Pork Slaughter HACCP Plan

Rosenthal Meat Science and Technology Center

Department of Animal Science Texas A&M University College Station, Texas January 6, 2000

Signature Page

Pork Slaughter HACCP Plan

Signature: _______________________________________________ _______________ Jeff W. Savell, HACCP Coordinator Date Department of Animal Science Texas A&M University College Station, Texas 77843-2471 Telephone: 409-845-3935 E-mail: j-savell@tamu.edu Web Site: http://meat.tamu.edu/

Member Dr. Gary Acuff, Professor Ivan Brigman, Graduate Student Darrell Demel, Meat Lab Foreman Mike De La Zerda, Graduate Student Dr. Davey Griffin, Associate Professor Dr. Dan Hale, Professor Dr. Kerri B. Harris Dr. Jimmy Keeton, Professor Lisa Lucia, Research Assistant Rob Maddock, Graduate Student Misty Pfeiffer, Communication Specialist Ray Riley, RMSTC Manager Dr. Jeff Savell, Professor

Telephone Number 409-845-4425 409-845-3957 409-845-5651 409-845-3957 409-845-0435 409-845-0435 409-862-3643 409-845-3936 409-845-4449 409-845-3957 409-862-2036 409-845-5651 409-845-3935

Pork Slaughter

HACCP Plan Summary Pork Slaughter

Monitoring Critical Limits No visible feces, milk or ingesta.

CCP CCP 1B Carcasses, Heads and Variety Meats Trim Zero Tolerance

Hazard Pathogens

What The carcasses heads and variety meats for visible feces, milk or ingesta

How Visual observation

Frequency Each carcass, head and variety meats

Who Carcass trimmer 1. 2.

Corrective Actions1 Identify and eliminate cause of deviation. Trimming of visible contamination will bring CCP under control after corrective action is taken. Measures to prevent recurrence are established, such as retraining employees and/or adjusting equipment, as needed. No product that is injurious to health or adulterated enters commerce. Identify and eliminate cause of deviation. Re-spraying the carcass with organic acid could bring CCP under control after corrective action is taken. Measures to prevent recurrence are established, such as retraining employees. No product that is injurious to health or adulterated enters commerce. All products will be sprayed.

Verification2 Visual observation of 10% of carcasses per kill by the plant manager or designee. On days that pork slaughter occurs, records will be reviewed daily by the plant manager or designee.

Records Pork Slaughter Log Deviation / Corrective Action Log

3.

4. CCP 2B Organic Acid Spray Pathogens Spray all carcasses, heads and variety meats with at least a 2% organic acid solution. Organic acid solution Proper formulation Every batch Organic acid
formulator

1. 2.

Application of organic acid to carcasses, heads and variety meats

Visual observation

Every carcass, head and variety meats

Carcass washer

3. 4.

Visual observation of: (1) Employee mixing organic acid spray, and (2) Employee applying the organic acid spray. Observation will be performed one time during the day of slaughter by plant manager or designee. On days that pork slaughter occurs, records will be reviewed daily by the plant manager or designee. Weekly calibration and/or verification of temperature monitoring device by the plant manager or designee. On pork slaughter days, records will be reviewed by the plant manager or designee.

Pork Slaughter Log Deviation / Corrective Action Log

CCP 3B Chilling Carcasses, Heads and Variety Meats

Pathogens

<50F internal temperature, for carcasses, heads and variety meats before fabrication/ shipping

Internal temperature of carcasses (ham), heads and variety meats.

Temperature Monitoring Device

25% of the kill; minimum of 1 carcass, head and variety meats per kill.

Cooler operator

1. 2. 3. 4.

Identify and eliminate cause of deviation. Bring CCP under control after corrective action is taken. Measures to prevent recurrence are established. No product that is injurious to health or adulterated enters commerce.

