Washington Slaughterhouses

Code: 01C01
Violation: 416.12(a), 416.16(a)

Citation: On 10/04/2011 at approximately 3:40 p.m.while reviewing the establishment’s records for operational sanitation, [redacted] observed that there was an ambient room temperature recording of [redacted] deg (f) in the Sausage Processing Area at 5:50 a.m . and an ambient room tempera ture recording of [redacted] deg (f) in the Bacon Processing Area at 5:54 a.m.which were the initial recordings of ambient room temperatures shortly after the start of the day’soperations. These ambient room temperature recordings are identified as “control points” in the establishment’swritten HACCP plans in their hazard analyzes for both Bacon processing and Sausage processing and are not identified to be associated as biological hazards in the establishment’s production processes. The control measures that are stated in the written hazard analyzes that can be applied to prevent the temperature exceeding is identified as GMP #3 which states the procedures for midshift clean-up. A notation was made at the bottom of the form to indicate that a midshift clean-up will be performed within 4 hours due to the temperature in both areas had exceeded [redacted] deg (f). The employee responsible for oversight of the midshift clean-up in the Sausage Processing Area indicated that the midshift clean-up was performed at 8:00 a.m. An ambient room temperature taken at 9:29 a.m. indicated that the room temperature was at [redacted] deg (f). The employee responsible for oversight of the midshift clean-up in the Bacon Processing Area ind icated that the midshift clean-up was performed at 10:00 a.m. An ambient room tempera ture taken at 9:25 a.m.indicated that the room temperature was still atlideg (f). At the time that the midshift clean-up was performed in the Bacon Processing Area there is no way of knowing what the ambient room temperature was because no ambient temperature monitoring occurred. From 5:54 a.m. until 10:00 a.m.the elapsed time was 4 hours and 6 minutes. The 4 hour time period was exceeded by 6 minutes. A review of the Operational Sanitation Records showed that at 9:10 a.m. in the Sausage Processing Area and at 10:00 a.m . in the Bacon Processing Area where midshift time checklist activities found that the “overall view of operations” in both areas were found to be acceptable. There were no records of midshift clean-up results for either processing area recorded. [redacted] indicated that the form entitled Operational Sanitation Record is a checklist only for operational sanitation inspection. The establishment ‘s written Sanitation SOP plan states that [redacted]. The written procedures do not state that the form is a checklist only form. There was no other documentation generated that provided information pertain ing to the a midshift clean-up in neither the Bacon Processing Area nor in the Sausage Processing Area. A review of past records indicated there was no documentation of resu lts of operational sanitation inspection performance nor corrective actions procedures that are/have been implemented by the establishment daily as required by 9 CFR 416.16(a). The establishment does not describe procedures that will be conducted daily during operations that are sufficient to prevent direct contamination or adulteration of product(s) as requ ired by 9 CFR 416.12(a) [redacted] was notified both verbally and with this NR that the establishment failed to meet regulatory requirements of the Sanitation SOP Inspection Regulations in conjunction with the Federal Meat & Poultry Inspection Acts.

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).

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

Code: 01001
Violation: 416.2(b)(3), 416.4(d)

Citation: On 08/22/2011 at approximately 10:34 a.m. while touring the facility, [redacted] observed that there was outside light seen at the bottom of the roll-up dock door where the door meets the loading/un loading floor ramps and protrud ing through the sides of the loading/un loading floor ramps. There were gaps with the sealing of both the dock doors and the loading/un loading floor ramps which were allowing the outside light to be seen. There are 8 dock doors. Only 1- 2 doors were not affected. [redacted] was both notified on 08/23/2011 that the establishment failed to meet requirements of the Sanitation Performance Standards section of the Sanitation SOP Inspection Regulations of the Federal Meat & Poultry Inspection Acts.

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

Code: 04804
Violation: 317.1

Citation: On May 10, 2011 at approximately 0730 hours, while conducting a general labeling inspection, [redacted] the following non-compliance. Three grey tubs of product which bore no form of identity. The tubs were located inside the man door in the tempering room on the bacon processing floor. [redacted] was notified verbally. It is the responsibility of the establishment to maintain proper identity of product to ensure wholesomeness and correct handling. [redacted] was notified with this written non-compliance record. No past similar NR’s.

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:  03J03
Violation:  310.18, 417.2(c)(4)

Citation:

At 0745 hours, I CSI conducted a zero tolerance check while observed. On the 11 side of 22 sides I found a ( ¼” x ¼” )piece of green fecal material and 3 pieces of yellow fiberous material each approximately 1/8” x ¼”  long. It was located on the second half just below the shoulder blade. The carcass was pulled out of production and trimmed. I notified that this would be documented as an NR. I then re-inspected the carcass and found no further contamination and released it. She placed the carcasses on hold from the last passing zero tolerance to the next passing zero tolerance. [newline] [newline]I notified the establishment both verbally and in writing (this NR) of the Non- Compliance.

Regulation:

310.18  Contamination of carcasses, organs, or other parts: 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:  01B02
Violation:  416.13(c)

Citation:

On Tuesday at 0540 while conducting a Pre Operational review and observation, accompanied by . I CSI   inspected the tendon washer located in the heart room of offal. I found a 1/2”x 4” piece of fat, a ¾” x  1” piece of fat and a 3” x ½” fat all in the bottom of the tendon washer, I notified  . This fat that was found  was on a non product contact area. I also found a ½” x ¼” piece of fat between the seal and metal of the machine. He pulled  out the pieces and washed and sanitized it. This area was a product contact area. I asked him to call to notify him I was documenting this as Non-Compliance. He could not be reached so came to offal. I informed her that this would be documented as Non-Compliance. I also found fecal on the door handle of the sliding door to the Tripas room on the Tripas room side. This is a product contact surface, due to the fact that it is not company policy to wash wash hands(gloves) when entering or leaving this room. Fecal and fat residue was also found on 5 places on the same wall in the Tripas room, as the sliding door. was notified and the area was cleaned and sanitized, this was a non product contact area. Upon further inspection I found 3 spots of blood residue on 2 different offal racks. was notified and they were cleaned and sanitized. These racks are a product contact surface. I notified that these would also be included in the Non-Compliance.[newline] [newline]The company was notified both verbally and in writing (this NR) of the Non-Compliance.

Regulation:

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

Code:  01D01
Violation:  416.2(a)

Citation:

On May 10th at 1230, while walking from the intestine room to the head room down the hallway. I CSI saw a hard bodied insect crawling on the wall. I collected the insect and notified . She said they would write it in the Pest Log book. I stated that this would be documented as a non-compliance.[newline]At 1105 on that same day I observed step on a hard bodied insect in that same vacinity.[newline]On May 11th at 0600 while performing Pre- Operation Sanitation I found another hard shelled crawling insect on the same wall in the hallway between the intestine room and the head room. was with me when I found the insect. I notified and , of the insect and showed them where it was found, and the insect itself. He stated he would let know. I informed him I was going to add this to the previous days non-compliance. [newline]Finding the 3 crawling insects in a short time span demonstrates the ineffectiveness of the company’s Pest and Rodent Management program.[newline]I notified the establishment both verbally and in writing (this NR) of the Non-compliance.

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:  03J03
Violation:  417.2(c)(4)

Citation:

At 1300 hours I inspector conducted a zero tolerance after the final rail, with observing. Ingesta was found on the 8th side of the 22 sides I observed, it was green and yellow in apperance. It was found on the inside of the carcass on the skirt, and outside surface of the brisket. It was an area 2 inches by 3 inches. I notified of the zero tolerance failure. She agreed it was ingesta, and said they would go back and tag the carcasses from the previous passing zero tolerance to the next passing zero tolerance which was conducted right after my check. I re-inspected the failed carcass, all identifiable ingest was removed and the carcass was released. [newline]I notified the establishement both verbally and in writing ( this NR) of the zero tolerance failure.

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:  01D01
Violation:  416.4(d)

Citation:

On March 8, 2012, at approximately 0842 hours, I was requested to inspect an export for ). The pallets of product were staged for shipment on the Shipping Dock and wrapped for loading. During my inspection of the product, the following non-compliance was observed: At approximately 0910 hours I noticed a box on the bottom row of a pallet with exposed meat protruding from the top of the box lid. The meat was approximately one inch by 3/8 inch in dimension. I immediately applied USDA Retain Tag #B38348029 to the case and requested that it be removed from the pallet. I continued my inspection of the next pallet and noticed a portion ofthe blue plastic liner that the product is packed in was outside a box. I requested that this box also be removed from the order to be inspected. A closer examination revealed small particles of brownish-tan fibers on the surface of the meat of the first box. These fibers were consistent with the fibers of the cardboard box lid. A small tear in the lid caused the product to push out of the opening at a point prior to freezing the product. The blue liner was not covering the product in this area, causing it to contact the exposed surface of the cardboard box. The cardboard box lids are not wax lined and are porous.The plain cardboard is not approved as a food contact surface.The second box of product was also making incidental contact with the interior surface of the cardboard box. The blue liner was not in place to protect the product from contacting this unprotected surface. At a point in the process, previous to the staging of the Frozen product, the top portion of the liner had come out of the box on one side and exposed the product to the incidental contact surface of the cardboard box. I verbally notified , of the company’s non-compliance with the above cited regulations and told him that a written record would be given to the facility. Mr. was in the area when the non-compliance was observed. He stated that he would remove the product to the QA Hold area for disposition by the company. I removed my USDA Retain Tag from the box and allowed the company to assume control of their product. Mr. marked out the export marks on the two boxes and wrote “Inedible” across the front panel of the boxes. The product was later disposed of into rendering. Two new boxes were added to the export load to complete the order. The company’s Damaged Goods SOP- Prerequisite Program dated 11/10/2011 states, ” The warehouse personnel failed to identify and segregate the affected boxes prior to completing the order for shipment. No similar non-compliances have been written for common causes.

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:  01C01
Violation:  416.15(a), 416.16(a), 416.4(d)

Citation:

On February 17, 2012, I reviewed the previous week’s records for the Trim Line Metal Detector used on the Fabrication Floor. I noticed the record, dated February 10, 2012,had not been initialled and dated as being reviewed at the end of the production day. On closer examination of the record, it showed that two pieces of metal were found in the product at 0751 hours. The pieces of metal were attached to the back of the sheet in a sealed bag. The only corrective action listed was the disposition of the affected product into inedible. On Monday, February 13, 2012, another instance of metal being found in product was recorded at0953 hours. Again, the only corrective action was the disposition of the product into inedible. was verbally informed of this non-compliance with the above cited Federal Regulations and that a written record would be given to the establishment.The company’s Metal Detectors are listed in a Pre-Requisite program dated February 02, 2012. Under the heading ‘ ‘, number 3 states, Though product disposition was taken, no further planned action is shown for either occurrence. No similar NR’s have been written for common causes.

Regulation:

416.15(a)  Corrective Action: 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.

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), 416.4(b)

Citation:

Pre-operational Sanitation of the Fabrication Area was conducted between 0515 and 0555 hours. Insanitary conditions were identified in the following food contact and non-food contact areas: A meat hook at the scale stand in the tunnel had fat residue on the handle and on the contact surface. Numerous fat scraps were identified inside the on the guide bar, the walls, and the floor. Numerous meat and fat scraps were identified on the Round Drop conveyor transfer belt for Table #5. The pieces were on the belt, the framework, and on the rollers. The pieces ranged from an 1/8th to 3 inches in length. USDA Reject Tag #B38349947 was applied to the conveyor. At 0550 hours the belt was reinspected, the USDA Tag was removed,and the area was released for production. The machine had numerous fat and meat pieces on the metal table surface, circular metal extractor, plastic belt rollers, and the framework behind the plastic rollers. Table #6 ( ) had numerous fat and meat pieces on the table, belt, plastic rollers, and framework. The East side Cutting Table on the had fat residue on the cutting surface and on the framework. The Fat Divert Incline Transfer Belt for the had numerous fat and meat pieces on the belt, plastic rollers, and framework. The Crossover Fat Conveyor had numerous fat and meat pieces on the conveyor, plastic rollers, and framework on the incline section near the CO2 Hoods. , was verbally informed of these non-compliances with the Federal Regulations and told that a written copy would be provided to the plant. These areas identified were re-cleaned, re-inspected, sanitized and released for production. The establishment’s SSOP program, on page #2 under the heading ” ,” states, .” Page #3 under the heading ” , ” ” The Pre-operational Sanitation Record did not identify any of these areas as being insanitary or having been re-cleaned prior to the USDA inspection. The monitoring was insufficient to prevent the above cited non-compliances.

Regulation:

416.13(c)  Implementation of SOP’s: 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:  01C02
Violation:  416.13(c)

Citation:

On Friday November 18, 2011 at approximately 0555 hours, while performing a routine sanitation overview of the Fabrication area, CSI observed the following. The Rib Cap Puller had fat residue from the previous day fabrication on the grab plate and the cable for the counter balance. The grab plant and the teeth for gripping the rib cap is a direct contact surface the cable is an incidental contact surface. CSI was able to locate Mr. ) who was in the general area and Ms. Ms, stopped the carcass chain at a distance far enough from the Rib Cap Puller to allow for cleaning. Mr. then used degree water to remove the residue from the Rib Cap Puller. CSI then re-inspected and passed the Rib Cap Puller. Ms re- started the fabrication carcass chain and fabrication resumed. Plant Personnel , Ms. took action and stopped the carcasses from coming into the affected area therefore no regulatory controls were required by the CSI. CSI reviewed the plant pre-operational records and the Rib Cap Puller had been marked as acceptable by the plant pre- operational inspection personnel. There was not an FSIS pre-operational sanitation inspection scheduled for Friday November 18, 2011 in the fabrication area. Plant carcass chain start up is at approximately 0545 hours, the carcasses were close enough to the area involved and to the Rib Cap Puller that Ms. had to stop the chain when CSI informed her of the deficiency to assure enough room to clean the Rib Cap Puller. The plant operational sanitation monitoring is not necessarily designed to monitor this type of Plant Pre-operational inspection failure which would indicate this piece of equipment would likely have been used. Page (1) of (16) paragraph (lll) of the plant SSOP’s states the following:   “    Page (3) of (16) Paragraph (B) (a) (i) also states the following: “   ”. (iii) states:    .

Regulation:

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

Code:  01B02
Violation:  416.13(c)

Citation:

On Tuesday November 15, 2011 at approximately 0535 hours, while performing a pre-operational review and observation CSI observed the following: Fat residue from the previous days production in two (2) of the holes in Table six (6) also known as the wizard table. The holes are located on the interlock conveyor section of the table which is a direct contact surface. CSI immediately informed Mr. who was accompanying the CSI during the pre-operation review and observation. Mr. instructed the available sanitation crew to use a hot water high pressure hose to remove the fat residue from the holes in the table. The sanitation crew washed Table six (6) presented it for re-inspection, Table six (6) was re-inspected, passed by CSI and Mr. [newline] and then sanitized prior to product being introduced into the area. [newline][newline]There are approximately 110-130 holes on the interlock conveyor section of Table six (6). Plant maintenance is researching a solution for the problem with the deterioration of the interlock conveyor.[newline][newline]Page (1) of (16) paragraph (lll) of the plant SSOP’s states the  following:       Page (3) of (16) Paragraph (B) (a) (i) also states the following:     (iii) states:   [newline][newline]There was a Non Compliance NR# 0038-2011- 17683 PBIS written on 10/13/2011 for Previous Ineffective Plant Actions: plant failed to identify deficiencies during plant pre- operational inspection.

