Pennsylvania Slaughterhouses

Code: 03C02
Violation: 317.24(a)

Citation: I have observed beef meat and beef fat stored in plastic bags. It was explained to me by the plant manager [redacted], that the beef/fat are stored in the freezer for use in further processing.
I reviewed the HACCP plan and HAZARD ANALYSIS for raw not ground product and at the process step for packaging materials plastic bags are mentioned. It also states that [redacted]
I requested to see the letter of guarentee for these plastic bags and plant management could not produce one.
I informed plant management that packaging materials must comply with CFR 317.24(a). All packaging materials must be safe for their intended use within the meaning of section 409 of the FFDCA and must specify the conditions of use.
This concern was discussed at last weeks weekly meeting (5-11-2012).
This document serves as a written notification that failure to comply with regulatory requirements could result in additional regulatory or administrative action.

Regulation:

317.24(a) Edible products may not be packaged in a container which is composed in whole or in part of any poisonous or deleterious substances which may render the contents adulterated or injurious to health. All packaging materials must be safe for their intended use within the meaning of section 409 of the Federal Food, Drug, and Cosmetic Act, as amended (FFDCA).

Code: 01C01
Violation: 416.4(b)

Citation: This morning on the kill floor at approximately 0810 hours I noticied the sanitizer at the sticking station did not appear to be the required [redacted] degrees F. as stated in the establishment SSOP’s.
I informed the kill floor foreman, [redacted] and the plant manager [redacted]. [redacted] checked the temperature and found it to be 100 degreesF.
No regulatory control action was needed as [redacted] immediately replaced the sanitizer and no animals were being slaughtered at this time.
This document serves as a written notification that your failure to comply with regulatory requirements could result in additional regulatory or administrative action.

Regulation:

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

Code: 01B02
Violation: 416.13(c)

Citation: At approximately 0710 hours, while performing a preoperational sanitation inspection in the slaughter area, I observed the following noncompliance:

1. The lamb/goat front leg spreader bar had blood, hair and fecal on it from the previous days production.
2. The pull cord for the rail switch at the gutting station was covered with dirty grease.
3. The pull cord for the rail switch at the cooler door was covered in dirty grease andfat.

All areas have the potential to contact product. The slaughter foreman was notified and immediate corrective action to clean and sanitize the affected areas was performed. There was no further regulatory action taken.

Mr. [redacted] was verbally notified of the noncompliance and the failure to comply with section 416.13(c) of the Meat Inspection Regulations and page 1 of the establishments SSOP. This noncompliance was not recorded on the establishments preoperational sanitation form, dated 03/13/2012. There are no similar noncompliance records on file.

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), 416.2(b)(2)

Citation: At approximately 1030 hours, while performing a Sanitation Performance Standards inspection in the Smokehouse Area, I observed the following noncompliance:

1. The plexiglass windows in the doors leading from the Processing Kitchen to the Smokehouse Area are broken with exposed wood.
2. The are several holes in the ceiling of the Smokehouse Area near the wall facing E. Cherry St.
3. There is peeling paint on the wall adjacent to the RTE Room, on the wall next to the fermentation chamber, around the door nearest to E. Cherry St.leading into the Processing Kitchen, and on the base of the exit door and step leading to E. Cherry Rd.

All areas are non product contact and no product was involved. There was no further regulatory action taken.
[redacted] and [redacted] were verbally notified of the noncompliance and the failure to comply with the Meat Inspection Regulations Sanitation Performance Standards. The establishments sanitation forms did not document this noncompliance. A similar SPS noncompliance was issued on Noncompliance Record YYD0410015425N, dated 01/25/2012.

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: 01D04
Violation: 416.2(b)(1), 416.2(b)(2), 416.4(b)

Citation: At approximately 10:30 hours, while performing a sanitation performance standards inspection in the processing areas, I observed the following noncompliance:
1. The floor drain in the RTE Packaging area is rusty.
2. The floor in the RTE Packaging area has a 10″ x 10″ area of peeling paint.
3. The door between the RTE Packaging area and the Deboning/Raw Processing area has rust on the door hinges.
4. The bottom of the legs on the deboning table in the Deboning/Raw Processing area are rusty.
There was no product involved and all areas are non product contact areas. There was no regulatory control action taken.
Mr. [redacted] was verbally notified of the noncompliance and the failure to comply with the Meat Inspection Regulations Sanitation Performance Standards. The establishments sanitation forms, dated 01/25/2012, did not document this noncompliance.