Pork Slaughter Log Deviation/ Corrective Action Log Temperature Monitoring Device Calibration and/or Verification Log

1 2

Plant manager or designee is responsible for performing corrective actions to ensure appropriate corrective actions are taken. Direct observation of corrective action by plant manager or designee will be conducted when a deviation is found during the pre-shipment record review. January 6, 2000 Version

PRODUCT DESCRIPTION
COMPANY NAME: Rosenthal Meat Science and Technology Center

PRODUCT NAME: Pork Carcasses, Heads, Variety Meats (Liver, Kidney, and Heart)

PRODUCT DESCRIPTION: Pork carcasses and by-products

INTENDED USE OF PRODUCT? Retail sale for general public consumption. Periodically, some products are used for teaching, research and extension activities.

TYPE OF PACKAGE? If shipped, carcasses are poly-bagged. Heads and variety meats are poly-bagged and boxed.

WHERE WILL IT BE SOLD? Retail sales area of the Rosenthal Meat Science and Technology Center Wholesale Samples for teaching, research and extension programs

LABELING INSTRUCTIONS: Safe handling label Keep refrigerated Keep frozen

DISTRIBUTION METHOD? If shipped, by refrigerated truck or insulated container.

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PRODUCTS/INGREDIENTS USED TO PRODUCE PRODUCT:

MEAT/POULTRY AND BYPRODUCTS

NONMEAT FOOD INGREDIENTS

BINDERS/ EXTENDERS

Live swine

SPICES/FLAVORINGS

RESTRICTED INGREDIENTS

PRESERVATIVES/ ACIDIFIERS

Organic acid spray

OTHER

Potable water Poly bag

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Rosenthal Meat Science and Technology Center Pork Slaughter Flow Chart
Hog Receiving and Holding Weighing Stunning Bleeding SKIN ON Scalding Hair Removal Pre-evisceration Wash SKIN OFF

Note: Ante-mortem inspection occurs after receiving swine and prior to weighing, and post-mortem inspection occurs throughout the process.

Skin Removal

Receiving Organic Acid Dry Storage

Head Processing Trim - Zero Tolerance

Heading/Splitting Sternum (CCP 1B) Evisceration Splitting Variety Meats Processing (CCP 1B) Trim - Zero Tolerance (CCP 2B) Organic Acid Spray (CCP 3B) Chilling

(CCP 2B)

Mix Organic Acid Spray

Organic Acid Spray

(CCP 2B) (CCP 1B) Trim - Zero Tolerance Final Wash Organic Acid Spray Weighing (CCP 3B) Chilling
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Chilling

(CCP 3B)

(CCP 2B)

