the plant manager verbally and in writing of these non-compliances listed above. Plant manager were notified of the failure to meet regulatory requirements. For (CFR.416.2) b.1-2-3 (CFR.416.)A (CFR.416.1) Plant manager immediately talk maintenance manager about the all non-compliances listed above. These types of noncompliance’s do not meet USDA Regulatory Requirements and this plants written SOP/S. USDA reviewed the Establishments SOP Record for these areas and all plant inspection checks were marked “A” for acceptable. These Records did not reflect the conditions observed by USDA during this Inspection. The establishment’s monitoring failed to detect or prevent these deviations from Sanitary Standard Operating Procedure and thereby presented a risk of product adulteration. U.S.D.A inspector explained to plant manager that this is considered a none product contact surface. But if not detected these noncompliance’s could cause product adulteration or the creation of insanitary conditions if allowed to come into contact with product, and could pose a public health issue if product entered commerce. The plants further planned actions has not been effective in correcting the deficiencies. Continue failure to meet regulatory requirements could result in further enforcement actions as described in 9 CFR Part 500- Rules of Practice.

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

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

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

416.2(b)(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: 06D01
Violation:  416.1, 416.2(a), 416.2(b)(1), 416.2(b)(2), 416.2(b)(3), 416.2(b)(4), 416.3(a), 416.3(c)

Citation: At approximately 0935 hours CSI observed the following noncompliance’s while performing a routine walkthrough with the plant manager throughout the establishment, I performed PBIS task 06D01.CSI observed multiple non-compliances, (1) evisceration room area, U.S.D.A observed multiple non-compliances, swimming door between evisceration area and big duck kill room area broken form the base and missing door seal all the way around, I also noted that the door was left open when the plant employee removed condemned product from the evisceration area to the outside, also in evisceration room area, U.S.D.A observed CSI observed insulation cooler unite pipe above the evisceration table Blood Fats feather grease and other forgin material, evisceration area also CSI observed rusted electric box located next to cooler NO.2. (2) shipping packing room area, U.S.D.A observed multiple non-compliances, grease marks stains rust specks missing paint or dirty all over the wall and I noted hanging un-used electrical wire threw out the area and maintence door in the same location if filthy with black grease stain and other unidentified forgian material. (3) Packing department CSI observed the following noncompliance’s dark brown substance, dust, debris and foreign material which was observed on an over head two ice machines unites. (4)) big buck kill room area U.S.D.A observed the non-compliances. Missing concrete or broken all over the department, preventive measure and corrective actions previous plant proposed further action were not done or are ineffective like the repair of concrete floor in big duck kill room. (5) U.S.D.A office, CSI observed the following noncompliance I observed live rodent and rodent droppings several places in the U.S.D.A office floor/wall juncture behind the desk, I also observed a dead mouse on the glue board in the U.S.D.A office underneath the desk. (6) Freezer No.1 ice buildup above addible package product Due to moisture or freezer door not closing tightly Observed an excessive amount of ice forming located directly above package product the ice buildup was not removed sins the last noncompliance NR. Dated 09/09/10. I immediately notified the plant manager verbally and in writing of these non-compliances listed above. Plant manager were notified of the failure to meet regulatory requirements. For (CFR.416.1) (CFR (416.2(b) (2) (4)-(416.4(a) (b) – (416.3) (a) (c) Plant manager immediately talk maintenance manager about the all non-compliances listed above. USDA reviewed the Establishments SOP Record for these areas and all plant inspection checks were marked “A” for acceptable. These Records did not reflect the conditions observed by USDA during this Inspection. The establishment’s monitoring failed to detect or prevent these deviations from Sanitary Standard Operating Procedure and thereby presented a risk of product adulteration. U.S.D.A inspector explained to plant manager that this is considered a none product contact surface. But if not detected these noncompliance’s could cause product adulteration or the creation of insanitary conditions if allowed to come into contact with product, and could pose a public health issue if product entered commerce. The plants further planned actions has not been effective in correcting the deficiencies. And this document serves as a written notification that failure to comply with 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(a) The grounds about an establishment must be maintained to prevent conditions that could lead to insanitary conditions, adulteration of product, or interfere with inspection by FSIS program employees. Establishments must have in place a pest management program to prevent the harborage and breeding of pests on the grounds and within establishment facilities. Pest control substances used must be safe and effective under the conditions of use and not be applied or stored in a manner that will result in the adulteration of product or the creation of insanitary conditions.

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

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

416.2(b)(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.

416.2(b)(4) Rooms or compartments in which edible product is processed, handled, or stored must be separate and distinct from rooms or compartments in which inedible product is processed, handled, or stored, to the extent necessary to prevent product adulteration and the creation of insanitary conditions.

416.3(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.

416.3(c) Receptacles used for storing inedible material must be of such material and construction that their use will not result in the adulteration of any edible product or in the creation of insanitary conditions. Such receptacles must not be used for storing any edible product and must bear conspicuous and distinctive marking to identify permitted uses.

Code: 06D01
Violation:  416.1, 416.2(b)(1), 416.2(b)(2), 416.2(b)(3)

Citation: At approximately 09:45 hours CSI observed the following noncompliance’s while performing a routine walkthrough, I performed PBIS task 06D01.CSI observed multiple non-compliances, 1) Freezer No.1 ice buildup above addible package product Due to moisture or freezer door not closing tightly Observed an excessive amount of ice forming located directly above package product the ice buildup was not removed sins the last noncompliance NR. Dated 09/09/10 plant manager stated on 09/09/10 that Freezer No.1 ice buildup above addible package product will be remove, CSI observed the same non-compliances on 09/20/10. Plant manager immediately verbally and in writing of these all non-compliances listed above. 2) ) freezer No.1 pallets and boxes blocks the freezer entrance, prevent the CSI from entering the area checking for rodent and other pests, 3) evisceration department area floor concrete missing or brooking thought out the department, Plant manager immediately verbally and in writing notified of these non-compliances, 4) big duck kill room area floor concrete missing or brooking throw out the department, manager immediately verbally and in writing notified of these non-compliances. The Plant manager was notified of the failure to meet regulatory requirements. (CFR.416.1) states General rules, 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. The establishment’s monitoring/implementation was ineffective in preventing the insanitary conditions and the regulatory noncompliance. CFR. 416.2) b.1-416.2) b-416.2) b3. U.S.D.A inspector explained to plant manager that this is considered a none product contact surface. But if not detected these noncompliances could cause product adulteration or the creation of insanitary conditions if allowed to come into contact with product, and could pose a public health issue if product entered commerce. The establishment’s monitoring/implementation was ineffective in preventing the insanitary conditions and the regulatory noncompliance. This is a repetitive noncompliance (NR) and therefore linked to NR: 0037-2010-13720 dated 09/09/2010: Past Similar NRs Previous Ineffective Plant Actions: procedures to prevent reoccurrence ineffective, plant manager responded to U.S.D.A inspector ice buildup above addible package product in Freezer No.1 will be remove immediately and concrete in evisceration department area and big duck room area will be repaired this weekend on 09/25/10.). And this document serves as a written notification that failure to comply with 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(b)(1) Establishment buildings, including their structures, rooms, and compartments must be of sound construction, be kept in good repair, and be of sufficient size to allow for processing, handling, and storage of product in a manner that does not result in product adulteration or the creation of insanitary conditions.

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

416.2(b)(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: 06D01
Violation:  416.1, 416.2(b)(1), 416.2(b)(2), 416.2(b)(3), 416.3(a), 416.4(b)

Citation: At approximately 1150 hours CSI observed the following noncompliance’s while performing a routine walkthrough with the plant manager throughout the Establishment, I performed PBIS task 06D01.CSI observed multiple non-compliances, (1) Outside plant premises CSI observed holes about 2 inches by12 inches along side the U.S.D.A office, this non-compliances holes in walls allowing the entrance of vermin, dirt, or dust in plant operations. 2) Freezer No.1 ice buildup above addible package product Due to moisture or freezer door not closing tightly. 3) CSI still observing flies in evisceration area which’s plant has done some improvement but not enough to eliminate flies throw out the establishment. 4) Loose unbolted floor sinks in three deferent Location In establishment (evisceration area) packing area (and cut up area) .5) evisceration area CSI observed rusted electric box located next to cooler NO.2. (6) Packing room area CSI observed open ceiling tiles throw out the packing area. (7) CSI observed freezer No.1 pallets and empty boxes blocks the freezer entrance prevent the CSI from entering the area checking for rodent and other pests. Plant manager immediately talk maintenance manager about the non-compliances. Plant manager verbally and in writing of these all non-compliances listed above. The Plant manager was notified the failure to meet regulatory requirements (CFR.416.1) states General rules, 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. And (CFR) 416.2(b)(1) states Establishment buildings, including their structures, rooms, and compartments must be of sound construction, be kept in good repair, 416.2(b)(3) states 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. And CFR (416.3)a states 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 their use will not cause the adulteration of product during processing, all these non-compliances listed above considered a non food contact surface (416.4)b if not detected could cause product adulteration or the creation of insanitary conditions if allowed to come into contact with product, and could pose a public health issue if product enter commerce. plant manager responded to U.S.D.A all non-compliances listed above will be repaired on 09/11/10 and 09/12/10. This document serves as written notification that your failure to comply with 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(b)(1) Establishment buildings, including their structures, rooms, and compartments must be of sound construction, be kept in good repair, and be of sufficient size to allow for processing, handling, and storage of product in a manner that does not result in product adulteration or the creation of insanitary conditions.

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

416.2(b)(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.

416.3(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: 06D01
Violation:  416.1, 416.2(a), 416.4(a), 416.4(b)

Citation: On Thursday, September 02 at approximately 1230 PM hours while performing PBIS procedure code 06D01, CSI observed multiple non-compliances, while performing a routine walkthrough with the plant manager throughout the establishment, 1) evisceration room CSI observed 2 fly that landed on the sealing the Plant Manager was in the area, immediately The insect was killed by Plant Manager. 2) Evisceration room, CSI observed open gaps at the bottom walls panels loose or missing silicone seal all around the evisceration room area, plant manager immediately talk maintenance manager about non-compliances. 3) Big duck kill room area CSI observed. Missing or broken concrete throughout the kill room area, plant manager immediately talk maintenance manager about the non-compliances. 4) freezer No.1 pallets and empty boxes blocks the freezer entrance, prevent the CSI from entering the area checking for rodent and other pests, Plant Manager immediately talks to shipping crew about non-compliances. 5) plant entrance and hallways, CSI observed mummers flies can not be counted so many, The establishment’s monitoring/implementation was ineffective in insanitary conditions preventing the flies from entering the departments throughout the establishment. Plant manager verbally and in writing of these non-compliances listed above. The Plant manager was notified of the failure to meet regulatory requirements. (CFR.416.1) states General rules, 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. And (416.4(b) states 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. and (CFR 416.2) (b) states. 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. Doors not closing tightly allowing the entrance of vermin, dirt, or dust. plant manager responded to U.S.D.A all non-compliances listed above will be repaired over the weekend. This is a repetitive noncompliance (NR) and therefore linked to NR: 0035-2010-13720 dated 08/23/2010 Past Similar NRs Previous Ineffective Plant Actions to prevent reoccurrence ineffective, CSI explained to plant manager all non-nompliances listed above if not detected could cause product adulteration or the creation of insanitary conditions if allowed to come into contact with product, and could pose a public health issue if product enter commerce. (CFR. 416.1-(416.3(a) – (416.4) (a) (b)(416.2(a). And this document serves as a written notification that failure to comply with 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(a) 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(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: 06D01
Violation:  416.1, 416.2(d), 416.3(a), 416.4(b)

Citation: At approximately 1015 hours CSI observed the following noncompliance’s while performing a routine walkthrough with the plant manager throughout the establishment, I performed PBIS task 06D01.CSI observed multiple non-compliances, (1) shipping an receiving area, trash and debris (plastic, paper, wood) pipes, boxes, being allowed to accumulate throughout the Receiving and shipping Dock Area outside of the shipping Cooler plant manager immediately remove all trash from the area. (2) packing room area, U.S.D.A observed condensation dripping one of the refrigerator unite above edible working station, no product was effected the work station not been used that day, plant manager immediately wiped off the condensation from refrigerator unite, (3) packing room area, U.S.D.A observed, swinging door between the packing area and box room area missing seal all the way around door, and door left open half way. plant manager responded to U.S.D.A, swinging door will be repair this weekend. (4) small duck kill room area observed the following multiple non-compliances, ceiling leaking water in three different area in kill room, The entire slaughter operation was halted for this day, and U.S.D.A took an immediate corrective action by immediately applying U.S. Rejected tag # B40198900. plant manager immediately provided the following preventive measure and corrective action by talking maintenance manager about the leak in kill room area, (5) small duck kill room area U.S.D.A observed the non-compliances. Missing concrete or broken in front door entrance, plant manager responded to U.S.D.A concrete will be repaired this weekend. (6) big duck kill room area, U.S.D.A observed multiple non-compliances, one ceiling tiles missing or broken, four sealing tiles has an open gapes about 1/2 wide by four inches long, plant manager responded to U.S.D.A ceiling tiles will be repaired this weekend, (7) evisceration room area, swinging door between evisceration area and big duck kill room area broken form the base and missing door seal all the way around, plant manager immediately provided the following talk maintenance manager, plant manager responded to U.S.D.A, swinging door will be repair this weekend. (8) Shipping and packing area, U.S.D.A observed multiple non-compliances, cooler door NO.2 door lock missing part or broken, plant manager immediately talk maintenance manager, plant manager responded to U.S.D.A, swinging door will be repair as soon as possible. (9) U.S.D.A observed multiple non-compliances, (flies, flies, flies, through out the establishment, in (packing room area) (evisceration room area) (2 kill rooms area) (box room area) and (shipping room area) and U.S.D.A office. The establishment’s monitoring/implementation was ineffective in preventing the insanitary conditions and the regulatory noncompliance. This is a repetitive noncompliance (NR) and therefore linked to NR: 0025-2010-13720 dated 07/06/2010: Past Similar NRs Previous Ineffective Plant Actions: procedures to prevent reoccurrence ineffective, all non-nompliances listed above if not detected could cause product adulteration or the creation of insanitary conditions if allowed to come into contact with product, and could pose a public health issue if product enter commerce. (CFR. 416.1-(416.3(a) (b) -(416.2(d). And this document serves as a written notification that failure to comply with 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(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.

416.3(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: 01B02
Violation:  416.3(a), 416.4(b)

Citation: FSIS pre-operational inspection procedure 06DO1was performed in the evisceration area department and cut-up area to assess compliance with sanitation requirements. At approximately 06:50 hours while performing PBIS task 06DO1 and after the QA had preformed pre-op sanitation and before the start of operations, the CSI observed multiple non-compliances. In the evisceration room and Big duck kill room area, prior to the start of operations in the evisceration room area I observed the following non-compliance, (1) fats blood and other forgin material found along side the drainage in the evisceration, department from the previous day’s operation (2) long pieces of (fat) (dry blood) (rust) And (Grease) found in the cart weal, establishment uses the cart to transfer product from one department to other department, U.S.D.A took an immediate corrective action by immediately applying U.S. Rejected tag # NO. B40198898, in evisceration room area. In Big duck kill room area, I observed the following non-compliance, fats stain blood specks and forgin material all over the bleed out line from the previous day’s operation, and U.S.D.A took an immediate corrective action by immediately applying U.S. Rejected tag #NO. B40198899, in big duck kill room area. I immediately notified the plant manager verbally and in writing of these non-compliances. The Plant manager was notified of the failure to meet regulatory requirements. (CFR.416.1) states General rules, 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. (416.3(a) states 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 , and (416.4(b) states: 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. plant manager immediately provided the following preventive measure and corrective action. I observed as the establishment implemented corrective actions by removing the the push cart from the evisceration area and pad scrubbing with soap water rinsed and sanitize. And the same for the bleed out line, pad scrubbing with soap water rinsed and sanitize. After sanitary conditions were restored I re-inspected, found it acceptable, and U.S. Rejected tag was removed, Plant manager added more personal for daily clean-up, and giving instructions to the clean-up crew to be more observant when noncompliance found in pre-up sanitation, U.S.D.A explained to plant manager immediately This is considered a non- product contact surface. But if not detected could cause product adulteration or the creation of insanitary conditions if allowed to come into contact with product, and could pose a public health issue if product enter commerce. These non-compliances are a failure to meet USDA Regulatory Requirements, (CFR.416.1) 416.4(b) (416.3(a) the establishment’s monitoring/implementation was ineffective in preventing the insanitary conditions and the regulatory noncompliance. . And this document serves as a written notification that failure to comply with regulatory requirements could result in additional regulatory or administrative action.

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.

416.4(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: 06D01
Violation:  416.1, 416.2(a), 416.2(b)(1), 416.2(b)(3), 416.4(b)

Citation: At approximately 12:15 hours CSI observed the following noncompliance’s while performing a routine walkthrough with the plant manager establishment ground and facility, I performed PBIS task 06D01. CSI observed multiple non-compliances, (1) shipping department, empty broken boxes all over the floor, (2) freezer NO. 2, broken empty boxes and packed edible product on the floor or on top of the boxes, corrugated boxes block the freezer door, prevent This inhibited the U.S.D.A inspector’s ability to check for rodent/insect activity in and around this area. I immediately notified the plant manager verbally and in writing of these non-compliances. plant manager immediately provided the following preventive measure and corrective action by cleaning the freezer from broken and empty boxes and organize the freezer (3) packing department, dark brown substance, dust, debris and foreign material which were observed on an over head fast freeze unit.The fast freeze unit had not been in use for that specific day, so no product was affected. Plant manager immediately provided the following preventive measure and corrective action by scrubbing the fast freeze unite with soap and properly cleaned and sanitized. After sanitary conditions were restored I re-inspected the fast freeze unite and found it acceptable.(4) CSI observed tall weeds, grass, trash, Aluminum paper, plastic bags, feather, alone side the establishment. U.S.D.A observed about 15 feet in length and four feet in height and six or seven feet deep of concrete foundation alone side the U.S.D.A office missing or broken U.S.D.A inspector noticed, there is no outside bait trap for rodent, Establishments does have in place a pest management program, but there was no bait trap outside along the side of the establishment to prevent the harborage and breeding of pests on the grounds and within establishment facilities. Plant manager notified U.S.D.A inspector outside rodent traps will be order and put in place.The Plant manager was notified of the failure to meet regulatory requirements. (CFR.416.1) . and 416.2 (b)(1) Establishment buildings, including their structures, rooms, and compartments must be of sound construction, and 461.4 (b) states 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, and 416.(2) (a) states The grounds about an establishment must be maintained to prevent conditions that could lead to insanitary conditions, adulteration of product, all these noncompliance list above that this is considered a product contact surface, and non product contact surface, These non-compliances if not detected could cause product adulteration or the creation of unsanitary conditions if allowed to come into contact with product, and could pose a public health issue if product entered commerce.CSI reviewed the SSOP records for this department and the records did not show this deficiency found by the Establishment.Continue failure to meet regulatory requirements could result in further enforcement actions described in 9CFR Part 500 – Rules of Practice. And this document serves as a written notification that failure to comply with 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(a) The grounds about an establishment must be maintained to prevent conditions that could lead to insanitary conditions, adulteration of product, or interfere with inspection by FSIS program employees. Establishments must have in place a pest management program to prevent the harborage and breeding of pests on the grounds and within establishment facilities. Pest control substances used must be safe and effective under the conditions of use and not be applied or stored in a manner that will result in the adulteration of product or the creation of insanitary conditions.