Regulation:

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

Code:  01D01
Violation:  416.4(b)

Citation:

On Friday November 11, 2011 at approximately 0520 hours while performing an pre-operational sanitation inspection, I CSI observed the following: 2 out 4 electric boxes that had fecal, hair and fat on them, one of the boxes is located left of inedible take away belt located in hide-on side area and the other is located on left hand side of side puller facing both areas from ground level, both areas being non-contact surfaces. Clean-up advised me that they change plastic covering on boxes every night. I immediatedly told about boxes and he had clean-up remove plastic and clean, no tag was issued because I stayed in immediate area entire time they cleaned boxes which were then released. I continued my inspection and at approximately 0540 I saw numerous pieces of fat on overhead rails, filter box and overhead structures, these areas are non-contact areas. I took immediate regulatory control action and applied USDA Reject Tag #B38349976 on equipment below affected area and told of affected area and he had clean-up immediately clean. I continued the rest of my inspection and then was informed rejected area was ready for re-inspection so I proceded to affected area, inspected and released. When I reviewed pre-operational records for 11-11-11 (today) I found that company had changed from acceptable to un-acceptable in both of these areas. The electrical boxes were marked acceptable on Page 1 of their (Prerequisite Programs) pre-operational plant inspection record under Area 1 Fans, then it was stated un-acceptable under Area 1 Fans/Electric Boxes after USDA findings. The other area was marked acceptable on Page 1 of their (Prerequisite Programs) pre-operational plant inspection record under Area 4 Overheads, then it was stated un-acceptable under Area 4 Overheads after USDA findings. I notified verbally of this noncompliance and that a written record would be issued.  No product injurious to public health was involved.  No similar NR’s have been written in past 90 days for same cause.

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), 416.4(d)

Citation:

On Thursday October 13, 2011 at approxiamately 05:40 hours while performing an O1BO2 procedure (pre-operational sanitation inspection) CSI observed the following: The product contact side of the Crossover Trim line had small particles of fat and meat residue from the previous days fabrication. The particles found ranged from ª inch to 2 inches in size. The product contact side of the Crossover Fat Line was also found with fat residue from the previous day’s fabrication and black grease like substance. CSI immediately notified Mr. and Mr. who were accompanying the CSI during the pre-operational sanitation inspection. Mr. and Mr. instructed the available sanitation crew to re-clean and sanitize the Crossover Trim line and the Crossover Fat line. The Crossover Trim line and the Crossover Fat line were re-inspected and passed by CSI and Mr. upon completion of the re-cleaning and sanitizing. Page one (1) of seventeen (17) of the Plant SSOP’s states the following: ” Page three (3) of seventeen (17) bullet (1) of the plant SSOP’s under the monitoring section also states: . Bullet (3) in that same section states I notified Ms. and Mr verbally and with this document of the above non-compliance. Fabrication had not started therefore no product was involved and no product injurious to the public health was allowed to enter into commerce. Past Similar NRs – Previous Ineffective Plant Actions: Failure ot identify deficiencies during plant pre-operational inspection NR: 24-2011 dated 9/12/2011

Regulation:

416.13(c)  Implementation of SOP’s: 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:  01C01
Violation:  416.14

Citation:

On Tuesday October 4, 2011 at approximately 0745 hours while performing a scheduled 01C01 procedure (review establishments SS0P records) I CSI observed the following: Establishments SSOP daily records dated from (09- 16-11 through 10-03-11 which consist of 13 production days with 1 day being Saturday) stated condensation present in drip #2 cooler on overhead rails (#32, #33, and #34) most consistently #33 and #34. The establishment’s maintenance of procedures on page (17) paragraph (2) states in part ” and also page (17) paragraph (2) states . Records are consistently documenting condensation on overhead rails above cattle with no preventive measure documented in recordkeeping as being met. As per SSOP’s for product under condensation establishment is following proper procedures for dripping or not dripping on cattle, segregating cattle and observing for contamination which is trimmed, then sprayed with . Establishment failed to meet requirements of CFR 416.4(d) states product must be protected from adulteration during storage at official establishments, and also CFR 416.14 states each establishment shall routinely evaluate the effectiveness of the Sanitation SOP’s and the procedures therein in preventing direct contamination or adulteration of product’s. Establishment did not meet procedure to prevent product from contamination. I notified verbally and with this document of the above non compliance. No product injurious to the public health was allowed to enter into commerce. There have been no other NR’s written for the same cause in the previous 90 days.

Regulation:

416.14  Maintenance of Sanitation SOP’s. 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:  03J02
Violation:  417.2(b), 417.4(a)(2) (i), 417.4(a)(2) (ii)

Citation:

Starting on June 7, 2011 a Comprehensive Food Safety Assessment was performed at Washington Beef Inc. Est. 00235 M. While reviewing the 03J Slaughter HACCP Plan EIAO and EIAO identified that the company failed to meet the requirements of the following regulations: 9 CFR 417.4(a)(2)(i) EIAO observed the employee conducting the calibration of hand held thermometers. The employee placed a hand held dial thermometer in a container of ice and water along with a thermometer certified for accuracy. The certified thermometer revealed a temperature of 32 degrees F and the hand held thermometer read 34degrees F. The firm’s employee failed to adjust the hand held thermometer to read the exact temperature of 32 degrees F and recorded the results as “0” indicating that the thermometer was reading correctly and no adjustment was required and the calibration of the thermometer was conducted. With the firm not conducting the calibration of thermometers to read correctly, the monitoring of CCPs (CCP 7-B and CCP 8-B .) could be inaccurate. The EIAO informed Ms. of the observations. Ms. advised the EIAO that the firm was following their supporting document, which states Ms. advised the EIAO that and changes were made to the firm’s implementation of the calibrations procedures. The same issue is also in the 03C Raw not Ground process because hand held thermometers are calibrated the same for the entire plant. 9 CFR 417.4(a) The review of the firm’s record titled ” ” from March 29, 2011, through May 29, 2011, revealed that the firm was not conducting the verification procedure of direct observation of monitoring ” as written in the firm’s O3J Slaughter HACCP plan. The firm only conducted the verification procedure of direct observation a total of four times out of 47 days worth of records. 9 CFR 417.2(b) On July 1, 2011, the EIAO observed the firm’s employee conducting the monitoring of The EIAO observed the firm’s employee monitoring five hindquarters from the kidney/diaphragm up to the top of the H bone (pelvic bone). The observations revealed that the employee conducting the CCP monitoring did not raise his head or eyes to a height that would enable him to look at the inside round, outside round and hock areas. It was also observed that if he did look at the hock area that the stand used for the monitoring of the CCP is too short for the employee to adequately inspect the hock area and assure that the hazards of fecal, ingesta and milk is not likely to occur. The company was notified of the above non-compliances at the Comprehensive Food Safety Assessment Exit Meeting.

Regulation:

417.2(b)  The HACCP plan. (1) Every establishment shall develop and implement a written HACCP plan covering each product produced by that establishment whenever a hazard analysis reveals one or more food safety hazards that are reasonably likely to occur, based on the hazard analysis conducted in accordance with paragraph (a) of this section, including products in the following processing categories: (i) Slaughter—all species. (ii) Raw product—ground. (iii) Raw product—not ground. (iv) Thermally processed—commercially sterile. (v) Not heat treated—shelf stable. (vi) Heat treated—shelf stable. (vii) Fully cooked—not shelf stable. (viii) Heat treated but not fully cooked—not shelf stable. (ix) Product with secondary inhibitors—not shelf stable.

417.4(a)(2)  Ongoing verification activities. Ongoing verification activities include, but are not limited to: (i) The calibration of process-monitoring instruments; (ii) Direct observations of monitoring activities and corrective actions; and (iii) The review of records generated and maintained in accordance with § 417.5(a)(3) of this part

417.4(a)(2)  Ongoing verification activities. Ongoing verification activities include, but are not limited to: (i) The calibration of process-monitoring instruments; (ii) Direct observations of monitoring activities and corrective actions; and (iii) The review of records generated and maintained in accordance with § 417.5(a)(3) of this part

Code:  03J02
Violation:  417.2(b), 417.4(a)(2) (i), 417.4(a)(2) (ii)

Citation:

Starting on June 7, 2011 a Comprehensive Food Safety Assessment was performed at Washington Beef Inc. Est. 00235 M. While reviewing the 03J Slaughter HACCP Plan EIAO and EIAO identified that the company failed to meet the requirements of the following regulations: 9 CFR 417.4(a)(2)(i) EIAO observed the employee conducting the calibration of hand held thermometers. The employee placed a hand held dial thermometer in a container of ice and water along with a thermometer certified for accuracy. The certified thermometer revealed a temperature of 32 degrees F and the hand held thermometer read 34degrees F. The firm’s employee failed to adjust the hand held thermometer to read the exact temperature of 32 degrees F and recorded the results as “0” indicating that the thermometer was reading correctly and no adjustment was required and the calibration of the thermometer was conducted. With the firm not conducting the calibration of thermometers to read correctly, the monitoring of CCPs (CCP 7-B and CCP 8-B .) could be inaccurate. The EIAO informed Ms. of the observations. Ms. advised the EIAO that the firm was following their supporting document, which states Ms. advised the EIAO that and changes were made to the firm’s implementation of the calibrations procedures. The same issue is also in the 03C Raw not Ground process because hand held thermometers are calibrated the same for the entire plant. 9 CFR 417.4(a) The review of the firm’s record titled ” ” from March 29, 2011, through May 29, 2011, revealed that the firm was not conducting the verification procedure of direct observation of monitoring ” as written in the firm’s O3J Slaughter HACCP plan. The firm only conducted the verification procedure of direct observation a total of four times out of 47 days worth of records. 9 CFR 417.2(b) On July 1, 2011, the EIAO observed the firm’s employee conducting the monitoring of The EIAO observed the firm’s employee monitoring five hindquarters from the kidney/diaphragm up to the top of the H bone (pelvic bone). The observations revealed that the employee conducting the CCP monitoring did not raise his head or eyes to a height that would enable him to look at the inside round, outside round and hock areas. It was also observed that if he did look at the hock area that the stand used for the monitoring of the CCP is too short for the employee to adequately inspect the hock area and assure that the hazards of fecal, ingesta and milk is not likely to occur. The company was notified of the above non-compliances at the Comprehensive Food Safety Assessment Exit Meeting.

Regulation:

417.2(b)  The HACCP plan. (1) Every establishment shall develop and implement a written HACCP plan covering each product produced by that establishment whenever a hazard analysis reveals one or more food safety hazards that are reasonably likely to occur, based on the hazard analysis conducted in accordance with paragraph (a) of this section, including products in the following processing categories: (i) Slaughter—all species. (ii) Raw product—ground. (iii) Raw product—not ground. (iv) Thermally processed—commercially sterile. (v) Not heat treated—shelf stable. (vi) Heat treated—shelf stable. (vii) Fully cooked—not shelf stable. (viii) Heat treated but not fully cooked—not shelf stable. (ix) Product with secondary inhibitors—not shelf stable.

417.4(a)(2)  Ongoing verification activities. Ongoing verification activities include, but are not limited to: (i) The calibration of process-monitoring instruments; (ii) Direct observations of monitoring activities and corrective actions; and (iii) The review of records generated and maintained in accordance with § 417.5(a)(3) of this part

417.4(a)(2)  Ongoing verification activities. Ongoing verification activities include, but are not limited to: (i) The calibration of process-monitoring instruments; (ii) Direct observations of monitoring activities and corrective actions; and (iii) The review of records generated and maintained in accordance with § 417.5(a)(3) of this part

Code:  03J02
Violation:  417.2(b), 417.4(a)(2) (i), 417.4(a)(2) (ii)

Citation:

Starting on June 7, 2011 a Comprehensive Food Safety Assessment was performed at Washington Beef Inc. Est. 00235 M. While reviewing the 03J Slaughter HACCP Plan EIAO and EIAO identified that the company failed to meet the requirements of the following regulations: 9 CFR 417.4(a)(2)(i) EIAO observed the employee conducting the calibration of hand held thermometers. The employee placed a hand held dial thermometer in a container of ice and water along with a thermometer certified for accuracy. The certified thermometer revealed a temperature of 32 degrees F and the hand held thermometer read 34degrees F. The firm’s employee failed to adjust the hand held thermometer to read the exact temperature of 32 degrees F and recorded the results as “0” indicating that the thermometer was reading correctly and no adjustment was required and the calibration of the thermometer was conducted. With the firm not conducting the calibration of thermometers to read correctly, the monitoring of CCPs (CCP 7-B and CCP 8-B .) could be inaccurate. The EIAO informed Ms. of the observations. Ms. advised the EIAO that the firm was following their supporting document, which states Ms. advised the EIAO that and changes were made to the firm’s implementation of the calibrations procedures. The same issue is also in the 03C Raw not Ground process because hand held thermometers are calibrated the same for the entire plant. 9 CFR 417.4(a) The review of the firm’s record titled ” ” from March 29, 2011, through May 29, 2011, revealed that the firm was not conducting the verification procedure of direct observation of monitoring ” as written in the firm’s O3J Slaughter HACCP plan. The firm only conducted the verification procedure of direct observation a total of four times out of 47 days worth of records. 9 CFR 417.2(b) On July 1, 2011, the EIAO observed the firm’s employee conducting the monitoring of The EIAO observed the firm’s employee monitoring five hindquarters from the kidney/diaphragm up to the top of the H bone (pelvic bone). The observations revealed that the employee conducting the CCP monitoring did not raise his head or eyes to a height that would enable him to look at the inside round, outside round and hock areas. It was also observed that if he did look at the hock area that the stand used for the monitoring of the CCP is too short for the employee to adequately inspect the hock area and assure that the hazards of fecal, ingesta and milk is not likely to occur. The company was notified of the above non-compliances at the Comprehensive Food Safety Assessment Exit Meeting.

Regulation:

417.2(b)  The HACCP plan. (1) Every establishment shall develop and implement a written HACCP plan covering each product produced by that establishment whenever a hazard analysis reveals one or more food safety hazards that are reasonably likely to occur, based on the hazard analysis conducted in accordance with paragraph (a) of this section, including products in the following processing categories: (i) Slaughter—all species. (ii) Raw product—ground. (iii) Raw product—not ground. (iv) Thermally processed—commercially sterile. (v) Not heat treated—shelf stable. (vi) Heat treated—shelf stable. (vii) Fully cooked—not shelf stable. (viii) Heat treated but not fully cooked—not shelf stable. (ix) Product with secondary inhibitors—not shelf stable.