Procedures for Slaughtering and Dressing Swine

1. Weighing, Stunning, Shackling and Sticking a. Balance the livestock scale (to zero) and gently drive the hog onto the platform. Allow the scale beam or needle to come to rest or, for digital scales, allow the digital readout to equilibrate and record the live animal weight. b. Gently drive the hog into the stunning chute and close the door. Stunning can be accomplished by administering electrical current to both temples or to the center of the forehead or by applying a sharp blow to the forehead with a mechanical stunning device. After proper stunning, tilt the stunning chute to release the hog into the dry landing area. c. The shackle is placed around one hind leg between the dewclaws and the hock. When the hog is suspended, steady it by placing the flat of the hand on the shoulder (do not grasp the leg) and insert the knife midway between the tip of the sternum and the throatlatch. With the tip pointed directly toward the tail and squarely in the middle of the ventral aspect, give an upward thrust to the hilt of the blade, dip the knife until it contacts the backbone and withdraw the knife through the entry slit making sure that the slit is as small as possible. Allow the hog to remain suspended over the bleeding pit for about 9 minutes before scalding. Sterilize knife prior to sticking the next animal. 2. Scalding and Dehairing a. Lower the hog into the scalding vat and, with the use of a pole, push and rotate the hog allowing each area of the body some opportunity to air during scalding. After about 3 minutes, begin to test for hair slippage over the back and sides by pulling a small tuft of hair out with the fingers. The last hair to slip is that in the region of the rear flanks. The flank is an excellent location for testing hair slippage. b. When the hair slips in the flank area, remove the hog from the vat and place it in the dehairing machine. Allow the hog to remain only so long as hair is being removed, then quickly remove the hog from the vat and move it to the scraping table and continue the hair removal process. 3. Cleaning the Head and Feet and Gambreling a. The legs, ears, face and jowls are regions where it is difficult to remove hair. Thus, great effort and perseverance must be used to remove hair in these areas. Upon removal of the hog from the dehairing machine, hair may be removed effectively from the hogs legs with a twisting and pulling motion with the hands. When the hair no longer yields to hand pressure, the knife may be used to remove the remaining hair and scurf. Special attention must be given to the areas of skin folds, beneath the shackle crease, on the lower feet, and around the snout and lips. b. The feet are cleaned by removing the toenails, cutting away the soles of the feet and cutting around and between the toes. The toenails and dewclaws are pulled by inserting a hook into the tip of the nail and pulling the nail away from the foot. c. Expose the gambrel tendons by cutting two parallel incisions through the skin on the backs of each hind leg from dewclaws to hock. With the incision made squarely in the center, the tendons will be exposed and the gambrel inserted for subsequent suspension on the rail. 4. Singeing and Shaving a. The carcass is singed by applying a gas-fired flame directly to the entire skin surface. Singeing removes most of the hair and visualizes the hair that was previously invisible. It is important to keep the flame moving to avoid burning the skin. b. Shave the remaining hair from the carcass with a knife. c. Wash the animal to remove foreign material on the outside surface before evisceration. 5. Head Removal

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a. Insert the knife in the stick opening with the cutting edge up, grasp it with both hands and pull upward, splitting the sternum. The sternum becomes thinner toward the rear edge; exercise caution when nearing the ventral point to avoid cutting the stomach or intestines. b. Remove the head by cutting between the atlas vertebra and the occipital condyles. The head should be removed by cutting just behind the ears, down around the jawbone crease and around to the chin. The jowls should be left on the carcass. Twist the head in a circular fashion to sever the connections around the occipito-atlantal space or cut through with a knife. 6. Evisceration a. Loosen the bung by pointing the tip of the knife downward and around the anus (and vulva in gilts). Pull the rectum forward (out), cutting its attachments to the pelvic cavity, tie with a string, and push in downward into the abdominal cavity. b. Facing the ventral aspect of the hog, score the belly between the hams to the point of the chin. Do not penetrate into the abdominal cavity. c. If the hog is a barrow, the pizzle (penis) and sheath should be dissected free, but left attached at the base between the hams. d. Make a short incision in the upper belly wall, grasp the knife with the thumb on the back of the blade and insert the fist into the body cavity with the blade pointed outward. Push downward cutting through the belly wall. With the severence of the abdominal wall, the viscera will fall forward and out. e. Divide the hams down the center of their medial juncture by following the cartilaginous seam to the pelvic symphysis. Split the aitch bone with the point of the knife. f. Grasp the viscera with the free hand, supporting the intestines with the free forearm. Sever the blood vessel near the top of the liver on the right side to release the liver. Insert the free hand behind the stomach and roll it forward and out. Sever the gullet (esophagus) to release the viscera. g. Cut around the juncture of the skirts and pillars of the diaphragm with the diaphragm membrane. Lift the hanging tender (pillar) to expose the dorsal aorta, cut across and then behind the aorta next to the backbone. Pull downward on the pluck and make two cuts, one on either side of the first ribs, to free the pluck. h. Remove the leaf fat by inserting the fingers beneath the layer of fat adhering to the abdominal wall near its juncture with the skirt at the center edge of the belly. Pull the fat upward slowly until the fist can be inserted, then fist the leaf fat to remove it from the belly pocket and ham base. The kidney is removed at the same time and is placed with the viscera for inspection. 7. Splitting and Preparation for Chilling a. Split through the center of the vertebral column and down the midline with a hand or power saw. Leave a section of skin attached over the shoulder to balance the carcass on the gambrel. b. Visually check the carcass for traces of hair or other foreign matter and remove it. Wash the carcass to remove traces of blood and bone dust from the split vertebrae. c. Weigh the carcass remembering to use the proper tare for the trolley and gambrel. Record the weight on the sheet and on the tag for the carcass. Place the tag(s) on the carcass. d. Spray the entire carcass with organic acid for approximately 8 seconds. e. Move the carcass into the initial or blast chill cooler for overnight chilling. 8. Preparation for Inspection a. The head is trimmed of any residual hair. Special attention is paid to the areas around the eyes and mouth. The inside portion of the ears and eye lids are removed. The head is washed before placing on the head rack. b. The viscera and pluck are placed on a pan or table and are identified with their carcass. c. The carcass, head, viscera, and pluck are presented to the inspector for final approval.

