U Marketing and

Regulatory

Programs

Agricultural

Marketing

Service

Specialty

Crops

Program

Specialty 

Crops 

Inspection

Division

AIM 

Inspection

Series

Quality Assurance 

Program (QAP) Manual

April 2018
“SCI moving forward in the 21st Century using technology, innovation, and old fashioned hard work”

Non-Discrimination Policy: In accordance with Federal civil rights law and U.S. Department of 

Agriculture (USDA) civil rights regulations and policies, the USDA, its Agencies, offices, and 

employees, and institutions participating in or administering USDA programs are prohibited from 

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Quality Assurance Program Manual

Table of Contents

INTRODUCTION .......................................................................................................................... 1

GUIDE FOR ELECTRONIC USAGE........................................................................................... 1

GENERAL...................................................................................................................................... 2

DEFINITIONS................................................................................................................................ 3

GUIDELINES FOR DEVELOPING A QAP PROGRAM............................................................ 3

Elements of the QAP ...................................................................................................................... 3

A QAP program must include the following elements:.............................................................. 3

Summary of Responsibilities...................................................................................................... 4

SCI Responsibilities After Official Approval of QC Program:.................................................. 4

USDA Documents Available for Use Under QAP......................................................................... 5

Implementation of the QAP............................................................................................................ 5

Assessment Criteria .................................................................................................................... 6

Temporary Approval................................................................................................................... 6

Official Approval........................................................................................................................ 7

Program Verification Groups.......................................................................................................... 7

QA Verification Sampling .............................................................................................................. 8

Product Rate................................................................................................................................ 8

Sampling Rates - Lot Procedures................................................................................................ 8

Selection of Lots for Verification of Each Product .................................................................... 9

Group Verification Procedures....................................................................................................... 9

Group I - Sample Units of Finished Product .............................................................................. 9

Group II - Sanitation Verification............................................................................................. 12

Group III - On-site Verifications Except Sanitation................................................................. 14

Action by Contractor on QA Verification Report, SC-148 .......................................................... 17

GROUP I DEVIATION VERIFICATION ACCEPTANCE TABLE.......................................... 18

STAGES OF IMPLEMENTATION TABLE............................................................................... 19

QAP - PRODUCT VERIFICATION PLANS.............................................................................. 20

QAP Product Verification Plan Background ................................................................................ 20

Procedure .................................................................................................................................. 20

Product Grouping...................................................................................................................... 20

GUIDE FOR QAP VERIFICATION WORK PLAN................................................................... 23

Process .......................................................................................................................................... 23

Approval Procedure .................................................................................................................. 23

Distribution ............................................................................................................................... 23

Guidelines - Verification Work Plan ........................................................................................ 24

QAP - VERIFICATION REPORT FORM (SC-148)................................................................... 26

Process .......................................................................................................................................... 26

Procedure .................................................................................................................................. 26

QA Verification Report, SC-148 .............................................................................................. 27

Group I - Finished Product Verification................................................................................... 29

Group II - Sanitation Verifications........................................................................................... 29

Group III - On-Site Verifications.............................................................................................. 30

Group IV - USDA Procedures/Verifications............................................................................ 31

VERIFICATION SUMMARY AND ANALYSIS - QAP PLANTS........................................... 31
ii

Format........................................................................................................................................... 32

Group I, Finished Product Deviations ...................................................................................... 32

Group II, Sanitation Deviations................................................................................................ 32

Group III - On-Site Verifications.............................................................................................. 32

Group IV - USDA Procedure Deviations................................................................................. 32

Summary of Analysis................................................................................................................ 32

REFERENCE LINKS................................................................................................................... 33

APPENDIX I – GUIDE FOR THE QAP MANUAL................................................................... 34

Responsibility ............................................................................................................................... 34

Distribution ................................................................................................................................... 34

Guidelines – QAP Manual............................................................................................................ 35

Cover page ................................................................................................................................ 35

Introduction............................................................................................................................... 35

Organization.............................................................................................................................. 35

Quality assurance program ....................................................................................................... 35

APPENDIX II – EXAMPLE OF AN ACCEPTABLE QAP MANUAL..................................... 38

APPENDIX III – ANNUAL CERTIFICATION OF QUALITY ASSURANCE PROGRAM 

REVIEW....................................................................................................................................... 39

APPENDIX IV – SAMPLE VERIFICATION WORK PLAN .................................................... 40

APPENDIX V – PROCEDURES FOR DETERMINING SIGNIFICANT DEVIATIONS........ 41

Procedure ...................................................................................................................................... 41

Table of Values of C for Variables Verification Procedure ......................................................... 43

Examples....................................................................................................................................... 43