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(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: 416.2(b)(1), 416.2(b)(2), 416.4(b)

Citation: At approximately 0900 hours, while performing a sanitation performance standards inspection in the processing area, I observed the following noncompliance: 1. The plastic corner trim at the wall corner near the floor scale has a large hole. 2. The electric cord plug for the floor scale has an accumulation of residue. 3. The exit door to the outside, the window frames along the wall facing Cherry Rd., and the door frame leading to the smokehouse area have areas of peeling paint and rust. 4. The electric box for the bowl chopper has rust along the bottom edge. 5. There is a rusty bracket holding the water purifier on the wall. 6. There is missing grout creating several holes in the wall between the processing area and the smokehouse area. 7. The Hobart Grinder has several areas of rust, peeling paint, and dirty, peeling silicone. 8. The Weiler Grinder has peeling paint on the screw gear box. All areas are non product contact and no product was affected. There was no further regulatory control action taken. Mr. [redacted] Plant Manager was verbally notified of the noncompliance and the failure to comply with sections 416.2(b)(1)(2) and 416.4(b) of the Meat Inspection Regulations Sanitation Performance Standards. The establishment SSOP forms, dated 12/07/2011, did not record that this noncompliance was observed during the establishments sanitation inspections.

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(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: 416.2(b)(1), 416.2(b)(2), 416.4(b)

Citation: At approximately 1000 hours, while performing a sanitation performance standards inspection in the Slicing/Packaging Room, I observed the following noncompliance:
1. There is mold starting to grow on the ceiling light fixtures, the doors, door frames and soap dispenser on the back wall, the door and silicone around the hole patch on the wall next to kitchen #1, and at numerous areas on all four walls.
2. The three cooling units are dirty, starting to grow mold, two units have old boxes covering openings and the fan covers are rusting.
3. There are numerous holes on all four walls where screws have been removed.
4. The old cameras and speakers on the front all are dirty and rusting.
5. The entrance door from the hallway is missing the plexiglass and has exposed wood, the door frame is rusting and missing screws.
6. The wall panel is cracked behind the soap dispenser at the sink.
7. Numerous trim pieces on all four walls are separated or pulled away from the wall panels.
8. The swing doors on the back wall have rust and peeling paint.
9. The strip down the center of the ceiling has pulled away from the ceiling in several places.
These are all non product contact areas and no product was involved. There was no further regulatory action taken.
Mr. [redacted] Plant Manager was verbally notified of the noncompliance and the failure to comply with the Meat Inspection Regulations Sanitation Performance Standards. There was no record of this noncompliance on the establishments SSOP forms.

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(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: 417.4(a)(2)(ii), 417.4(a)(2)(iii), 417.5(a)(3), 417.5(b), 417.5(c)