417.4(a)(2)  Ongoing verification activities. Ongoing verification activities include, but are not limited to: (i) The calibration of process-monitoring instruments; (ii) Direct observations of monitoring activities and corrective actions; and (iii) The review of records generated and maintained in accordance with § 417.5(a)(3) of this part

417.4(a)(2)  Ongoing verification activities. Ongoing verification activities include, but are not limited to: (i) The calibration of process-monitoring instruments; (ii) Direct observations of monitoring activities and corrective actions; and (iii) The review of records generated and maintained in accordance with § 417.5(a)(3) of this part

Code:  03J02
Violation:  417.2(b), 417.4(a)(2) (i), 417.4(a)(2) (ii)

Citation:

Starting on June 7, 2011 a Comprehensive Food Safety Assessment was performed at Washington Beef Inc. Est. 00235 M. While reviewing the 03J Slaughter HACCP Plan EIAO and EIAO identified that the company failed to meet the requirements of the following regulations: 9 CFR 417.4(a)(2)(i) EIAO observed the employee conducting the calibration of hand held thermometers. The employee placed a hand held dial thermometer in a container of ice and water along with a thermometer certified for accuracy. The certified thermometer revealed a temperature of 32 degrees F and the hand held thermometer read 34degrees F. The firm’s employee failed to adjust the hand held thermometer to read the exact temperature of 32 degrees F and recorded the results as “0” indicating that the thermometer was reading correctly and no adjustment was required and the calibration of the thermometer was conducted. With the firm not conducting the calibration of thermometers to read correctly, the monitoring of CCPs (CCP 7-B and CCP 8-B .) could be inaccurate. The EIAO informed Ms. of the observations. Ms. advised the EIAO that the firm was following their supporting document, which states Ms. advised the EIAO that and changes were made to the firm’s implementation of the calibrations procedures. The same issue is also in the 03C Raw not Ground process because hand held thermometers are calibrated the same for the entire plant. 9 CFR 417.4(a) The review of the firm’s record titled ” ” from March 29, 2011, through May 29, 2011, revealed that the firm was not conducting the verification procedure of direct observation of monitoring ” as written in the firm’s O3J Slaughter HACCP plan. The firm only conducted the verification procedure of direct observation a total of four times out of 47 days worth of records. 9 CFR 417.2(b) On July 1, 2011, the EIAO observed the firm’s employee conducting the monitoring of The EIAO observed the firm’s employee monitoring five hindquarters from the kidney/diaphragm up to the top of the H bone (pelvic bone). The observations revealed that the employee conducting the CCP monitoring did not raise his head or eyes to a height that would enable him to look at the inside round, outside round and hock areas. It was also observed that if he did look at the hock area that the stand used for the monitoring of the CCP is too short for the employee to adequately inspect the hock area and assure that the hazards of fecal, ingesta and milk is not likely to occur. The company was notified of the above non-compliances at the Comprehensive Food Safety Assessment Exit Meeting.

Regulation:

417.2(b)  The HACCP plan. (1) Every establishment shall develop and implement a written HACCP plan covering each product produced by that establishment whenever a hazard analysis reveals one or more food safety hazards that are reasonably likely to occur, based on the hazard analysis conducted in accordance with paragraph (a) of this section, including products in the following processing categories: (i) Slaughter—all species. (ii) Raw product—ground. (iii) Raw product—not ground. (iv) Thermally processed—commercially sterile. (v) Not heat treated—shelf stable. (vi) Heat treated—shelf stable. (vii) Fully cooked—not shelf stable. (viii) Heat treated but not fully cooked—not shelf stable. (ix) Product with secondary inhibitors—not shelf stable.

417.4(a)(2)  Ongoing verification activities. Ongoing verification activities include, but are not limited to: (i) The calibration of process-monitoring instruments; (ii) Direct observations of monitoring activities and corrective actions; and (iii) The review of records generated and maintained in accordance with § 417.5(a)(3) of this part

417.4(a)(2)  Ongoing verification activities. Ongoing verification activities include, but are not limited to: (i) The calibration of process-monitoring instruments; (ii) Direct observations of monitoring activities and corrective actions; and (iii) The review of records generated and maintained in accordance with § 417.5(a)(3) of this part

Code:  03J02
Violation:  417.2(b), 417.4(a)(2) (i), 417.4(a)(2) (ii)

Citation:

Starting on June 7, 2011 a Comprehensive Food Safety Assessment was performed at Washington Beef Inc. Est. 00235 M. While reviewing the 03J Slaughter HACCP Plan EIAO and EIAO identified that the company failed to meet the requirements of the following regulations: 9 CFR 417.4(a)(2)(i) EIAO observed the employee conducting the calibration of hand held thermometers. The employee placed a hand held dial thermometer in a container of ice and water along with a thermometer certified for accuracy. The certified thermometer revealed a temperature of 32 degrees F and the hand held thermometer read 34degrees F. The firm’s employee failed to adjust the hand held thermometer to read the exact temperature of 32 degrees F and recorded the results as “0” indicating that the thermometer was reading correctly and no adjustment was required and the calibration of the thermometer was conducted. With the firm not conducting the calibration of thermometers to read correctly, the monitoring of CCPs (CCP 7-B and CCP 8-B .) could be inaccurate. The EIAO informed Ms. of the observations. Ms. advised the EIAO that the firm was following their supporting document, which states Ms. advised the EIAO that and changes were made to the firm’s implementation of the calibrations procedures. The same issue is also in the 03C Raw not Ground process because hand held thermometers are calibrated the same for the entire plant. 9 CFR 417.4(a) The review of the firm’s record titled ” ” from March 29, 2011, through May 29, 2011, revealed that the firm was not conducting the verification procedure of direct observation of monitoring ” as written in the firm’s O3J Slaughter HACCP plan. The firm only conducted the verification procedure of direct observation a total of four times out of 47 days worth of records. 9 CFR 417.2(b) On July 1, 2011, the EIAO observed the firm’s employee conducting the monitoring of The EIAO observed the firm’s employee monitoring five hindquarters from the kidney/diaphragm up to the top of the H bone (pelvic bone). The observations revealed that the employee conducting the CCP monitoring did not raise his head or eyes to a height that would enable him to look at the inside round, outside round and hock areas. It was also observed that if he did look at the hock area that the stand used for the monitoring of the CCP is too short for the employee to adequately inspect the hock area and assure that the hazards of fecal, ingesta and milk is not likely to occur. The company was notified of the above non-compliances at the Comprehensive Food Safety Assessment Exit Meeting.

Regulation:

417.2(b)  The HACCP plan. (1) Every establishment shall develop and implement a written HACCP plan covering each product produced by that establishment whenever a hazard analysis reveals one or more food safety hazards that are reasonably likely to occur, based on the hazard analysis conducted in accordance with paragraph (a) of this section, including products in the following processing categories: (i) Slaughter—all species. (ii) Raw product—ground. (iii) Raw product—not ground. (iv) Thermally processed—commercially sterile. (v) Not heat treated—shelf stable. (vi) Heat treated—shelf stable. (vii) Fully cooked—not shelf stable. (viii) Heat treated but not fully cooked—not shelf stable. (ix) Product with secondary inhibitors—not shelf stable.

417.4(a)(2)  Ongoing verification activities. Ongoing verification activities include, but are not limited to: (i) The calibration of process-monitoring instruments; (ii) Direct observations of monitoring activities and corrective actions; and (iii) The review of records generated and maintained in accordance with § 417.5(a)(3) of this part

417.4(a)(2)  Ongoing verification activities. Ongoing verification activities include, but are not limited to: (i) The calibration of process-monitoring instruments; (ii) Direct observations of monitoring activities and corrective actions; and (iii) The review of records generated and maintained in accordance with § 417.5(a)(3) of this part

Code:  03J02
Violation:  417.2(b), 417.4(a)(2) (i), 417.4(a)(2) (ii)

Citation:

Starting on June 7, 2011 a Comprehensive Food Safety Assessment was performed at Washington Beef Inc. Est. 00235 M. While reviewing the 03J Slaughter HACCP Plan EIAO and EIAO identified that the company failed to meet the requirements of the following regulations: 9 CFR 417.4(a)(2)(i) EIAO observed the employee conducting the calibration of hand held thermometers. The employee placed a hand held dial thermometer in a container of ice and water along with a thermometer certified for accuracy. The certified thermometer revealed a temperature of 32 degrees F and the hand held thermometer read 34degrees F. The firm’s employee failed to adjust the hand held thermometer to read the exact temperature of 32 degrees F and recorded the results as “0” indicating that the thermometer was reading correctly and no adjustment was required and the calibration of the thermometer was conducted. With the firm not conducting the calibration of thermometers to read correctly, the monitoring of CCPs (CCP 7-B and CCP 8-B .) could be inaccurate. The EIAO informed Ms. of the observations. Ms. advised the EIAO that the firm was following their supporting document, which states Ms. advised the EIAO that and changes were made to the firm’s implementation of the calibrations procedures. The same issue is also in the 03C Raw not Ground process because hand held thermometers are calibrated the same for the entire plant. 9 CFR 417.4(a) The review of the firm’s record titled ” ” from March 29, 2011, through May 29, 2011, revealed that the firm was not conducting the verification procedure of direct observation of monitoring ” as written in the firm’s O3J Slaughter HACCP plan. The firm only conducted the verification procedure of direct observation a total of four times out of 47 days worth of records. 9 CFR 417.2(b) On July 1, 2011, the EIAO observed the firm’s employee conducting the monitoring of The EIAO observed the firm’s employee monitoring five hindquarters from the kidney/diaphragm up to the top of the H bone (pelvic bone). The observations revealed that the employee conducting the CCP monitoring did not raise his head or eyes to a height that would enable him to look at the inside round, outside round and hock areas. It was also observed that if he did look at the hock area that the stand used for the monitoring of the CCP is too short for the employee to adequately inspect the hock area and assure that the hazards of fecal, ingesta and milk is not likely to occur. The company was notified of the above non-compliances at the Comprehensive Food Safety Assessment Exit Meeting.

Regulation:

417.2(b)  The HACCP plan. (1) Every establishment shall develop and implement a written HACCP plan covering each product produced by that establishment whenever a hazard analysis reveals one or more food safety hazards that are reasonably likely to occur, based on the hazard analysis conducted in accordance with paragraph (a) of this section, including products in the following processing categories: (i) Slaughter—all species. (ii) Raw product—ground. (iii) Raw product—not ground. (iv) Thermally processed—commercially sterile. (v) Not heat treated—shelf stable. (vi) Heat treated—shelf stable. (vii) Fully cooked—not shelf stable. (viii) Heat treated but not fully cooked—not shelf stable. (ix) Product with secondary inhibitors—not shelf stable.

417.4(a)(2)  Ongoing verification activities. Ongoing verification activities include, but are not limited to: (i) The calibration of process-monitoring instruments; (ii) Direct observations of monitoring activities and corrective actions; and (iii) The review of records generated and maintained in accordance with § 417.5(a)(3) of this part

417.4(a)(2)  Ongoing verification activities. Ongoing verification activities include, but are not limited to: (i) The calibration of process-monitoring instruments; (ii) Direct observations of monitoring activities and corrective actions; and (iii) The review of records generated and maintained in accordance with § 417.5(a)(3) of this part

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

Citation:

During a Comprehensive Assessment of the Execution and Design of an Establishment’s Food Safety System that began June 7, 2011 the following SPS noncompliances were identified by EIAO and : The Establishment failed to meet the requirements of 9 CFR 416.2(b)(i) and 416.2(b)(2). EIAO observed that in the slaughter paunch separation/emptying room that the south wall had peeling paint and mold black in color on it. The area of peeling paint and mold measured approximately 4 feet by 6 feet. The metal wall above the paunch auger had a brown colored buildup on it from previous day’s operations that measured approximately 4 feet by 12 inches. In the slaughter paunch separation/emptying room and the intestine cleaning/braiding room the overhead electrical junction boxes, electrical conduit clips, rods used to hold up pipes and the exhaust vent were observed to be heavily rusted and not being maintained in good repair. The company failed to meet the requirements of 9 CFR 416.2(e)(3) On July 1, 2011, the EIAO observed that the slaughter floor had three insulated water lines above the firm’s beef carcass trim stations that transverse from the north to the south ends of the slaughter floor. The water lines had approximately 10 dead end pipes that measured from approximately 12 inches up to 48 inches in length. Dr. , Supervisory Public Health Veterinarian/Inspector In Charge (SPHV/IIC), Mr. , Supervisory Consumer Safety Inspector, (SCSI), Mr. and an unknown maintenance supervisor were informed and observed the EIAOs observations. The company was informed of these noncompliances in the Comprehensive Food Safety Assessment Exit Meeting.

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(b)(2) , 416.2(e)(3)

Citation:

During a Comprehensive Assessment of the Execution and Design of an Establishment’s Food Safety System that began June 7, 2011 the following SPS noncompliances were identified by EIAO and : The Establishment failed to meet the requirements of 9 CFR 416.2(b)(i) and 416.2(b)(2). EIAO observed that in the slaughter paunch separation/emptying room that the south wall had peeling paint and mold black in color on it. The area of peeling paint and mold measured approximately 4 feet by 6 feet. The metal wall above the paunch auger had a brown colored buildup on it from previous day’s operations that measured approximately 4 feet by 12 inches. In the slaughter paunch separation/emptying room and the intestine cleaning/braiding room the overhead electrical junction boxes, electrical conduit clips, rods used to hold up pipes and the exhaust vent were observed to be heavily rusted and not being maintained in good repair. The company failed to meet the requirements of 9 CFR 416.2(e)(3) On July 1, 2011, the EIAO observed that the slaughter floor had three insulated water lines above the firm’s beef carcass trim stations that transverse from the north to the south ends of the slaughter floor. The water lines had approximately 10 dead end pipes that measured from approximately 12 inches up to 48 inches in length. Dr. , Supervisory Public Health Veterinarian/Inspector In Charge (SPHV/IIC), Mr. , Supervisory Consumer Safety Inspector, (SCSI), Mr. and an unknown maintenance supervisor were informed and observed the EIAOs observations. The company was informed of these noncompliances in the Comprehensive Food Safety Assessment Exit Meeting.

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(b)(2) , 416.2(e)(3)

Citation:

During a Comprehensive Assessment of the Execution and Design of an Establishment’s Food Safety System that began June 7, 2011 the following SPS noncompliances were identified by EIAO and : The Establishment failed to meet the requirements of 9 CFR 416.2(b)(i) and 416.2(b)(2). EIAO observed that in the slaughter paunch separation/emptying room that the south wall had peeling paint and mold black in color on it. The area of peeling paint and mold measured approximately 4 feet by 6 feet. The metal wall above the paunch auger had a brown colored buildup on it from previous day’s operations that measured approximately 4 feet by 12 inches. In the slaughter paunch separation/emptying room and the intestine cleaning/braiding room the overhead electrical junction boxes, electrical conduit clips, rods used to hold up pipes and the exhaust vent were observed to be heavily rusted and not being maintained in good repair. The company failed to meet the requirements of 9 CFR 416.2(e)(3) On July 1, 2011, the EIAO observed that the slaughter floor had three insulated water lines above the firm’s beef carcass trim stations that transverse from the north to the south ends of the slaughter floor. The water lines had approximately 10 dead end pipes that measured from approximately 12 inches up to 48 inches in length. Dr. , Supervisory Public Health Veterinarian/Inspector In Charge (SPHV/IIC), Mr. , Supervisory Consumer Safety Inspector, (SCSI), Mr. and an unknown maintenance supervisor were informed and observed the EIAOs observations. The company was informed of these noncompliances in the Comprehensive Food Safety Assessment Exit Meeting.