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

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

Citation: FSIS pre-operational inspection procedure 01B02 was performed in the evisceration area department and cut-up room area to assess compliance with sanitation requirements. At approximately 06:47 hours while performing PBIS task 01B02 and after the QA had preformed pre-op sanitation and before the start of operations, the CSI observed multiple non-compliances. In the evisceration room and cut-room area prior to the start of operations in the cut -up area I observed the following non-compliance, tipper tie machine, establishment uses these equentment for closing tight edible product in bags, dirty, was brownish-green in color. Dry specks of fats in the whole entire tipper tie machine from the previous day’s operation., U.S.D.A took a immediate corrective action by immediately I applied U.S. Rejected tag # B40198840, in evisceration room area I observed the following non-compliance, stain, rust specks, black Greases, fats, inside and outside all over the large edible medal bulk container, immediately I applied U.S. Rejected tag #B40198839. I immediately notified the plant manager verbally and in writing of these non-compliances. Plant manager were notified of the failure to meet regulatory requirements. (CFR.416.1) states General rules, 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. 416.3(a) states 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, 416.4)(a) states 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(a)(b)(c) This type of noncompliance does not meet USDA Regulatory Requirements and this plants written SOP/Sanitation plan responsibilities. CSI reviewed the SSOP records for this department and the records did not show these deficiencies found by the Establishment. plant manager immediately provided the following preventive measure and corrective action. I observed as the establishment implemented corrective actions by removing the medal bulk container and a tipper tie machine from the cut-up area, and evisceration room area and pad scrubbing with soap water rinsed and sanitize. After sanitary conditions were restored I re-inspected the , found it acceptable, Plant manager giving instructions to the kill room crew to be more observant when noncompliance found in pre-up sanitation area, I explained to , plant manager immediately This is considered a product contact surface. But if not detected could cause product adulteration or the creation of insanitary conditions if allowed to come into contact with product, and could pose a public health issue if product enter commerce. . As is evident by this Nr the previous plant proposed further action were not done or are ineffective. Past Similar Nrs. -0030-2010-13720 Previous Ineffective Plant Actions: and all CFRS listed above. And this document serves as a written notification that failure to comply with regulatory requirements could result in additional regulatory or administrative action.

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

Citation: FSIS pre-operational inspection procedure 01B02 was performed in the evisceration area department to assess compliance with sanitation requirements prior to the start of operations. At approximately 0645, I observed the following non-compliance, stain, rust specks in the center of edible medal bulk container about ® inch in diameter, immediately I applied U.S. Rejected tag #B40198805. I immediately notified the plant manager verbally and in writing of these non-compliances. plant manager immediately provided the following preventive measure and corrective action by removing the medal bulk from evisceration area to be scrub clean and sanitized, After sanitary conditions were restored I re-inspected the non-compliances listed above , and found it acceptable and U.S. Rejected tag were removed, these noncompliance that this is considered a product contact surface, These non-compliances if not detected could cause product adulteration or the creation of unsanitary conditions if allowed to come into contact with product, and could pose a public health issue if product entered commerce. These non-compliances are a failure to meet USDA Regulatory Requirements, 9CFR416.4(a) 416.13(c) 416.3(a) 416.1 ).states: each official establishment must be operated and maintained in a manner sufficient to prevent the creation of unsanitary conditions and to ensure that product is not adulterated, and 9CFR 416.13(c) states Each official establishment shall monitor daily the implementation of the procedures in the Sanitation SOP’s..416.4(a) states 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 unsanitary conditions and the adulteration of product. And 416.3(a) states 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, . These non-compliances are a failure to meet USDA Regulatory Requirements, 9CFR416.4(a) 416.13(c) 416.3(a) 416.1 ). And this document serves as a written notification that failure to comply with regulatory requirements could result in additional regulatory or administrative action.

Regulation:

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. (b)

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: 06D01
Violation:  416.1, 416.2(e)(1), 416.2(e)(3), 416.2(e)(4), 416.2(e)(5)

Citation: At approximately 12:30 hours CSI observed the following noncompliance’s while performing PBIS task 06D01 in the small duck kill room area, flooded drainage about 2 inches deep of water all over the kill room area, plant employee working in the area walking through the water, blood, feathers, immediately U.S.D.A. took a corrective action by stopping the operation in the kill room, I applied U.S. Rejected tag # 40198837 , I immediately notified the plant manager verbally and in writing of these non-compliances. plant manager immediately provided the following preventive measure and corrective action by removing all live ducks from the kill room area, and plant manager stop the slaughter for rest of the day, and immediately call the maintenance crew. Plant manager giving instructions to the kill room crew to be more observant when noncompliance found in kill room area, This noncompliance is a failure to meet USDA Regulatory Requirements (416.2(e) that states Plumbing systems must be installed and maintained to 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 ;and Carry sufficient quantities of water to required locations throughout the establishment; CSI reviewed the SSOP records for this department and the records did not show this deficiency found by the Establishment And 416.(1).states: each official establishment must be operated and maintained in a manner sufficient to prevent the creation of unsanitary conditions and to ensure that product is not adulterated, , U.S.D.A explained to, plant manager that this is considered a non- product contact surface These non-compliances if not detected could cause product adulteration or the creation of unsanitary conditions if allowed to come into contact with product, and could pose a public health issue if product entered commerce. CFR (416.2(e) (1) 416.(1) 416.2(e)(5e).416.2(e) (4) Continue failure to meet regulatory requirements could result in further enforcement actions described in 9CFR Part 500 – Rules of Practice.

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)(1) Carry sufficient quantities of water to required locations throughout the establishment;

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

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

416.2(e)(5) Prevent back-flow conditions in and cross-connection between piping systems that discharge waste water or sewage and piping systems that carry water for product manufacturing

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

Citation: At approximately 06:45 hours while performing PBIS task 01B02 and after the QA had preformed pre-op sanitation and before the start of operations, the CSI observed multiple non-compliances. In the evisceration room the CSI observed unidentified black specks, blood, lack feathers, Fats, and stains in the bottom of the sink from the previous day’s operation. This sink is located next to a stunner in the large ducks kill room area, and is used by the establishment for washing and re-washing their hands. I applied U.S. Rejected tag #B4198835. (2) Also in the large ducks kill room, the CSI observed five yellow aprons dirty with Blood Feathers and unidentified black specks all over the aprons. I applied U.S. Rejected tag were the aprons was hanh on the rack # B38807381.(3) in cut-up area The CSI observed mosquitoes, Blood and stains in a large plastic containers used by the establishment for transferring edible product from one department to other department. I also applied U.S. Rejected tag #B40198836 (4) also in cut-up area CSI observed Blood Fats and stains on the walls from previous day operation. (5) In the small duck evisceration room area, the CSI observed a fan cover above the scolder full with rust stains and other residue from previous day operation. The CSI immediately notified the plant manager Mr. verbally and in writing of these non-compliances. Mr. immediately scrubbed the walls in the cut -up room and with soap and properly cleaned and sanitized the equipment and all these non-compliances listed above. After sanitary conditions were restored I re-inspected all the non-compliances are listed above , and found it acceptable and U.S. Rejected tag were removed, I explained to, Mr. that this is considered a product contact surface in one department, and non product contact surface in the other departments. These non-compliances if not detected could cause product adulteration or the creation of insanitary conditions if allowed to come into contact with product, and could pose a public health issue if product entered commerce. These non-compliances are a failure to meet USDA Regulatory Requirements, 9CFR 416.13(c) 416.4(a)(b) and 416.(1). 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 and 416.1 that states “Each official establishment shall monitor daily the implementation of the procedures in the Sanitation SOP’s, Requirements (416.4 (a)(b) that states “(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, Mr. cleaned and sanitized All food-contact surfaces. As is evident by this Nr the previous plant proposed further action were not done or are ineffective. Past Similar Mrs. -007-2010-13720 Previous Ineffective Plant Actions: and all CFRS listed above. And this document serves as a written notification that failure to comply with regulatory requirements could result in additional regulatory or administrative action.

Regulation:

416.13(c) 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.

416.4(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(a), 416.13(c), 416.4(a)

Citation: At approximately 06:49 hours CSI observed while performing PBIS task 01B02 after sanitation and QA had preformed their pre op sanitation Area had been checked by QA and no deficiencies found, CSI observed (1) in the evisceration area one of five plastic container use by establishment for washing and re-washing product has a blood stain in the center from the proves day operation, (2) evisceration area CSI observed blood stain, fats, all over the wall, (3) evisceration area cut up belt has one hair about 4 inches long and second hair about 3 inches long, CSI immediately notified plant manager Mr. of this noncomplianc, Mr. immediately provided the following preventive measure and I observed the establishment implement corrective actions by scrub the walls and cut -up belt with soap was properly cleaned and sanitized, After sanitary conditions were restored I re-inspected the area, and found it acceptable. I explained to, Mr. that this is considered a product contact surface. But if not detected these could cause product adulteration or the creation of insanitary conditions if allowed to come into contact with product, and could pose a public health issue if product entered commerce. these noncompliance is a failure to meet USDA Regulatory Requirements (416.4(a) that states “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 in sanitary conditions and the adulteration of product. and 416.13(c) that states “Each official establishment shall monitor daily the implementation of the procedures in the Sanitation SOP’s. and 416.1 General Rules “Each official establishment must be operated and maintained in a manner sufficient to prevent the creation of insanitary conditions and to ensure that product is not adulterated and (416.4(a) 416.13(c) 416.1 this document serves as a written notification that failure to comply with regulatory requirements could result in additional regulatory or administrative action.

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.

Code: 06D01
Violation:  416.3(a)

Citation: At approximately 0930 hours CSI observed the following noncompliance’s while performing PBIS task 06D01 in the slaughter department area, during operations, I observed an open gap approximately four inches in length and half inches wide in one of the five U.S.D.A condemn barrel, prior to be used by plant employee, at the same time Mr. plant manager was touring slaughter area with me Mr. notified both verbally and in writing for noncompliance. Mr. immediately provided the following preventive measure and corrective actions. By immediately removing the empty U.S.D.A condemn barrel in my presence to disposal, Plant Manager was in the area with me, and immediate corrective actions were taken and since no product was contaminated, there was no need for a U.S. Rejected tag. .Mr. was notified of the failure to meet regulatory requirements. establishment fail to meet USDA Regulatory Requirements that 416.3(a) states Equipment and utensils used forprocessing 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. I explained to, Mr. that this is considered a non- product contact surface. But if not detected could cause product adulteration or the creation of insanitary conditions if allowed to come into contact with product, and could pose a public health issue if product entered commerce. Mr. plant manager giving instructions to the kill room crew to be more observant using U.S.D.A condemn barrel has holes or gaps prier to be use. and 416.3(a) This document serves as written notice that your continue failure to meet these Regulatory Requirements could result in additional Regulatory Enforcement or Administrative Actions as described in 9 CFR Part 500 – Rules of Practice.

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.

Code: 06D01
Violation:  416.1, 416.2(b)(3)

Citation: At approximately 0930 hours while performing procedure code 06D01, I observed the following non-compliance, two flies were observed in the evisceration room area. One of these landed on the duck rack, the other fly was killed by a plant employee. I noted that the door inside the evisceration area was not closed all the way. I also noted that the door was left open when the plant employee removed condemned product from the evisceration area to the outside. Mr. the Plant Manager was in the area and immediate corrective actions were taken and since no product was contaminated, there was no need for a U.S. Rejected tag. Mr. was notified of the failure to meet regulatory requirements. Mr. immediately provided the following preventive measure and corrective actions. I observed the establishment implement corrective actions by removing duck caresses from the rack, and scrub the duck rack with soapy water as well as rinse it and sanitize. After sanitary conditions were restored I re-inspected the duck rack, and found it acceptable. I explained to, Mr. that this is considered a product contact surface. But if not detected these flies could cause product adulteration or the creation of insanitary conditions if allowed to come into contact with product, and could pose a public health issue if product entered commerce. 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. and 416.2(b) states.(1) 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.(2) Doors not closing tightly allowing the entrance of vermin, dirt, or dust. 416.1 And 416.2(b) this document serves as a written notification that failure to comply with 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(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: 06D01
Violation:  416.2(b)(1)

Citation: At 1315 hours on this date, I was in the small duck slaughter kill room observing poultry for humane slaughter activities. I noticed a hole in the bottom portion of the wall located adjacent to the entrance door for the room. The hole is triangular in shape and extends about one foot in length. While trying to close the door upon leaving the area I noticed that the door was off the guide bar and could not be shut completely. The area where the non-compliance was noted is away from the product zone and no product is affected. I notified Plant Manager at 1400 hours on this date that 9CFR 416.2(b)(1) is not being met in this area. 416.2(b)(1) states that “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 creation of insanitary conditions.” Continued failure to meet these regulatory requirements could result in additional regulatory or administrative action.

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: 03J02
Violation: 417.3(c), 417.5(c)

Citation: Upon reviewing the responses that you provided for NR#0053-2010-12907 and NR#0052-2010-12907, it states “For a period of one week daily direct observations will be conducted by two employees including two initials on the direct observation of CCP 1 and CCP 2. Also for the same one week period two employees will sign the pre-shipment review.” I have found the following noncompliance’s on Slaughter Inspection Reports dated June 23, June 22, and on June 21 there is only one person signing the pre-shipment review ([redacted]) and on June 21, only one person is documented as performing the direct observation of CCP 1 & 2. ([redacted]) Also on the SRM Removal Records and SRM Identification Records dated June 22, there is only one person that performed the pre-shipment review on June 22. [redacted], Plant Manager has been informed of these noncompliance’s in both writing and orally. This document serves as a written notification that failure to comply with regulations could result in further regulatory and or administrative actions. Past Similar NRs – Previous Ineffective Plant Actions: This noncompliance is still open at this time. Response that was unacceptable : ” pre-shipment review will be signed off at the end of slaughter, as too when carcasses are shipped.” NR: 56-2010 dated 6/17/2010 NR 52-2010 & NR 53-2010 were written for the lack of documentation for pre-shipment reviews, and direct obsersavations.

Regulation:

417.3(c) All corrective actions taken in accordance with this section shall be documented in records that are subject to verification in accordance with §417.4(a)(2)(iii) and the recordkeeping requirements of §417.5 of this part.

417.5(c) Prior to shipping product, the establishment shall review the records associated with the production of that product, documented in accordance with this section, to ensure completeness, including the determination that all critical limits were met and, if appropriate, corrective actions were taken, including the proper disposition of product. Where practicable, this review shall be conducted, dated, and signed by an individual who did not produce the record(s), preferably by someone trained in accordance with §417.7 of this part, or the responsible establishment official.

Code: 04C02
Violation: 313.1

Citation: Category II – Truck Unloading: On June 30, 2010 at approximately 0830 after a load of a few lambs were unloaded, I walked over toward the back of the truck, and found the following noncompliance: The ramp that is used to unload animals from trucks is not maintained in good repair. There are holes in some of the boards, there are broken boards, loose boards, and unnecessary metal rods with gaps under them that could allow for animals to get their feet caught up on. , Kill Floor Supervisor/HACCP Manager was out there and I notified him of this noncompliance. I then applied US REJECT tag # B19114129 to the unloading ramp. The lambs that I observed coming off of the truck onto the ramp did not get injured. Section 313.1 states: (a) Livestock pens, driveways and ramps shall be maintained in good repair. They shall be free from sharp or protruding objects which may, in the opinion of the inspector, cause injury or pain to the animals. Loose boards, splintered or broken planking and unnecessary openings where the head, feet, or legs of an animal may be injured shall be repaired. (b) Floors of livestock pens, ramps, and driveways shall be constructed and maintained so as to provide good footing for livestock. Slip resistant or waffled floor surfaces, cleated ramps and the use of sand, as appropriate, during winter months are examples of acceptable construction and maintenance. , Plant Manager has been informed of these noncompliance’s in both writing and orally. This document serves as a written notification that failure to comply with regulations could result in further regulatory and or administrative actions.

Regulation:

313.1 (a) Livestock pens, driveways and ramps shall be maintained in good repair. They shall be free from sharp or protruding objects which may, in the opinion of the inspector, cause injury or pain to the animals. Loose boards, splintered or broken planking, and unnecessary openings where the head, feet, or legs of an animal may be injured shall be repaired.

Code: 06D01
Violation: 416.2(b)(1), 416.2(b)(2), 416.3(a)

Citation: On July 1, 2010 at approximately 0730 I was asked by Kill Floor Supervisor/HACCP Manager to perform pre-operational sanitation. Upon doing so, I checked the SSOP Records and didn’t see any deviations mentioned. While performing 01B02, I found the following noncompliance’s on the small animal slaughter floor: The first, second and third rails upon entering the main entrance, both had a rusty film buildup on them. On the first rail, one of the support beams, also had a rusty film buildup. I took regulatory control action and placed US Reject tag # B19114138 to the floor, because the first and second rails are the primary rails that product are on daily. , Plant Manager has been informed of these noncompliance’s in both writing and orally. This document serves as a written notification that failure to comply with regulations could result in further regulatory and or administrative actions.

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.

 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.

416.3(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.

Code: 03J02
Violation: 417.2(c)(7)

Citation: On July 2, 2010 while performing the above procedure, I reviewed the E-Coli records, and have found the following noncompliance. There has been no 0157:H7 testing since March 26, 2010. You HACCP Plan states that ” ” According to this, there should of had been two samples taken from April 1, 2010 – June 30, 2010. , Plant Manager has been informed of these noncompliance’s in both writing and orally. This document serves as a written notification that failure to comply with regulations could result in further regulatory and or administrative actions.

Regulation:

417.2(c)(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.

Code: 06D01
Violation: 416.2(a)

Citation: On July 2, 2010 while performing the above procedure outside of the establishment, I have found the following noncompliance. The grass and weeds around the entire establishment have grown over 10 inches. According to your HACCP Plan it states, “[redacted].” , Plant Manager has been informed of these noncompliance’s in both writing and orally. This document serves as a written notification that failure to comply with regulations could result in further regulatory and or administrative actions.

Regulation:

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.

Code: 01B02
Violation: 416.4(a)

Citation: On July 6, 2010 while performing the above procedure, I found the following noncompliance on the Beef Slaughter Floor: The brisket saw blade was covered in rust. I took regulatory control action and placed U.S. Rejected Tag on the saw. Tag # B18815282. , Kill Floor Supervisor was immediately notified. The saw was then re-cleaned. , Plant Manager has been informed of this noncompliance in both writing and orally. This document serves as a written notification that failure to comply with regulations could result in further regulatory and or administrative actions. Past Similar NRs – Previous Ineffective Plant Actions: this NR is still open at this time. NR: 45-2010 dated 5/5/2010

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.

