Putting Glass Walls on Delaware Slaughterhouses So We Can See Behind Closed Doors
Mountaire Farms of Delaware, Inc.

Address: 29005 John J. Williams Highway, Millsboro, DE 19966
Establishment No.: P3

USDA Inspection Report: 13 Mar 2012

Code: 01B02
Violation: 416.1, 416.4(a), 416.13(c), 416.4(b)

Citation: Breast Debone Area- At 0735 hours after pre-operational sanitation was complete by QSI and the establishment, while QSI was spraying sanitizer the area I observed clumps of meat and fat on the floor under table #1 rib-cage conveyor. I asked a QA Technician that was in the area to walk with me between tables (lines) and As we walked I observed meat and fat from the previous day operation on conveyor belts, cones, overhead support structures (direct product contact surfaces) as well as indirect product contact surfaces. I informed the QA Technician to get her supervisor as well as the QSI Plant Manager, Mr. . When they arrived I showed them the meat and fat on the direct and indirect product contact surfaces. Mr. was notified of the establishment failure to meet the regulatory requirements of 9 CFR 416.1, 416.4(a), 416.4(b) and 416.13(c) and that a regulatory control action was being assumed as per 9 CFR 500.2(a)(1) on breast debone tables #1 and #2. Both tables (lines) were rejected with U.S. Rejected Tag #B 34351476. I then proceeded to the other two tables (#3 and #4) where meat and fat from the previous day operation that was consistent with what was observed on (tables #1 and #2. I informed Mr. that the same U.S. Rejected Tag will be applied for the entire Breast Debone Area. At 0750 hours Mr. informed me that tables #1 and #2 were ready for re-inspection. Due to meat and fat still present on direct product surfaces the area remained rejected. At 0803 hours after sanitary conditions were restored as per the QSI re-cleaning procedures the regulatory control action was relinquished in the breast deboning area. A review of the QA Preoperational Sanitation Check Sheet dated March 13, 2012 revealed that though QA did randomly selected IU's within the area, none with meat and fat from the previous day operation was observed on direct product contact surfaces. Had it not been for my intervention wholesome product would have been contaminated with the aforementioned product on direct product contact surfaces from the previous day operation. During the weekly meeting dated February 22, 2012 we discussed a similar finding in the breast deboning area but a NR was not generated. The establishment response to that topic was, "The line leader that was responsible for this area was removed from their position and replaced with a new line leader. In addition, personnel have been instructed to continue inspecting in the area for any deficiencies, even after release by QA or USDA, prior to start up of production". Mr. , Plant Manager is being notified through this NR of the establishments failure to meet the regulatory requirements and that continued failure could result in enforcement action as per 9 CFR 500.4.

Regulation:

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

416.4(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.

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

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

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