Putting Glass Walls on Pennsylvania Slaughterhouses So We Can
See Behind Closed Doors
Jaindl Turkey Sales Inc.
Address: 3150 Coffeetown Rd, Orefield, PA 18069
Establishment No.: p460
USDA Inspection Report: 14 Apr 2011
Violation: 417.2(c), 417.5(a)(1), 417.5(a)(2)
Citation: On this day, while holding a meeting with plant management related to the Verification Plan dated March 3, 2011 regarding a Notice of Intended Enforcement action; non-compliance was observed. Prior to this meeting Inspection reviewed establishment HACCP Plan signed and dated 3-31-2011, monitoring procedures for CCP1B (Hot Package) included [redacted] Establishment officials stated that this was the wrong HACCP Plan on file, this plan was then replaced with an updated HACCP Plan signed by HACCP Coordinator Review of the updated HACCP Plan reveals the following concerning the establishment's CCP's. Review by Inspection revealed that the establishment had used a continuous monitoring device to monitor temperature of the product in the cooker as it was being packaged, with the continuous monitoring device then moved to the final package of product. CCP2B (Chilling) time and temperature of each batch of product is to be monitored manually by an employee. Plant management will use a calibrated handheld thermometer and insert the thermometer into two random locations in the product container, recording the single lowest temperature. To comply with separate portions of the critical limit, the time and temperature will be monitored multiple times throughout stabilization. Review by Inspection revealed that a continuous monitoring device was used to record the entire stabilization process, no hand held thermometers were in use. The establishment has failed to monitor their production of turkey BBQ as per their own written HACCP Plan and procedures. Review of establishment decision making documents for CCP1B and CCP2B reveals the following statement made by establishment; "The determination has been made that continuous monitoring is not feasible in our operation.", the decision making documents do not support the actual monitoring procedures as they were performed by the establishment. Review of establishment's supporting documentation reveals that there is not adequate support for their "Hot Fill" process; the establishment Hazard Analysis states . Documentation must support the process and confirm the status of the product as not exposed post lethality. The documentation must validate that the lethality temperature and sanitary handling are maintained during the time period in which the product moves from the cooker to the sealed package. Specifically, the establishment's continuous monitoring device recorded the "Hot Fill" process temperatures to range between approximately deg.F at the start to deg.F, back to deg. F at the finish of packaging (total 1/2 hour) time period. Observations by Inspection represent a failure of the establishment to follow their HACCP Plan as written, failure to maintain and provide supporting documentation for the production of their RTE Turkey BBQ product, and failure to provide adequate decision making documents for their 03G HACCP Plan. Violations of 9 CFR 417.2(c)(4), 417.5(a)(1), and 417.5(a)(2). was informed of this non-compliance with regulations both verbally and in writing with the issuance of this Non-compliance Report.
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;
417.5(a)(1) 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 reasonable possibility that it will occur in the particular type of product being processed, in the absence of those controls.
417.5(a)(2) 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.