Code: 03J02
Violation: 310.18

Citation: On July 6, 2010 while performing post-mortem inspection, I have found the following noncompliance. After beef carcass #2 was presented to me for inspection, I found fecal, hair and ingesta on the brisket, front shank, and under the shoulder. On the final rail, prior to entering the cooler, I preformed a zero tolerance check on carcass number 3. On this carcass, I found fecal, and or ingesta under the front shoulder and there was still spinal cord left intact. , HACCP Manager/Kill Floor Supervisor was immediately notified and he instructed that employee remove it. US Retained Tag # B28365921 was applied to the 1/2 carcass. Tag was removed after contamination and spinal cord was removed. , Plant Manager has been informed of this noncompliance. This document serves as a written notification that failure to comply with regulations could result in further regulatory and or administrative actions. Past Similar NRs – Previous Ineffective Plant Actions: employee was instructed to trim all needed areas of carcasses before washing. NR: 37-2010 dated 4/15/2010

Regulation:

310.18(a) Carcasses, organs, and other parts shall be handled in a sanitary manner to prevent contamination with fecal material, urine, bile, hair, dirt, or foreign matter; however, if contamination occurs, it shall be promptly removed in a manner satisfactory to the inspector.

Code: 06D01
Violation: 416.2(b)(2), 416.2(b)(3), 416.4(b), 416.4(d)

Citation: On July 7, 2010 while performing the above procedure, a review of the establishment was conducted and the following noncompliance’s were found: On the small animal slaughter floor: There are numerous spots on the support beams that are covered in white flashing that has peeling and or flaking caulking, and there is one light fixture that is missing a bulb and has a wire hanging out of it. The base of the viscera table had peeling paint and or peeling rust. Directly in front of the sink and to the left of it there is peeling paint. In the hook room: There is no drain cover over the drain, numerous cobwebs through out the entire room, a black moldy substance on the table, rusty rails, and on the back of the door that leads onto the small animal slaughter floor is rusty, there is a hole in it, and the metal frame is coming off. Hook room was reject tag. Tag # B18815306. In the employee bathroom: there were cigarette buts on the floor, contamination on the wall of the shower, numerous dead insects, and blood smears on the door. Bathroom was rejected with Reject tag # B19113731. In the basement: there were dirty garments on the steps and on the floor. There is a pipe that is directly behind the washer that has an unidentifiable orange substance on it. Water is dripping off of the pipe, onto the substance, then on to the floor. There is a blue cart that has garbage in it, along with cobwebs. There are numerous cobwebs and dead insects throughout the entire basement area. Underneath the garage door there is small gap that is a potential entry for pests and or rodents. There is also an area that has numerous carts, and other objects that is cluttering up the room, and is not allowing for inspection to take place. There are numerous pipes that have condensation dripping from them. On the Large Beef Slaughter Floor: The knocking pen had rusty and or paint chipping off it and has holes in it. The beef cradle has holes, the welds have cracks allowing for bacteria to build up and has rust on it. There are numerous rails that have rust on them. In the inspection office bathroom: The sink is leaking water onto the floor. , Plant Manager has been informed of these noncompliance’s in both writing and orally. This document serves as a written notification that failure to comply with regulations could result in further regulatory and or administrative actions.

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(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.

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: 416.3(a), 416.4(a)

Citation: On July 7, 2010 as I was performing the above procedure, I have found the following noncompliance. On the Large Beef Slaughter floor, the large splitting saw is unacceptable. There are holes on the end of it, collecting debris, and there are welds that have been made that are still allowing for fat, blood, and other particles to accumulate. Upon asking for documentation stating that the welds are food grade, it has not been made available. After reviewing the PIP, I noticed that the Saw was to be repaired by July 1st, then changed to July 31, 2010. There was no reason documented as to why the saw was unable to be repaired by the first projected date. Also, the saw is a SSOP issue, not an SPS issue therefore shouldn’t be documented on a PIP. The saw was rejected with Reject tag # B18815287. Plant Manager has been informed of these noncompliance’s in both writing and orally. This document serves as a written notification that failure to comply with regulations could result in further regulatory and or administrative actions.

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.

416.4(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: 03J02
Violation: 417.2(c)(4), 417.5(a)(3)

Citation: On July 12, 2010 while performing the above procedure and I have found the following noncompliance. There were 12 beef slaughtered. The first beef slaughtered was >30 months of age. Upon monitoring the procedures, the vertebrae column was not inked and the vertebrae column was removed on the slaughter floor. According to you HACCP Plan Flow Diagram for the Beef/Veal process, it shows that [redacted]. It also states “[redacted].” This is CCP 1B. Upon reviewing the SRM Removal Record and the SRM Identification Record they both state ” [redacted]” , Plant Manager has been informed of these noncompliance’s in both writing and orally. This document serves as a written notification that failure to comply with regulations could result in further regulatory and or administrative actions.

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;

417.5(a)(3) Records documenting the monitoring of CCP’s and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment’s HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter production lot. Each of these records shall include the date the record was made.

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

Citation: On July 13, 2010 at approxitemaly 0745 I performed the above procedure and found the following noncompliance’s on the small animals slaughter floor: the wall directly behind the final wash area had maggots crawling up the wall and on the floor. The wall behind the blood pit had maggots as well as the wall behind where the final trim takes place. The hose that is used for washing the carcasses had a grimy substance accumulated on the hose, along with fat, blood, and hair in and around the nozzle of the hose. The entire small animal slaughter floor was Rejected with tag #B18815292 and the hose was rejected with tag #B18815283. Slaughter was able to start at 0930 after the establishment re-cleaned and sanitized the entire floor. , Plant Manager has been informed of these noncompliances in both writing and orally. This document serves as a written notification that failure to comply with regulations could result in further regulatory and 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(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: 03J02
Violation: 417.2(c)(4), 417.3(a)(3)

Citation: On July 15, 2010 while performing the above procedure, I have determined the following are noncompliance’s. In your response to the Notice of Reinstatement of Suspension, you offered the following corrective actions: “A sign has been posted on the chill cooler door that reads “Over 30? Vertrabre Inked? – place on designated rail” to serve as a visual reminder for anyone working on the Beef Kill Floor, and also “We have volunteered to have a HACCP weekly rotation till the end of the validation period (90 days). and are the two selected individuals. will begin the HACCP rotation.” There is a sign on the Beef Cooler door that only reads “OVER 30.” Also, there has not been any HACCP weekly rotations going on since June 14, 2010. , Plant Manager has been informed of these noncompliance’s in both writing and orally. This document serves as a written notification that failure to comply with regulations could result in further regulatory and or administrative actions. Past Similar NRs – Previous Ineffective Plant Actions: noncompliance’s are both still open at this time. NR: 59-2010 dated 6/22/2010; NR: 56-2010 dated 6/17/2010

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;

417.3(a)(3) Measures to prevent recurrence are established; and

Code: 03J01
Violation: 417.2(c)(4), 417.3(a)(3)

Citation: On July 20, 2010 while performing the above procedure I have found the following noncompliance: On NR#0066-2010-12907 that is dated 7/19/2010 the further planned action states “We shall double our monitoring procedure for zero tolerance from one per twenty carcasses to one per ten carcasses for a period of three days.” This response was presented to FSIS on 7/20/10. Upon reviewing the Slaughter Inspection Report record dated 7/19/2010, it is unclear what is documented as being slaughtered. The record indicates that there were [redacted] lambs slaughtered and then another [redacted] lambs and the Carcass I.D. Checked were [redacted]. Goats are also checked off as being slaughtered and no head count is documented. Upon reviewing FSIS records, there were [redacted] lambs and [redacted] goats slaughtered. Also, underneath the daily verification activities there is no Carcass ID or findings documented for monitoring verification/observations for CCP 1 & 2, although it is documented as to who verified this with a time and date. , Plant Manager has been informed of these noncompliance’s in both writing and orally. This document serves as a written notification that failure to comply with regulations could result in further regulatory and or administrative actions.

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;

417.3(a)(3) Measures to prevent recurrence are established; and

Code: 03J02
Violation: 310.18, 417.2(c)(4), 417.3(a)(3)

Citation: On July 21, 2010 at approximately 1345 hrs, while performing the above procedure, I have found the following noncompliance’s: Upon doing post-mortem inspection, there were 8 carcasses that were presented to me for inspection. I found 7 of the carcasses to be contaminated with either hair, hide, fecal, and or ingesta. was immediately notified and instructed another employee to trim these carcasses. Also, there were numerous flies flying around and numerous flies on carcasses. I immediately took regulatory control action and placed US Reject Tag # B18815310 to the small animal slaughter floor. The product was in control by the retain tag. I witnessed the carcasses all being trimmed before entering the cooler. , Plant Manager has been informed of these noncompliance’s in both writing and orally. This document serves as a written notification that failure to comply with regulations could result in further regulatory and or administrative actions. Past Similar NRs – Previous Ineffective Plant Actions: Further planned actions from NR#66 stated “we shall double our monitoring procedure for zero tolerance from one per twenty to one per ten carcasses for a period of three days.” NR: 66-2010 dated 7/6/2010

Regulation:

310.18 (a) Carcasses, organs, and other parts shall be handled in a sanitary manner to prevent contamination with fecal material, urine, bile, hair, dirt, or foreign matter; however, if contamination occurs, it shall be promptly removed in a manner satisfactory to the inspector.

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;

417.3(a)(3) The written HACCP plan shall identify the corrective action to be followed in response to a deviation from a critical limit. The HACCP plan shall describe the corrective action to be taken, and assign responsibility for taking corrective action, to ensure: Measures to prevent recurrence are established;

Code: 06D01
Violation: 416.2(b)(2), 416.4(b)

Citation: On July 22, 2010 at approximately 07:45 hours after plant pre-operational inspection and prior to start of slaughter operation I performed procedure code 01B02, and I found the following noncompliance: The small animal cooler had blood on each wall from the previous day use. I took a regulatory control action applied a U.S. Reject tag # B18815305 to the small animal cooler. I checked the pre operational records, this deficiency was not found. I notified Kill Floor Supervisor/HACCP Manager of this noncompliance. The area was immediately cleaned sanitized and then re-inspected and acceptable. The room was released from my regulatory control action at approximately 0805., Plant Manager has been informed of these noncompliance’s in both writing and orally. This document serves as a written notification that failure to comply with regulations could result in further regulatory and or administrative actions.

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.

416.4(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: 01B01
Violation: 416.15(a), 416.15(b)

Citation: On July 22, 2010 while performing the above procedure, I have found the following noncompliance. According to your Response to Notice of Reinstatement of Suspension dated May 26, 2010, you state that “For those select carcasses where corrective actions may be taken, the temperature will be recorded on the Contaminated Carcass Form.” According to your HACCP plan, it states that “[redacted] ” Yesterday, there were carcasses that were contaminated, as identified by FSIS. Upon reviewing the records for yesterday, there is no Carcass Contamination Form. The same goes for July 6, 2010 when there were beef carcasses that were contaminated. On this form, there is to be a thermometer calibration preformed. As of today, there has been no documentation of this being done. Nor has this form ever been filled out. , Plant Manager has been informed of these noncompliance’s in both writing and orally. This document serves as a written notification that failure to comply with regulations could result in further regulatory and or administrative actions.

Regulation:

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

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

Code: 03J01
Violation: 310.22(f)(1)(ii)

Citation: On July 23, 2010 while performing the above procedure, I found the following noncompliance. There was an >30 beef carcass slaughtered and an employee used the saw for cutting the brisket, he then dipped it in the sterilizer. I looked at the saw and there was still numerous pieces of fat and/ or meat particles on the saw. He was then going to use the saw to cut the brisket of an <30 months beef. I immediately notified of this noncompliance and the employee was instructed to completely clean all of the visible contamination off of the saw before using it on the < 30 months of age beef. I had complete control of the product, as the saw did not come in contact with it. 9CFR310.22(f)(1)(ii) states ” (ii) Clean and sanitize equipment used to cut through specified risk materials before the equipment is used on carcasses or parts from cattle younger than 30 months of age.” , Plant Manager has been informed of this noncompliance in both writing and orally. This document serves as a written notification that failure to comply with regulations could result in further regulatory and or administrative actions.

Regulation:

310.22(f)(1)(ii) [Reserved]

Code: 1.00E+01
Violation: 310.25(a)

Citation: After reviewing the generic E. Coli testing program it was found that after coming under inspection the week of July 17th that there was no name inserted for the person doing the sampling and evaluating the results. Further, it was found that there has been no results listed for the first week and also no testing for the second week. Results may not have been in for the second week but the test should have been taken. Failure to address this non-conformance could result in further regulatory or administrative action.

Regulation:

310.25(a) Criteria for verifying process control; E. coli testing. (1) Each official establishment that slaughters livestock must test for Escherichia coli Biotype 1 (E.coli) Establishments that slaughter more than one type of livestock or both livestock and poultry, shall test the type of livestock or poultry slaughtered in the greatest number. The establishment shall:

Code: 03J03
Violation: 310.18

Citation: On August 2, 2011 while performing final inspection on the small animal slaughter floor, I found the following noncompliance. After a goat carcass had passed through the establishments CCP for zero tolerance, I checked a goat carcass at final inspection and found an area approximately 3 inches by 1 1/2 inches that had fecal and/or ingesta on the front shank. I immediately notified the slaughter floor personnel, and he immediately trimmed the contaminated carcass, i re-inspected the carcass and found it to be acceptable.

Regulation:

310.18(a) Carcasses, organs, and other parts shall be handled in a sanitary manner to prevent contamination with fecal material, urine, bile, hair, dirt, or foreign matter; however, if contamination occurs, it shall be promptly removed in a manner satisfactory to the inspector.

Code: 03J02
Violation: 417.4(a)(2)(iii), 417.5(a)(3), 417.5(c)

Citation: On August 18, 2011 while reviewing HACCP records for the weeks of August 1-12th, I found the following noncompliances:

On 8/1/11 – SRM Identification and Removal Record, the lot numbers are identified in the date carcasses are released for shipment, instead of the date.[newline][newline]On 8/4/11 – SRM Identification and Removal Record, for carcass #21WE5616 it is not documented yes or no under “applied to the vertebrae column? CCP 2B.”

On 8/11/11 – SRM Identification and Removal Record, there are no initials in the last column.

Regulation:

417.4(a)(2)(iii) The review of records generated and maintained in accordance with §417.5(a)(3) of this part.

417.5(a)(3) Records documenting the monitoring of CCP’s and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment’s HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter production lot. Each of these records shall include the date the record was made.

417.5(c) Prior to shipping product, the establishment shall review the records associated with the production of that product, documented in accordance with this section, to ensure completeness, including the determination that all critical limits were met and, if appropriate, corrective actions were taken, including the proper disposition of product. Where practicable, this review shall be conducted, dated, and signed by an individual who did not produce the record(s), preferably by someone trained in accordance with §417.7 of this part, or the responsible establishment official.

Code: 01C02
Violation: 416.13(b)

Citation: On August 8, 2011 during a conference call with your establishment it was discussed with your establishment that as stated in your Sanitation Standard Operating Procedures that . [newline]On August 17, 2011 it has been determined that your establishment has not been doing a complete clean up before switching from species to species.

Regulation:

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

Code: 01C01
Violation: 416.15(a), 416.16(a)

Citation: On August 18, 2011 while reviewing your establishment SSOP records from August 1-12th, I have found the following noncompliances:[newline][newline]On 8/1/11 – Small Slaughter SSOP Report, there is documentation on whom did the inspection.

On 8/5/11 – Daily SPS Report, on the bottom of the record under the “SPS deviation procedures”, there is no time documented. Also on this form there are numerous deficiency noted, but in the column for “re-inspection”, it is not being documented with a check mark if after the corrective actions were taken if they then passed the re-inspection.

On 8/8/11 – Small Slaughter SSOP Report, there is no documentation on whom did the inspection. Also on this form there are numerous deficiency noted, but in the column for “re-inspection”, it is not being documented with a check mark if after the corrective actions were taken if they then passed the re-inspection.

On 8/10/2011 – Daily SPS Report, there is no time documented. Also on this form there is a deficiency noted, but in the column for “re-inspection”, it is not being documented with a check mark if after the corrective actions were taken if they then passed the re-inspection. There is also no further planned actions documented.

On 8/11/2011 – Beef Slaughter SSOP Report, there is documentation on whom did the inspection. Also on this form there is a deficiency noted, but in the column for “re-inspection”, it is not being documented with a check mark if after the corrective actions were taken if they then passed the re-inspection

On 8/11/2011 – Daily SPS Report, under the “SPS deviation procedures”, neither box is checked for acceptable SPS procedures, or unacceptable SPS procedures.

Regulation:

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

416.16(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: 03J02
Violation: 417.5(c)

Citation: On August 18, 2011 while reviewing HACCP records (JHM-HACCP-FORM-003, as well as JHM-HACCP-FORM-010) from July 18-August 18, 2011 it has been determined that the HACCP employee(s) that have been signing the pre-shipment review on records is the same person that has been producing the record. [newline]According to your HACCP plans, it states in there, “[redacted] .”

Regulation:

417.5(c) Prior to shipping product, the establishment shall review the records associated with the production of that product, documented in accordance with this section, to ensure completeness, including the determination that all critical limits were met and, if appropriate, corrective actions were taken, including the proper disposition of product. Where practicable, this review shall be conducted, dated, and signed by an individual who did not produce the record(s), preferably by someone trained in accordance with §417.7 of this part, or the responsible establishment official.

Code: 03J02
Violation: 310.22(e)(4)(i)

Citation: On August 23, 2011 while reviewing your SRM Identification and Removal Record (JHM-HACCP-FORM-010), dated 08/18/2011, I found the following noncompliances: The 3rd carcass that was slaughter, in the column that states “[redacted]” both boxes are checked and initialed, its still unclear as to which box is actually supposed to be checked. The 6th carcass that was slaughtered, in the column that states “[redacted]” both of the boxes are checked. The 7th and 8th carcasses that were slaughtered, in the column that states “[redacted] ” both “no” are crossed out, and the “yes” box is checked, there are no initials to clarify the changes.

Regulation:

310.22(e)(4)(i) Recordkeeping requirements. (i) Establishments that slaughter cattle and establishments that process the carcasses or parts of cattle must maintain daily records sufficient to document the implementation and monitoring of the procedures for the removal, segregation, and disposition of the materials listed in paragraph (a) of this section, and any corrective actions taken.

Code: 03J02
Violation: 417.5(b)

Citation: On August 30, 2011 while visiting the establishment, at approximately 1505 hours I reviewed the Slaughter Inspection Report and the only species that was documented was 10 beef. On August 31, 2011 while reviewing this same record I noticed that it now had 1 veal and 35 goat documented. The time documented for monitoring of the CCP1B (Zero Tolerance) for the veal was 1500 hours, and the goat were documented at 1300 hours and 1430 hours. This would be a noncompliance as HACCP records are to be documented at the time the event occurs. Also on this record, there is no date documented on the top.