Citation: On Tuesday, October 25, 2011, at approximately 1500 hours, I observed a truck at the shipping dock being loaded with sheep, goat and beef carcasses. I noticed that the inventory of carcasses in the cooler did not appear to represent the day’s kill of [redacted] beef, [redacted] veal, and [redacted] sheep and goats. I immediately reviewed the HACCP records associated with the day’s slaughter production. Review of HACCP Form #ALM-003 indicated that results had been documented for CCP 1 Zero Tolerance; however, no daily verification results for direct observation or record review had been documented. Likewise, review of HACCP Form #ALM-005 indicated that no results had been documented for either monitoring or verification of CCP [redacted]. In addition, review of HACCP Form # ALM-003 indicated that no Pre-shipment Review had been documented for today’s slaughter production. I then began to inquire as to which carcasses had been loaded on the truck. Employees immediately available were not able to communicate effectively in English. I requested to speak to Mr. [redacted] Slaughter Floor Manager. Mr. [redacted] initially stated that the carcasses loaded were from the previous day’s slaughter. In the meantime, the truck with the carcasses had left the premises. [newline]After counting carcasses in the cooler with Mr. [redacted] it was determined that in fact 1 veal and 24 lambs from today’s slaughter had been shipped prior to the completion of the pre-shipment review and without completion of required HACCP records documenting the monitoring and verification that critical limits had been met at identified Critical Control Points as described above. Mr. [redacted] stated that all of the procedures identified in the HACCP plan, including the monitoring and verification of Critical Control Points had been performed; however, due to the high volume kill and the busyness of the day, they had not been documented. Mr. [redacted] then immediately filled out the forms and had the verifier complete the forms as well. The Pre-shipment review, including record review of the Slaughter Inspection Report, was completed by [redacted] and a time of 1:30 PM was recorded; however, the review occurred at 3:30PM, after product had been shipped. I immediately had the form corrected with to document the actual time the review occurred. The Lactic Acid report was signed and a monitoring time of 1:30 PM was recorded. The verification section of the Lactic Acid Report was signed and a time of 3:40 PM was recorded. I explained to plant management that the pre-shipment review could not have been properly completed at 3:30 PM if the Lactic Acid Report had not been completed until 3:40 PM. [newline]The actions of establishment employees as described above have resulted in noncompliance with 9 CFR 417.4(a)(2)(ii), 417.4(a)(2)(iii), 417.5(a)(3), 417.5(b), and 417.5(c). Furthermore, the actions of establishment employees as described above indicate a lack of understanding of the regulatory requirements for record keeping, specifically for the regulatory requirements of the pre-shipment review. Mr. [redacted] and Mr. [redacted] Plant Manager, were verbally notified of this noncompliance at approximately 1530 hours and in writing with the issuance of this noncompliance record. [newline][newline]The purpose of the Pre-shipment Review, as provided for in 9 CFR 417.5(c), is to ensure public safety by verifying, prior to shipping product, that all records associated with the production of that particular product are complete and accurate, thus furth

Regulation:

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

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

Citation: At approximately 1000 hours, while performing a sanitation performance standards inspection in the coolers, I observed the following noncompliance:[newline]1. Cooler # 3 – The top of the door frame has several areas of peeling paint.[newline]2. Cooler # 1 – The overhead light has an inch of water in the cover.[newline]3. Kill Floor Cooler#1 – The silicone caulk around the entrance door is dirty and has areas of mold growth.[newline]All the affected areas are non product contact areas. There was no product affected and no further regulatory control action was taken. [newline] Mr. [redacted] Plant Engineer/Manager was verbally notified of the noncompliance and the failure to comply with sections 416.2(b)(1)and (2) of the Meat Inspection Regulations. There are no similar noncompliance records on file. The establishments SSOP form, dated 10/19/2011, did not record that this noncompliance was observed during the establishments sanitation inspections.

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: 03J03
Violation: 301.2_Adulterated, 310.18

Citation: On Wednesday, August 31, 2011, at approximately 1040 hours, I performed a Zero Tolerance check in the carcass cooler to verify that all visible fecal, ingesta, and milk had been removed from the beef carcasses in accordance with regulatory requirements. I randomly selected two carcasses, four sides, out the available 9 carcasses in the cooler, in accordance with the establishment’s frequency of “1 in 5 cattle”. The two carcasses selected, #3568 and #369, each had visible fecal contamination on the tail in excess of 1” diameter. Carcass # 3568 also had visible fecal contamination on the brisket, an area measuring approximately ¾” diameter. Carcass #369 was observed to have additional fecal contamination on the exterior surface of the sirloin measuring approximately ¼” in diameter. In light of these findings I continued to expand my zero tolerance inspection to include two more carcasses, #2659 and #2852. Both carcasses were observed to have visible fecal contamination on the tail. Carcass # 2659 had an area of fecal contamination approximately 6½“x½” and also had fecal contamination on the right fore shank measuring approximately ½” in diameter. Carcass #2852 had an area of fecal contamination on the tail approximately 3/8” in diameter. Mr. Kill Floor Supervisor, was [redacted] notified of these deficiencies at approximately 1100 hours. The establishment is in violation of the regulatory requirements of 9 CFR 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”. Mr. [redacted] took immediate corrective action, all carcasses were reinspected and any visible contamination was removed. It was not deemed necessary to retain any of the affected product. I conducted a 100% reinspection of the carcasses at approximately 1440 hours and found all carcasses to be in compliance. Mr. [redacted] Plant Manager, was verbally notified of the noncompliance at approximately 1130 hours and in writing with the issuance of this Noncompliance Record. Fecal material is an adulterant, in that is a recognized source of pathogenic bacteria such as E. coli O157:H7 and Salmonella. It is therefore imperative that an establishment prevent and/or adequately remove all visible fecal contamination prior to shipping or further processing carcasses, carcass parts, or organs.

