# Presentation: 660282

## Foreign Material ContaminationHACCP and Prerequisite Programs

**Troie Burch**
**Director of Quality Assurance **
**Quik-to-Fix Foods **
**Southwest Meat Association**

- FSIS Technical Conference; Omaha, Nebraska

- September 24, 2002

## Food Safety Hazard

**PR/HACCP Final Rule definition:**
**Any biological, chemical, physical property that may cause a food to be unsafe for human consumption**
**Does not take into account “significance” in risk to human health**

- FSIS Technical Conference; Omaha, Nebraska

- September 24, 2002

## Food Safety Hazard

**NACMCF definition:**
**a biological, chemical, physical agent that is reasonably likely to cause illness or injury in the absence of its control.**
**Takes into account “significance”**

- FSIS Technical Conference; Omaha, Nebraska

- September 24, 2002

## HACCP - Hazard Analysis

**Product History - ingredients, processes**
**Customer Complaints**
**Is it a food safety hazard or a contaminate?**

- FSIS Technical Conference; Omaha, Nebraska

- September 24, 2002

## Extraneous Matter

**Any object/material which may become a part of the product being produced, which is not designed to be a part of such product**
**Not usually a significant risk, but depends on size, shape, and type**

- FSIS Technical Conference; Omaha, Nebraska

- September 24, 2002

## Adulteration or Contamination

**Adulteration - the bearing of any deleterious substance which may render the food injurious to health**
**Contamination must be addressed in SSOP, not in HACCP**

- FSIS Technical Conference; Omaha, Nebraska

- September 24, 2002

## HACCP - Hazard Analysis

**Evaluate information on hazards to decide which are significant and reasonably likely to occur and must be addressed in the HACCP plan**
**If not significant and reasonably like to occur - not covered by HACCP, but in Prerequisite Programs**

- FSIS Technical Conference; Omaha, Nebraska

- September 24, 2002

## HACCP - Hazard Analysis

**Low risk, low frequency- not HACCP**
**Low risk, high frequency-depends**
**High risk, low frequency-depends**
**High risk, high frequency-HACCP**

- FSIS Technical Conference; Omaha, Nebraska

- September 24, 2002

## Prerequisite Programs

**Multiple Points of Evaluation**
**Supplier Certification**
**Incoming Inspection**
**Sanitation/Preventive Maintenance**
**Processing Steps**
**Employee Practices**
**Finished Product Inspection**
**Employee Training**

- FSIS Technical Conference; Omaha, Nebraska

- September 24, 2002

## Supplier Certification

**Meats **
**Metal Detection - 10.5 mm ferrous**
**Dry Ingredients**
**Letters of Guarantee**
**Sifters and Magnets**
**Packaging**
**Letters of Guarantee**

- FSIS Technical Conference; Omaha, Nebraska

- September 24, 2002

## Incoming Inspection

**Product packaging condition**
**Food Code 3-202.15 Package Integrity**
**“****Food packages shall be in good condition and protect the integrity of the contents so that the food is not exposed to adulteration or potential contaminants.”**

- FSIS Technical Conference; Omaha, Nebraska

- September 24, 2002

## Sanitation/Preventive Maintenance

**Proper assembly of equipment**
**No extraneous material**
**No missing or damaged parts**

- FSIS Technical Conference; Omaha, Nebraska

- September 24, 2002

## Grinding

**Checks after every batch**
**Large object metal detection before pre-grind**
**Grind plate and knife blade check**
**Bone meat check**
**Knives and plates sharpened and inspected at end of each day**
**Metal detection before final grind**

- FSIS Technical Conference; Omaha, Nebraska

- September 24, 2002

## Sifters and Magnets

**Dry ingredients**
**Magnets remove enrichment**

- FSIS Technical Conference; Omaha, Nebraska

- September 24, 2002

## Employee Practices

**Colored vs clear plastic gloves**
**Proper placement of gloves when not in use**
**Small Tool Policy**

- FSIS Technical Conference; Omaha, Nebraska

- September 24, 2002

## Finished Product

**Visual at Packing**
**Finished Product Metal Detection**
**1.5 - 2.0 mm ferrous**
**2.5 mm non-ferrous**
**3.0 mm stainless steel 316**

- FSIS Technical Conference; Omaha, Nebraska

- September 24, 2002

## Foreign Material

**In meat and non-meat items**
**Wood**
**Plastic**
**Cardboard**
**Metal - biggest concern**
**UFO - unidentified foreign object**

- FSIS Technical Conference; Omaha, Nebraska

- September 24, 2002

## Wood

**Likely source **
**pallets**
**Pallet inspection program**
**Pallet rebuild program**
**Transfer to plastic pallets**
**Slip sheets**
**Wrap combo and wood pallet**

- FSIS Technical Conference; Omaha, Nebraska

- September 24, 2002

## Plastic

**Likely source**
**Processing or measuring tools**
**Packaging**
**Liners frozen in meat**
**Chub ends frozen in meat**
**Gloves**
**Small tool program**

- FSIS Technical Conference; Omaha, Nebraska

- September 24, 2002

## Cardboard

**Likely source **
**faulty incoming packaging - frozen boxed meat and poultry products**
**sticks to the meat**
**frozen in the meat**

- FSIS Technical Conference; Omaha, Nebraska

- September 24, 2002

## Metal

**Lead shot **
**finished product metal detection**
**Injection Needles**
**Inspect equipment during production**
**Meat Hooks**
**Boning knives**
**Incoming 10.5 mm metal detection**

- FSIS Technical Conference; Omaha, Nebraska

- September 24, 2002

## Metal continued

**Metal to metal rubbing**
**Equipment - missing bolts, etc**
**Metal detectors expensive for small processors**
**Cost of equipment**
**Trained employees**

- FSIS Technical Conference; Omaha, Nebraska

- September 24, 2002

## Bone

**Not necessarily a contaminant - inherent**
**Prevention/reduction methods**
**Visual inspection**
**Incoming Specifications**
**Grinding Specifications**
**Bone elimination equipment **
**Lack of re-use of bone meat**

- FSIS Technical Conference; Omaha, Nebraska

- September 24, 2002

## Suspected Contamination

**Metal**
**If no finished product metal detection**
**Use another resource that has equipment to inspect**
**X-ray < 0.8mm or lowest detectable level**
**Double pass at 90 degrees**

- FSIS Technical Conference; Omaha, Nebraska

- September 24, 2002

## Suspected Contamination

**With use of metal detection**
**Re-inspect product at higher sensitivity**
**< 0.8 mm ferrous or lowest detectable level**
**Double pass at 90 degrees**

- FSIS Technical Conference; Omaha, Nebraska

- September 24, 2002

## Suspected Contamination

**Plastic - depends on density****	**** and material characteristics**
**X-ray < 0.8mm or lowest detectable level**

- FSIS Technical Conference; Omaha, Nebraska

- September 24, 2002

## Challenges for Small Plants

**Lack of resources**
**Small number of employees**
**Large number of products**

- FSIS Technical Conference; Omaha, Nebraska

- September 24, 2002

## Challenges for Small Plants

**Need flexibility for implementation**
**Non capital alternatives**
**Best means available**
**Based on strengths of company**

- FSIS Technical Conference; Omaha, Nebraska

- September 24, 2002