Regulation:

417.5(b) Each entry on a record maintained under the HACCP plan shall be made at the time the specific event occurs and include the date and time recorded, and shall be signed or initialed by the establishment employee making the entry. 

Code: 01C01
Violation: 416.13(b), 416.16(a)

Citation: On August 31, 2011 while reviewing the Daily SPS Report I found the following noncompliance. The actual date of the form is 8/30/11 but it is documented as 8/31/11. Also on this record it is not documented if the inspection of “[redacted]” took place.

Regulation:

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

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: 03J02
Violation: 417.4(a)(2)(ii), 417.5(a)(3)

Citation: While reviewing the Slaughter Inspection Report dated 8/29/2011 the following noncompliance was found: The record states that a total of [redacted] sheep were slaughtered, and that carcasses 13, 29, and 44 were the carcass IDs that were checked at CCP 1B (zero tolerance). Also on this record it is not checked if whether or not the scale challenge was acceptable or unacceptable.

Regulation:

417.4(a)(2)(ii) ) Direct observations of monitoring activities and corrective actions;

417.5(a)(3) Records documenting the monitoring of CCP’s and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment’s HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter production lot. Each of these records shall include the date the record was made.

Code: 03J03
Violation: 310.18

Citation: On September 19, 2011 while performing final inspection I found the following noncompliances. At approximately 1200 hours I inspected a beef carcass and found feces on the flank and also in the inside of the flank. On the top of the rump, there was also a piece of gray material that appeared to be a piece of paint chipping. Both were trimmed, and I immediately showed this to both Mr. and Mr. At approximately 1326 hours while inspecting the last beef carcass at the final inspection, I found that the tail of the carcass had feces on it. I informed the employee and the tail was immediately removed from the carcass. [newline][newline]A previous similar noncompliance (XVH2610081316N) was issued on August 2, 2011, and remains open at this time due to an inadequate response.

Regulation:

310.18(a) Carcasses, organs, and other parts shall be handled in a sanitary manner to prevent contamination with fecal material, urine, bile, hair, dirt, or foreign matter; however, if contamination occurs, it shall be promptly removed in a manner satisfactory to the inspector.

Code: 01B02
Violation: 416.1, 416.2(b)(2), 416.4(a), 416.4(b)

Citation: On September 19, 2011 while performing pre-operational sanitation at approximately 0800 hours on the Beef slaughter floor, I found the following noncompliances:[newline]I was asked to perform a pre-op on the large splitting saw prior to the employee putting the blade on the saw. When I inspected the saw, I found numerous pieces of fat inside the saw guide. There were numerous pieces of fat and blood on the water house that is near the brisket saw. Also the final rail stand has some paint peeling off of it, as does the walls.[newline][newline]At approximately 1305 hours I was asked to perform pre-operational sanitation on the small animal slaughter floor and found the following noncompliances:[newline]The wall behind final trim and wash had numerous pieces of fat on it. The knife that is used for the Ritual Slaughter still had a large amount of blood and hair on it from the slaughter of beef. The stands used for final wash and trim had blood on it. Also, the stand has paint peeling off it.

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(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: 03J03
Violation: 417.5(a)(3)

Citation: On October 4, 2011 at approximately 1150 hours I reviewed your Slaughter Inspection Report (DOC. # JHM-FORM-003) and found the following noncompliance:

The record was documented that Zero Tolerance (CCP 1B) checks were being performed, but the species/offal was not yet documented. I immediately informed and he stated to me that this was not filled out because “he was unsure of what the establishment was going to be slaughtering next.” I informed Mr. that the species needed to be documented as they are slaughtered and checked for Zero Tolerance (CCP 1B).

Regulation:

417.5(a)(3) Records documenting the monitoring of CCP’s and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment’s HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter production lot. Each of these records shall include the date the record was made.

Code: 03J03
Violation: 417.5(a)(3)

Citation: On October 21, 2011 while reviewing the records I found the following noncompliance. On DOC. # JHM-FORM-003 dated 10/12/2011 there is no documented initials for the 3rd Zero Tolerance (CCP 1B) check for the goats that were slaughtered.

Regulation:

417.5(a)(3) Records documenting the monitoring of CCP’s and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment’s HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter production lot. Each of these records shall include the date the record was made.

Code: 03J02
Violation: 417.5(b)

Citation: On October 25, 2011 I visited your establishment and reviewed your record, the Slaughter Inspection Report (DOC. # JHM-FORM-003), dated 10/25/11. Upon reviewing the record at approximately 1400 hours, the only documentation was [redacted] sheep slaughtered with the two zero tolerance checks. On October 26, 2011 while visiting your establishment to perform a records review, I again reviewed this same document and found the following noncompliance: On this record it was now documented that [redacted] goat and [redacted] lamb were slaughtered. The times of checks for the goats are documented as being performed at 11:37, 12:10, and 2:20. This would be noncompliant as the 11:37 and 12:10 checks were not documented on this record, at the time the event occurred.[newline][newline]A previous noncompliance was issued on August 31, 2011 (Noncompliance #XVH1811083231N) for the same issue.

Regulation:

417.5(b) Each entry on a record maintained under the HACCP plan shall be made at the time the specific event occurs and include the date and time recorded, and shall be signed or initialed by the establishment employee making the entry.

Code: 03J02
Violation: 417.5(a)(3)

Citation: On 10/25/11 a noncompliance was written in regards to a Zero Tolerance check not being initialed by the employee. On 10/26/11 FSIS received back the noncompliance with the following Plant Management response from : “Will recheck all records daily for two weeks with another trained (in recordkeeping) employee.” After speaking to Mr. he stated to CSI that [redacted] “daily in evenings that him and another individual will review records and initial them.” [newline]On 10/28/11 while visiting your establishment CSI [redacted] reviewed records dated 10/26 and 10/27/2011 and there were no additional record checks performed or initialed by Mr. and another employee. Therefor, your further planned action(s) are either not adequate or they are ineffective.

Regulation:

417.5(a)(3) Records documenting the monitoring of CCP’s and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment’s HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter production lot. Each of these records shall include the date the record was made.

Code: 01B02
Violation: 416.13(a)

Citation: At approximately 7:30 am I was asked by the HACCP monitor [redacted] to preform a pre operational inspection on the large animal floor. Upon inspection for the spinal cord remover I noticed pieces of fat and blood and what appeared to be rust on the device and rust on the hook were it was hanging. Inspection of the electrical cord and connection device to the split saw I noted several pieces of fat,hair and a bloody build up. On the handwash sink located on the floor I noted on the underside a large amount of bloody buildup, on the carcass cradle I noted a large amount of blood, hair, hay and buildup on the front of the frame. All deviancies were addressed to the HACCP monitor [redacted] who directed the recleaning of these areas to company employees. These areas were then recleaned and I reinspected them before releasing the floor to production. I notified HACCP monitor that I would be writing a NC at this time.

Regulation:

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

Code: 01D01
Violation: 416.2(b)(1), 416.2(b)(3), 416.3(a), 416.4(b)

Citation: While conducting a walk thru inspection with EIAO Dr. on 01/04/2012 the following SPS noncompliances were noted: Rust was found on the rails in the beef holding cooler, beef chill cooler, large and small slaughter floors and transfer rail from the small to large slaughter floor. No rust debris was noticed on the carcasses and some of these rails are not used to transfer carcasses. Flaking paint was noticed on the east and west walls in the large and small slaughter floor, this issue was documented on the establishments PIP and was noted to be completed by 12/31/2011, this has not been completed at this time. This is noncompliant with regulation 9 CFR 416.2(b) (1). Rusty rollers were found on the gambrel hooks being used to hang the small animals on the small animal slaughter floor; the rollers are non food contact surfaces. The hooks are food contact surfaces and were clean. This is noncompliant to regulation 9 CFR 416.3(a) and 416.4(b). While in the basement area of the establishment an exit/entry door was found to have a 6 inch gap in the insulation which was used to seal the door. In the holding pens the sliding livestock unloading door is unsealed at the base leaving a gap sufficient enough in size to allow for rodent or other vermin entry, also at the junction of the doorframe and the floor on the left hand side of the door was a gap which was sufficient in size to allow for vermin entry. This is in violation of 9CFR 416.3(a) and 416.4(b) Mr. and Mr. were notified of these noncompliances.

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.

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.

416.3(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: 03J02
Violation: 417.5(a)(3)

Citation: While reviewing records with EIAO Dr. on 01/04/2012 the following noncompliance was noted:[newline]On the November 22, 2011 Slaughter Inspection Report, there are no monitor’s initials and time for the CCP 3b application. This is in violation with 9CFR 417.5(a) (3).[newline]Mr. and Mr. were notified of this noncompliance.

Regulation:

417.5(a)(3) Records documenting the monitoring of CCP’s and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment’s HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter production lot. Each of these records shall include the date the record was made.

Code: 01C02
Violation: 416.12(a), 416.3(a), 416.4(a)

Citation: While conducting a walk thru inspection with EIAO Dr. on 01/04/2012 the following SSOP noncompliance’s were noted: In the beef holding cooler there was a knife scabbard hanging on the wall containing a wooden handled knife, both scabbard and knife were dirty containing blood and fat from a previous days production, the knife also had a rusty blade. On the loading dock area there was a scabbard attached to the wall containing a white plastic handled knife, the knife and scabbard were dirty, both had blood and fat particles on them. These knives are used for breaking carcasses and other trimming purposes prior to shipping. These knives are food contact surfaces and are not included in the SSOP procedures. These issues are noncompliant with 9 CFR 416.3(a), 416.4(a) and 416.12(a). Mr. and Mr. were notified of these noncompliances.

Regulation:

416.12(a) The Sanitation SOP’s shall describe all procedures an official establishment will conduct daily, before and during operations, sufficient to prevent direct contamination or adulteration of product(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(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: 01D01
Violation: 416.2(b)(1), 416.2(b)(2), 416.2(c)

Citation: At approximately 8:30am on 4/4/2012&nbsp;while performing a scheduled SPS check, the following noncompliance’s were noted:&nbsp;A window pane on the outside wall by the drive alley and square pen was broken, 3 lights above the square pen and the suspect pen were not working and 3 lights in the large holding pen were not working. In both the large and small kill floors there is cracking cement in several different areas of these floors. In the&nbsp;small kill, by the exit/entry door and by the pluck table, in the large kill, in the blood pit,&nbsp;were loose pieces of cement were noticed, and by the cattle restrainer. The establishment’s HACCP plan states that [redacted]. It goes on to state that [redacted]. After reviewing the establisments records these areas of concern were not documented. These issues are noncompliant with 9CFR 416.2(b)(1),416.2(b)(2) and 416.(2)(c).[newline]Mr. and Mr. were notified of these noncompliance’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.

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(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.

Code: 01B02
Violation: 416.13(a), 416.13(c), 416.14

Citation: At approximately 8:00 am while performing Pre. Op inspection in the small kill floor I noticed a large water leak coming from the ceiling above the area by the handwash sink, the water was falling on an I-beam above a transfer rail. This issue had not been addressed prior to my inspection. The room was&nbsp; retained &nbsp;with U.S. Rejected tag # B 19 113955.&nbsp;This is in violation of&nbsp; regulations 9CFR 416.13 and 416.14. After establishment took corrective action by hanging plastic to divert the water off the rail the area was reinspected and&nbsp;released, the&nbsp;retain tag was removed and the establishment was allowed access to the room for production. was notified of this non 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.

416.14 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: 01D01
Violation: 416.1, 416.2(b)(1), 416.4(b)

Citation: At approximately 2:30pm while performing a routine SPS verification on the large slaughter floor it was noted that the transfer rail, which is primarily used to store and hold the gamberel hooks for the hanging of cattel, near the cattle restrainer, was rusty to the extent that when wiped with a bare hand&nbsp;it would be covered with rust. This is noncompliant with 9cfr 416.1,416.2(b)(1) and 416.4(b). was notified of this noncompliance.

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)(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(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: 04B05
Violation: 312.2, 316.5

Citation: .On 6/19/2012 While performing a general labeling task with SPHV it was noticed in the small animal holding cooler there were&nbsp;4 lamb carcasses that had illegible brands on them. Each&nbsp;carcass was marked with 4 brands, all four brands had been smeared or were running due to what appeared to be too&nbsp;much ink and the carcass being too wet. This is noncompliant with Regulations 312.2&nbsp; which states: 312.2(b)(1) The official inspection legend to be shown on all labels for inspected and passed products of cattle, sheep, swine, and goats shall be in the following form except that it need not be of the size illustrated, provided that it is a sufficient size and of such color as to be conspicuously displayed and readily legible and the same proportions of letter size and boldness are maintained as illustrated, and 316.5 which states: 316.5(f) Ink used must assure legibility and permanence of the markings and the color of ink shall provide acceptable contrast with the color of the product which it is applied. Establisment employee’s and were notified of the noncompliance at the time it was noticed and the carcasses were rebranded and were found to be acceptable. HACCP Supervisor was notified of the noncompliance at the start of business 6/20/12.

Regulation:

312.2 The official inspection legend required by part 317 of this subchapter to be shown on all labels for inspected and passed products of cattle, sheep, swine, and goats shall be in the following form1 except that it need not be of the size illustrated, provided that it is a sufficient size and of such color as to be conspicuously displayed and readily legible and the same proportions of letter size and boldness are maintained as illustrated:

316.5 Ink used must assure legibility and permanence of the markings and the color of ink shall provide acceptable contrast with the color of the product to which it is applied.

Code: 01D01
Violation: 416.2(b)(2)

Citation: At aproximatly 2:15 on 6/20/12 I was told by establishment employee that the cob webs in the animal pens had been taken down. I went to reinspect and they had not been removed. They were in every pen, walk ways and overheads. this is noncompliant with regulation 416.2(b)(2) , cleaned as necessary to prevent the creation of insanitary conditions. and were notified of this non compliance.

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: 05A02
Violation: 310.25(a)

Citation: Tuesday, January 25, 2011 while reviewing the establishment’s Prerequisite Program for E. coli 0157:H7, I observed the following non-compliance. I discovered that the establishment didn’t update their Prerequisite Program for E. coli 0157:H7 to reflect the guideline of the Robust Testing Method. When informed of the non-compliance Mr. Simon (plant owner) replied he was using the Robust Testing Method which is recommended by the FSIS for swabbing beef carcasses, but forgot to document it. Plant management need to comply with the FSIS regulation 9 cfr 310.25(a).

Regulation:

310.25(a) Criteria for verifying process control; E. coli testing. (1) Each official establishment that slaughters livestock must test for Escherichia coli Biotype 1 (E.coli) Establishments that slaughter more than one type of livestock or both livestock and poultry, shall test the type of livestock or poultry slaughtered in the greatest number. The establishment shall:

Code: 03J02
Violation: 417.2(a)(2)

Citation: During the Comprehensive Food Safety Assessment conducted at this Establishment by EIAO [redacted], the following Hazard Analysis Critical Control Point (HACCP) Noncompliance was observed. While reviewing the Process Control Steps (PCS), the following steps– [redacted] are not listed in the Beef Flow Chart Diagram. These steps are listed in the Beef Slaughter HACCP Plan and also the Hazard Analysis. The flow chart does not correlate with the Beef Slaughter HACCP Plan and Hazard Analysis. The requirements of 417.2(a)(2) of the Meat & Poultry Regulations have not been met. There have not been any Noncompliances of the same root cause observed in the previous 90 days. Mr. has been notified verbally and in writing with this Noncompliance Record.

Regulation:

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

Code: 01C01
Violation: 416.12(d)

Citation: During the Comprehensive Food Safety Assessment conducted at this Establishment by EIAO [redacted], the following Sanitation Standard Operating Procedure (SSOP) Monitoring Noncompliance was observed. The Establishment’s written SSOP plan states as a Monitoring Frequency: “[redacted]. The frequency of “[redacted] is not a specific frequency. The Establishment needs to select a specific frequency as stated by 9 CFR 416.12(d). The requirements of 416.12(d) of the Meat & Poultry Regulations have not been met. There have not been any Noncompliances of the same root cause observed in the previous 90 days. Mr. has been notified verbally and in writing with this Noncompliance Record.

Regulation: 

416.12(d) The Sanitation SOP’s shall specify the frequency with which each procedure in the Sanitation SOP’s is to be conducted and identify the establishment employee(s) responsible for the implementation and maintenance of such procedure(s).

Code: 03J02
Violation: 417.5(b), 417.5(c)

Citation: At approximately 0950 hrs I observed the following non-compliances. While performing my regular inspection on goats that had been slaughtered I noticed that the belly fat from the lambs we had just finished slaughtering was gone. I asked the slaughter employees and they informed me that , a Halal slaughterer, had taken the lamb belly fat with him when he left. I looked at the Pre-shipment review records and there was no record of the lambs (lamb fat) being reviewed for shipment. While looking through the pre-shipment review records I also found that on 6/15/2010 the pre-shipment review for whole pigs was signed and it stated that all CCPs had been met, but there was no record of the temperature being recorded. The temperature of the product is the CCP that needed to be recorded and met for this record to be complete. Federal Regulation 9 CFR 417.5(b) states, “Each entry on a record maintained under the HACCP plan shall be made at the time the specific event occurs and include the date and time recorded, and shall be signed or initialed by the establishment employee making the entry.” Federal Regulation 9 CFR 417.5(c) states, “Prior to shipping product, the establishment shall review the records associated with the production of that product, documented in accordance with this section, to ensure completeness, including the determination that all critical limits were met and, if appropriate, corrective actions were taken, including the proper disposition of product. Where practicable, this review shall be conducted, dated, and signed by an individual who did not produce the record(s), preferably by someone trained in accordance with õ 417.7 of this part, or the responsible establishment official. This document serves as notice of non-compliance within Federal Regulation 9 CFR 417.5(b) and 417.5(c).

Regulation:

417.5(b) Each entry on a record maintained under the HACCP plan shall be made at the time the specific event occurs and include the date and time recorded, and shall be signed or initialed by the establishment employee making the entry.

417.5(c) Prior to shipping product, the establishment shall review the records associated with the production of that product, documented in accordance with this section, to ensure completeness, including the determination that all critical limits were met and, if appropriate, corrective actions were taken, including the proper disposition of product. Where practicable, this review shall be conducted, dated, and signed by an individual who did not produce the record(s), preferably by someone trained in accordance with §417.7 of this part, or the responsible establishment official.

Code: 01B01
Violation: 416.16(a)

Citation: At approximately 1120 hrs I observed the following non-compliance. In the Pre-operation inspection log there is no record for 7/12/10. I myself saw the pre-operation inspection completed but did not observe a record being completed for the date. Federal Regulation 9 CFR 416.16(a) states, “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.” This document serves as notice of non-compliance within Federal Regulation 9 CFR 416.16(a).