Regulation:

301.2 Adulterated. This term applies to any carcass, part thereof, meat or meat food product under one or more of the following circumstances

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: 01C02
Violation: 416.2(b)(2), 416.2(d)

Citation: On this date at 0734, I inspected the processing cooler and found water dripping from overhead condensation. There was a square stainless barrel with ground product that had a lid on it in a corner of the room. There was no water dripping on the barrel. The cooler was rejected with US Rejected tag # B38862892. There was no contamination of product.[redacted] Processing Manager, was verbally notified of the noncompliance and the product was removed from the cooler and the cooler was shut down.

Regulation:

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

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

Code: 06D01
Violation: 416.1, 416.2(e)(2)

Citation: Today at approximately 1115 hours while performing inspection duties on the kill floor I noticed waste water backflowing onto the kill floor from a drain plug. This area is located near the hand wash sink as you enter the kill floor. The liquid appeared to be clear but, emitted a foul odor when standing in close proximity to the area. The kill floor supervisor and the plant manager observed this noncompliance with me and immediately cordoned off the area, therefore no regulaory action was needed. I informed [redacted] and [redacted] that since this is creating an insanitary condition I will issue an NR. There is no product adulteration. I reviewed the establishments SSOP form 001 dated 3/1/2011 and signed by [redacted] and there was no documentaton of this insanitary condition. I reviewed the establishments prequisite for sewage and plumbing and it has not been met, as welll as CFR 416.1 and 416.2(e)(2) of the meat and poultry regulations. This document serves as a written notification that your failue to comply with the regulatory requirements could result in additional regulatory or administrative 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.

416.2(e)(2) Plumbing. Plumbing systems must be installed and maintained to: Properly convey sewage and liquid disposable waste from the establishment

Code: 03J01
Violation: 417.3(b)(1), 417.3(b)(2), 417.3(b)(3), 417.3(b)(4)

Citation: On January 3,2011, I collected and submitted tissue samples from a non formula fed veal calf. The analysis results from the midwestern laboratory were violative. I informed the kill floor supervisor, [redacted] and the production manager, [redacted] of this unforseen hazard. The calf carcass was on “HOLD” by plant management pending sample results and did not enter commerce. The calf was purchased at [redacted] in PA. The producer was [redacted] (BT# 3482). A copy of the lab report provided by LEARN is attached to this NR. This is a violation of CFR 417.3 (b) (1) and 417.3 (b)(2). This document serves as a written notification that your failure to comply with the regulatory requirements could result in additional regulatory or administrative action.

Regulation:

417.3(b)(1) If a deviation not covered by a specified corrective action occurs, or if another unforeseen hazard arises, the establishment shall: Segregate and hold the affected product, at least until the requirements of paragraphs (b)(2) and (b)(3) of this section are met;

417.3(b)(2) Perform a review to determine the acceptability of the affected product for distribution

417.3(b)(3) Take action, when necessary, with respect to the affected product to ensure that no product that is injurious to health or otherwise adulterated, as a result of the deviation, enters commerce

417.3(b)(4) Perform or obtain reassessment by an individual trained in accordance with § 417.7 of this part, to determine whether the newly identified deviation or other unforeseen hazard should be incorporated into the HACCP plan.

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

Citation: Today at approximately 0800 hours I performed an unscheduled 06D01 procedure to verify sanitation performance standards are being met in one or more areas of the plant. In the processing room I observed the framework of the Hanteman lift for the dumper to have peeling/lifting paint. I also noticed serveral areas of the floor to have peeling/lifting paint. In the RTE packaging room the floor also has lifted and or peeling paint. These areas are not product contact surfaces. [redacted] production manager observed these deficiencies with me. These deficiencies I have discussed with plant management at two weekly meetings. I also informed Beste and the office manager that I would issue an NR. I reviewed the establishments pre-requisite program for construction . The establishments SPS program for construction as well as CFR 416.1 and CFR 416.2(b)(1) have not been met. This document serves as a 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.

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

Citation: This morning at approximately 1030 hrs. while performing inspection duties on the kill floor I observed the following: !. The overhead steel structure above the carcass rail at the final carcass wash station had encrusted or dried product residues from previous days’ production. Kill floor supervisor [redacted] observed this deficiency with me. This is a non product contact surface. I reviewed the Slaughter SSOP record dated 10-19-2010 and signed by [redacted] I saw no mention of this SPS deficiency. CFR 416.1 and 416.4(b) of the regulations have not been met as well as section VII- miscellaneous sanitation in the establishment SSOPs’ page 7. 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.

