Putting Glass Walls on Pennsylvania Slaughterhouses So We Can
See Behind Closed Doors
B.C. Natural Chicken
Address: 2609 U.S. Rt 22, Fredricksburg, PA 17026
Establishment No.: p493
USDA Inspection Report: 4 Nov 2011
Citation: At approximately 0856 hours, while performing a 04C04 ISP Code procedure for Finished Product Standards (Processing/Trims Nonconformance) Test at the Pre-chill Station) on the West Evisceration Line, my test exceed the absolute limit of 30, the FPS for Processing Category on the test was not in the absolute limit.. My test results subgroup total was 31, the processing nonconformance's were one (1) extraneous material <, nine (9) oil glands-remnant, one (1) lung-whole, one crop-partial-with mucosa, thirteen (13) feathers and/or pinfeathers, and one (1) feathers. I immediately notified (Quality Assurance) of my findings. (1st Processing Superintendent) was informed of my findings. Quality Assurance performed a retested for Finished Product Standard processing nonconformance's on the west evisceration line at 0901 hours for trim nonconformance's and failed the retest with a result of 41 with exceeded the tolerance for processing category, and placed the west evisceration line in action mode. I informed (1st Processing Superintendent) and (SCSI) of the results. There was no post chill test perform using prechill criteria until the chicken carcasses exited the chilling at 0954 hours (Company Break for Packing Department). Quality Assurance performed a retested for Finished Product Standard processing nonconformance's on the west evisceration line at 0914 hours for processing nonconformance's and failed the retest with a result [redacted] with exceeded the tolerance for processing category (0930 hours with results [redacted] and 0940 hours with results of [redacted]uality Assurance performed two consecutive retested for Finished Product Standard on the west evisceration line at 0945 hours and 0949 hours for processing nonconformance's and both tests pass. Quality Assurance tags 3 carcasses with red tags to mark the end of the failure mode at approximately 0954 hours, Quality Assurance performed r for processing nonconformance at the post chill station using prechill criteria, and failed the retest with a result o[redacted]with exceeded the tolerance for processing category (1004 hours with results o[redacted]with exceeded the tolerance). Quality Assurance performed Finished Product Standard for processing nonconformance's at the post chill station using prechill criteria's and pass at approximately 1018 hours, and 1048 hours. At approximately 1109 hours, the red tags came out of the chiller marking the end of the failure mode. I retained approximately 1000 whole poultry carcasses for reworks with US Rejected Tag B40 170436 (Eight (8) QA Retained Tag 4179, 4180, 4181, 4191, 4192, 4193, 4196, and 4543) for eight (8) combo bins. Establishment management has received oral and written notification concerning this noncompliance. This document serves as a written notification that your failure to comply with regulatory requirement could result in additional enforcement action described in 9 CFR part 500. Past Similar NRs - Previous Ineffective Plant Actions: No establishment response to this noncompliance. NR: 134-2011 dated 11/2/2011
381.76(b) Finished Product Standards: Finished Product Standards (FPS) are criteria applied to processed birds before and after chill to ensure that the product being produced is consistently wholesome and unadulterated. These criteria consist of nonconformances (listed in Table 1), the incidence of which is determined from 10 bird subgroup samples, reduced to a CUSUM number, and measured against the standards (Table 2). The standards are applied to permit the Agency to estimate when the production process is in control and when it is out of control. The establishment is responsible for maintaining FPS which, in turn, is monitored by the inspector. FPS is applied in two separate parts. The first is called prechill testing. It is designed to ensure that the slaughter and evisceration procedures are in control. Compliance is measured by determining the CUSUM on consecutive 10-bird subgroup samples collected prior to product entering the chilling system. The second part of the FPS is called postchill testing. It is designed to monitor the production through the chill system to ensure that it meets the postchill FPS. This test is independent of the prechill test. Compliance is measured by determining the CUSUM on consecutive 10-bird subgroup samples as they exit the chilling system. When the system is operating within compliance, the establishment applies the FPS to product samples at the prechill reinspection station. Testing time and time between tests are such that birds represented by the test are still within the chiller. If an out-ofcompliance condition is found, the product leaving the chiller is segregated for rework and retested before it may proceed into commerce. A second 10 bird subgroup sample of the birds is taken after they leave the chiller to ensure that the product meets the postchill FPS. Since the product is closer to the end of processing, the controls on releasing reworked product are stricter than controls under prechill testing, again to ensure that no adulterated product enters into commerce.