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: 03C02
Violation: 310.22(e)(4)(i), 417.5(b)

Citation: At approximately 1330 while looking through plant records I found the following non-compliance. There are two beef over 30 months that do not have a record for the vertebral column being removed. I looked through all of the carcasses in the cooler and neither one of the carcasses are in the cooler. The carcasses that have a missing record are: 320 which was slaughtered on 7/1/10 and 724 which was slaughtered on 6/30/10. The beef for [reacted] has had a pre-shipment review record that is signed and dated for 7/2/10. After discussing the missing information with [redacted] she informed me that the vertebral columns were removed and that there is just no record of the task being performed. I also believe this to be the case because they usually bone out the plants bulls and they ship the Halal carcasses semi-whole and I know they use the marks on the carcass for determining over 30 months as well. Federal Regulation 9 CFR 310.22(e)(4)(i) states, “Establishments that slaughter cattle and establishments that process the carcasses or parts of cattle must maintain daily records sufficient to document the implementation and monitoring of the procedures for the removal, segregation, and disposition of the materials listed in paragraph (a) of this section, and any corrective actions taken.” Federal Regulation 9 CFR 417.5(b) states, “Each entry on a record maintained under the HACCP plan shall be made at the time the specific event occurs and include the date and time recorded, and shall be signed or initialed by the establishment employee making the entry.” This document serves as notice of non-compliance within Federal Regulation 9 CFR 310.22(e)(4)(i) and 417.5(b).

Regulation:

310.22(e)(4)(i) [Reserved]

 417.5(b) Each entry on a record maintained under the HACCP plan shall be made at the time the specific event occurs and include the date and time recorded, and shall be signed or initialed by the establishment employee making the entry.

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

Citation: At approximately 0705 hrs while performing pre-operational inspection I observed the following non-compliances. In the processing room I found a « inch by ó inch smear of what appeared to be ground beef on the side of the patty machine by the gears. I also found small particles of what appeared to be ground beef on the bottom side of the hopper for the patty machine. On the underside of the main table in the processing room I found fatty buildup on the rails of the table. U.S. Reject tag B39879085 was placed on both the patty machine and the table. After showing these areas he proceeded to have them cleaned immediately. The tag was then removed and they proceeded to begin processing. In the slaughter room I found fatty buildup on two hand saws. I also found the wall behind the carcass wash stand and the wall behind the scale controls to be unclean with fat and other debris on the wall. U.S. Reject tag B39879086 was placed on the saws and the walls. , a slaughter floor employee, proceeded to have both areas cleaned. The tag was removed and they proceeded with slaughter. This document serves as notice of non-compliance within Federal Regulation 9 CFR 416.13(c), 416.4(a) and 416.4(b).

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(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: 03C02
Violation: 417.5(c)

Citation: At approximately 0935 hrs while reviewing the pre-shipment review records I observed the following non-compliances. Eight swine were shipped this morning at approximately 0700 hrs for the customer. There is no record of the pre-shipment review record being completed and there is no temperature recorded for the swine. At 0940 hrs I proceeded to take a temperature of the swine of similar size and weight that were slaughtered on the same day and the temperature was 45 degrees Fahrenheit. This document serves as notice of non-compliance within Federal Regulation 9 CFR 417.5(c). 417.5(c) “Prior to shipping product, the establishment shall review the records associated with the production of that product, documented in accordance with this section, to ensure completeness, including the determination that all critical limits were met and, if appropriate, corrective actions were taken, including the proper disposition of product. Where practicable, this review shall be conducted, dated, and signed by an individual who did not produce the record(s), preferably by someone trained in accordance with õ 417.7 of this part, or the responsible establishment official.” Past Similar NRs – Previous Ineffective Plant Actions: Completeing the pre-shipment review. NR: 11-2010 dated 7/16/2010

Regulation:

417.5(c) Prior to shipping product, the establishment shall review the records associated with the production of that product, documented in accordance with this section, to ensure completeness, including the determination that all critical limits were met and, if appropriate, corrective actions were taken, including the proper disposition of product. Where practicable, this review shall be conducted, dated, and signed by an individual who did not produce the record(s), preferably by someone trained in accordance with §417.7 of this part, or the responsible establishment official.

Code: 03C02
Violation: 417.2(c)(5)

Citation: At approximately 1145 hrs I observed the following non-compliance. I manually took the temperature for raw not ground pork that was being packaged. I observed the temperature of the pork to be 48 degrees Fahrenheit. The plants HACCP plan states that [redacted]. The plant has failed to keep the product at an adequate temperature to prevent the growth of pathogens. After informing them of the increase in temperature I asked what they were going to do and they said they were going to finish packaging it. I told them that they cannot do that and that the temperature needs to be brought back into compliance. They then took the proper corrective action of re-chilling the product to an acceptable temperature. This document serves as notice of non-compliance within Federal Regulation 9 CFR 417.2(c)(5). 417.2(c)(5) Include all corrective actions that have been developed in accordance with õ 417.3(a) of this part, to be followed in response to any deviation from a critical limit at a critical control point;

Regulation:

417.2(c)(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;

Code: 03B02
Violation: 417.2(c)(5)

Citation: At approximately 1545 hrs I observed the following non-compliance. I manually took the temperature for ground beef that was being packaged. I observed the temperature of the ground beef to be 49 degrees Fahrenheit. The plants HACCP plan states that [redacted]. I discussed this with a plant employee () and he told me that he was informed to package the product even though they new it was over the critical limit of degrees Fahrenheit by [redacted]. I informed – that he needed to take the proper corrective action, and that I would discuss the issue with plant management. took the proper corrective action of re-chilling the product to an acceptable level. The plant has failed to keep the product at an adequate temperature to prevent the growth of pathogens and failed to implement a corrective action. This document serves as notice of non-compliance within Federal Regulation 9 CFR 417.2(c)(5). 417.2(c)(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;

Regulation:

417.2(c)(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;

Code: 03J01
Violation: 417.5(b)

Citation: At approximately 1250 hrs while reviewing plant records I found the following non-compliance. For the week of September 10th there is no record of a record review in the slaughter log being completed. After informing  of the non-compliance she informed me that she remembers doing the verification but must have forgotten to record that she had done it. The plants HACCP plan states, “[redacted]” According to Federal Regulation 9 CFR 417.5(b) states “Each entry on a record maintained under the HACCP plan shall be made at the time the specific event occurs and include the date and time recorded, and shall be signed or initialed by the establishment employee making the entry.” This document serves as notice of non-compliance within Federal Regulation 9 CFR 417.5(b).

Regulation:

417.5(b) Each entry on a record maintained under the HACCP plan shall be made at the time the specific event occurs and include the date and time recorded, and shall be signed or initialed by the establishment employee making the entry.

Code: 03C02
Violation: 417.2(c)(4)

Citation: At approximately 1315 hrs I observed the following non-compliance. I manually took the temperature of pork ribs that were about to be packaged. I observed the temperature was 50 degrees Fahrenheit. The plants HACCP plan states that [redacted]. I informed a plant employee () that the product was outside of the plants critical limits and he immediately put the product into the cooler to bring the temperature back into compliance. took the proper corrective action of re-chilling the product to an acceptable level. The Plant has failed to keep the product at an adequate temperature to prevent the growth of pathogens and to stay within compliance of the critical limits during the packaging step of their process. This document serves as notice of non-compliance within Federal Regulation 9 CFR 417.2(c)(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;

Code: 06B01
Violation: 303.1(a)(2)(iii)

Citation: At approximately 0800 hrs I observed the following non compliance. In the processing room cooler there are 2 carts with uninspected product in them that are not marked uninspected. 9 CFR 303.1(a)(2)(iii) states that, “The custom prepared products are plainly marked ”Not for Sale” as provided in õ 316.16 of this subchapter, immediately after being prepared and are kept so identified until delivered to the owner.” U.S. Retain tag numbers B39879081 and B39879082 were placed on the product to mark it as uninspected until the plant could mark the product accordingly. After informing of the non-compliance he proceeded to mark the carts “Uninspected/Not For Sale.” This document serves as notice of non-compliance within Federal Regulations 9 CFR 303.1(a)(2)(iii).

Regulation:

303.1(a)(2) The custom slaughter by any person of cattle, sheep, swine, or goats delivered by the owner thereof for such slaughter, and the preparation by such slaughterer and transportation in commerce of the carcasses, parts thereof, meat and meat food products of such livestock, exclusively for use, in the household of such owner, by him and members of his household and his nonpaying guests and employees; nor to the custom preparation by any person of carcasses, parts thereof, meat or meat food products derived from the slaughter by any individual of cattle, sheep, swine, or goats of his own raising or from game animals, delivered by the owner thereof for such custom preparation, and transportation in commerce of such custom prepared articles, exclusively for use in the household of such owner, by him and members of his household and his nonpaying guests and employees: Provided, That the following requirements are met by such custom operator; (iii) The custom prepared products are plainly marked ‘‘Not for Sale’’ as provided in §316.16 of this subchapter, immediately after being prepared and are kept so identified until delivered to the owner;

Code: 06D01
Violation: 416.2(a)

Citation: At approximately 1040 hrs I observed the following non-compliance. There are several boards up against the back of the plant that obstructs the ability to verify that plant is free of an area to harborage pests and rodents. According to 9 CFR 416.2(a) for 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.” This document serves as notice of non-compliance within Federal Regulation 9 CFR 416.2(a).

Regulation:

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.

Code: 04C02
Violation: 313.2

Citation: HATS CATEGORY III At approximately 0710 while going out to the pens I observed the following non-compliance. There were 6 bovine in the alleyway of the pens without water. The alley way was being used as a holding pen since all other pens were full. The bovine arrived at the plant either early this morning, before 0700 hrs, or late last night, after 1800 hrs. The plant manager, , could not tell me with certainty when they had arrived. After informing a plant employee, , he immediately gave the animals water. Federal Regulation 9 CFR 313.2(e) states, “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.” This document serves as notice of non-compliance within Federal Regulation 9 CFR 313.2(e).

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: 06D01
Violation: 416.2(d)

Citation: At approximately 1050 hrs I observed the following non-compliance. While in the slaughter floor I observed condensation falling from the ceiling. I placed U.S. Reject Tag NO. B39879072 in the area to stop production until the area could be brought back into compliance. I informed of the non-compliance and he proceeded to have the slaughter floor employees wipe down and remove the condensation. After this was done, the U.S. Reject tag was removed and slaughter resumed. Federal Regulation 9 CFR 416.2(d) states that there needs to be, “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.” This document serves as notice of non-compliance within Federal Regulation 9 CFR 416.2(d).

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.

Code: 06D01
Violation: 416.2(d)

Citation: At approximately 1500 hrs while performing routine inspection I observed the following non-compliance. In the slaughter floor I observed condensation falling from the ceiling. I placed U.S. Reject tag NO. B39879074 in the area to stop slaughter until the area could be brought back into compliance. I informed of the non-compliance and she proceeded to have a slaughter floor employee wipe down and remove the condensation. After the condensation was removed/ wiped down, the U.S. Reject tag was removed and slaughter resumed Federal Regulation 9 CFR 416.2(d) states that there needs to be, “ventilation adequate to control odors, vapors, and condensation to the extent necessary to prevent adulteration of product and creation of insanitary conditions must be provided.” This document serves as notice of non-compliance within Federal Regulation 9 CFR 416.2(d). Past Similar NRs – Previous Ineffective Plant Actions: No plan/ actions/ monitoring performed to prevent condensation from accruing . NR: 21-2010 dated 11/3/2010

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.

Code: 06D01
Violation: 416.2(d)

Citation: At approximately 1130 hrs Mr. observed the following non-compliance. In the slaughter floor cooler near the southwest corner were the government retain cage is located Mr. observed condensation on the ceiling in the corner. He informed me (Inspector) and (plant foreman) who then proceeded to have the area wiped down to prevent possible carcass contamination. The condensation was not observed falling onto any carcasses by Mr. . No product was retained. This document serves as notice of non-compliance within Federal Regulation 9 CFR 416.2(d). Past Similar NRs – Previous Ineffective Plant Actions: No plan/actions/monitoring performed to prevent condensation from reoccurring. NR: 22-2010 dated 11/8/2010

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.

Code: 03J02
Violation: 417.5(b)

Citation: At approximately 1240 hrs while reviewing slaughter records I observed the following non-compliance. This morning at approximately 0800 hrs I observed , a plant employee, make a mixture used for the antimicrobial intervention step after the washing of bovine, ovine, and caprine carcasses as well as the SOP step for spraying along the midline on bovine before eviceration and splitting of the briskit. At 1240 hrs I went to check the antimicrobial intervention log and found no record of the wash being mixed. According to 9 CFR 417.5(b), “each entry on a record maintained under the HACCP plan shall be made at the time the specific event occurs and include the date and time recorded, and shall be signed or initialed by the establishment employee making the entry.” After I informed of the non-compliance she proceeded to have the entry completed as the corective actions procedure form states that it will be done. This document serves as notice of non-compliance within Federal Regulation 9 CFR 417.5(b).

Regulation:

417.5(b) Each entry on a record maintained under the HACCP plan shall be made at the time the specific event occurs and include the date and time recorded, and shall be signed or initialed by the establishment employee making the entry.

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

Citation: At approximately 0700 hrs while performing pre-operational inspection I observed the following non-compliances. On the band saw in the middle of the processing room I saw several pieces of meat particles on the saw blade (contact surface) and in the groove of where the saw blade comes up thru the table top of the saw (contact surface). On the southern wall of the processing room I saw several meat particles on the upper auger of the grinder (contact) and on the clamp (non-contact) that holds the bottom auger housing in place. USDA Reject tag NO. B39879078 was placed on the band saw and USDA Reject tag NO. B39879079 was placed on the Grinder. After informing of the rejected equipment he proceeded to have both areas re-cleaned. After the re-cleaning, USDA Reject tag NO. B39879078 and USDA Reject tag NO. B39879079 were removed and use of the processing equipment was allowed. In the slaughter floor there were several meat particles found on the outside of the head wash cabinet (non-contact) located next to the hand wash sink on the middle wall. I also observed rust build up on the brisket saw blade (contact) which was located next to the hand wash sink and head wash cabinet on the middle wall. USDA Reject tag NO. B39879080 was applied to both pieces of equipment. then proceeded to re-clean both pieces of equipment. After the re-cleaning, USDA Reject tag NO. B39879080 was removed and slaughter was allowed to commence. This document serves as notice of non-compliance within Federal Regulation 9 CFR 416.4(a) and 416.4(b).

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(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), 416.4(b)

Citation: At approximately 0715 hrs while performing pre-operational inspection I observed the following non-compliance. In the center of the processing room on the tables with nylon cutting board tops I found several pieces of meat/fat particles on the bottom of the nylon cutting boards as well as on the tops rails holding the table top up (non-contact). I also found small meat/fat particles in approximately 4 grey totes (contact) used to hold product during production. U.S. Reject tag NO. B39879075 was applied to the tables and the grey totes adjacent to the table. After informing of the non-compliance he proceeded to have the table and totes re-cleaned. After re-inspection of the totes and table, the U.S. Reject tag was removed and the tubs and table were released for use. This document serves as notice of non-compliance within Federal Regulation 9 CFR 416.4(a) and 416.4(b). Past Similar NRs – Previous Ineffective Plant Actions: Ineffective cleaning and ineffective plant pre-operational inspection to ensure sanitary conditions. NR: 24-2010 dated 11/16/2010

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(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: 03J02
Violation: 417.5(b), 417.5(c)

Citation: At approximately 1215 hrs I observed the following non-compliance. The pre-shipment review was not completed for parts of 2 beef carcasses that were slaughtered on November 19, 2010 and shipped for , a Halal slaughterer, on November 20, 2010. After informing of the non-compliance she immediately had the records reviewed and the pre-shipment review record for the beef carcass completed for what was taken from the beef carcasses. This document is notification of non-compliance within Federal Regulation 9 CFR 417.5(b) and 417.5(c).

Regulation:

417.5(b) Each entry on a record maintained under the HACCP plan shall be made at the time the specific event occurs and include the date and time recorded, and shall be signed or initialed by the establishment employee making the entry.

417.5(c) Prior to shipping product, the establishment shall review the records associated with the production of that product, documented in accordance with this section, to ensure completeness, including the determination that all critical limits were met and, if appropriate, corrective actions were taken, including the proper disposition of product. Where practicable, this review shall be conducted, dated, and signed by an individual who did not produce the record(s), preferably by someone trained in accordance with §417.7 of this part, or the responsible establishment official.

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

Citation: At approximately 0945 I observed the following non-compliance. In the processing Freezer there is ice build up on the ceiling of the freezer and there is ice build up on several boxes in the freezer. There is frozen exposed product that is on a rack. U.S. Reject tag NO. B39879076 was applied to the rack until the adulterated product is reconditioned or disposed of. There is box and pallet debris on the floor as well as pieces of fat scattered on the floor. The area in the back of the freezer is also filled with boxes and it is very difficult to fully inspect the area. This document serves as notice of Non-compliance within Federal Regulation 9 CFR 416.4(b) and 416.4(d).

Regulation:

416.4(b) Each entry on a record maintained under the HACCP plan shall be made at the time the specific event occurs and include the date and time recorded, and shall be signed or initialed by the establishment employee making the entry.

416.4(d) Records maintained on computers. The use of records maintained on computers is acceptable, provided that appropriate controls are implemented to ensure the integrity of the electronic data and signatures.

Code: 04C02
Violation: 313.2

Citation: HAT Category III At approximately 1640 while performing odd hour inspection for the month of November I observed the following non-compliance. There were 4 lambs in the upper pens that had no water available in the pen. There was a bucket for water in the pens but it was completely empty. In the lower pens on the far north side there was approximately 10 lambs/goats in a pen that did not have any water available. After informing of the non-compliance he had a slaughter floor employee immediately give water to the animals. This document serves as notice of non-compliance within Federal Regulation 9 CFR 313.2(e). Past Similar NRs – Previous Ineffective Plant Actions: Failure to ensure that animals in the pen area have access to water. NR: 20-2010 dated 10/19/2010

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: 03J02
Violation: 417.4(a)(2)(iii), 417.5(b)

Citation: At approximately 1300 hrs while reviewing slaughter records I found the following non-compliance. For the week ending 12/4/10 there is no record review recorded in the slaughter monitoring log. The plant’s HACCP plan under verification procedures for CCP1 (final trim) states that, “[redacted] .” After informing of the non-compliance she informed me that she did review the records and that she forgot to record it in the slaughter monitoring log. She then proceeded to re-review the slaughter records and sign, date, and record the time for completing the record review. This document serves as notice of non-compliance within Federal Regulation 9 CFR 417.4(a)(2)(iii) and 417.5(b).

Regulation:

417.4(a)(2)(iii) The review of records generated and maintained in accordance with §417.5(a)(3) of this part.

417.5(b) Each entry on a record maintained under the HACCP plan shall be made at the time the specific event occurs and include the date and time recorded, and shall be signed or initialed by the establishment employee making the entry.

Code: 01C01
Violation: 416.12(a), 416.13(b)

Citation: While the EIAO performed an FSA (Food Safety Assessment) at Est. 4253 the following noncompliance was found. The plant mentions training and does not document that sanitation training has been performed. Therefore, the plant may not be able to demonstrate maintaining the facilities in a sanitary condition or demonstrate adequate knowledge in handling product in a sanitary manner, which may lead to product contamination. These issues are noncompliant with 9 CFR 416.12(a) and 9 CFR 416.13(b).