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(b)(2) , 416.2(e)(3)

Citation:

During a Comprehensive Assessment of the Execution and Design of an Establishment’s Food Safety System that began June 7, 2011 the following SPS noncompliances were identified by EIAO and : The Establishment failed to meet the requirements of 9 CFR 416.2(b)(i) and 416.2(b)(2). EIAO observed that in the slaughter paunch separation/emptying room that the south wall had peeling paint and mold black in color on it. The area of peeling paint and mold measured approximately 4 feet by 6 feet. The metal wall above the paunch auger had a brown colored buildup on it from previous day’s operations that measured approximately 4 feet by 12 inches. In the slaughter paunch separation/emptying room and the intestine cleaning/braiding room the overhead electrical junction boxes, electrical conduit clips, rods used to hold up pipes and the exhaust vent were observed to be heavily rusted and not being maintained in good repair. The company failed to meet the requirements of 9 CFR 416.2(e)(3) On July 1, 2011, the EIAO observed that the slaughter floor had three insulated water lines above the firm’s beef carcass trim stations that transverse from the north to the south ends of the slaughter floor. The water lines had approximately 10 dead end pipes that measured from approximately 12 inches up to 48 inches in length. Dr. , Supervisory Public Health Veterinarian/Inspector In Charge (SPHV/IIC), Mr. , Supervisory Consumer Safety Inspector, (SCSI), Mr. and an unknown maintenance supervisor were informed and observed the EIAOs observations. The company was informed of these noncompliances in the Comprehensive Food Safety Assessment Exit Meeting.

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(b)(2) , 416.2(e)(3)

Citation:

During a Comprehensive Assessment of the Execution and Design of an Establishment’s Food Safety System that began June 7, 2011 the following SPS noncompliances were identified by EIAO and : The Establishment failed to meet the requirements of 9 CFR 416.2(b)(i) and 416.2(b)(2). EIAO observed that in the slaughter paunch separation/emptying room that the south wall had peeling paint and mold black in color on it. The area of peeling paint and mold measured approximately 4 feet by 6 feet. The metal wall above the paunch auger had a brown colored buildup on it from previous day’s operations that measured approximately 4 feet by 12 inches. In the slaughter paunch separation/emptying room and the intestine cleaning/braiding room the overhead electrical junction boxes, electrical conduit clips, rods used to hold up pipes and the exhaust vent were observed to be heavily rusted and not being maintained in good repair. The company failed to meet the requirements of 9 CFR 416.2(e)(3) On July 1, 2011, the EIAO observed that the slaughter floor had three insulated water lines above the firm’s beef carcass trim stations that transverse from the north to the south ends of the slaughter floor. The water lines had approximately 10 dead end pipes that measured from approximately 12 inches up to 48 inches in length. Dr. , Supervisory Public Health Veterinarian/Inspector In Charge (SPHV/IIC), Mr. , Supervisory Consumer Safety Inspector, (SCSI), Mr. and an unknown maintenance supervisor were informed and observed the EIAOs observations. The company was informed of these noncompliances in the Comprehensive Food Safety Assessment Exit Meeting.

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(b)(2) , 416.2(e)(3)

Citation:

During a Comprehensive Assessment of the Execution and Design of an Establishment’s Food Safety System that began June 7, 2011 the following SPS noncompliances were identified by EIAO and : The Establishment failed to meet the requirements of 9 CFR 416.2(b)(i) and 416.2(b)(2). EIAO observed that in the slaughter paunch separation/emptying room that the south wall had peeling paint and mold black in color on it. The area of peeling paint and mold measured approximately 4 feet by 6 feet. The metal wall above the paunch auger had a brown colored buildup on it from previous day’s operations that measured approximately 4 feet by 12 inches. In the slaughter paunch separation/emptying room and the intestine cleaning/braiding room the overhead electrical junction boxes, electrical conduit clips, rods used to hold up pipes and the exhaust vent were observed to be heavily rusted and not being maintained in good repair. The company failed to meet the requirements of 9 CFR 416.2(e)(3) On July 1, 2011, the EIAO observed that the slaughter floor had three insulated water lines above the firm’s beef carcass trim stations that transverse from the north to the south ends of the slaughter floor. The water lines had approximately 10 dead end pipes that measured from approximately 12 inches up to 48 inches in length. Dr. , Supervisory Public Health Veterinarian/Inspector In Charge (SPHV/IIC), Mr. , Supervisory Consumer Safety Inspector, (SCSI), Mr. and an unknown maintenance supervisor were informed and observed the EIAOs observations. The company was informed of these noncompliances in the Comprehensive Food Safety Assessment Exit Meeting.

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:  01B02
Violation:  416.13(c)

Citation:

On Monday September 12, 2011 at approximately 0530 hours, while performing an O1BO2 procedure (pre-operational inspection) CSI observed the following: The support rollers for the fat and trim conveyors on the west side of Boning table (1) had residue from the previous day of production. CSI notified Mr. who was accompanying the CSI during the pre-operational inspection. Mr. instructed the available sanitation staff to re-clean and sanitize the rollers and the associated fat and trim conveyors prior to product being introduced to the area. The fat and trim conveyors and the support rollers were re-inspected and passed before use. The support rollers are in contact with the direct contact surface of the fat and trim conveyors. Page one (1) of seventeen (17) of the Plant SSOP’s states the following: . Page three (3) of seventeen (17) bullet (1) of the plant SSOP’s under the monitoring section also states: Bullet (3) in that same section states I notified Ms. and Mr. verbally and with the document of the above non-compliance. There was no product involved, therefore, no product injurious to the public health entered into commerce. Past Similar NRs – Previous Ineffective Plant Actions: Failure to identify deficiencies during plant pre-operational inspection NR: 23-2011 dated 8/17/2011 The above linked Non-Compliance had the same root cause though NR 23 was written for foreign material not residue on the contact surfaces.

Regulation:

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

Code:  01B02
Violation:  416.13(c)

Citation:

On Wednesday August 17, 2011 at approximately 0525 hours, while performing an 01B02 task (pre-operational inspection) CSI observed the following: The trim line on the west side of Boning Table (1) had shavings from the belt on the framework inside (non contact surface) and outside (contact surface) of the trim conveyor. The conveyor also had loose pieces still attached on the edge. The shavings and loose pieces on the edge were the same material as the conveyor and were from the belt dragging across a belt guard that was bent and in contact with the conveyor. CSI notified Mr. who was accompanying the CSI on the pre-operational inspection. Mr. immediately notified Mr. and Mr. of the issue with the conveyor. Mr. then directed the maintenance staff to sand the edge of the belt until all the lose pieces were removed. When this was accomplished Mr. directed his sanitation crew to clean and sanitize the affected conveyor and associated framework. The trim line on the west side of Boning Table (1) was re-inspected and accepted by plant personnel and CSI Plant SSOP’s state in part on page (3) of (17): Plant SSOP’s also include also page (3) of (17). The plant Pre-Operational Sanitation Record had marked the Trim Conveyor on the west side of table (1) as acceptable for August 17, 2011 prior to the FSIS findings. The plant did update the Pre-Operational Sanitation Record to show corrective actions had been implemented for the belt. However, plant personnel identified the fat line on the west side of table (1) as the affected line not the trim line. The actual affected conveyor was the trim line on the west side of Table (1). CSI notified Ms. and Mr. of the above non compliance verbally and with this document. No product was affected therefore no product injurious to the public health was allowed to enter into commerce. On July 05, 2011 an NR was written when plant personnel failed to identify foreign material on food contact surfaces during pre-operational inspection.

Regulation:

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

Code:  06D01
Violation:  416.2(d)

Citation:

At approximately 0710 hours on Monday August 8, 2011 while performing operational sanitation verification procedures (ISP Code 01C02) in the south end of the tunnel area of the fabrication division, I observed water dripping from overhead structures. The water was coming from the drip pan under the refrigeration unit in that area. The water was not dripping on carcasses. I verbally notified of the problem and took the regulatory control action of stopping production to prevent contamination of carcasses. No tag was issued for regulatory control since I stayed in the immediate area the entire time. Once production was stopped maintenance was called. showed up and I explained the situation to him. Carcasses were removed from the area. Then water begin to leak across the entire length of the drip pan including directly above the drag chain. Maintaince began working on the drain of the drip pan. arrived at around 0735 hours. She explained that corrective actions would be taken according to the company’s condensation corrective actions listed on page 11 of 17 of the company’s SSOP’s dated 5-31-11. She explained that this was done because water dripping from overhead structures is similar to condensation dripping. She explained that carcasses would be examined , trimmed of any visible contamination and then sprayed with prior to them entering Fabrication. At approximately 0745 hours after verifying that there was no more dripping water, I allowed production to begin again. A check of the company’s records for monitor of the company’s Food Safety Support Programs showed that this area was found acceptable during pre-operational sanitation. stated that there had been no operational sanitation verification procedures in that area prior to this time. Ms. was notified verbally that a noncompliance record would be written for this incident. No Similar noncompliance records have been written in the last 90 days.

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:  01B02
Violation:  416.13(c)

Citation:

On Tuesday July 05, 2011 at approximately 0530 hours while performing a scheduled O1BO2 task (pre-operational inspection) on the fabrication equipment CSI observed the following: The #1 incline middle meat conveyor that transports product from table #1 to table #3 had black flecks to numerous to count on the top side of the conveyor which would be a direct product contact surface. Mr. who was accompanying CSI immediately instructed the available clean up staff to re-clean and sanitize the conveyor and the area was then found acceptable. CSI also observed black flecks and a black grease like substance on the cross over trim line at the end of table #5. Mr. again instructed the available clean up staff to re-clean and sanitize the cross over trim line and the area was then found acceptable. Plant Pre-Operational SSOP’s (pg. 3 of 17) states the following: and Plant SSOP’s also state in part that the plant will; The plant Pre-operational sanitation record for the incline middle meat conveyor that transports product from table #1 to table # 3 was marked with a check indicating the area had been inspected and passed. I notified Ms. and Ms. of the above non- compliance verbally and with this document. All areas were inspected and passed prior to shift start up, therefore, no product injurious to the public health entered into commerce There have been no NR’s written within the last 90 days with the same root cause.

Regulation:

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

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

Citation:

On Thursday, June 16, 2011 at approximately 0525 while conducting Pre-operational Sanitation inspection, the following non- compliances were identified: The second Steam Vac for the first legger was identified as having residue from the previous day’s production. The area identified was clean on the upper surface, but the underside of the hose had visible residue. The residue was a mixture of blood and miscellaneous substances. The drop hose used by the Trolley Chain Remover was covered on the backside with fecal material that was fibrous in texture and green and yellow in appearance. The handle and nozzle had fat residue mixed with fecal material that was fibrous in texture and green and yellow in appearance. When the Yo-Yo Lift for the first leg was examined fibrous material was identified on the chain and hook that make contact with the carcass. The Yo-Yo’s control switch and cord had fat and blood residue on them. As the clean-up personnel were present at the time of these findings, they immediately cleaned and sanitized these areas as they were identified. Each area was released prior to continuing to the next. These areas are direct product contact or indirect product contact with the exposed carcasses. At the Udder Removal Station, the rubber drain hose for the sanitizer had been pulled out of the main drain line and a thick residue, including fibrous material, was present on the lower part of the hose. This area was cleaned and sanitized then re-inspected before continuing. This finding was a non-food contact surface. At approximately 0625 prior to the heads arriving in the head room, the hose and nozzle for the hand sprayer for the cheek meat was identified as having blood residue from the previous day’s production. Regulatory control action was immediately taken and USDA Rejected Tag #B38336570 was applied to the area. , came to the area and had the hose and nozzle cleaned and sanitized prior to the first head arriving in the area. , was verbally informed of this non-compliance and that a written copy would be provided. These findings are a non-compliance with the above cited Federal Regulations for food contact and non-food contact areas. The company’s SSOP Manual on page #1 states in part that The monitoring was insufficient to prevent the potential of product contamination. Past Similar NRs – Previous Ineffective Plant Actions: Sanitation Manager’s review of monitoring process was ineffective to detect non-compliance. NR: 18-2011 dated 6/4/2011 This document serves as written notification that your failure to comply with regulatory requirement(s) could result in additional 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:  01C02
Violation:  416.2(d), 416.4(d)

Citation:

On Wednesday June 15, 2011 at approximately 0612 hours while performing a routine sanitation walk through of the fabrication plant production area. CSI observed the following: Condensation had formed on PVC pipes above the XF trim bin. The condensation beads were running the length of the pipe approximately 4 feet and dripping from the PVC pipe to the stainless steel hood and into the XF trim bin. The drips were approximately 7-10 seconds apart and consistent. CSI immediately took the regulatory control action of retaining the bin with retain tag# B25073189. CSI then notified who immediately instructed plant personnel to remove the USDA retained product bin from the affected area and to dry all the condensation that had formed on the PVC pipe above the product bins. The binning process was allowed to continue after all condensation was removed and the sanitary condition restored… The plant monitors and documents condensation through their SSOP’s which state the following: The plant followed these procedures after notification of the condensation issue. NR # 0019 was written for a similar incident June 09, 2011. The plant did the short term corrective action/ preventative measure of using paper towels wrapped tightly around the base of the PVC pipe to capture the condensation before it dripped into the bin and to change the towels at a frequency that maintained a sanitary condition. There was no paper towel on the PVC pipe at this time. The plant’s investigation for the long term preventive measures has not yet been completed. CSI notified Ms. and Ms. verbally and with this document of the above non compliance. The plant condemned the affected product, approximately 250 lbs by placing it in the inedible auger for rendering. Therefore, no product injurious to the public health was allowed to enter into commerce. Past Similar NRs – Previous Ineffective Plant Actions: failure to identify insanitary condition (condensation) NR: 19-2011 dated 6/9/2011

Regulation:

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

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

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

Citation:

On Thursday June 09, 2011 while performing a direct , hands on review of the plants standard sanitation operating procedures as part of a scheduled O1CO2 task, I observed the following: Condensation had formed on PVC pipes above the 90% trim bin and was dripping into the bin and on the product in the bin. I immediately took the regulatory control action of retaining the bin with retain tag# B25073190. I notified and who immediately instructed the plant personnel to move the retained product bin from the affected area and to dry all the condensation that had formed on the PVC pipe above the product bins. The binning process was allowed to continue after all condensation was removed and the insanitary condition eliminated. The plant monitors and documents condensation through their SSOP’s which state the following: ” The plant followed these procedures after notification of the condensation issue. I notified and verbally and with this document of the above non compliance. The plant reworked the affected product per their SSOP’s which state in part that FSIS, CSI observed the plant reworking the product and verified the above procedure was followed. Plant QA staff monitored the rework process as well. Therefore no product injurious to the public health was allowed to enter into commerce. There have been no other NR’s written for the same root cause in the previous 90 days.