416.4(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 produc

Code: 03G02
Violation: 417.5(a)(2)

Citation: During the course of a Food Safety Assessment conducted at this establishment (Est. 9672; dates 08/05/2010 to 10/15/2010), the following noncompliance was observed by the EIAO. The establishment does not maintain documents supporting the monitoring procedures and frequencies listed in all Fully Cooked Not Shelf Stable HACCP programs. In addition, the establishment does not maintain documents supporting the verification procedures and frequencies listed in the HACCP plans with the exception of thermometer calibration. The requirements of 417.5(a)(2) of the Meat and Poultry regulations (9 CFR417)have not been met. Ms. [redacted] (Production manager) was informed verbally of the noncompliance.

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: 03G02
Violation: 417.4(a)(2)(i)

Citation: During the course of a Food Safety Assessment conducted at this establishment (Est. 9672; dates 08/05/2010 to 10/15/2010), the following noncompliance was observed by the EIAO. The process-monitoring instrument calibration activities are not being conducted as per the HACCP plans for the Data logger. A review of the HACCP records from 06/01/2010 to 08/15/2010 was conducted; along with a conversation with Ms. [redacted]; Production Supervisor and Mr. [redacted] Plant Manager/Engineer that revealed the establishment has not sent the Data Logger in for maintenance to the manufacturer once per year as stated in the HACCP plans. The requirements of 417.4 (a)(2)(i)of the Meat and Poultry regulations (9 CFR417) as well as those of the establishment’s Fully Cooked Not Shelf Stable HACCP plans (03G products-last reassessed 02/23/2010) have not been met.

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: 06D01
Violation: 417.2(a)(1), 417.5(a)(2)

Citation: During the course of a Food Safety Assessment conducted at this establishment (Est. 9672; dates 08/05/2010 to 10/15/2010) the following noncompliances were observed by the EIAO. Within the Lamb & Goat Slaughter HACCP program, the establishment failed to address Salmonella as a hazard reasonably likely to occur. Additionally, at Process Step #9 “Skinning”, the establishment failed to address any potential Food Safety Hazards (Biological, Chemical or Physical) as reasonably likely to occur (at this step). The requirements of 417.2(a)(1) and 417.2(a)(3) of the Meat and Poultry regulations (9 CFR417) have not been met. Additionally the establishment does not maintain documents supporting the monitoring procedures and frequencies listed in all HACCP Slaughter plans. Also, the establishment does not maintain documents supporting the verification procedures and frequencies listed in the HACCP plans with the exception of the thermometer calibration and titration. The requirements of 417.5(a)(2) of the Meat and Poultry regulation (9 CFR417) have not been met. Ms. [redacted] Production manager) was informed verbally of the noncompliances.

Regulation:

417.2(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: 06D01
Violation: 416.2(b)(1), 416.2(b)(2)

Citation: During the course of a Food Safety Assessment conducted at this establishment (Est. 9672 dates 08/05/2010 to 10/15/2010), the following noncompliance was observed by the EIAO. The Fermentation chamber, located in the Smokehouse area, has rusted out spaces in the floor. There are two areas, approximately 6 inches long by 6 inches wide by a ¬ of an inch deep. The diamond plating appears to be the original flooring. The continued deterioration of the flooring in this room could lead to the creation of insanitary conditions. Ms. [redacted] (Production manager) and Mr. [redacted] (Plant manager) were informed verbally of the noncompliance. The requirements of 416.2 (b)(1) and 416.2(b)(2) of the Meat and Poultry regulations (9 CFR416) as well as those of the establishment’s prerequisite program “SPS for Construction” (reassessment dated 2-23-2010) were not met. This document serves as written notification that failure to comply with regulatory requirements could result in additional regulatory or administrative action outlined in 9 CFR500.