Regulation:

416.12(a) The Sanitation SOP’s shall describe all procedures an official establishment will conduct daily, before and during operations, sufficient to prevent direct contamination or adulteration of product(s).

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

Code: 06D01
Violation: 416.2(b)(2), 416.2(b)(3), 416.4(b)

Citation: While the EIAO performed an FSA (Food Safety Assessment) at Est. 4253, the following noncompliances were found. Small gaps were observed around the top of the outside door in the slaughter floor area. The gap is approximately one inch wide and three inches long; the gap is located around the top edges. Upon examining the inedible area and the rooms in the rest of the facility, no rodent droppings or other evidence of rodents or pest in the facility were observed. However, this is noncompliant with 9 CFR 416.2(b)(3). Flaking and peeling paint was observed on the ceiling and pipes directly above the mixer/grinder equipment, which is located in the raw meat processing area. This is noncompliant with 9 CFR 416.2(b)(2) and 416.4(b).

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(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: 03J01
Violation: 417.2(a)(1)

Citation: While the EIAO performed an FSA (Food Safety Assessment) at Est. 4253 the following noncompliance was found. The beef, calves, lamb/sheep and goat HACCP slaughter plan flow diagram identifies step. This is not listed or identified in the HACCP plan or hazard analysis; however, the . The flow chart of the beef, calves, lamb/sheep and goat HACCP slaughter plan steps in the flow chart/diagram and hazard analysis do not correlate with each other. Because of concerns about both microbial contamination and SRMs, splitting should be identified as a vulnerable step in the hazard analysis. This is noncompliant with 9 CFR 417.2(a)(1).

Regulation:

417.2(a)(1) Hazard analysis. Every official establishment shall conduct, or have conducted for it, a hazard analysis to determine the food safety hazards reasonably likely to occur in the production process and identify the preventive measures the establishment can apply to control those hazards. The hazard analysis shall include food safety hazards that can occur before, during, and after entry into the establishment. A food safety hazard that is reasonably likely to occur is one for which a prudent establishment would establish controls because it historically has occurred, or because there is a reasonable possibility that it will occur in the particular type of product being processed, in the absence of those controls.

Code: 03C01
Violation: 417.2(c), 417.3(a)(4)

Citation: While the EIAO performed an FSA (Food Safety Assessment) at Est. 4253 the following noncompliances were found. The review of the Raw Not Ground HACCP plan shows that the plan does not list the direct observation of corrective actions as a verification activity, a violation of 9 CFR 417.2(c)(7). The Verification Procedures Form states, “[redacted] .” Also, the Raw Not Ground HACCP plan does not list that no product injurious to health or otherwise adulterated as a result of the deviation enters commerce. This is noncompliant with 9 CFR 417.3(a)(4). The same noncompliances aforementioned are observed in the Raw Ground HACCP Plan.

Regulation:

417.2(c)(7) The contents of the HACCP plan. The HACCP plan shall, at a minimum: 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.

417.3(a)(4) The written HACCP plan shall identify the corrective action to be followed in response to a deviation from a critical limit. The HACCP plan shall describe the corrective action to be taken, and assign responsibility for taking corrective action, to ensure: No product that is injurious to health or otherwise adulterated as a result of the deviation enters commerce.

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

Citation: At approximately 0710 hrs I observed the following non-compliances. In the slaughter floor there was hair swine on the de-hairer from previous days use (non-contact). There was also what appeared to be built up fat on the bottom part of the rails on several carts used to move the small grey totes from place to place (non-contact). After informing of the insanitary conditions he proceeded to re-clean both the de-hairer and all of the carts. In the Processing room I found meat/fat pieces on the underside of the removable steel top cutting surface for the band saw (non-contact). On the patty machine’s plastic pieces I found several pieces of small fat on the outside in the crevices of the plastic piece (non-contact). After informing of the insanitary conditions he proceeded to re-clean both the bottom of the steel top cutting surface and the crevices of the plastic pieces of the patty machine. This document serves as notice of non-compliance within Federal Regulations 9 CFR 416.13(c) and 416.4(b).

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.

Code: 04C02
Violation: 313.16

Citation: At approximately 1100 hrs I observed the following non-compliance. While stunning a bull for slaughter, the plant took multiple attempts to render the bull insensible to pain. After the plant took the immediate corrective action of rendering the animal unconscious, I proceeded to tag the knocking pen using U.S. Reject tag NO. B39878916. After informing of the non-compliance he informed me that the slaughter floor employees were using the wrong bullets. I looked at both sets of bullets to confirm this and found that there is a different grain count in the bullets that were used and which ones should have been used. I was informed that the bullets (29 grain) they were using are typically used for small bovine, such as a calf. They have 40 grain bullets for the larger bovine. After verifying this, the knocking pen was released and slaughter was allowed to continue. It is very infrequent for the plant to require multiple attempts to render an animal unconscious. According to Federal Regulation 9 CFR 313.16(a)(1), “Utilization of firearms, required effect; handling. (1) The firearms shall be employed in the delivery of a bullet or projectile into the animal in accordance with this section so as to produce immediate unconsciousness in the animal by a single shot before it is shackled, hoisted, thrown, cast, or cut. The animal shall be shot in such a manner that they will be rendered unconscious with a minimum of excitement and discomfort.” This document serves as notice of non-compliance within Federal Regulation 9 CFR 313.16(a)(1).

Regulation:

313.16 (a)(1) Utilization of firearms, required effect; handling. The firearms shall be employed in the delivery of a bullet or projectile into the animal in accordance with this section so as to produce immediate unconsciousness in the animal by a single shot before it is shackled, hoisted, thrown, cast, or cut. The animal shall be shot in such a manner that they will be rendered unconscious with a minimum of excitement and discomfort.

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

Citation: At approximately 0810 hrs I observed the following non-compliance. I observed eating in the break room with his red apron on. He then proceeded go out and begin processing swine without removing the apron that he was just eating in, and replacing it with a clean apron. After I informed that he was returning to work with a possibly contaminated apron, he proceeded to change his apron into a clean apron. The Plants General Manufacturing Practices state that, “[redacted].” I have explained to in a previous encounter of the same time that the reasoning for not eating in an apron that is used to prepare food can be insanitary due to crumbs and such that could possibly fall out of the mouth and onto the apron unnoticed. I also explained the some foods have allergens in them and that they too could possibly contaminate the apron and food that is touched by the apron after contamination and then in turn be injurious to a person with that allergy. This document serves as notice of non-compliance within Federal Regulation 9 CFR 416.4(d) and 416.5(b).

Regulation:

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

 416.5(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.

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

Citation: At approximately 0710 hrs I observed the following non-compliance during pre-operational inspection. In the slaughter floor I found several pieces of fat that ranged in size from miniscule to ¦ inch on the back saw drop down cable and hook holding the back saw off of the ground (non-contact). On the saw like tool used to stride bovine backbones there was a couple pieces of fat stuck onto the saw part of the tool (contact). In the Processing room I found several pieces of what appeared to be fat/meat particles on the top part of the band saw on a rail where the top cutting surface sits on the saw as well as caked on fat in the wheel of the band saw in the corners of the outer part of the supports for the wheel (non-contact). On the large mixing auger for the grinder I found several pieces of fat ranging in size from miniscule to 1/8 inch (contact). After informing the employees of the non-compliance they proceeded to re-clean the equipment and bring the areas back in compliance. This document serves as notice of non-compliance within Federal Regulation 9 CFR 416.13(c), 416.4(a), and 416.4(b). Past Similar NRs – Previous Ineffective Plant Actions: Failure to effectively train employees to clean the facility. NR: 1-2011 dated 1/11/2011

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(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: 307.4(a), 316.3

Citation: At approximately 1350 hrs I observed the following non-compliance. In the processing room I found packages of 5 lb. bulk ground Italian sausage that was processed and labeled on Saturday February 12, 2011, without inspection. All 6 of the Packages had the marks of inspection on the packages. U.S. Retain tag NO. B39878907 was applied to the product. After talking with plant employees, they informed me that it was done for the retail store. I proceeded to look in the freezer for more sausage that was completed on that date. I then came across a box of more Italian sausage in the freezer that was packaged on February 5, 2011 with the marks of inspection. Again these 7, 5 lb. bulk packages were produced on a Saturday without inspection. U.S. Retain tag NO. B39878908 was applied to the box with the 7 packages of 5 lb. bulk Italian sausage. I informed the plant employees that these packages cannot have the marks of inspection applied to them because they were produced outside of approved inspection hours and they did not have an inspector on duty nor did they have the authorization to process with inspection outside of inspection hours and that this was noncompliant with in Federal Regulations. After I informed the plant employees of the non-compliance they proceeded to remove the marks of inspection from all of the retail packages that were retained. After I re-inspected the packages to ensure that the marks of inspection were removed I removed both of the U.S. Retain tags and custody of the bulk Italian sausage was released back to the establishment. This document serves as notice of non-compliance with in Federal Regulation 9 CFR 307.4(a) and 316.3.

Regulation:

307.4(a) No operations requiring inspection shall be conducted except under the supervision of a Program employee. All slaughtering of animals and preparation of products shall be done with reasonable speed, considering the official establishment’s facilities.

316.3(a) No person shall affix or place, or cause to be affixed or placed, the official inspection legend or any other official mark, or any abbreviation or simulation of any official mark, to or on any product, or container thereof, except under the supervision of a Program employee, or as authorized by part 317 of this subchapter in connection with the manufacture of containers.

Code: 03B02
Violation: 417.2(c)(4), 417.2(c)(5)

Citation: At approximately 1345 I observed the following non-compliance. While performing a temperature verification check on raw ground product I observed the temperature of the ground beef to be at 50 degrees Fahrenheit in a grey tote of product that was almost completely packaged. I informed of the non-compliance for the failure to keep product under the critical limit of degrees Fahrenheit. I then began to check the rest of the lot to ensure that the critical limit had not been reached or passed and all of grey totes that I checked were at 50 degrees Fahrenheit. I then took a regulatory control action and tagged the 3 carts with the 11 grey totes of ground product using U.S. Retain tags NO. B39878909, NO. B39878910 and NO. B39878911. I told that their corrective actions per the establishments HACCP plan was to “[redacted].” He then proceeded to grind the rest of the ground product out of the grinder and placed all 3 carts with the 11 grey totes into the freezer. The product was moved from the freezer to the cooler because it is going to be left in the cooler overnight since it was close to the end of the shift and because the product requires inspection and there was not enough time to have the product brought down to an acceptable temperature and for it to be packaged. This document serves as notice of non-compliance with in Federal Regulations 9 CFR 417.2(c)(4) and 417.2(c)(5).

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;

417.2(c)(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;

Code: 06B01
Violation: 303.1(a)(2)(ii)

Citation: At approximately 0800 hrs I observed the following non-compliance. In the western most holding cooler off of the slaughter floor there were inspected and uninspected beef carcasses comingled and in direct contact with inspected beef carcasses. I informed , a slaughter floor employee and he immediately separated the inspected and un-inspected beef carcasses. I re-inspected the inspected carcass for possible contamination and none was found. I then informed plant manager of the non compliance. This document serves as notice of non-compliance with in Federal Regulation 9 CFR 303.1(a)(2)(ii).

Regulation:

303.1(a)(2)(ii) ) If the custom operator prepares or handles any products for sale, they are kept separate and apart from the custom prepared products at all times while the latter are in his custody;

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

Citation: While performing pre-operational inspection I found the following non-compliance. In the slaughter floor, on the large stand in the final trim area I found several pieces of fat ranging in size from miniscule to « inch by ¬ inch in size. There were also several spots on the stand that had what appeared to be fatty residue from previous day’s production. After I informed the slaughter floor employees they proceeded to re-clean the stand. This document serves as notice of non-compliance within Federal Regulations 9 CFR 416.13(c) and 416.4(b). Past Similar NRs – Previous Ineffective Plant Actions: Ineffective monitoring NR: 4-2011 dated 2/10/2011

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.

Code: 03C02
Violation: 417.2(c)(4)

Citation: At approximately 1400 hrs I observed the following non-compliance. In the processing room there were 2 grey totes with product that were left in the room since they stopped processing at approximately 1130 hrs. The room is not currently being refrigerated and after I noticed that the product was still out of the coolers and not being monitored or being processed any further I proceeded to verify that the products temperature had been kept in compliance and under the plants established critical limits. One grey tote that was halfway full of beef fat trim that is to be used in ground beef was 51 degrees Fahrenheit. The other grey tote held a single kidney from a bovine that also had a temperature of 51 degrees Fahrenheit. The temperature of the processing room was 51 degrees Fahrenheit. While the main portions of the animal were packaged beginning at 1045 hrs, the product temperature recorded by the establishment was 39 degrees Fahrenheit. I then proceeded to tag both the kidney and the grey tote of beef fat trim using U.S. Reject tags NO. B39878918 and B39878919. I informed plant employee of the non-compliance and he proceeded to place the beef fat trim in the freezer and the beef kidney into the cooler. This document serves as notice of non-compliance within Federal Regulation 9 CFR 417.2(c)(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;

Code: 01C02
Violation: 416.13(c)

Citation: At approximately 0950 hrs I observed the following non-compliance. There was a customer on the processing floor talking to without the proper attire on to be in the processing area. The customer was not wearing any form of hat or hair net to prevent the possibility of the customer’s hair contaminating the product. The customer was also not in the proper uniform to be in the processing area. According to the plant’s GMPs, ” [redacted].” After giving the plant employees a sufficient amount of time to inform the customer of their rules, I informed of the non-compliance. By this time the customer had left the processing area without any instruction from any plant employees. This document serves as notice of non-compliance within Federal Regulation 9 CFR 416.13(c).

Regulation:

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

Code: 03B02
Violation: 417.4(a)(2)(iii)

Citation: At approximately 1315 hrs I observed the following non-compliance. While reviewing the plants raw ground and raw not ground temperature/ pre-shipment review log I found that no record review was performed for the month of March. The plants HACCP plan states both the raw ground and raw not ground, .” This document serves as notice of non-compliance within Federal Regulation 9 CFR 417.4(a)(2)(iii).

Regulation:

417.4(a)(2)(iii) Ongoing verification activities. Ongoing verification activities include, but are not limited to:  The review of records generated and maintained in accordance with §417.5(a)(3) of this part.

Code: 06D01
Violation: 416.2(d)

Citation: At approximately 1315 hrs I observed the following non-compliance. In the slaughter floor while slaughtering pigs I observed condensation falling from the ceiling above the de-hairer. I took a regulatory control action and stopped the slaughter line from continuing slaughter until the slaughter floor personnel could move the pig that was on the de-hairer and then wipe the condensation off of the ceiling. After they moved the pig and wiped the area of condensation and rinsed the equipment, I inspected the area to make sure that the condensation was not taken care of and not falling anymore. After I confirmed this I allowed slaughter to resume. No product was affected because the hogs were still whole and they would still be rinsed and singed before they were finally inspected and pushed into the cooler. This document serves as notice of non-compliance within Federal regulation 9 CFR 416.2(d).

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.

Code: 03C02
Violation: 417.5(b), 417.5(c)

Citation: Today at approximately 1145 I observed the following non-compliance. While reviewing the re-shipment review records I found several entries that had been shipped this morning without a pre-shipment review being performed. The animals that were slaughtered on 4/19/2011 for Halal slaughterers, and, were the entries that were shipped whole (carcass) without a pre-shipment review. The list for animals that were shipped without a pre-shipment review are as follows:: 2 goats, 1 bovine (under 30 months) : 3 bovine (under 30 months) This document serves as notice of non-compliance within Federal Regulations 9 CFR 417.5(b) and 417.5(c).

Regulation:

417.5(b) Each entry on a record maintained under the HACCP plan shall be made at the time the specific event occurs and include the date and time recorded, and shall be signed or initialed by the establishment employee making the entry.

417.5(c) Prior to shipping product, the establishment shall review the records associated with the production of that product, documented in accordance with this section, to ensure completeness, including the determination that all critical limits were met and, if appropriate, corrective actions were taken, including the proper disposition of product. Where practicable, this review shall be conducted, dated, and signed by an individual who did not produce the record(s), preferably by someone trained in accordance with §417.7 of this part, or the responsible establishment official.

Code: 04C02
Violation: 313.2

Citation: HATs Category III At approximately 1110 hrs I observed the following non-compliance. While performing ante-mortem inspection I observed that there were 10 market swine in the alleyway that did not have any access to water. I observed this when a plant employee and I went down to do ante-mortem inspection on these animals. They arrived sometime between 0900 to 1100 hrs. Since there was not a large amount of time for the animals being held without water I allowed them to be ran up for slaughter. According to Federal Regulation 9 CFR 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.” This document serves as notice of non-compliance within Federal Regulation 9 CFR 313.2(e).

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: 01B02
Violation: 416.16(a)

Citation: At approximately 1500 hrs I observed the following non-compliance. In the pre-operation check book there is no record of a pre-operational inspection being performed for 5/13/11 for the slaughter. I myself observed the pre-operation check being performed on 5/13/11. I informed of the non-compliance for the records not being completed. This document serves as notice of non-compliance within Federal Regulation 9 CFR 416.16(a).

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: 01B02
Violation: 416.13(a)

Citation: While waiting on the plant to perform pre-operational inspection I observed the following non-compliance. Before the plants pre-operational inspection of the slaughter floor and slaughter floor equipment I observed starting to break down a bovine so that it could be taken into the processing room and further processed. The processing room was in the process of having its pre-operational inspection, and I informed that the pre-operational inspections need to be performed before they start their operations. This document serves as notice of non-compliance within Federal Regulation 9 CFR 416.13(a). Regulation 416.13(a) states that, “Each official establishment shall conduct the pre-operational procedures in the Sanitation SOP’s before the start of operations.”

Regulation:

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

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

Citation: While performing pre-operational Inspection I observed the following non-compliance. On the slaughter floor I observed several chunks of swine hair and other debris on the de-hairer (non-contact). I also observed a chunk of fat that was stuck next to the teeth of the strider (contact) and a cart that had fat build up on it (non-contact). There were also pieces of fat on the 2 hand saws (contact). I applied U.S. Reject tag B39878922 to the equipment. I informed the slaughter floor employees who immediately re-cleaned all of the items. I then re-checked the equipment and released it back to the establishment. This document serves as notice of non-compliance within Federal Regulation 9 CFR 416.13(c), 416.4(a) and 416.4(b).

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(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: 06B01
Violation: 303.1(a)(2)(ii)

Citation: At approximately 0800 hrs while inspecting the coolers I observed the following non-compliance. There is a rail in the cooler that has 2 un-inspected beef on it. There is 1 inspected beef that is in direct contact and sandwiched in-between the un-inspected beef carcasses. I informed of the non-compliance. He then had an employee go and move the inspected carcass away from the uninspected carcasses. This document serves as notice of non-compliance within Federal Regulation 9 CFR 303.1(a)(2)(ii).