Regulation:

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

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

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

Citation:

On Saturday June 4, 2011 at approximately 0520 while conducting Pre-operational Sanitation inspection I identified the following non-compliances: The Hot Box Wash Cabinet was identified as having numerous areas in the bottom of the cabinet that had residue from the previous day’s production. The areas identified were clean on the upper surface, but the undersides of the pipes had visible residue. Also identified within the cabinet were a stainless steel rake type piece and the plastic exit trap-door with residue on them. The residue varied from hard to soft in appearance and pasty green and brown in texture and was a mixture of blood, fat, and miscellaneous substances. These areas are partially submerged in the hot water during operations. I immediately took regulatory control action and applied USDA Rejected Tag #B38336574 to the water valve of the cabinet. Clean-up personnel started re-cleaning the area. The Cabinet had numerous fat scraps on the inside edges of the cabinet, at both the entrance and the exit. A small piece of fat, less than 1/2 inch in length was identified on the carcass guide bar inside the cabinet. The bottom lip of the cabinet (on the underside), where the carcasses exit and the underside of the cabinet were also covered in residue. I informed , verbally of this non- compliance and that a written copy would be provided. The Pre-operational Sanitation Sheet showed that these areas were inspected and released by the clean-up crew prior to USDA inspection. At approximately 0615 I re-inspected the Hot Box Wash Cabinet and the cabinet, removed the USDA Reject Tag, and released the area for production. These findings are a non-compliance with the above cited Federal Regulations for food contact and non-contact areas. The company’s SSOP Manual on page #1 states in part that The monitoring was insufficient to prevent the potential of product contamination. A similar Non- compliance (#0012-2011-15549) was written on April 1st, 2011. The Further Planned Action stated that “the monitoring procedure for the cabinets was changed so that it is conducted when cleaning the entire cabinet area has been completed rather than conducting it when individual sections are completed.” This was ineffective to prevent the re-occurrence 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 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:  03J02
Violation:  417.2(c)(7), 417.4(a)(2) (i), 417.4(a)(2) (iii)

Citation:

While performing a 03J02 HACCP task for the Slaughter Process, I reviewed the supporting documents for the Slaughter HACCP plan for the CCP’s. I verified that the daily monitoring tasks were being performed as written. I reviewed the CCP descriptions for required documents to support their CCP’s and I noticed that the plan did not include the calibration or verification of the pressure gages used to verify the PSI of the Hot water (CCP 2B) in the list of records that would be reviewed. The CCP cites ” as an activity to verify the accuracy of the CCP requirement of . When reviewing CCP 5-B ( ) application to Processing Products (Offal Products), there is no mention of a record or activity for the verification or calibration of the pressure gages used to monitor the PSI. The company is verifying these pressure gages on the Verification sheet ” “, but it does not list the pressure gage for the Beef Heart Sprayer. The sheet lists a ” “, but the cabinet was never installed, so the line has been left blank. The hearts are sprayed while they are hanging on a rack, by a dedicated line. A pressure gage is mounted in-line to monitor and adjust the setting of the PSI. There is no way to attach a secondary gage to verify or calibrate the accuracy of the primary PSI gage for this CCP. The ‘ sheet does not have a space for Record Review as required by 9 CFR 417.4. Calibration/Verification records for process- monitoring instruments are included in the list of records that are required to have a Record Review. These non-compliances were verbally conveyed to , and told that a written copy would be provided to the company. The HACCP plan for these two CCP’s (2B, 5B), both list the PSI along with Temperature as critical for the CCP. Federal Regulations require the calibration of monitoring equipment and the review of such records that support the CCP. No similar non- compliances were written for common causes.

Regulation:

417.2(c)(7)  Hazard Analysis and HACCP Plan: 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)  Ongoing verification activities. Ongoing verification activities include, but are not limited to: (i) The calibration of process-monitoring instruments; (ii) Direct observations of monitoring activities and corrective actions; and (iii) The review of records generated and maintained in accordance with § 417.5(a)(3) of this part

417.4(a)(2)  Ongoing verification activities. Ongoing verification activities include, but are not limited to: (i) The calibration of process-monitoring instruments; (ii) Direct observations of monitoring activities and corrective actions; and (iii) The review of records generated and maintained in accordance with § 417.5(a)(3) of this part

Code:  01C01
Violation:  416.14

Citation:

In reviewing the SSOP Daily Operational records and the Hold Log for the past three months (March 1, 2011-May 25, 2011), there were a total of 107 carcass halves identified, on 47 out of 61 individual days worked, where a foreign material was reported on the carcass. The company’s Hold Log and SSOP records identified the foreign material as “grease”. The source of the foreign material was listed consistently as the “shocker” or “stimulator” after the final carcass Wash Cabinet. The company’s records indicate that the carcasses were acceptably trimmed and released according to the Foreign Material Procedures. A SSOP Maintenance Record dated on 05/21/2011 addressed the problem of ” ” The record shows on 5/25/2011 that the corrective actions initiated on 05/24/2011 were ineffective. This is a non-compliance with the federal regulation cited above in block #6 and 9 CFR 416.4(d).Even though corrective actions were properly completed for each occurrence of the foreign material, the evaluation of the SSOP procedures was untimely and ineffective to prevent the repetitive contamination of product and to maintain the effectiveness of their SSOP as per the written program cited in the following paragraph. , was verbally notified of this non- compliance and informed that a written copy would be provided. The company’s SSOP Manual on page #5 states that, Page #6 continues by identifying the action taken when repetitive foreign material is found. The company will, ” On page #17 under the heading it states in part that . It concludes by stating that No similar non- compliances have been written for common causes.

Regulation:

416.14  Maintenance of Sanitation SOP’s. 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:  04A03
Violation:  318.24

Citation:

On Friday May 20, 2011 FSIS in plant personnel sampled product produced by the Advanced Meat Recovery process (AMR 01). The product tested is the product produced when skeletal bones are placed into the Advanced Meat Recovery machine ( ) and the meat is seperated from the bone by being pressed against a rotating drum. The sample was tested and found to be positive for Central Nervous System material (CNS). The presence of the CNS material (spinal cord tissue) in the sample disallows the product to be used or labeled as an ingredient of a meat food product. 9CFR 318.24 (i) (ii), 9CFR 301.2 (meat)(1)(ii). The plant labels the product as beef trim fine for use as mear or in meat products therefore the product in the CNS positive lot would be misbranded. The plant defines a lot from the Advanced Meat Recovery system as all the product produced in a single day by the AMR machine. Regulatory control tag #-B25073185 was use to retain the product produced on May 20, 2011 which is the day the FSIS positive (CNS) sample was taken. Regulatory control tags were also used to retain lots (all product produced) from May 21 – May 24, 2011 tag #’s -B25073184, B25073183, B073182. Regulatory control tag#- B25073196 was placed on the AMR equipment until corrective actions which control the introduction of CNS material are provided by the plant. The plant also tests each lot produced by the AMR system for the presence of CNS material. The results from samples taken on the above dates were received by the plant Thursday May 26, 2011. The results of the plant CNS sampling found no CNS material detectable. The Plant also places all lots on hold in their inventory system until acceptable results are received from their sampled lots. As stated above, all product produced by the AMS system on May 20, 2011 the day the FSIS, CNS positive sample was taken is retained using USDA regulatory and plant controls. Therefore no product injurious to the public health was allowed to enter into commerce. I notified of the above non-compliance verbally and with this document. All correspondence from the FSIS Lab pertaining to the above sample has also been made available to the plant.

Regulation:

318.24  Product prepared using advanced meat/bone separation machinery; process control: General. Meat, as defined in § 301.2 of this subchapter, may be derived by mechanically separating skeletal muscle tissue from the bones of livestock, other than skulls or vertebral column bones of cattle 30 months of age and older as provided in § 310.22 of this subchapter, using advances in mechanical meat/bone separation machinery (i.e., AMR systems) that, in accordance with this section, recover meat— (1) Without significant incorporation of bone solids or bone marrow as measured by the presence of calcium and iron in excess of the requirements in this section, and (2) Without the presence of any brain, trigeminal ganglia, spinal cord, or dorsal root ganglia (DRG).

Code:  01C01
Violation:  416.16(a)

Citation:

On Tuesday April 5, 2011 while performing a records review of the Operational Sanitation for Monday April 04, 2011 I observed the following: Value added department documented a deviation for parts per million (ppm) of ( on the Operational Sanitation Report. The plant and FSIS maximum ppm level is 220ppm. The highest recorded ppm of ( in Value Added department was 305ppm. The highest recorded ppm reading was taken at the mixing station which is the central source for application of ( for fabrication operations as well as the Value Added operations. The Operational Sanitation Report for the Value Added department stated ” When it was used ( the reading was 193ppm to spray top sirloins”. This indicates the corrective action was not to use the product until it was within acceptable perimeters. When reviewing the Operational Sanitation Report dated April 4, 2011 for the fabrication operation I observed the following statement in the remark section. ” “. There is no explanation as to what maintenance needed to follow up on, there is no corrective actions there is no information concerning the ppm of the ( other than the 210ppm high ppm and the138ppm low ppm. Verbally the plant indicated that corrective actions had been implemented for the Fabrication Operation but there was no documentation of any corrective actions written on the Daily Operational Sanitation Report. On March 24, 2011 and received a memorandum of information from the In plant FSIS, CSI about the need for clear communication on the corrective actions and the need for the written account to reflect as close as possible what actually takes place within those corrective actions. This may be the only record of what took place if information about the event is needed in the future. I notified and of the above non-compliance verbally by way of voice mail due to their absence and with this document.

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:  06D01
Violation:  416.3(a)

Citation:

On Tuesday, April 5, 2011, while performing a Pre-operational Sanitation Inspection the following non-compliances were noted: At approximately 0535 hours I found build-up of dust and grease on the rail above the first De-horner Station. The build-up was black in color and was covering the entire length of the rail. , stated that he would have it cleaned and notify me when it was finished. I continued my inspection and at approximately 0540 hours I saw numerous pieces of flaking paint on the Down puller Framework. This area has been discussed in the last two weekly meetings with the plant (Item #5 Facilities) and has yet to be resolved. The verbal corrective action given last week to me by , was that it would be scraped daily prior to Pre-operational Inspection. This has not resolved the peeling paint. I took immediately applied USDA Reject Tag #B38349860 to the Down puller until the loose paint was removed. requested to come to the area to view the peeling paint. then assigned a maintenance employee to remove the loose paint. At approximately 0555 hours I viewed the gray metal support beams next to the 30+ Head Splitter on the East wall of the Tripe Room. The beams had been painted the previous night, but the loose paint had not been completely removed prior to painting. Several areas could be seen with peeling paint. The area most affected was next to the Head and Tongue Hook Sanitizer. The lower part of the beam had been painted but the upper portion was not painted and peeling paint covered much of the beam. A similar condition was also seen above the large doorway leading North out of the Heart Spraying Room. The paint was peeling above this doorway. , , was verbally informed that these findings are non-compliant with the above cited Federal Regulation in Box #6 and that a written record would be issued. The Company Prerequisite Program for SOP under the heading ” ” on page #1section #2 (b, e) states . The section under the heading page #1 (section d) states that The monitoring of these above areas was insufficient to prevent the findings during Pre-operational Inspection. The above areas were re-inspected, the USDA Rejected Tag was removed, and were released at 0625 hours for production. No similar NR’s have been written in the past 90 days for common causes.

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

Citation:

At approximately 1520 hours on Tuesday, March 29, 2011, I observed the packaging operations of the Offal Department. A worker walked out of the head boning Room with a cone shaped piece of metal. He said that it had come up the conveyor belt with the tripe and did not know were it came from. I identified it as the cap for the Tripe Refiner final wash. The product being produced was covered in small abrasive material from the Refiner. The , stated that for corrective action they would dispose of the entire affected product. The previous batch was checked to ensure it was not adulterated and released. Maintenance met me at the Tripe wash room and confirmed which washer it came from. The maintenance person said that they would straighten the piece and re-attach the cap. The metal nuts under the cap were rusty in appearance. On Thursday morning, March 31, 2011, at approximately 0545 during Pre-operational Sanitation Inspection I saw that the Tripe Refiner Cap was missing and that the metal nuts were rusty in appearance. I immediately took Regulatory Control and applied USDA Retained Tag #38348009 to the Tripe Refiner. In gathering further information it was determined that the cap had been thrown away and was never put back on the machine. I informed of the situation verbally and informed her that a written Non-compliance Record would be provided. I asked for corrective action for the product that had been produced on Wednesday and exposed to the rusty nuts. She stated that the product would be put on hold until they were able to re-inspect the product. A review of the records shows this incident from Tuesday was not recorded and the stated corrective actions were not followed correctly to completion. There was no monitoring of the equipment to ensure that the cap was in place at the start of operations on Wednesday. These are a non- compliance with the above cited regulations in box #6. The company’s SSOP Manual on page #1 states in part that The monitoring was insufficient to prevent the potential product contamination. Page #16 states that . . The product that had been retained by the company was re-inspected for visible contamination and released back to inventory. No similar Non-compliances were written for common causes in the last 90 days.

Regulation:

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

416.15(a)  Corrective Action: 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:  06D01
Violation:  416.4(b)

Citation:

On Monday March 28, 2011 at approximately 0540 hrs. while performing an O1BO2 procedure (pre-operational inspection) on the fabrication area, I observed the following: The crossover fat and crossover trim conveyors located at the end of the boning tables had numerous pieces of fat residue from the previous day’s production. The pieces were 1/8″ to 3/4″ inch in size and were located on the inside framework of the crossover belts between boning tables (3) and (4), the frame of the crossover between boning tables (2) and (3) and the frame of the crossover between boning tables (1) and (2). I notified the of the findings. Mr. instructed the cleanup personnel present to re- wash and re-sanitize the entire crossover trim and fat belts and the associated framework. The belts were re-inspected and passed by plant personnel and USDA. The plant food safety support program in the ” ” section for non- contact equipment surfaces and utensils states the following; . Plant pre-operational sanitation report had the crossover trimlines and crossover fat lines checked as acceptable on Monday March 28, 2011. I notified verbally and with this document of the above non compliance. There was no product involved therefore no product injurious to the public health was allowed to enter into commerce. There have been no NR’s written with a similar root cause in the previous 90 days.