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Pork Slaughter

Pork Slaughter Hazard Analysis

Ingredient/ Process Step Potential hazard introduced, controlled, enhanced or reduced at this step Physical: Buckshot Metal or plastic eartags Chemical: Antibiotic residues Pesticides Growth promotants Is the potential food safety hazard significant? (Risk:Severity) No Justification for decision What control measures can be applied to prevent the significant hazard(s)? Is this step a critical control point (CCP)?

Swine Receiving and Holding

Unlikely to occur. No reported incidences of these hazards have been made at this facility Jan. 1, 1998 to January 6, 2000. Unlikely to occur. USDA Residue Monitoring Program indicates that the great majority of livestock are free of violative residues when slaughtered in inspected facilities. Any animals used for research involving chemical exposure will follow protocol for proper use. Live animals are potential reservoirs of pathogens. No control measures exist within this facility for trichina. Subsequent steps: Organic acid spraying will reduce potential pathogens. Proper chilling of the carcass will reduce potential for pathogen growth. No

No

Biological: Enteric pathogens (i.e., Salmonella, Campylobacter, and verotoxigenic E. coli) and Listeria monocytogenes Trichinella spiralis

Yes

Physical: None identified at this time. Weighing Chemical: None identified at this time. Biological: None identified at this time.
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No

Unlikely to occur. Only USDA approved insecticides are used.

Pork Slaughter
Ingredient/ Process Step Potential hazard introduced, controlled, enhanced or reduced at this step Physical: Bone fragments Stunning Is the potential food safety hazard significant? (Risk:Severity) No Justification for decision What control measures can be applied to prevent the significant hazard(s)? Is this step a critical control point (CCP)?

Unlikely to occur. Mechanical stunning mechanism may fracture the skull, but as required by inspection, the brain cavity is flushed with water. Electrical stunning may break the vertebrae due to contraction, but it is a rare occurrence during normal slaughter processing.

Chemical: None identified at this time. Biological: None identified at this time. Physical: None identified at this time. Bleeding Chemical: None identified at this time. Biological: Pathogens Yes Live animals may be a reservoir for pathogens. Hide opening and sticking may introduce pathogens. Subsequent steps: Organic acid spraying will reduce potential pathogens. Proper chilling of the carcass will reduce potential for pathogen growth. No

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Pork Slaughter
Ingredient/ Process Step Potential hazard introduced, controlled, enhanced or reduced at this step Physical: None identified at this time. Chemical: Hard Scald Biological: Pathogens No Unlikely to occur. Approved chemicals used in scalding vat. Potential for pathogen contamination from animal to animal in common scalding water. Subsequent steps: Organic acid spraying will reduce potential pathogens. Proper chilling of the carcass will reduce potential for pathogen growth. No Is the potential food safety hazard significant? (Risk:Severity) Justification for decision What control measures can be applied to prevent the significant hazard(s)? Is this step a critical control point (CCP)?

Scalding (Skin On)

Yes

Hair Removal (Skin On)

Physical: None identified at this time. Chemical: None identified at this time. Biological: Pathogens No Unlikely to occur.