Regulation:

303.1(a)(2)(ii) If the custom operator prepares or handles any products for sale, they are kept separate and apart from the custom prepared products at all times while the latter are in his custody;

Code: 04B04
Violation: 307.4(a), 316.3

Citation: At approximately 0805 hrs while inspecting the coolers, I observed the following non-compliance. I found a cart with 4 grey totes full of boneless pork. The cart was labeled inspected and that it was cut up on 7/9/11 which was a Saturday. I informed of the non-compliance he proceeded to remove the mark of inspection and labeled it retail. This document serves as notice of non-compliance within Federal Regulation 9 CFR 307.4(a) and 316.3.

Regulation:

307.4(a) No operations requiring inspection shall be conducted except under the supervision of a Program employee. All slaughtering of animals and preparation of products shall be done with reasonable speed, considering the official establishment’s facilities.

316.3 (a) No person shall affix or place, or cause to be affixed or placed, the official inspection legend or any other official mark, or any abbreviation or simulation of any official mark, to or on any product, or container thereof, except under the supervision of a Program employee, or as authorized by part 317 of this subchapter in connection with the manufacture of containers.

Code: 01B01
Violation: 416.16(a)

Citation: At approximately 1225 hrs I observed the following non-compliance while reviewing the establishment’s pre-operational inspection records. For Monday July 11, 2011 there is no record of a pre-operational inspection being performed on the slaughter floor. On that date I ([redacted]) performed a pre-operational inspection check. I know that the establishment did perform the pre-operational inspection check because I observed them perform the check. I informed of the non-compliance. He proceeded to have the slaughter floor employee complete the record. This document serves as notice of non compliance within Federal Regulation 9 CFR 416.16(a).

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: 04C02
Violation: 313.2

Citation: At approximately 0845 I observed the following non-compliance. While the plant was performing Halal slaughter they shackled and raised a non-formula fed veal to perform the cut to euthanize the animal. I took a regulatory control action and placed U.S. retain tag B39878924 to the knocking pen. I informed Dr. and he informed me that this might be part of the ritual slaughter so I removed the U.S. Retained tag per his request. I discussed the issue of shackling and hanging an animal with the Halal Slaughterer and he said that shackling and hanging an animal is not part of the ritual slaughter. He informed me that he would not be able to get a letter stating that it is allowed per his religious beliefs. So According to the Humane Methods of Slaughter Act and FSIS’s implementing regulations require that livestock be rendered insensible to pain before being shackled (7 USC 1902(a) and 9 CFR part 313). Thus, livestock cannot be shackled prior to being rendered unconscious or surgically anesthetized, or euthanized. Livestock are considered to be shackled when a device (e.g. rope, chain) used to shackle the animal has been placed around the animal’s leg, even if the device has not been drawn tight. Therefore, placing any device around the leg of livestock before stunning, even if loosely placed, is considered a noncompliance of 9 CFR sections 313.5 (a) (1), 313.15 (a) (1), 313.16 (a) (1), or 313.2 (f) with 313.30 (a) (1) as appropriate. This document serves as notice of non-compliance within Federal Regulation 9 CFR 313.2(f).

Regulation:

 313.2 (f) Stunning methods approved in §313.30 shall be effectively applied to animals prior to their being shackled, hoisted, thrown, cast, or cut.

313.5 (a)(1) Administration of gas, required effect; handling. The carbon dioxide gas shall be administered in a chamber in accordance with this section so as to produce surgical anesthesia in the animals before they are shackled, hoisted, thrown, cast, or cut. The animals shall be exposed to the carbon dioxide gas in a way that will accomplish the anesthesia quickly and calmly, with a minimum of excitement and discomfort to the animals. In swine, carbon dioxide may be administered to induce death in the animals before they are shackled, hoisted, thrown, cast, or cut.

313.15 (a)(1) Application of stunners, required effect; handling. The captive bolt stunners shall be applied to the livestock in accordance with this section so as to produce immediate unconsciousness in the animals before they are shackled, hoisted, thrown, cast, or cut. The animals shall be stunned in such a manner that they will be rendered unconscious with a minimum of excitement and discomfort.

313.16 (a)(1) Utilization of firearms, required effect; handling. The firearms shall be employed in the delivery of a bullet or projectile into the animal in accordance with this section so as to produce immediate unconsciousness in the animal by a single shot before it is shackled, hoisted, thrown, cast, or cut. The animal shall be shot in such a manner that they will be rendered unconscious with a minimum of excitement and discomfort.

313.30 (a)(1) Administration of electric current, required effect; handling. The electric current shall be administered so as to produce, at a minimum, surgical anesthesia, i.e., a state where the animal feels no painful sensation. The animals shall be either stunned or killed before they are shackled, hoisted, thrown, cast, or cut. They shall be exposed to the electric current in a way that will accomplish the desired result quickly and effectively, with a minimum of excitement and discomfort.

Code: 06B01
Violation: 303.1(a)(2)(ii)

Citation: At approximately 1600 hrs I observed the following non-compliance. There is a rail that has all of the uninspected carcasses produced on it. On this rail I found 1 beef carcass in direct contact with an uninspected beef carcass on the beginning of the rail and 1 inspected beef carcass in contact with the liver and another uninspected carcass on the end of the rail. I informed a plant employee of the problem and he immediately moved the inspected carcasses away from the inspected carcasses. I re-inspected the inspected carcasses for possible cross contamination and found none. I then informed of the non-compliance. This document serves as notice of non-compliance within Federal Regulation 9 CFR 303.1(a)(2)(ii). Past Similar NRs – Previous Ineffective Plant Actions: Failure to keep inspected product seperate from un-inspected product. NR: 18-2011 dated 7/11/2011 Past Similar NRs – Previous Ineffective Plant Actions: Failure to keep inspected product seperat from un-inpected product. NR: 18-2011 dated 7/11/2011

Regulation:

303.1(a)(2)(ii) If the custom operator prepares or handles any products for sale, they are kept separate and apart from the custom prepared products at all times while the latter are in his custody;

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

Citation: While performing pre-operational inspection starting at 0705 hrs I observed the following non-compliances. In the processing area I observed the following: 1. several pieces of fat, fat build up and meat chunks on the floor. (Non-contact) 2. Fat build-up around the opening in the hopper on the patty machine. (Contact) 3. Small pieces of fat on the upper wheel of the band saw. (Non-contact) 4. Pieces of meat stuck in the cubing wheels of the cuber. (Contact) 5. Small pieces of meat and fat on the hooks used to bring product into the processing area. (Contact) 6. Fat residue and small pieces of fat in the inedible tubs. (Non-contact) In the slaughter area I observed the following: 1. There was still hair on the de-hairer used for the slaughter of swine from previous days use. (Non-contact) 2. There was build-up of fat residue on the front of the large final trim stand. (Non-contact) U.S. Reject tag B39878925 was used to reject the equipment in the processing room and U.S. Reject tag B39878926 was used to reject the equipment in the slaughter floor. I informed the persons performing the pre-operational inspection and they proceeded to re-clean the areas. After all of the above areas were re-cleaned I re-inspected the equipment and released it back to the establishment. This document serves as notice of non-compliance within Federal Regulation 9 CFR 416.13(c), 416.4(a) and 416.4(b). Past Similar NRs – Previous Ineffective Plant Actions: Failure to effectively clean and monitor the cleaning of the establishment. NR: 17-2011 dated 7/7/2011

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(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), 416.4(b)

Citation: At approximately 0705 hrs while performing pre-operational inspection I observed the following non-compliances. In the processing room I found product reside from previous day’s production built up on two of the patty machine’s parts (contact). I also fond small particles of product on the large auger and the small auger housing (contact). Upon further inspection I found several pieces of meat and fat on the floor and on the door to the cooler and the door into the slaughter floor (non-contact). While on the slaughter floor I found fatty residue on the gambles that are hanging up on a steel rack (contact). U.S. Reject tag NO. B39878929 was used to reject the equipment in the processing room and U.S. Reject tag NO. B39878930 was used to tag the equipment in the slaughter floor. I informed the persons performing the pre-operational inspection and the proceeded to re-clean the equipment. After all of the above areas were re-cleaned I re-inspected the equipment and released and released it back to the establishment. This document serves as notice of non compliance within Federal Regulations 9 CFR 416.13(c), 416.4(a) and 416.4(b). Past Similar NRs – Previous Ineffective Plant Actions: Failure to effectively clean and monitor the cleaning of the establishment. NR: 23-2011 dated 7/20/2011

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(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: 06B01
Violation: 303.1(a)(2)(ii)

Citation: At approximately 0805 while in the cooler I observed the following non-compliance. There were inspected lamb carcasses in direct contact with an uninspected beef. I informed of the non-compliance and he proceeded to have the inspected and un-inspected product separated. I re-inspected the lamb carcass for possible contamination and found none. This document serves as notice of non-compliance within Federal Regulation 9 CFR 303.1(a)(2)(ii). Past Similar NRs – Previous Ineffective Plant Actions: Failre to keep inspected products seperate from un-inspected products. NR: 22-2011 dated 7/19/2011

Regulation:

303.1(a)(2)(ii) If the custom operator prepares or handles any products for sale, they are kept separate and apart from the custom prepared products at all times while the latter are in his custody;

Code: 01C02
Violation: 416.13(b)

Citation: At approximately 1400 hrs I found the following non-compliance. [newline]The establishment began the day by cutting up un-inspected product. After they were finished processing the un-inspected product the rinsed the equipment and utensils with hot water and returned to processing inspected product. The plant is in non-compliance because their SOP plan states that, “ [redacted].” [newline]9 CFR 416.13(b) states that, “Each official establishment shall conduct all other procedures in the Sanitation SOP’s at the frequencies specified.”[newline]This document serves as notice of non-compliance within Federal Regulations 9 CFR 416.13(b).

Regulation:

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

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

Citation: Beginning at 0700 hrs while performing pre-operational inspection I observed the following non-compliances. In the processing room I found several chunks of meat and fat particles on the inside door and the inside box on the lower portion of the band saw (non-contact). I also found approximately 28 grey totes with product particles and product residue on the insides and outsides of the grey totes. (contact) There were also pieces of meat on the 3 carts holding the grey totes (non-contact). U.S. Reject tags NO. B39879001 and B39879002. There was also a set of knives and the scabbard holding them that had meat stuck to them (contact). U.S. Reject tag NO. B39879003 was applied to the knives and scabbard. After informing the plant employee of the non-compliances he proceeded to re-clean the grey totes and the carts so U.S. Reject tags NO. B39879001 and B39879002 were removed. The scabbard and knives have remained tagged beacause they have not been recleaned. Once the scabbard and knives are re-cleaned they will be released back to the establishment. This document serves as notice of non-compliance within Federal Regulations 9 CFR 416.4(a), 416.4(b) and 416.13(b).

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.

416.4(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), 416.4(b)

Citation: Beginning at 0710 hrs while performing pre-operational inspection I observed the following non-compliances. In the processing room I found several chunks of meat and fat particles on 2 sets of scabords and knives (contact). There were also what appered to be debris on the underside of the rails for the main table in the processing room (non-contact). No U.S. tags were applied because after each piece of equipment that was found to be in non-compliance was immediately re-cleaned by a plant employee. In the slaughter floor I found 2 carts that had chunks of meat stuck in the wheels (non-contact). I also found 3 large stainless steel tubs with product particles and fat residue in them (contact). In the head was cabinent there were 2 offal holders that had blood left on them from previous days usage as well as what appeared to be fat particles in the head was cabinent (contact). No U.S. tags were applied because after each piece of equipment that was found to be in non-compliance was immediately re-cleaned by a plant employee. This document serves as notice of non-compliance within Federal Regulations 9 CFR 416.4(a), 416.4(b) and 416.13(b).

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(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: 01C01
Violation: 416.15(a)

Citation: At approximately 1500 hrs I performed a record review task on the establishments SSOP plan and found the following non-compliance. [newline]In the establishment’s SSOP record book there was a sanitizer temperature recorded as degrees Fahrenheit for the slaughter floor. According to the establishment’s SSOP plan, “[redacted] ” The temperature was recorded as Fahrenheit on 11/7/11 and no corrective action was written to alleviate the problem. I talked with and she was not sure whether a corrective action was performed and not recorded or if neither a corrective action was not performed and that is why no corrective action was written.

Regulation:

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

Citation: At approximately 0700 hrs while performing a routine pre-operational inspection I found the following non-compliances.[newline]In the processing room I found 27 grey totes with meat and fat on the inside and outside of the totes (contact). U.S. Reject tag NO. B39879007 was applied to the totes. There were a 2 knives and a scabbard used for processing product that were in the processing area that had small pieces of meat stuck to them (contact). U.S. Reject tag NO. B39879009 was applied to the scabbard and knives. By the end of my pre-operational inspection, neither the totes nor the scabbard with knives were cleaned so both U.S. Reject tags have remained attached to the items.[newline]In the slaughter floor I found what appeared to be a fat residue on the hog dehairer (non-contact). U.S. Reject tag NO. B39879008 was applied to the dehairer. A slaughter floor employee immediately re-cleaned the equipment and U.S. Reject tag NO. B39879008 was removed.

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(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: 03C02
Violation: 417.5(b), 417.5(c)

Citation: At approximately 0800 hrs I reviewed the establishment’s slaughter pre-shipment review records I observed the following non-compliance.[newline]A pre-shipment review record for a Halal slaughtered beef carcass was not completed. Part of the animal had been shipped on Saturday 11/26/11. There were also 3 lambs and 5 goats that were shipped to the same person that did not have a pre-shipment review performed on them. After I informed of the non-compliance he proceeded to complete the pre-shipment reviews. [newline]This document serves as notice of non-compliance within Federal Regulations 9 CFR 417.5(b) and 417.5(c).

Regulation:

417.5(b) Each entry on a record maintained under the HACCP plan shall be made at the time the specific event occurs and include the date and time recorded, and shall be signed or initialed by the establishment employee making the entry.

417.5(c) Prior to shipping product, the establishment shall review the records associated with the production of that product, documented in accordance with this section, to ensure completeness, including the determination that all critical limits were met and, if appropriate, corrective actions were taken, including the proper disposition of product. Where practicable, this review shall be conducted, dated, and signed by an individual who did not produce the record(s), preferably by someone trained in accordance with §417.7 of this part, or the responsible establishment official.

Code: 06B01
Violation: 303.1(a)(2)(ii)

Citation: At approximately 1150 hrs I observed the following non-compliance. [newline]In the processing part of the cooler I observed 4 inspected bovine shanks touching uninspected carcasses as well as one full half carcass directly up against an uninspected carcass. Upon this discovery I informed of the non-compliance. She immediately had a plant employee separate the uninspected and inspected carcasses. I then review the inspected carcasses and found no visible contamination on the carcasses. [newline]This document serves as notice of non-compliance within Federal Regulation 9 CFR 303.1(a)(2)(ii).

Regulation:

303.1(a)(2)(ii) If the custom operator prepares or handles any products for sale, they are kept separate and apart from the custom prepared products at all times while the latter are in his custody;

Code: 04C02
Violation: 313.16

Citation: On Friday December 2, 2011 I observed the following noncompliance. [newline]On the slaughter floor I observed 2 bovine shot once and not rendered unconscious until it was shot again. While the second shot was immediately after the first shot, according to Federal Regulation 9 CFR 313.16(a)(1), “The firearms shall be employed in the delivery of a bullet or projectile into the animal in accordance with this section so as to produce immediate unconsciousness in the animal by a single shot before it is shackled, hoisted, thrown, cast, or cut. The animal shall be shot in such a manner that they will be rendered unconscious with a minimum of excitement and discomfort” and 9 CFR 313.16(a)(3), “Immediately after the firearm is discharged and the projectile is delivered, the animal shall be in a state of complete unconsciousness and remain in this condition throughout shackling, sticking and bleeding.” [newline]On 11/17/2011, 11/22/2011, twice on 11/23/2011 and 11/28/2011 a second shot was required to bring a bovine, on each date, into a complete unconscious state.

Regulation:

313.16 The slaughtering of cattle, calves, sheep, swine, goats, horses, mules, and other equines by shooting with firearms and the handling in connection therewith, in compliance with the provisions contained in this section, are hereby designated and approved as humane methods of slaughtering and handling of such animals under the Act.

Code: 01D01
Violation: 416.2(b)(1), 416.2(b)(2)

Citation: On 12/7/2011 I observed the following non-compliance.[newline]In the processing room there is 1 plastic board that is attached to the wall that has had a hole in them allowing product debris and moisture to get behind them. On the slaughter floor there are also 1 piece of the same kind of plastic boards that are attached to the wall that have had a hole in them allowing product debris and moisture to get behind them. I had discussed the issue on several occasions to let the establishment handle the problem. Both completion dates for repairing the wall have been surpassed with only one wall piece being repaired since the plant was first notified of the issue on 9/14/2011.

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.

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: 03C02
Violation: 417.3(a)(2)

Citation: At approximately 1310 hrs I observed the following non-compliance.[newline]In the processing room I observed the establishment processing several goats. I asked if these were the goats from that were slaughtered this morning. He informed me that there was one goat that was slaughtered this morning. I then took the temperature on 2 separate pieces of meat. The first piece was 36 degrees Fahrenheit. The second piece was 55 degrees Fahrenheit. According to the establishments HACCP plan [redacted]. By the time all of this had occurred, the establishment employees were already in the process of taking trays of the partially processed goats into the freezer, no regulatory control action was taken.

Regulation:

417.3(a)(2) The written HACCP plan shall identify the corrective action to be followed in response to a deviation from a critical limit. The HACCP plan shall describe the corrective action to be taken, and assign responsibility for taking corrective action, to ensure: The CCP will be under control after the corrective action is taken;

Code: 04B04
Violation: 307.4(a), 316.3

Citation: On 1/3/2012 at approximately 0430 hours I observed the following non-compliance after returning to the establishment to collect a personal item that I had forgotten in the government office. I had originally left at 0400 hours when the establishment informed me that they no longer required inspection for the day because they would only be producing retail/custom products.[newline]I observed plant employee’s sealing packaged product that was marked inspected outside of inspection hours and without and inspection program employee present. When I asked a plant employee, he informed me that there were just the 2 trays of beef liver, beef tongue and beef hearts. I immediately took a regulatory control action and applied U.S. Retain Tag NO.B39879010 to one tray and U.S. Retain Tag NO.B39879011 to the other tray. I then informed of the non-compliance and informed him that I had applied a tag to both trays of product. On 1/4/2012 I talked to the employee who was sealing the product and he informed me that the beef hearts and beef tongues had already been packaged and labeled and that the beef liver had already been cut up but they were in fact packaged, labeled and sealed inspected without an inspector present or even notified.

Regulation:

307.4(a) No operations requiring inspection shall be conducted except under the supervision of a Program employee. All slaughtering of animals and preparation of products shall be done with reasonable speed, considering the official establishment’s facilities.

316.3 Use of official marks prohibited except under supervision of Program employee; removal of official marks, when required.