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:  01B01
Violation:  416.13(b), 416.15(a)

Citation:

On Wednesday March 09, 2011 at approximately 06:00 hrs. while performing an O1BO2 procedure (pre-operational inspection) in the Value Added area I observed the following: There was no monitor observing employee’s equipment (utensils) used in the processing of the product in the Value Added department. The daily pre-operational sanitation report for this area shows that 5% of the employee’s equipment will be checked daily for employee equipment sanitation. I then decided to perform an O1BO1 (pre-operational sanitation records review) and noted that there were no initials or checks in the space provided on the pre-operational sanitation records for the dates Monday March 7th, Tuesday March 8th or for Wednesday March 9th 2011. The spaces provided on the pre-operation sanitation record should be initialed by the person performing the inspection. I asked about the failure to sign or initial this part of the pre-operational sanitation record who stated it was the responsibility of the daily operations supervisor for the Value Added department. At 1230 hours I again reviewed the records for pre-operational sanitation for this day March 10, 2011 and found the records had been filled out (initialed) for Monday March 7th, Tuesday March 8th and Wednesday March 9th 2011. I also observed while reviewing the pre-operational record that there was not a corrective action or notation on the document that would indicate the monitoring was performed for the above mentioned dates. While discussing my findings with , she indicated that her investigation into the non-compliance found the monitoring was performed; it was only the initialing of the document that was not completed. I also discussed with Miss. that since the employee equipment is considered a contact surface, corrective actions that indicate the monitoring was performed would be the only way to know an insanitary condition had not been created by the absence of the equipment monitoring procedure. The plants state the following: . The employee equipment (utensils) are listed on the daily pre- operational sanitation record. The also states: . I notified of this non-compliance verbally and with this document. The monitoring had been performed therefore no product injurious to the public health was allowed to enter into commerce. There have been no NR”s written in the past 90 days with a similar or same root cause.

Regulation:

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

416.15(a)  Corrective Action: 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:  01C02
Violation:  416.2(d), 416.4(d)

Citation:

On Thursday, March 3, 2011, at approximately 1145 hours, while walking through Drip Cooler #2, I noticed beaded condensation on the black pipes above the carcasses on the North end of the Cooler. On closer inspection it was noted that the condensation was dripping on the carcasses below. The condensation in the area of the rail (#DN-209, 210) was also visible on the drip pans and was dripping from the corners also. I immediately took Regulatory Control and applied USDA Retained Tag #B38349926 to the carcass half on the North end of the rail. A total of 15 carcass halves on each rail were identified as being under the condensation. The area above the doorway between Drip #1 and Drip #2 also had beaded condensation above the main rail for transporting the carcasses through the cooler. A white pipe just inside the doorway of Drip #1 also had beaded condensation on the exposed areas (The black wrap on the pipe had been torn off). Condensation was also noted in Drip #2 on the South wall on the drain pipes for the cooling units and on the ceiling above the walkway. No product was below this area and it was not seen to be dripping. I entered the Offal packaging area and asked , for corrective action. He entered the cooler and had the areas mopped in drip #1, the doorway of #1 and #2, and the drain pipes of Drip #2. At 1525 hours I showed the above mentioned areas to , and verbally informed her of this non-compliance with the Federal Regulations cited in block #6 above, stating that a written record would be provided to the company. Miss stated that she would attach her Company Control Tag to the carcasses and follow the corrective action procedures for trimming the affected carcasses. At approximately 1540 hours, I removed the USDA Retained Tag after verifying that the Company’s Process Control Tags had been applied. The company’s SSOP Manual on page #1 states in part . The monitoring was insufficient to prevent the potential product contamination. Past Similar NRs – Previous Ineffective Plant Actions: Monitoring was insufficient or ineffective to prevent condensation dripping in this area. NR: 3-2011 dated 1/25/2011 This document serves as written notification that your failure to comply with regulatory requirement(s) could result in additional regulatory or administrative action.

Regulation:

416.2(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:  416.4(d), 416.5(a)

Citation:

On Thursday March 3, 2011, at approximately 0730 hrs. while performing a routine sanitation walk through of the Value Added department, I observed the following: An employee wearing a dark blue smock, wrapping his arms around multiple bags of product, pulling the product to his chest and abdomen and putting the bagged product on a stainless steel table. The same employee also handles boxes of product, wooden pallets, bloody combo liners etc. while wearing the same blue smock. By pulling the product into his chest and abdomen which are covered by the dark blue smock the employee is causing potential cross contamination of the contact surface of stainless steel table. This could also result in the contamination of the product after the bag is removed and the exposed product is placed on the same stainless steel table. states the following: The employee involved immediately changed his method of handling the bagged product to better protect the exposed product. The employee began to only handle one or two pieces of product at a time and was careful to make sure the dark blue smock (frock) did not contact the bagged or exposed product. I informed and of the above non-compliance verbally and with this document. Each followed up to make sure the employee continued the improved method of not pulling bagged product into his chest and abdomen and that he handled fewer bagged products at a time. An inspection by the CSI discovered no visual contamination on the exposed products involved. No product injurious to the public health was allowed to enter into commerce. There have been no NR’s written in the previous ninety (90) days with the same or similar root cause.

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(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:  317.17, 317.2(j)

Citation:

On Saturday, February 19, 2011, at approximately 0745 hours, I observed the mixing of the for use in the “Corned Beef Briskets” that were being produced in Value Added. The ingredients list for the cure listed as the last ingredient. The product label that was being produced however stated , not I immediately notified , of this labeling non-compliance. We went upstairs to the label storage room and determined that the present batch of labels was sent to the company on January 12, 2010. I informed that the product would not be able to ship as labeled. She stated that she would place company hold tags on each pallet of product that was produced. At approximately 0830 I noticed that , was at the plant and informed her verbally of the non-compliance and that a written record would be provided on Monday. I asked her if she could determine when the new label had been put into use and how much product had the misprinted label. This is a Misbranding non-compliance with 9 CFR 317.2(f)(1) as the ingredients list does not identify as an ingredient. The list of ingredients must be accurate and complete in order of predominance. The company’s QA Procedures Manual, document #WB-QA-123 with a date of 08/11/2008, states concerning Product Labels . Under the sub-heading ‘ ‘ it states: . The company failed to identify the difference between the misprinted label and the product specifications. After further discussion with USDA District Office and RMS, the company was allowed to release the product from hold for shipment. No similar NR’s have been written for common causes.

Regulation:

317.17  Interpretation and statement of labeling policy for cured products; special labeling requirements concerning nitrate and nitrite: With respect to sections 1(n) (7), (9), and (12) of the Act and § 317.2, any substance mixed with another substance to cure a product must be identified in the ingredients statement on the label of such product. For example, curing mixtures composed of such ingredients as water, salt, sugar, sodium phosphate, sodium nitrate, and sodium nitrite or other permitted substances which are added to any product, must be identified on the label of the product by listing each such ingredient in accordance with the provisions of § 317.2. (b) Any product, such as bacon and pepperoni, which is required to be labeled by a common or usual name or descriptive name in accordance with § 317.2(c)(1) and to which nitrate or nitrite is permitted or required to be added may be prepared without nitrate or nitrite and labeled with such common or usual name or descriptive name when immediately preceded with the term ‘‘Uncured’’ as part of the product name in the same size and style of lettering as the product name, provided that the product is found by the Administrator to be similar in size, flavor, consistency, and general appearance to such product as commonly prepared with nitrate or nitrite, or both.

317.2(j)  Labels: definition; required features: (j) Labels of any product within any of the following paragraphs shall show the information required by such paragraph for such product.

Code:  01C02
Violation:  416.13(c)

Citation:

On Thursday February 10, 2011 at approximately 0720 hours, while performing a sanitation walk through of the packaging area, as part of a scheduled O1CO2 procedure, I observed the following: The soaker pads used on product inside the vacuum bags, which are a direct product contact item were stored on cardboard boxes of vacuum bags, by vacuum machine #(3). The cardboard boxes of vacuum bags are not designed for, or considered as, a contact surface and when not in use are stored in an area where box dust on the surface is likely to occur. The plant’s SSOP’s page 4 of 17 paragraph titled ” ” (all divisions) states in part ” “. Also while performing the same walk through and in the same area, I observed a box of vacuum bags being stored on a “finger bagger” piece of equipment. Finger baggers are normally for direct contact not for storing boxes of bags. There was also an exposed piece of product stored in a stainless steel gondola beneath the same box of vacuum bags. As previously stated these boxes are stored in an area where box dust etc. is likely to be on the surface and may be a source of contamination to the exposed product beneath. I notified who immediately had the soaker pads thrown away and moved the box of vacuum bags from the “finger bagger” and the exposed product from beneath the box of vacuum bags. There was no visible contamination seen on the exposed product. I notified and of the above non-compliance both verbally and with this document. Due to the above corrective actions no product injurious to the public health was allowed to enter into commerce. There have been no other NR’s documented with the same root cause in the previous 90 days.

Regulation:

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

Code:  06D01
Violation:  416.4(b)

Citation:

On Thursday, January 27, 2011, I performed a scheduled Pre-op Sanitation inspection of the Processing Floor. At approximately 0525 hours I began inspection at the Knocking Box Area. A plastic bag was covering a box that was mounted against the wall. The bag had fecal, blood and hair from the previous day’s production on the outside of it and had dirty water on the inside of the bag. The first De-horner had numerous hairs and a thick smear of fecal and hair on one side of the blade. The electrical box for the dehorner was also covered with a thin layer, on all sides, with fecal and hair. The Tail Chute had several clods of hair and fecal material on the top edge and a long smear of fecal material on the underside of the pan. The toe guards on the stands (Flanking Bench, Rumping Stand, Side Puller Platform, and Brisket Stand) all had small drops of blood, hair, and fecal material. Various parts of the framework supporting the Toe Guards were also covered in dried blood, hair, and fecal material. The first few rows of the grey grating material, nearest the toe guards, of the Flanking Bench and the Rumping Stand had clumps of hair and dried blood. The two clamps of the Side Puller had thick smears of fecal material on the ribbed area and on the support arms. The overall framework of the Side Puller had various spots of fat and dried blood. The underside of the framework by the ‘J’ Hook’s sanitizer was covered with a thin layer of fecal material. At this point I requested , be called to discuss the insanitary conditions that had been found. I took Mr. back to the Flanking Bench to show him the areas that the clean-up crew had re-cleaned. Visible hairs and fecal material were still visible on the grating material behind the toe guards of the Flanking Bench and the Rumping Stand, and on the Side Puller Clamps. These areas were re-cleaned and re-inspected. These findings demonstrate a non-compliance with the Federal Regulation cited in block six. Non-food contact surfaces in production areas must be cleaned as necessary to prevent insanitary conditions. I verbally informed , of these findings and that a written Non- compliance Report would be given to the company. The above areas are each listed on their daily Pre-operational Sanitation Report. A review of the company’s Pre-op Report showed these were marked as acceptable prior to USDA inspection. The company’s Food Safety Support Program states on page #2, of the section ‘ “, under the subheading ‘ ‘ states ” It continues, The insanitary conditions described above demonstrate the company’s Pre-operational Inspection was inadequate or insufficient to prevent the creation of insanitary conditions in the Hide-On area of Processing. A similar NR (#0002) was written on Monday, January 24, 2011 for similar conditions. The areas of insanitary conditions found on Monday were also marked as acceptable during the company’s Preoperational Sanitation Inspection. The company’s SSOP Program states on page #3 ‘ in part that This document serves as written notification that your failure to comply with regulatory requirement(s) could result in additional 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:  01C02
Violation:  416.2(d), 416.4(d)

Citation:

On Tuesday, January 25, 2011, at approximately 1440 hours, while walking through Drip Cooler #2 I noticed beaded condensation on a rail above the carcasses. On closer inspection it was noted that the condensation was dripping on the carcasses below. The condensation in the area of the rail (#DN-206) was also visible on the fluorescent light next to the rail. I immediately took Regulatory Control and applied USDA Retained Tag #B38337709 to the carcass half on the North end of the rail. A total of 10 carcass halves were identified as being under the condensation. At 1505 hours I showed the area to , and verbally informed her of this non-compliance with the Federal Regulations cited in block #6 above, stating that a written record would be provided to the company. Miss stated that she would attach her Company Control Tag to the carcasses and follow the corrective action procedures for trimming the affected carcasses. At approximately 1640 hours, I removed the USDA Retained Tag after verifying that the Company’s Hold Tag (#137676) had been applied. I informed Miss that I had identified a similar food safety hazard, of dripping condensation, in this area on Saturday, January 22, 2011. A company QA employee was nearby in the cooler at the time and I showed the condensation to him and allowed him to control the situation and apply company Hold Tag #137668 to the affected carcasses. A review of the records shows this incident was recorded and the corrective actions were followed correctly. At approximately 1710 I identified two racks of livers in Drip Cooler #3 along the North wall. The first rack had one liver on the stainless steel drip pan that was hanging over the edge and contacting the painted framework of the rack (a non-food contact surface). The second rack had several livers laying in the stainless steel drip pan and three of the livers were making contact with the rubber wheel and the painted framework of the rack (both non-food contact surfaces). I took Regulatory Control action and applied USDA Retained Tag #B38337708 and #B38337709 respectively, to the racks. As company management had left for the evening, I informed Miss of these findings when I arrived at work on January 26, 2011. At approximately 0705 hours I accompanied , to the liver racks to discuss corrective actions. Mrs. stated that the livers that were in contact with the non-food contact areas would be condemned. Once they were removed, I released the remaining livers for production. The company’s SSOP Manual on page #1states in part that . The monitoring was insufficient to prevent the potential product contamination. No similar NR’s were written for common causes within the last 90 days.

Regulation:

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

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

Code:  06D01
Violation:  416.4(b)

Citation:

On Monday January 24, 2011, I performed a scheduled Pre-operational Sanitation inspection of the Processing Floor. At approximately 0535 hours I inspected the outside hide belts. The portion of the belt that is outside, that carries the hides from the down-puller to the outside incline belt, had numerous medium sized clumps of fecal material between the upper and lower portion of the belt, and on the drip pan underneath. There were also blood and fat residue covering the belt, drip pan, and the outside wall. The lower portion of the outside incline belt had similar findings. The concrete drain area next to the belt also contained numerous large clumps of fecal material. At approximately 0555 hours, I inspected the storage room next to the Offal Area. Four offal racks were in this room. The drip trays had been removed and the contact surfaces had been cleaned but the non-contact surfaces had blood residue on them. At approximately 0605 I inspected the Tram Dock Room. The disposition table had blood residue on the underside of it. The non-contact areas of the sink also had residue on them. The step ladder for trimming and the small inspection stand both had numerous fat scraps on them. These findings are a non-compliance with the Federal Regulation cited in block six above. Non-food contact surfaces in production areas must be cleaned as necessary to prevent insanitary conditions. I verbally informed , of these findings and that a written Non-compliance Report would be given to the company. The above areas are all listed on their daily Pre-operational Sanitation Report. They were marked as inspected and acceptable prior to USDA inspection. The company’s Food Safety Support Program states on page #2, of the section , under the subheading ‘ states ” It continues, The above mentioned areas are all non-food contact surfaces and were re-cleaned and inspected prior to start of operations. No similar NR’s were written for common causes in the last 90 days.