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: 06D01
Violation: 416.1, 416.4(b)

Citation: At approximately 0710 hours, while performing a scheduled preoperational sanitation inspection on the slaughter floor, I observed the following Sanitation Performance Standards noncompliance: 1. The Brisket Saw had oil on the top of the motor housing and the clasp on the overhead support cable had pieces of fat and residue. 2. The Gutting Stand had fat residue on the underside of the hand rail. 3. The underside of the rail at the Final Wash Stand had an accumulation of fat and meat residue from the previous days operation. All areas are non product contact. The slaughter foreman was notified and immediate corrective actions were taken to clean and sanitize the affected areas. There was no further regulatory action taken. Mr. [redacted] Slaughter Foreman was verbally notified of the compliance and the failure to comply with sections 416.1 and 416.4(b) of the Meat Inspection Regulations Sanitation Performance Standards. The establishments sanitation form dated 10/4/2010 did not document this noncompliance. There are no similar noncompliance records on file. 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.

416.4(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), 416.2(b)(2)

Citation: At approximately 0800 hours, while performing a scheduled operational sanitation inspection in the smokehouse area, I observed the following Sanitation Performance Standards noncompliance: 1. Cobwebs were on top of the electrical boxes on the side of the fermentation room and in the wall/ceiling junction behind the Alkar oven. 2. There was peeling paint around the edge of the fan vent in the ceiling between the Alkar and Kerr ovens. 3. There was peeling paint on the north wall near the door leading to the raw processing area. 4. The electrical panel on the west wall next to the data logger has areas of rust. There was no product or product contact areas involved and no further regulatory action was taken. Mr. [redacted] was verbally notified of the noncompliance and the failure to comply with sections 416.1, 416.2(b)(1), and 416.2(b)(2) of the Meat Inspection Regulations Sanitation Performance Standards. This noncompliance was not documented on the establishments sanitation form dated 08/17/2010. A similar SPS structural noncompliance was documented on Noncompliance Record # 8-2010, dated 07/20/2010. 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) 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: 417.5(a)(3)

Citation: At approximately 1100 hours, while performing a scheduled 03J02 procedure on the today’s beef slaughter, I observed that the weekly Lactic Acid thermometer calibration was being recorded on the Thermometer Calibration Log and not on the Lactic Acid Report as stated in the establishments HACCP plan for Beef Slaughter. Page 13 of the establishment’s Beef Slaughter HACCP plan states “[redacted].” Mr. [redacted] was verbally notified of the noncompliance and the failure to comply with section 417.5(a)(3) of the Meat Inspection Regulations and page 13 of the establishments Beef Slaughter HACCP plan. No similar noncompliance reports are on file. This document serves as written notification that your failure to comply with regulatory requirements could result in additional regulatory or administrative action.

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, 416.2(a), 416.2(b)(1), 416.2(b)(2), 416.4(b)

Citation: At approximately 0710 hours, while performing an unscheduled preoperational sanitation inspection on the slaughter floor, I observed the following Sanitation Performance Standards noncompliance: 1. The four skylights have peeling paint on the wood surfaces. 2. There were spider webs on the overhead beams above the blood pit, bleed area, and final wash area. 3. There were numerous blood spots from the previous days operation on the wall at the beef gutting area. There were no product contact areas involved, no product affected and no further regulatory control action taken. Mr. [redacted] Slaughter Foreman, was verbally notified of the noncompliance and the failure to comply with sections 416.1, 416.2(a), 416.2(b)(1), 416.2(b)(2), and 416.4(b) of the Meat Inspection Regulations Sanitation Performance Standards. No documentation of the noncompliance was recorded on the establishments preoperational sanitation form dated 07/20/2010. A similar Noncompliance was recorded on Noncompliance Record # 7-2010, dated 07/08/2010. 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(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)(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: 06D01
Violation: 416.1, 416.4(b)

Citation: At approximately 0705 hours, while performing a scheduled preoperational sanitation inspection on the slaughter floor, I observed the following Sanitation Performance Standards noncompliance: 1. The top rail of the beef gutting stand had dried blood on the outside surface from the previous days operation. 2. The cooler door and adjacent wall had grease from the rail and hooks on an area approximately 2 ft. x 2 ft. The kill floor foreman was notified and both areas were immediately cleaned and sanitized. There were no product contact areas involved and no further regulatory control action was taken. [redacted] was verbally notified of the noncompliance and the failure to comply with sections 416.1 and 416.2(b) of the Meat Inspection Regulations Sanitation Performance Standards. There are no similar noncompliance records on file. The establishments preoperational sanitation form did not document this noncompliance. 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.

416.4(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.