Code: 04C02
Violation: 313.16

Citation: On 1/5/11,&nbsp; while conducting a humane handling assessment, I witnessed the following non-compliance.&nbsp; At approximately 8am in the morning a plant employee attempted to shoot a steer with a .22 caliber rifle.&nbsp; The first shot was unsuccessful at producing immediate unconsciousness.&nbsp; Immediate corrective action was taken by the plant employee, who shot the steer again with a 410 gauge shotgun.&nbsp; This shot produced immediate unconsciousness.&nbsp; 9 CFR 313.16(a)(1) states, in part:&nbsp; The firearms shall be employed in the delivery of a bullet or projectile into the animal in accordance with this section so as to produce immediate unconsciousness in the animal by a single shot before it is shackled, hoisted, thrown, cast, or cut.

Regulation:

313.16 The firearms shall be employed in the delivery of a bullet or projectile into the animal in accordance with this section so as to produce immediate unconsciousness in the animal by a single shot before it is shackled, hoisted, thrown, cast, or cut. The animal shall be shot in such a manner that they will be rendered unconscious with a minimum of excitement and discomfort.

Code: 04B04
Violation: 307.4(a), 316.3

Citation: At approximately 1115 hrs I found the following non-compliance. I found 33, 5 lb. boxes of ground beef hamburger patties that were produced on January 21, 2012 that were produced under the retail exemption but all of the packages had the marks of inspection applied to the label. As soon as I observed this non-compliance I informed the plant manager, , and took a regulatory control action and applied U.S. Retain Tag NO.B39879012 to the shelf that was holding the 33, 5 lb. boxes of ground beef hamburger patties that was marked inspected. Upon further investigation I found 7 more 5 lb. boxes of ground beef hamburger patties in the retail area. I informed the plant that they needed to take the product back to the shelf where the other improperly marked boxes were because they needed to be accounted for with concern to the marking of retail exempt products inspected. They were then placed in the same retained area in the establishment’s freezer with the other 33 boxes. According to the plant records they ground up a total of [#] pounds on Saturday January 21, 2012. [#] lbs were ground at 8:45 a.m. and [#] lbs were ground at 11:00 a.m. The cases add up to a total of [#] pounds. Through records of what the establishment produced on Saturday January 21, 2012 and with discussing the retail ground that was produced with the plant employee who produced the ground product under the retail exemption, I determined the plant more than likely only had the cases of 5 lb. ground beef patties that amounted to [#] lbs. I determined that the other [#] lbs was put in the retail display case and not packaged and or labeled inspected.

Regulation:

307.4(a) No operations requiring inspection shall be conducted except under the supervision of a Program employee. All slaughtering of animals and preparation of products shall be done with reasonable speed, considering the official establishment’s facilities.

316.3(a) No person shall affix or place, or cause to be affixed or placed, the official inspection legend or any other official mark, or any abbreviation or simulation of any official mark, to or on any product, or container thereof, except under the supervision of a Program employee, or as authorized by part 317 of this subchapter in connection with the manufacture of containers.

Code: 03J02
Violation: 310.22(g)(4)

Citation: At approximately 1200 hrs I observed the following non-compliance. [newline][newline]A bovine that was over the age of 30 months was not properly marked and the records indicated that it was less than 30 months. After discussing the issue with the slaughter floor employees I found the head that was over 30 months old and the tooth that indicated that it was over was removed. The slaughter floor employee that removed the head also confirmed that the animal was over 30 months old. The slaughter floor employees then proceeded to properly mark the animal over 30 months old and then they changed the records to reflect the animal&rsquo;s true age. No regulatory control action was taken due to the fact that this was taken care of promptly and before the animal was pushed into the cooler.

Regulation:

310.22(g)(4) Maintains records that verify that the official establishment that received the carcasses or parts removed the portions of the vertebral column designated as specified risk materials in paragraph (a)(1) of this section and disposed of them in accordance with §314.1 or §314.3 of this subchapter.

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

Citation: Today at approximately 0710 while performing a pre-operational inspection I observed the following non-compliance.[newline][newline]In the processing area I found several pieces of fat/ meat particles on the band saw (Contact). There was also dried fat/meat particles stuck to the pan that catches the saw dust in the band saw (Non-contact). I found a large piece of fat on the large scale on the south wall (Contact). USDA Reject tag was NO.B39879017 was applied to the large scale, the band saw and the band saw&rsquo;s tub. I then informed a plant employee ) of the non-compliant areas. He proceeded to re-clean all the equipment. After the rejected equipment was re-cleaned, I re-inspected the equipment and found it to be back in compliance. I then released the equipment back to the establishment.[newline][newline]In the slaughter area I found fat build up and fat pieces on two cart that are used to hold tubs of product/ product (Contact). I also found small pieces of what appeared to be debris and small pieces of product particles in the bottom of a small stainless steel tub (Contact). USDA Reject tag was applied NO.B39879018 was applied to the two carts and the stainless steel tub. I then informed a plant employee ) of the non-compliant areas. He proceeded to re-clean all the equipment. After the rejected equipment was re-cleaned, I re-inspected the equipment and found it to be back in compliance. I then released the equipment back to the establishment.[newline][newline]

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(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: 04C02
Violation: 313.16

Citation: HATS Category VIII At approximately 1140 while verifying the humane handling stunning effectiveness regulation I observed the following non-compliance. While inspecting a bovine skull I found two bullet holes in the head from the plants stunning procedure. One was the size of a .22 caliber and the other was the size from a 410 shell. At that time I reviewed the plants insensibility records and found that it had not been recorded as failing the first insensibility check. I asked the plant employee ( ) if he had shot it twice and he confirmed that he did. I informed him that if the animal had to be re-stunned that it needed to be recorded in the log. He fixed the records to accurately to portray that the animal was first shot with the .22, then immediately re-stunned with the 410. I notified of the non-compliance. This was a Halal slaughtered bovine and they use the .22 caliber rifle to stun the animals if possible.

Regulation:

313.16 The firearms shall be employed in the delivery of a bullet or projectile into the animal in accordance with this section so as to produce immediate unconsciousness in the animal by a single shot before it is shackled, hoisted, thrown, cast, or cut. The animal shall be shot in such a manner that they will be rendered unconscious with a minimum of excitement and discomfort.

Code: 03J02
Violation: 310.22(c), 417.5(c)

Citation: At approximately 0815 hrs I observed the following non-compliance.[newline][newline]The plant had separated the back bone from the rest of a carcass in a bovine over 30 months old. The back bone was left intact in 3 pieces for each side. The thoracic (rib) piece was observed missing from the rest of the backbone pieces for the over 30 month bovine. I asked the plants processing employees and if they knew where the missing piece was. They did not know where the piece was so I took a Regulatory Control Action and retained the backbone pieces using U.S. Retain Tag NO.B39879020. I informed that the piece needed to be found and accounted for.[newline][newline]After reviewing the records for the pre-shipment review of other parts of the over 30 month old bovine that was shipped on 03/03/2012 I found that the carcass had a pre-shipment review completed for the whole carcass including the vertebral column. The plant had not performed the process of removing the vertebral column as well as not completing the records for the removal of SRMs so therefore the whole carcass had not met the qualifications to have the pre-shipment review completed.

Regulation:

310.22(c) Specified risk materials must be removed from the carcasses of cattle, segregated from edible materials, and disposed of in accordance with §314.1 or §314.3 of this subchapter. The spinal cord from cattle 30 months of age and older must be removed from the carcass at the establishment where the animal was slaughtered.

417.5(c) Prior to shipping product, the establishment shall review the records associated with the production of that product, documented in accordance with this section, to ensure completeness, including the determination that all critical limits were met and, if appropriate, corrective actions were taken, including the proper disposition of product. Where practicable, this review shall be conducted, dated, and signed by an individual who did not produce the record(s), preferably by someone trained in accordance with §417.7 of this part, or the responsible establishment official.

Code: 04C02
Violation: 313.16

Citation: HATS Category VIII: At approximately 1020 hours while reviewing the insensibility records I observed the following non-compliance. A bovine (under 30 month steer) required a double stun to render the animal unconscious. The animal was first shot with the 410, which did not render it unconscious, and then the plants immediate action was to shoot the animal again using the 410. The animal was rendered unconscious on the second shot. I found the bovine head and confirmed that it had been shot twice with the 410. I then discussed the issue with the HACCP Coordinator, and the plant Manager . and both informed me that the employee who performed the stunning on the bovine () would not be allowed to stun any animals using a firearm.

Regulation:

313.16(a)(1) The firearms shall be employed in the delivery of a bullet or projectile into the animal in accordance with this section so as to produce immediate unconsciousness in the animal by a single shot before it is shackled, hoisted, thrown, cast, or cut. The animal shall be shot in such a manner that they will be rendered unconscious with a minimum of excitement and discomfort.

Code: 03C02
Violation: 417.5(a)(3), 417.5(b)

Citation: At approximately 1330 hrs I reviewed the plants pre-shipment review log and the plants cut sheets that are considered HACCP documents because that is where they record HACCP temperature before moving them to the pre-shipment review log.[newline]In both sets of records I found there was no data entered for March 9th 2012 and March 16th 2012 for the Raw not ground temperatures. I verified with the establishment, and , that inspected product was produced on both days. According to the establishments Raw, Not Ground HACCP plan, &ldquo;A random order from each days delivery will be selected for monitoring.&rdquo;

Regulation:

417.5(a)(3) Records documenting the monitoring of CCP’s and their critical limits, including the recording of actual times, temperatures, or other quantifiable values, as prescribed in the establishment’s HACCP plan; the calibration of process-monitoring instruments; corrective actions, including all actions taken in response to a deviation; verification procedures and results; product code(s), product name or identity, or slaughter production lot. Each of these records shall include the date the record was made.

417.5(b) Each entry on a record maintained under the HACCP plan shall be made at the time the specific event occurs and include the date and time recorded, and shall be signed or initialed by the establishment employee making the entry.

Code: 06B01
Violation: 303.1(a)(2)(iii), 317.16

Citation: At approximately 0800 hrs I observed the following non-compliance. In the holding cooler I found 25 lamb carcasses that were slaughtered under the custom exemption. Federal Regulation 9 CFR 303.1(a)(2)(iii) states that, &ldquo;The custom prepared products are plainly marked &ldquo;Not for Sale&rdquo; as provided in &sect;316.16 of this subchapter, immediately after being prepared and are kept so identified until delivered to the owner; and&rdquo;. The carcasses were not marked &ldquo;Not for Sale&rdquo; and the labels that were attached to the carcasses were also not labeled &ldquo;Not for Sale&rdquo;. They were labeled with a retail label. Federal Regulation 9 CFR 317.16 states, &ldquo;Products that are custom prepared under &sect;303.1(a)(2) of this subchapter must be packaged immediately after preparation and must be labeled (in lieu of information otherwise required by this part 317) with the words &ldquo;Not For Sale&rdquo; in lettering not less than three-eighth inch in height. Such exempted custom prepared products or their containers may bear additional labeling provided such labeling is not false or misleading.&rdquo; I notified , Plant Manager, and he proceeded to have the carcasses stamped &ldquo;Not for Sale&rdquo;. I took a Regulatory Control Action and applied U.S. Retain tags NO.B39879024 to 5 lambs, NO.B39879025 to 8 lambs, NO.B39879026 to 5 lambs, NO.B39879027 to 2 lambs, NO.B39879029 to 3 lambs and NO.B398790230 to 2 lambs. I observed the plant relabeled the product correctly with a &ldquo;Not for Sale&rdquo; label and I then removed all U.S. Retain tags.

Regulation:

303.1(a)(2)(iii) The custom prepared products are plainly marked ‘‘Not for Sale’’ as provided in §316.16 of this subchapter, immediately after being prepared and are kept so identified until delivered to the owner; and

317.16 Products that are custom prepared under §303.1(a)(2) of this subchapter must be packaged immediately after preparation and must be labeled (in lieu of information otherwise required by this part 317) with the words ‘‘Not For Sale’’ in lettering not less than three-eighth inch in height. Such exempted custom prepared products or their containers may bear additional labeling provided such labeling is not false or misleading.

Code: 01C01
Violation: 310.22(e)(1)

Citation: At approximately 0730 hrs I observed the following non-compliance. In the Chill cooler I found an uninspected bovine. After reviewing the plants records I found the bovine to be an over 30 month dairy cow. The plant did not mark the carcass over 30 months. Since the custom operations are conducted in an official establishment they are subject to all of 9 CFR Part 416 including SSOPs per 9 CFR 303.1(a)(2)(i). In the establishment’s SSOP plan there is an SOP procedure for beef slaughter, it states that, ” “The plant did not apply the green tape that is supposed to be applied according to the establishment’s previous corrective action in non-compliance record 0025-2011-18096 regarding uninspected slaughtered animals. In the response to the non-compliance the plant stated that, “Plant management further action will be to wrap a green tape completely around the carcass. The tape will be placed near the brisket area.” I informed slaughter employee of the non-compliances and he immediately marked the bovine over 30 months and applied the green tape to the carcass. For failure to implement procedures for the segregation of specified risk materials this is non-compliant with Federal Regulation 9 CFR 310.22(e)(1).

Regulation:

310.22(e)(1) Establishments that slaughter cattle and establishments that process the carcasses or parts of cattle must develop, implement, and maintain written procedures for the removal, segregation, and disposition of specified risk materials. These procedures must address potential contamination of edible materials with specified risk materials before, during, and after entry into the establishment. Establishments must incorporate their procedures for the removal, segregation, and disposition of specified risk materials into their HACCP plans or Sanitation SOPs or other prerequisite programs.

Code: 03B02
Violation: 310.22(e)(4)(i), 417.5(b), 417.5(c)

Citation: While reviewing the pre-shipment review log I found the following non-compliance. The lambs and/or goats that were slaughtered on 3/29/12, 3/30/12, 4/4/12, 4/5/12, 4/6/12 and 4/9/12 did not have a pre-shipment review recorded for them. I informed of the non-compliance.[newline]While reviewing the pre-shipment review log I found that there was half of an over 30 month beef carcass that did not have a pre-shipment review record completed for it. I also found that the SRM log had not been completed for this half carcass. I observed the establishment bone out the half carcass and remove all SRMs. I informed of the non-compliance.

Regulation:

310.22(e)(4)(i) Establishments that slaughter cattle and establishments that process the carcasses or parts of cattle must maintain daily records sufficient to document the implementation and monitoring of the procedures for the removal, segregation, and disposition of the materials listed in paragraph (a) of this section, and any corrective actions taken.

417.5(b) Each entry on a record maintained under the HACCP plan shall be made at the time the specific event occurs and include the date and time recorded, and shall be signed or initialed by the establishment employee making the entry.

417.5(c) Prior to shipping product, the establishment shall review the records associated with the production of that product, documented in accordance with this section, to ensure completeness, including the determination that all critical limits were met and, if appropriate, corrective actions were taken, including the proper disposition of product. Where practicable, this review shall be conducted, dated, and signed by an individual who did not produce the record(s), preferably by someone trained in accordance with §417.7 of this part, or the responsible establishment official.

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

Citation: At approximately 0715 while performing pre-operational inspection I found the following non-compliances. In the retail area that was being used for inspected product today I found several areas with fat and meat build up on the band saw and band saw pieces. There were also meat particles on the outside of the band saw (contact/non-contact). In the processing room there were several pieces of meat and meat particles on the outside of the grinder (non-contact). In the slaughter area there was still hair on the de-hairer from the previous day’s slaughter of swine (non-contact). No U.S. Reject tags were applied because the machines were immediately re-cleaned and re-inspected upon notifying the plant that the machines were out of regulatory compliance with sanitation standards.

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(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: 04C02
Violation: 313.2

Citation: HATS Category III[newline]At approximately 0715 I observed the following non-compliance. In the pens there was a pen with 1 calf, 3 sheep, and 3 goats that had no water. I informed of the non-compliance. immediately had an employee give the animals in the pen water. This document serves as notice of non-compliance within Federal Regulation 9 CFR 313.2(e).

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: 04B04
Violation: 317.1

Citation: At approximately 0820 while passing through the processing room I noticed a two-wheeled dolly cart with 6 boxes on it. These boxes contained a ground, frozen, then band saw cut product, each container was full of these approximate 2″ square cubes of “not for Human Consumption” product. Five of These boxes yet were still labeled as USDA inspected and passed beef chuck and beef top round, originating from . When I asked about this, he immediately took corrective actions by removing the labels, and new labels stating the boxes’ intended use and contents were made and applied to the boxes therefore no regulatory control action was taken. Upon further investigation it appears no other product was affected

Regulation:

317.1 (c) No covering or other container which bears or is to bear a label shall be filled, in whole or in part, except with product which has been inspected and passed in compliance with the regulations in this subchapter, which is not adulterated and which is strictly in accordance with the statements on the label. No such container shall be filled, in whole or in part, and no label shall be affixed thereto, except under supervision of a Program employee.

Code: 04A05
Violation: 310.22(e)(1)

Citation: On 6/5/12, while reviewing the SRM logs I found the following non-compliance. There were 2 bovine that were recorded in the SRM log as over 30 months. I went in the cooler to verify that the bovine were still in the cooler since the SRM log for the vertebral column hadn’t been completed. When I found both carcasses neither one had been marked over 30 months. I then placed U.S. Reject tags NO. B39879044 and U.S. Reject tags NO. B39879045 to both carcass halves designated as 56. I also placed U.S. Reject tags NO. B39879046 and U.S. Reject tags NO. B39879047 the other 2 half carcasses designated as 59. I informed of the non-compliance. He proceeded to have a slaughter floor employee mark the carcasses over 30 months.

Regulation:

310.22(e)(1) ) Procedures for the removal, segregation, and disposition of specified risk materials. (1) Establishments that slaughter cattle and establishments that process the carcasses or parts of cattle must develop, implement, and maintain written procedures for the removal, segregation, and disposition of specified risk materials. These procedures must address potential contamination of edible materials with specified risk materials before, during, and after entry into the establishment. Establishments must incorporate their procedures for the removal, segregation, and disposition of specified risk materials into their HACCP plans or Sanitation SOPs or other prerequisite programs. 

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

Citation: Today at approximately 0730 hrs I observed the following non-compliance. In the retail area that was being used for inspected product today, I found several pieces of dried fat on the band saw. There were pieces ranging in size from minuscule to a 3 inch long piece of fat on both the contact and non-contact surfaces of the machine. The plant has previously been informed that if they need to use part of the retail area for USDA inspected products they are subject to all USDA regulatory requirements. The plant failed to meet Federal Regulations 9 CFR 416.4(a), 416.4(b) and 416.13(a). The plant immediately re-cleaned the band saw and band saw parts, no USDA reject tag was applied.

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(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: 04C02
Violation: 313.16

Citation: At approximately 1025 I heard 2 gunshots go off on the slaughter floor. The second shot did come immediately after the first. I proceeded to go back to the slaughter floor and review the shot location on the bovine that was just stunned. I found 2 bullet holes from 2 shots from the 410. I then notified of the non-compliance and he nodded ok.

Regulation:

313.16 (a) Utilization of firearms, required effect; handling. (1) The firearms shall be employed in the delivery of a bullet or projectile into the animal in accordance with this section so as to produce immediate unconsciousness in the animal by a single shot before it is shackled, hoisted, thrown, cast, or cut. The animal shall be shot in such a manner that they will be rendered unconscious with a minimum of excitement and discomfort.