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(b)

Citation:

On Thursday January 13, 2011 at approximately 1130 hours while completing an O3CO2 procedure from January 11, 2011 I observed the following: On October 26, 2010 samples were taken from all the bins of 50/50 trim produced that day. On October 27, 2010 six (6) of the bins from October 26, 2010 were identified as being presumptive positive. The plant’s CCP 2B is in place to provide the actions taken by the plant to keep the presumptive positive product under control. CCP 2B states The monitoring of this process is by Quality Assurance Personnel. The CCP states in part each positive lot will have a . The documentation of the monitoring and verification of this process is recorded on the . On that document under ” the document states ” There is also signature lines for monitoring, direct observation verification, record review verification and the pre- ship review. While reviewing the documents associated with the reworking of this product many of the steps had initials of the QA personnel involved ( ). The showed the product was correctly reworked. The findings indicate the monitoring, direct observation and the verification was completed but no signatures , initials or “OK’s”were recorded on the which is the record associated with the completing of the CCP 2B. I informed of the record keeping non-compliance. Miss reviewed documents with me to assure all aspects of the rework were performed to assure food safety and initiated a corrective action log. I informed of this non compliance verbally as stated previously and with this document. Due to steps taken by plant personnel no product injurious to the public health was allowed to enter into commerce. There have been no NR’s written in the previous 90 days with a similar root cause.

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:  416.14

Citation:

On Tuesday December 21, 2010 at approximately 0900 hours while performing operational sanitation records verification activities in the Slaughter QA office, I discovered that condensation on overhead structures in Drip cooler #2 was listed on the following days: 1. Monday December 6, 2010 2. Tuesday December 7, 2010 3. Wednesday December 8, 2010 4. Thursday December 9, 2010 5. Friday December 10, 2010 6. Monday December 13, 2010 7. Tuesday December 14, 2010 8. Wednesday December 15, 2010 9. Thursday December 16, 2010 10. Friday December 17, 2010 11. Monday December 20, 2010 During this time period the condensation observed and recorded was in the same general area of drip cooler #2. Procedures for dealing with ” ” are found in the Sanitation SOP dated 10-26-10 on page 14 of 17. They were followed and documented. Repetitive incidents of condensation are addressed in the company’s Sanitation SOP dated 10-26-10 on page 11 of 17 in the section entitled ” This section states in part, These findings demonstrate an inadequate meeting of USDA Meat and Poultry Regulations. 1. Part 416.2(d) concerning adequate ventilation 2. Part 416.14 Routine evaluation of the effectiveness and procedures of the Sanitation SOP’s 3. Part 416.14 Revision of the Sanitation SOP and procedures as necessary to keet them effective Condensation being identified in drip cooler #2 in the same general area for eleven production days in a row is repetitive. It also would question the effectiveness of the Sanitation SOP and/or its procedures. This is a SSOP Recordkeeping noncompliance because a. There is no evidence that the Sanitation SOP and/or procedures have effectively controlled condensation in drip cooler #2. b. There are no changes to the Sanitation SOP or procedures to control condensation in drip cooler #2. c. There is no recorded re-evaluation of the effectiveness of the Sanitation SOP or its procedures. No Noncompliance records have been written for similar findings.

Regulation:

416.14  Maintenance of Sanitation SOP’s. 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:  04B04
Violation:  312.2, 316.7, 317.10

Citation:

On Saturday, December 18, 2010, at approximately 0545 I noticed a covered bin of product identified as “Inedible”. This was handwritten on the cover of the bin along with the weight of 737 pounds. The bin was located in the C/D Row of the Cooler outside of VAP Department. I noticed a label on the side of the bin that stated “Edible Bones” product ID #29904. The USDA mark of inspection bug (US Inspected and Passed, EST. 235) was still present on all three sides of the bin. When I removed the corner of the cover, I saw that the product inside was a mixture of trimmings of meat and fat. It was not denatured to identify it as inedible product. This is a non-compliance with the above cited Federal Regulations, as the product labels and marks of inspection for the previous product that was USDA inspected and passed were not removed or obliterated prior to use for inedible product. This caused a misleading or false identification of the inedible product. As stated by 9 CFR 314.3(a) all condemned or inedible products must be denatured to preclude its use for food purposes. A spray bottle marked denaturant was in the scale area but was empty. The company’s Pre-Requisite Programs Manual under the heading of ‘ ‘ states in part on page #1 paragraph #5, regarding inedible containers, The Operational Plant Inspection Record (form #FS-FM- 9030F-123109) shows that the proper use of inedible containers is . Under the heading ‘ ‘ it states, I informed , verbally of this non-compliance and told her that a written report would be issued. She corrected the non-compliance by removing the old labels from the bin, marked out the inspection bug, and properly denatured the product. She stated that she had spoke with her floor personnel the previous week in response to a similar incident on Saturday, December 11, 2010. She stated that she would speak to them again and follow up that it was being done properly. No similar NR’s were written for common causes.

Regulation:

312.2  Official marks and devices to identify inspected and passed products of cattle, sheep, swine, or Goats: 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.

316.7  Marking devices not to be false or misleading; style and size of lettering; approval required.

317.10  Reuse of official inspection marks; reuse of containers bearing official marks, labels, etc,: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. (b) All stencils, marks, labels, or other labeling on previously used containers, whether relating to any product or otherwise, shall be removed or obliterated before such containers are used for any product, unless such labeling correctly indicates the product to be packed therein and such containers are refilled under the supervision of a Program employee.

Code:  01C02
Violation:  416.13(c)

Citation:

On December 16, 2010 while performing OC102 verification procedures I was concentrating on proper ventilation in the drip coolers at approximately 1110 hrs. I observed the following: beads of condensation on the ceiling in an area about 10’x12’on the south end in drip cooler #2 rails #36-37 and the entire bottom side of the east refrigeration unit above rails #31-32-33. There are exposed carcasses directly below this area. I observe drips of condensation drop onto the top of the rounds of carcasses. I informed of the findings and of the carcasses to be retained. He then tagged the rails to be retained. He then had one of the cooler personnel wipe the condensation from the ceiling area. Since the area under the refrigeration unit had carcasses on the rails they would need to wait until the carcasses where removed from this area to take corrective actions. The plants SSOP’s Dated 10-26-2010 state in part: Paragraph 1 page4 of 17, The plant performed these actions on Friday December 17, 2010. These findings show that the plant is inadequately monitoring the coolers to prevent the contamination of product by preventing the buildup of condensation. The plants ventalation standard operating procedures Dated 9-9-2010 states: Page 1 of 2, . USDA Meat and Poultry Regulations Part 416.2(d) states: that adequate ventilation must be provided to prevent the adulteration of product and the creation of insanitary conditions. Part 416.4(d) states: Product must be protected from adulteration during storage. These findings show that these requirements were not met. Ther are no similar NR’s at this time.

Regulation:

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

Code:  03A01
Violation:  417.2(a)(1)

Citation:

On November 23, 2010 while reviewing the plant’s written HACCP Beef Slaughter Plan and Hazard Analysis, I CSI did not observe any documentation addressing assessment or re-assessment of U.S. Retained beef carcasses identified by online USDA Inspection Personnel as suspect for USDA VMO disposition as a food safety hazard. These carcasses may be held in the USDA designated area for VMO carcass disposition in the absence of a USDA VMO on the establishment kill floor until after the slaughter operation has concluded for the day from the time a carcass is railed our and off the main line. In accordance with 9 CFR 310.3 the beef carcasses are not trimmed or washed. The plant’s written Sanitary Dressing Procedure located in the Food Safety Support Program states that . These beef carcasses fall outside of the population of carcasses that have been subjected to the plant’s HACCP Program. The HACCP Plan does not reference parts and organs of accompanying beef carcasses being held under U.S. Retention. Previous plant actions include trimming and spraying to carcasses that have been passed by an FSIS VMO, however there is no reference to these actions in the plant’s written HACCP Program as being included as an alternative CCP or addressing a food safety hazard. Mr. was notified of these findings which were discussed with him. Mr. was informed that an NR would be issued for basic HACCP non-compliance per 9 CFR 417.2 and that would be informed.

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 reason- able possibility that it will occur in the particular type of product being processed, in the absence of those controls.

Code:  06D01
Violation:  310.18, 416.4(d)

Citation:

3 November 2010, at approximately 0830 hours, while observing sanitary operations of the hide off side of the establishment kill floor, during beef slaughter operations, I, CSI observed the following insanitary condition: Behind the second beef carcass split saw, carcass tag number 374 was observed to have a plant Process Control Tag on the leading half of the carcass. The fore shank of the leading half of this beef carcass was grossly contaminated with ingesta material. As the carcass with the contaminated fore shank passed by the low spinal cord remover platform, then passed directly in front of the SRM Monitor and approached the first high rail trimmer station, I observed the contaminated fore shank make direct contact with the fore shank of the trailing half of the preceding beef carcass, (carcass tag number 373) as the carcass halves were turning on the line. Contact time lasted approximately one second as the fore shanks made contact with each other, then the two half carcasses remained separated. While the preceding half carcass traveled down the low trim line, I did not observe plant personnel observe or trim the fore shank of the half carcass that had made direct contact with the contaminated fore shank. When the preceding half carcass arrived in front of the USDA Final Rail Inspection platform, I directed USDA Food Inspector to stop the main carcass chain per 9 CFR 500.2(a)(1). Mr. , , arrived, and I reviewed what had occurred on the main line and the two beef carcasses with him. The fore shank of the preceding half carcass was inspected, while no visible contaminants were observed, I explained a carcass that comes in direct contact with contamination requires trimming of the contact area. Mr. then directed a low trim employee to trim the area of the fore shank that had made contact with the fore shank that bore visible contamination. Mr. was informed that this was in non-compliance with regulatory requirements and product must be protected from adulteration per definitions under 9 CFR 302.1. Mr. was notified that an NR would be issued. was informed.

Regulation:

310.18  Contamination of carcasses, organs, or other parts: 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.

416.4(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), 416.4(b)

Citation:

October 25, 2010 at approximately 0535 hours and after verifying that the establishment slaughter areas had been released from plant pre-operational inspection, I CSI observed the following insanitary conditions involving direct product contact and non direct product contact surface areas of equipment while performing a scheduled 01B02 PBIS procedure: While inspecting the edible paunch dump room I observed leftover ingesta residue in the paunch content dump auger. The residue ran the length of the augur and pieces of straw and seed or grain material could visibly be seen covering the sides and bottom of the auger chute. These pieces were too numerous to count. Inspection of the tripe hooks from which edible product is suspended revealed a piece of leftover product residue from previous operations. This residue was approximately three inches in length and was attached to one of the hooks from which edible tripe product is attached to. The material was dry in appearance and was dark brown in color. A second hook was identified with pieces of fat residue. These pieces were approximately one eighth of an inch in size. A third hook was identified with what appeared to be dried blood residue. Upon further inspection of this room, approximately eight pieces of leftover fat residue were observed on the south wall of the room. Directly below the several of these pieces on the wall is a stainless steel chute on which product is passed to the cleaning room. Mr. was immediately notified of these conditions. Corrective actions to restore sanitary conditions were requested. Regulatory control action was taken and U.S. Reject Tag # B38348008 was placed at the entrance to the Edible Paunch Dump Room. When corrective actions had been completed I was notified that the room was available for re-inspection. While performing re-inspection of the edible paunch dump room, two pieces of leftover fat residue were observed inside the metal bracket on the chain from which one of the tripe hooks is bolted to. The top of the chain drive sprocket located over the paunch dump table and partially over the collection chute was littered with leftover pieces of fat residue, too numerous to count. This sprocket has three open holes approximately one inch in diameter and run through the plate of the sprocket, creating openings from top to bottom of the sprocket. The west wall of the room contained five pieces of leftover fat residue. These areas of the room were reviewed with Mr. and measures were taken to restore sanitary conditions. When actions to restore sanitary conditions were completed the room was re-inspected. No further deficiencies were observed. The room was released for production. No product was affected at this time. Mr. was informed that this represented non-compliance with regulatory requirements and that an NR would be issued. was informed. A review of plant NR history demonstrates that no similar NR’s were issued in the last 30 days.

Regulation:

416.13(c)  Implementation of SOP’s: 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:  01C02
Violation:  416.13(c), 416.4(a), 416.4(d)

Citation:

On October 15, 2010 at approximately 0800 hours while observing sanitary operations in the plant head boning room, I CSI observed the following insanitary condition: Suspended directly over the center of the beef head table conveyor was a clear plastic sheet. The plastic sheet was below an overhead ceiling vent. The date 10-15-10 was written in black ink on this sheet. Condensation droplets of water could be observed on the side of the sheet which was facing the ceiling vent. Upon closer observation water droplets could also be observed on the side of the plastic sheet directly above the table. Water droplets were observed beading on the bottom of the plastic sheet and then dripping onto the conveyor table where beef head product was being harvested. A stop button for the line could not be readily observed and was immediately notified and informed of this condition. arrived. Corrective actions were implemented to restore sanitary conditions. No further beef heads were allowed to be processed until sanitary conditions were restored. The plastic sheet was removed and replaced with a new sheet. informed Inspection that this new sheet of plastic would be monitored more frequently throughout the remaining production day. informed Inspection that product harvested from the affected table would be treated as if condensation had dripped directly on product per the plant’s written SSOP program. Page 11 of 17 states in part: ” . Inspection verified that the corrective actions were performed. Page 11 of 17 in the plant’s written SSOP program titled states in part: . was informed that a non-compliance report would be issued.

Regulation:

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

416.4(a)  All food-contact surfaces, including food-contact surfaces of utensils and equipment, must be cleaned and sanitized as frequently as necessary to prevent the creation of insanitary conditions and the adulteration of product.

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

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

Citation:

October 14th, 2010 at approximately 1115 hours, while observing slaughter operations on the kill floor directly in front of the USDA final inspection platform I observed the plant place a beef carcass from the rail out reconditioning area back onto the main carcass chain. This beef carcass had been placed in the designated reconditioning area by the plant and subjected to corrective actions per the establishment’s written SSOP program. USDA Food Inspector, was on station at the USDA final rail platform. Inspector stopped the line when the beef carcass placed back onto the main chain arrived in the final rail inspection platform area. I observed a piece of contamination on the mid-line of the leading half of this beef carcass directly above the brisket. This piece of ingesta was yellow in color, straw like in texture, and approximately one eighth of an inch in size and dimension. I notified Mr. of the contamination and this was reviewed with him. This area of the beef carcass was trimmed and the contamination was removed. The ingesta material was trimmed from the carcass. After re-inspecting the beef carcass no further contamination was observed. I informed Mr. that this was a failure follow the establishment’s written SSOP program per regulatory requirements, and that a non-compliance report would be issued. The establishment’s written SSOP program page 7 of 17 titled contaminated carcass in the rail out area states in part: was informed of the non-compliance and was subsequently notified.