Preevisceration Wash (Skin On)

Physical: None identified at this time. Chemical: None identified at this time. Biological: None identified at this time.
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Pork Slaughter
Ingredient/ Process Step Potential hazard introduced, controlled, enhanced or reduced at this step Physical: None identified at this time. Skin Removal Chemical: None identified at this time. Biological: Pathogens from the hide (i.e., Salmonella, Campylobacter, and verotoxigenic E. coli and Listeria monocytogenes) Yes Live animals are a potential reservoir for pathogens. Pathogens may be potentially introduced during skin removal. Subsequent steps: Organic acid spraying will reduce potential pathogens. Proper chilling of the carcass will reduce potential for pathogen growth. No Is the potential food safety hazard significant? (Risk:Severity) Justification for decision What control measures can be applied to prevent the significant hazard(s)? Is this step a critical control point (CCP)?

Physical: None identified at this time. Heading/ Splitting Sternum Chemical: None identified at this time. Biological: Pathogens Yes Pathogens may be found on the outside of the animal and may be introduced to the inside. Subsequent steps: Organic acid spraying will reduce potential pathogens. Proper chilling of the carcass will reduce potential for pathogen growth.
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No

Pork Slaughter
Ingredient/ Process Step Potential hazard introduced, controlled, enhanced or reduced at this step Physical: Plastic bag and tying device
Evisceration

Is the potential food safety hazard significant? (Risk:Severity) No

Justification for decision

What control measures can be applied to prevent the significant hazard(s)?

Is this step a critical control point (CCP)?

Tying devices are used to secure bung during evisceration. Viscera is removed and discarded at this facility.

Chemical: None identified at this time. Biological: Pathogens from the gastrointestinal tract (i.e., Salmonella, Campylobacter, and verotoxigenic E. coli) and Listeria monocytogenes Yes Visceral contents may contain pathogens. Pathogens may be introduced during evisceration. Subsequent steps: Organic acid spraying will reduce potential pathogens. Proper chilling of the carcass will reduce potential for pathogen growth. No

Splitting

Physical: Metal fragments from a damaged saw blade Chemical: None identified at this time. Biological: None identified at this time.

No

Unlikely to occur.

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Pork Slaughter
Ingredient/ Process Step Potential hazard introduced, controlled, enhanced or reduced at this step Physical: None identified at this time. Trim Zero Tolerance Chemical: None identified at this time. Biological: Visible feces, milk or ingesta may indicate potential pathogen contamination. Yes Removal of visible contamination is required by a Federal Register notice from USDA/FSIS entitled Livestock Carcasses and Poultry Carcasses Contaminated With Visible Fecal Material published on Nov. 28, 1997. Trim all visible feces, milk or ingesta. Yes Is the potential food safety hazard significant? (Risk:Severity) Justification for decision What control measures can be applied to prevent the significant hazard(s)? Is this step a critical control point (CCP)?

Physical: None identified at this time. Final Wash Chemical: None identified at this time. Biological: None identified at this time. Physical: None identified at this time. Organic Acid Spray Chemical: Organic acid Biological: Pathogens No Unlikely to occur. A food-grade organic acid is used in a recognized method of application. The proper application of food-grade organic acids can reduce pathogens. Organic acid spray Yes

Yes

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Ingredient/ Process Step Potential hazard introduced, controlled, enhanced or reduced at this step Physical: Carcass tags and carcass tag fasteners Is the potential food safety hazard significant? (Risk:Severity) No Justification for decision What control measures can be applied to prevent the significant hazard(s)? Is this step a critical control point (CCP)?

Weighing

Unlikely to occur. Carcass tags and fasteners are easily removed before further processing. No reported incidences of these hazards have been made at this facility Jan. 1, 1998 to January 6, 2000.

