Putting Glass Walls on Arizona Slaughterhouses So We Can See Behind Closed Doors
JBS Tolleson, Inc.

Address: 651 South 91st Ave., Tolleson, AZ 85353
Establishment No.: 00267 M or M267

USDA Inspection Report: 27 April 2012

Code:  03J02
Violation:  417.2(a)(2), 417.2(b), 417.2(c), 417.2(c)(5), 417.4(a)(2) (iii), 417.5(a)(1), 417.5(a)(2)

Citation:

On 27 April 2012 I was informed by in-plant Inspection that a process change had occurred involving the application of at the head and tongue wash cabinet. After a review of the Offal HACCP plan, it was confirmed that there was not a documented reference to the addition of as a processing step at the step 3 head and tongue wash station. I also noted that there was no reference to the application of at the head and tongue station, in the hazard analysis or HACCP flow chart. 9 CFR 417.4 (a) 3, Reassessment of the HACCP plan, states that every Establishment shall reassess the adequacy of the HACCP Plan annually and whenever changes occur that can affect the Hazard Analysis and/or alter the HACCP Plan. At 8:45 AM was informed of the HACCP non compliance and that a non compliance record would be issued regarding this failure to reassess the HACCP Plan prior to the implementation of this processing aid. After a review of the non compliance records for the past 90 days, non compliances with a similar root cause were not noted.

Regulation:

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

417.2(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 processingcategories: (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.

417.2(c)  The contents of the HACCP plan: The HACCP plan shall, at a minimum: (1) List the food safety hazards identified in accordance with paragraph (a) of this section, which must be controlled for each process. (2) List the critical control points for each of the identified food safety hazards, including, as appropriate: (i) Critical control points designed to control food safety hazards that could be introduced in the establishment, and (ii) Critical control points designed to control food safety hazards introduced outside the establishment, including food safety hazards that occur before, during, and after entry into the establishment.

417.2(c)(5)  Include all corrective actions that have been developed in accordance with § 417.3(a) of this part, to be followed in response to any deviation from a critical limit at a critical control point

417.4(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.

(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.

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

417.5(a)(2)  The establishment shall maintain the following records documenting the establishment’s HACCP plan: The written HACCP plan, including decision making documents associated with the selection and development of CCP’s and critical limits, and documents supporting both the monitoring and verification procedures selected and the frequency of those procedures.

Next Report: USDA Inspection Report: 17 May 2012
Previous Report: USDA Inspection Report: 26 April 2012
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