Regulation:

416.13(c)  Implementation of SOP’s: 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(b)(1) , 416.2(b)(2)

Citation:

On Thursday September 30, 2010 at approximately 0715 hours while performing a scheduled 06D01 (Facilities and Equipment Standard procedure) I observed the following: The wall on the west side of the intestine room had two pieces of detached whiteboard. The junction of the detached whiteboard had on one piece an exposed seam of approximately 4 feet on top and approximately 8 feet on the side, while the other piece of whiteboard was exposed on top approximately 3 feet. The whiteboard has a particle board backing that when exposed to moisture behind it the particle board dissolves and creates an unsanitary condition. According to MPI regulations establishment buildings must be kept in good repair and walls must be built of durable materials impervious to moisture. This wall does not meet this standard. The Company’s Food Safety Support Program dated 11/27/02, states on page #1, of the section ” “SOP, that “. The wall is monitored daily was marked on the Company’s Food Safety Support Program as acceptable. I notified of this non-compliance verbally and with this document. No product injurious to public health entered into commerce.

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:  04B04
Violation:  317.8

Citation:

Near the end of the workday, Monday, September 27, I observed the company producing its carcasses that were all over 30 months in age. The box code that is normally associated with this age of cattle is the 17000 series of numbers. I noticed several different codes in the 18000 series which are associated with this lot of carcasses when under 30 months of age. Two of the codes (#18710, #18729) identified on the daily production sheet are ones that are exported under the company’s Export Verification Program. Under the EV Program these codes identify them as meeting the various country requirements of being less than 30 months of age. No product was produced with the box code #18710. Thirty-five cases of box code #18729 were produced. The next morning I went to the shipping office and asked , for the dates that were in stock of the above mentioned item codes. I took these dates and checked the kill records to see if any of these dates corresponded to any other lots of 30+ month old SRF cattle. On September 3, 2010 another lot of 30+ month old cattle from were also produced, with 37 cases of item #18729 being produced. and , were both present when I informed them verbally of the labeling non-compliance. I informed them that a written copy of the non-compliance would be presented to later. I went to the Shipping Dock and had bring the two pallets of product that was mislabeled and applied a USDA Retained Tag to each pallet (Tag #B38349917-37 cases produced on 9/03/10; Tag #B38349918-35 cases produced on 9/27/10). Since the 18729 code is assigned to less than 30 month old carcasses that are included in the BEV Program for exports, the cases of product that were produced on September 3rd and 27th are mislabeled due to the product inside the boxes are over 30 months of age and should have been labeled with a #17629 series label. This is a non-compliance with the above cited Federal Regulation at section (a). It states in part that the product label must not bear any false or misleading statements. The company’s QA Procedures Manual for their QSA Program under the attachment (D1) ” ” #14 states, ” This was not being followed on these two production days. No mislabeled product entered commerce. The 72 cases of product were re-labeled by the company to reflect the proper ID code, released from USDA hold and returned to production. No similar NR’s have been written for common causes.

Regulation:

317.8  False or misleading labeling or practices generally; specific prohibitions and requirements for labels and containers: 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:  416.13(c), 416.4(a), 416.5(b)

Citation:

On September 7, 2010 at approximately 0529 hours after verifying that the plant had released all slaughter processing areas from plant inspection, I CSI observed the following sanitation deficiencies of direct product contact surfaces while performing a scheduled 01B02 PBIS procedure: While inspecting the hide off employee apron and clean up room I observed a yellow raingear suit which was hanging over the blue slaughter (hide off) employee aprons, with leftover blood residue on the jacket of the raingear. The back of the jacket bore the name, written in black ink. After further inspection of the yellow rain jacket I observed several more blood patches of leftover residue from previous operations. The patches of blood were approximately 3 to 4 inches in diameter. At this time I also observed several pieces of leftover beef fat clinging to the jacket. These pieces varied in size from one-eighth of an inch in size and dimension to one-quarter of an inch. The yellow rain jacket and leftover product residue made direct contact with product contact surface(s) of the aprons below and next to it. This represented an unclean food contact surface. Mr. was present and I reviewed the insanitary condition of direct product contact surfaces with him. Continuing inspection of the slaughter employee aprons, I observed a second yellow rain jacket intermingled with the aprons. This yellow rain jacket was observed to be in an insanitary condition as the first apron. This yellow rain jacket and leftover product residue made direct contact with the direct product contact surface(s) of the aprons below it. I observed a third yellow rain jacket with similar sanitation deficiencies and took regulatory control action per 9 CFR 500.1(a) and placed U.S. Reject Tag # B38348006 on these aprons and the remaining aprons with yellow rain jackets dispersed amongst them. I requested immediate corrective actions to restore sanitary conditions. Mr. informed Inspection that the yellow rain suits were used by the plant employees who work in the beef carcass coolers located after the slaughter process. After corrective actions had been completed and presented for inspection, the affected aprons and remaining aprons were re-inspected. No further deficiencies were observed. Mr. and Mr. were informed that this was a failure to comply with regulatory requirements and that an NR would be issued. The plant’s written SSOP Program General Cleaning Procedures documented on page 2 of 17 states in part: . Page 2 of 17 of the written SSOP Program contained under Monitoring states in After reviewing page 4 of 6, Processing Floor/ Area 4 of the plant Daily Pre-Operational Sanitation Report, it was observed that no sanitation deficiencies had been observed during plant pre-operational sanitation inspection of the employee aprons in the clean up room. was notified.

Regulation:

416.13(c)  Implementation of SOP’s: 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.

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

Citation:

On August 20, 2010 at approximately 1122 hours while walking through the Offal Spray Room, where beef hearts are removed from stainless steel gondolas and placed on racks to be sprayed with antimicrobial spray, I observed a rack of beef hearts directly under what appeared to be a white plastic pipe from which a bead of condensation was suspended. The white pipe, approximately 8 inches in diameter originated from the overhead concrete ceiling and dropped approximately 18 inches where it formed an elbow that was wrapped in a white tape. It was under this elbow where the bead of condensation was suspended directly over the rack of beef hearts. From the elbow, the pipe continued running east into the wall between the Offal Spray Room and the Beef Intestine Collection Room. I observed that a plant employee had just completed spraying the beef hearts with the which is a Critical Control Point as designated in the establishments HACCP Plan. The employee left the Spray Room and went into the Intestine Collection Room. The bead of condensation began growing in size until it fell from the elbow and onto a beef heart on the rack of beef hearts directly below it. At this time I did not observe plant personnel take corrective action which included ensuring appropriate disposition of contaminated product or preventing reoccurrence as another bead of condensation was forming to replace the bead that had previously fallen. I took regulatory control action per 9 CFR 500.1(a) and placed USDA Retain Tag # B38348010 on the rack of beef hearts. I contacted and requested that he notify plant supervisory personnel responsible for this area. I reviewed the condensation and contaminated product with Upon further review the white plastic pipe was a thin layer or shield of plastic which covers a pipe or pipes hidden from view underneath the shielding. The beaded water droplets appeared from between the wrapping of white tape around the elbow of this shielding. informed Inspection that the beef hearts would be reconditioned to ensure appropriate product disposition and that racks containing beef hearts would not be stored under the elbow of the pipe. The rack of beef hearts containing affected product was released to plant control. The plant’s written SSOP program which addresses condensation, (page 10 to 11) states in part: . was informed that this represented non-compliance with regulatory requirements and that a non-compliance report would be issued. was notified.(b) (6)

Regulation:

416.13(c)  Implementation of SOP’s: 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(b)(2) , 416.4(b)

Citation:

August 18, 2010 at approximately 0527 hours after verifying that the plant had released the slaughter areas from company pre-operational sanitation and while performing a scheduled PBIS 01B02 procedure, I CSI observed the following insanitary conditions; While inspecting the north end of the tripe room I observed pieces of leftover product residue on the on the three overhead pipes coming out of the north wall of the tripe room and passing over the tripe wash machine. The pipes are white and approximately 6 inches in diameter. The three pipes make a 90 degree turn towards the east wall of the tripe room. The tripe washer rests immediately below this 90 degree turn in the overhead pipes. I observed several pieces of leftover product residue from previous product on these pipes ranging in size from approximately one quarter of an inch to one inch in size on two of the white overhead pipes directly above the tripe wash machine. These pieces were white in color. Upon further observation of the three white pipes running to the north wall of the tripe room I observed numerous pieces of leftover product residue on the three pipes. These pieces ranged from approximately one quarter of an inch to one inch in size and were white in color. The count was stopped at eleven pieces. At this time I also observed leftover product residue on the exhaust hood directly above the band saw. I notified Mr. and reviewed the insanitary condition with him. Mr. instructed clean up crew employees to restore sanitary conditions. Continuing inspection of the remaining pre-operational sanitation inspection units in the kill floor area, I observed pieces of leftover product residue on one of the three doors of the south hot water tank located in the process equipment room. The maintenance representative for lock/out tag/out safety identified this hot water tank as operating Port C of the hot water carcass wash cabinet which is designated as a Critical Control Point for pathogen reduction in the plant’s HACCP Plan for beef carcasses. The product residue observed was brown and black in color, approximately one eighth of an inch and size and counted 5 pieces. In addition, there were a variety of smaller specks too numerous to count. When the door is closed on this hot water tank these pieces of leftover product residue could fall into the hot water that is used in the hot water cabinet for the beef carcasses. I reviewed this finding with Mr. who took actions to restore sanitary conditions. When corrective actions had been completed, the door was re-inspected and found to be in sanitary condition. Mr. informed me that the north end of the tripe room had been re-inspected and was ready for review. Upon observing the north end of the tripe room I observed two pieces of leftover product residue on the 90 degree turn of the white pipes directly over the tripe wash machine. These pieces were removed and the area cleaned. I informed Mr. that the findings in the Tripe Room and the Process Equipment Room failed to meet regulatory requirements and that a non-compliance report would be issued. was notified. A review of past plant NR history demonstrates that a similar NR was issued on 8/07/10. Plant management received copy of NR on the 8/17/10. Past Similar NRs – Previous Ineffective Plant Actions: Plant failed to address non-direct product contact areas and maintain sanitary conditions. NR: 24-2010 dated 8/7/2010

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.

416.4(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 August 7, 2010 at approximately 0540 hours I, CSI , performed a 01B02 (Pre-operational Sanitation Verification) and observed the following: Several pieces of fat and blood residue from the previous day’s production on the foot guard of the bunging stand. I also observed blood residue on the front and bottom sides of the hand washing sinks on the liver side of the evisceration table. During further inspection of the carcass stimulator (after the Hot Water Cabinet), I observed several pieces of fat all about 1/2 inch and larger in size on the post and insulators on the back side and top of the stainless steel plating. I also found numerous pieces of fat and blood on the floor through out the entire offal room. I informed the , of these findings. He immediately instructed the accompanying clean-up personnel to re-clean and sanitize the areas affected. The items were then re-inspected and passed prior to start of the processing operation. These findings are non-compliant with CFR 416.4(b) which states in part that the non food contact surfaces must be cleaned as necessary to prevent insanitary conditions and the adulteration of product. I verbally informed of these non-compliances and that a written document would be presented to the ). The company’s Food Safety Support Program dated 11/27/02, states on page #1, of the section ‘ , that . On page #2 under the heading ‘ , it states ” ” No similar NR’s have been written for non-contact surfaces during pre-operational inspection.

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), 416.15(b), 416.4(a), 416.4(b)

Citation:

July 9, 2010 at approximately 0527 hours after verifying that all slaughter areas had been released from plant pre- operational sanitation inspection, I CSI observed direct product contact surface sanitation deficiencies while performing an FSIS pre-operational sanitation inspection of the Tripe/ collection and processing room. During pre-operational sanitation inspection of the tripe washer I observed two pieces of leftover product residue inside the tripe washer resting on top of the screen inside the machine. Product comes into direct contact with the surface of this screen when it enters the Tripe Washer. These pieces were approximately one eighth of an inch in size and dimension and appeared dark white in color. One of these pieces was identified as possible seed from inside the tripe products that are washed in the machine. Upon further inspection of the hot water pipe which feeds the sanitizer/sterilizer for the product hooks and which is directly above the tripe washer, I observed pieces of dirty straw and dried dirt like material attached to the hot water pipe. I immediately notified Mr. , about these deficiencies. I took immediate regulatory control action per 9 CFR 500.1(a) and placed U.S. Reject Tag # B38349967 on the tripe washer and requested corrective actions to restore sanitary conditions. At approximately 0531 hours while conducting further inspection of the accumulation table located inside the head boning room I observed a piece of leftover product residue from previous production on the steel drain screen for the table. This piece of residue was approximately three quarters of an inch in length and one half inch in width. It was a dark brown to dark red color and was located partially on the top of the screen where it could make direct contact with product and on the side of the screen. Two more pieces of leftover product residue were located on the side of the drain screen. These pieces were white in color, and approximately three quarters of an inch in length and one quarter of an inch in width. I informed Mr. who was present and reviewed these pieces of leftover product residue with him. I requested immediate corrective actions. When corrective had been completed I re- inspected the drain screen and observed no further insanitary conditions. Returning to the Tripe Washer I was informed that the machine was ready for re-inspection. Upon re-inspecting the Tripe Washer I observed several pieces of leftover product residue on the inside of the door of the machine. Product is directly exposed to this surface during operations. These pieces were approximately one eighth of an inch in size and dimension, white and light red in color. I requested corrective action to restore sanitary conditions. Upon re-inspection of the Tripe Washer and hot water pipe overhead, I did not observe any further sanitation deficiencies and removed the U.S. Reject Tag releasing the Tripe Washer. I informed Mr. that the deficiencies observed represented non-compliance and that an NR would be issued. A review of plant pre- operational sanitation inspection for this day demonstrated that the plant did not observe any deficiencies with these units. Mr. was notified and informed of the non-compliance. Past Similar NRs – Previous Ineffective Plant Actions: Plant failed to adequately monitor and prevent direct product surface. NR: 21-2010 dated 6/24/2010

Regulation:

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

416.4(a)  All food-contact surfaces, including food-contact surfaces of utensils and equipment, must be cleaned and sanitized as frequently as necessary to prevent the creation of insanitary conditions and the adulteration of product.

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

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

Citation:

On Thursday June 24, 2010 at approximately 0530 hrs. while performing a scheduled 01B02 procedure (pre-operational observation) I observed the following: Water dripping directly onto cover of tripe wash machine which is at a slight angle causing the water to run directly into bowl where it is a direct product contact surface. I immediately applied US Rejected tag #B38349829 to tripe wash machine and informed and of findings, that the observed problem was a leaking water valve directly over tripe wash machine. Valve was immediately replaced to resolve problem, then instructed the accompanying clean up personnel to re-clean and sanitize the affected areas. I then re-inspected and accepted the tripe wash machine prior to start of operations. I then removed US rejected tag. These findings and actions were after the company performed their pre-operational sanitation procedures. Plants SSOP’s on page (3) paragraph (1) states in part” The piece of equipment was marked on the operational sanitation report as acceptable prior to FSIS findings. I notified , , and of this non-compliance verbally and with this document. No product injurious to public health entered into commerce. Past Similar NRs – Previous Ineffective Plant Actions: company failed to adequately monitor product contact surfaces NR: 19-2010 dated 5/21/2010

Regulation:

416.13(c)  Implementation of SOP’s: 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.