Chemical: None identified at this time. Biological: None identified at this time. Physical: None identified at this time. Chilling Chemical: None identified at this time. Biological: Pathogens Physical: Bone fragments Head Processing Chemical: Sanitizer (BI QUAT) Biological: Staphylococcus aureus No Unlikely to occur. Yes No Chilling can reduce pathogen growth. Unlikely to occur. Temperature Yes

No

Unlikely to occur. Stunning mechanism may fracture the skull, but as required by inspection, the brain cavity is flushed with water.

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Pork Slaughter
Ingredient/ Process Step Potential hazard introduced, controlled, enhanced or reduced at this step Physical: None identified at this time. Trim Zero Tolerance Chemical: None identified at this time. Biological: Visible feces milk or ingesta may indicate potential pathogen contamination. Physical: None identified at this time. Organic Acid Spray Chemical: Organic acid Biological: Pathogens Physical: None identified at this time. Chilling Chemical: None identified at this time. Biological: Pathogens Yes Chilling can reduce pathogen growth. Temperature Yes No A food-grade organic acid is used in a recognized method of application. Food-grade organic acids can reduce enteric pathogens (literature to be cited in appendix). Organic acid spray Yes Yes Removal of visible contamination is required by a Federal Register notice from USDA/FSIS entitled Livestock Carcasses and Poultry Carcasses Contaminated With Visible Fecal Material published on Nov. 28, 1997. Trim all visible feces, milk or ingesta. Yes Is the potential food safety hazard significant? (Risk:Severity) Justification for decision What control measures can be applied to prevent the significant hazard(s)? Is this step a critical control point (CCP)?

Yes

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Pork Slaughter
Ingredient/ Process Step Potential hazard introduced, controlled, enhanced or reduced at this step Physical: None identified at this time. Variety Meats Processing Chemical: None identified at this time. Biological: Pathogens Yes Raw variety meats are potentially contaminated with pathogens. Subsequent step: Proper chilling of the variety meats will reduce potential for pathogen growth. No Is the potential food safety hazard significant? (Risk:Severity) Justification for decision What control measures can be applied to prevent the significant hazard(s)? Is this step a critical control point (CCP)?

Physical: None identified at this time. Trim Zero Tolerance Chemical: None identified at this time. Biological: Visible feces milk or ingesta may indicate potential pathogen contamination. Yes Removal of visible contamination is required by a Federal Register notice from USDA/FSIS entitled Livestock Carcasses and Poultry Carcasses Contaminated With Visible Fecal Material published on Nov. 28, 1997. Trim all visible feces, milk or ingesta. Yes

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Pork Slaughter
Ingredient/ Process Step Potential hazard introduced, controlled, enhanced or reduced at this step Physical: None identified at this time. Organic Acid Spray Chemical: Organic acid Biological: Pathogens Physical: None identified at this time. Chilling Chemical: None identified at this time. Biological: Pathogens Physical: None identified at this time. Receiving Organic Acid Chemical: Organic acid Biological: None identified at this time. No Food-grade organic acid is used. No Unlikely to occur. A food-grade organic acid is used in a recognized method of application. The proper application of food-grade organic acids can reduce pathogens. Organic acid spray Yes Is the potential food safety hazard significant? (Risk:Severity) Justification for decision What control measures can be applied to prevent the significant hazard(s)? Is this step a critical control point (CCP)?

Yes

Yes

Proper chilling can reduce pathogen growth.

Temperature

Yes

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Pork Slaughter
Ingredient/ Process Step Potential hazard introduced, controlled, enhanced or reduced at this step Physical: None identified at this time. Receiving Packaging Material Chemical: Residue Biological: None identified at this time. Physical: None identified at this time. Dry Storage Chemical: None identified at this time. Biological: None identified at this time. Physical: None identified at this time. Mix Organic Acid Chemical: None identified at this time. Biological: Enteric pathogens No Yes Food-grade organic acid is used. Food-grade organic acids can reduce enteric pathogens. Organic acid spray Yes No Food-grade packaging materials are used. Is the potential food safety hazard significant? (Risk:Severity) Justification for decision What control measures can be applied to prevent the significant hazard(s)? Is this step a critical control point (CCP)?

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Pork Slaughter

CCP Description, Critical Limits, Monitoring Procedures, Corrective Actions

PRODUCT: Process Step Pork Slaughter CCP Number CCP Description Critical Limits Establishment Monitoring Procedures: (What/How/Frequency/Responsible Person) What: Carcass, head and variety meats for visible feces, milk or ingesta How: Visual observation Frequency: Every carcass, head and variety meats Responsible Person: Carcass trimmer Corrective Actions1 1. Carcasses, Heads and Variety Meats Trim Zero Tolerance CCP 1B No visible contamination. No visible feces, milk or ingesta. 2. Identify and eliminate cause of deviation. Trimming of visible contamination will bring CCP under control after corrective action is taken. Measures to prevent recurrence are established, such as retraining employees and/or adjusting equipment, as needed. No product that is injurious to health or adulterated enters commerce. Identify and eliminate cause of deviation. Re-spraying the carcass with organic acid could bring CCP under control after corrective action is taken. Measures to prevent recurrence are established, such as retraining employees. No product that is injurious to health or adulterated enters commerce. All products will be sprayed.

3.

4. 1. Mixing and Spraying Organic Acid CCP 2B Organic Acid Spray 1. 2. The concentration of the organic acid solution must be at least 2%. That each carcass, head and variety meats are sprayed with the organic acid solution. What: Organic acid concentration How: Proper formulation Frequency: Every batch Responsible person: Organic acid formulator What: Application to carcass, head and variety meats How: Visual Frequency: Every carcass, head and variety meats Responsible person: Carcass washer 2.

3. 4.

1. Chilling carcasses, heads and variety meats CCP 3B Chilling of carcasses, heads and variety meats < 50F internal temperature before fabrication/shipping. What: Internal temperature of carcasses (ham), heads, and variety meats How: Temperature Monitoring Device Frequency: 25% of the kill; minimum of 1 carcass, head and variety meats per kill Responsible person: Cooler operator 2. 3. 4.

Identify and eliminate cause of deviation. Bring CCP under control after corrective action is taken. Measures to prevent recurrence are established. No product that is injurious to health or adulterated enters commerce.

Unforeseen Hazards
There are chances that unforeseen hazards may occur at the Rosenthal Meat Science and Technology Center. Therefore, if an unforeseen hazard occurs, this establishment will: 1. Segregate and hold the affected product, at least until the requirements of (2) and (3) are met; 2. Perform a review to determine the acceptability of the affected product for distribution; 3. Take action, when necessary, with respect to the affected product to ensure that no product that is injurious to health or otherwise adulterated, as a result of the deviation, enters commerce; 4. Perform or obtain reassessment by an individual trained in accordance with section 417.7 of the USDA/FSIS Pathogen Reduction; Hazard Analysis and Critical Control Point (HACCP) Systems; Final Rule, to determine whether the newly identified deviation or other unforeseen hazard should be incorporated into the HACCP plan.
1

Plant manager or designee is responsible for performing corrective actions to ensure appropriate corrective actions are taken.

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Pork Slaughter

Pork Slaughter Verification and Recordkeeping

PROCESS STEP/CCP CCP 1B Carcasses, Heads and Variety Meats Trim Zero Tolerance VERIFICATION1 Visual inspection of 10% of carcasses, heads and variety meats per kill by the plant manager or designee. On days that beef slaughter occurs, records will be reviewed daily by the plant manager or designee. Visual observation of: (1) Employee mixing organic acid spray, and (2) Employee applying the organic acid spray. Observation will be performed one time during the day of slaughter by plant manager or designee. On days that pork slaughter occurs, records will be reviewed daily by the plant manager or designee. Weekly calibration and/or verification of temperature monitoring device by the plant manager or designee. Prior to fabrication/shipping, records will be reviewed daily by the plant manager or designee. Pork Slaughter Log Deviation/Corrective Action Log Temperature Monitoring Device Calibration Log Pork Slaughter Log Deviation/Corrective Action Log RECORDS Pork Slaughter Log Deviation/Corrective Action Log

CCP 2B Mixing and Spraying Organic Acid

CCP 3B Chilling Carcasses, Heads and Variety Meats

Direct observation of corrective action by plant manager or designee will be conducted when a deviation is found during the pre-shipment record review. January 6, 2000 Version

Rosenthal Meat Science and Technology Center Texas A&M University Temperature Monitoring Device Calibration and/or Verification Log
Date Time Temperature Monitoring Device Identification Temperature Reading at: 32F 212F Action Taken Performed by

Date

Time

Location

Temperature Monitoring Device Reading F

Calibrated Thermometer Monitoring Device Reading F

Action Taken

Performed by

Holding Cooler Aging Cooler Cooked Meat Cooler Cured Meat Cooler Freezer Smokehouse Probe 1 Smokehouse Probe 2 Chill-Down Probe 1 Chill-Down Probe 2

Reviewed by:_____________________________________

Date:_____________________________

Pork Slaughter Carcass Log

Slaughter Number Critical Limit CCP 1 CCP 2

Processing Date:
Performed By Time CCP 1 Trim Zero Tolerance; Critical Limit: No visible feces, milk or ingesta. CCP 2 Organic Acid Spray; Critical Limit: Spray all carcasses, heads and variety meats with at least a 2% organic acid solution.

Acceptable Statements: No Visible FMI; Carcass Sprayed; VM Sprayed; Head Sprayed CCP Verification

Organic Acid Concentration CCP 2

Chilling CCP 3 Critical Limit: <50F internal temperature (ham), variety meats, and heads before fabrication/ shipping
Time
Carcass # Temp. F Date/Time Initial

Amount of Acid

Amount of Water

Performed By

CCP 2 Verification
Signature_____________________________________ Date:__________________

Pre-shipment Review Signature:_________________________________________ Approved Date:____________________ Time:_________________

CCP 3 Verification Record Review

Signature_____________________________________ Date:__________________

Pork Slaughter Heads and Variety Meats Log

Slaughter Number Critical Limit CCP 1 CCP 2

Processing Date:
Performed By Time CCP 1 Trim Zero Tolerance; Critical Limit: No visible feces, milk or ingesta. CCP 2 Organic Acid Spray; Critical Limit: Spray all carcasses, heads and variety meats with at least a 2% organic acid solution.

Acceptable Statements: No Visible FMI; Carcass Sprayed; VM Sprayed; Head Sprayed CCP Verification

Chilling CCP 3 Critical Limit: <50F internal temperature (ham), variety meats, and heads before fabrication/ shipping
Carcass # Temp. F Date/Time Initial

Pre-shipment Review Signature:_________________________________________ Approved Date:___________________ Time:______________

CCP 3 Verification Record Review

Signature_____________________________________Date:__________________

Deviation/Corrective Action Log

CCP 1 CCP 2 CCP 3

1. 2. 3.

4.

Identify & eliminate cause of deviation Trimming of visible contamination will bring CCP under control after corrective action is taken Measures to prevent recurrence are established. Such as retraining employees and/or adjusting equipment, as needed. No product that is injurious to health or adulterated enters commerce.

1. 2. 3. 4.

Identify & eliminate cause of deviation Re-spraying the carcass with organic acid could bring CCP under control after corrective action is taken Measures to prevent recurrence are established. Such as retraining employees. No product that is injurious to health or adulterated enters commerce.

1. 2. 3. 4.

Identify & eliminate cause of deviation Bring CCP under control after corrective action is taken Measures to prevent recurrence are established. No product that is injurious to health or adulterated enters commerce.

CCP No.

Product I.D.

Deviation

Corrective Action No. 1

Corrective Action No. 2

Corrective Action No. 3

Corrective Action No. 4

Performed By

Time

Pre-shipment Review Signature:________________________________________

Approved Date:____________________

Time:_________________