APPENDIX VI – PRODUCT PLANS ......................................................................................... 47

Plan numbers - Canned products .................................................................................................. 47

Plan Number 1C: Canned Apricots, Cherries, Peaches, Pears, Plums, Grapes....................... 47

Plan Number 2C: Canned Fruits.............................................................................................. 48

Plan Number 3C: Canned Tomatoes ....................................................................................... 49

Plan Number 4C: Canned Tomato Paste and Puree ................................................................ 50

Plan Number 5C: Canned Tomato Juice.................................................................................. 51

Plan Number 6C: Tomato Catsup, Chili Sause, Tomato Sauce............................................... 52

Plan Number 7C: Canned Other Tomato Products and NAGs................................................ 53

Plan Number 8C: Canned Leafy Greens.................................................................................. 54

Plan Number 9C: Canned Non-Standardized Fruit Products .................................................. 55

Plan Number 10C: Canned Green Beans, Wax Beans ............................................................ 56

Plan Number 11C: Canned Sweet Peppers.............................................................................. 57

Plan Number 12C: Canned Corn ............................................................................................. 58

Plan Number 13C: Canned Apples, Applesauce ..................................................................... 59

Plan Number 14C: Canned Ripe Olives.................................................................................. 60

Plan Number 15C: Canned/Frozen Citrus Juice ...................................................................... 61

Plan Number 16C: Other Citrus Products................................................................................ 64

Plan Numbers - Frozen Products .................................................................................................. 65

Plan Number 1F: Frozen Asparagus, Green Beans ................................................................. 65

Plan Number 2F: Frozen Broccoli, Leafy Greens, Squash...................................................... 66

Plan Number 3F: Frozen Brussel Sprouts, Cauliflower .......................................................... 67

Plan Number 4F: Frozen Lima Beans, Peas............................................................................ 68

Plan Number 5F: Frozen Carrots, Sweet Peppers.................................................................... 69
iii

Plan Number 6F: Frozen Melon Balls..................................................................................... 70

Plan Number 7F: Frozen Apricots, Apples, Peaches, Strawberries......................................... 71

Plan Number 8F: Frozen French Fried Potatoes...................................................................... 72

Plan Number 9F: Frozen Preformed and Hash Brown Potatoes ............................................. 73

Plan Number 10F: Frozen Corn............................................................................................... 74

Plan Number 11F: Frozen Mixed Vegetables, Peas and Carrots, Succotash .......................... 75

Plan Numbers – Dehydrated Products.......................................................................................... 76

Plan Number 1D: Dehydrated Tomatoes................................................................................. 76

Plan Number 2D: Dehydrated Orange Juice............................................................................ 77

APPENDIX VII – REQUEST FOR GROUP IV VERIFICATION............................................. 78

APPENDIX IIX – VERIFICATION DEVIATION TRACKING FORM ................................... 79

APPENDIX IX – QAP PLANT ANTICIPATED WORK SCHEDULE..................................... 80

APPENDIX X – QUALITY ASSURANCE VERIFICATION REPORT EXAMPLES............. 81

Example G .................................................................................................................................... 87

APPENDIX XI – FILL WEIGHT VERIFICATION GUIDE: PEARS ...................................... 88

Procedure ...................................................................................................................................... 88

Example ........................................................................................................................................ 89

APPENDIX XII – FILL WEIGHT VERIFICATION GUIDE: PEACHES................................ 94

Procedure ...................................................................................................................................... 94
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INTRODUCTION

This document is designed to give guidance to personnel of the United States Department of 

Agriculture (USDA), Agricultural Marketing Service (AMS), Specialty Crops Inspection (SCI) 

Division in the implementation of the Quality Assurance Program.

Compliance with the AMS guidelines does not excuse failure to comply with the Food, Drug, 

and Cosmetic Act or any other applicable Federal or State laws or regulations. The SCI Division 

is responsible for grading/inspection, audit, and standardization programs for fresh and/or 

processed fruits and vegetables and related products. The Agricultural Marketing Acts of 1936 

and 1946, as amended, provide legal authority for the Division’s grading, auditing, and 

standardization activities.

Applicants may obtain inspections of any fresh and/or processed fruit and vegetable and related 

products for which they have a financial interest. The inspection service is voluntary and offered 

on a fee-for-service basis.

GUIDE FOR ELECTRONIC USAGE 

The AIM system of instructional manuals is available electronically in Adobe Acrobat Portable 

Document Format (PDF) at the following intranet address: https://emsteam.usda.gov/sites/AMS/AMS-SCI/AIM/_layouts/15/start.aspx#/. 

When accessed electronically, AIM materials have hyperlinks and hypertext (visible as 

underlined blue text) available to the PDF user. Clicking on a hyperlink takes the reader to a 

web site with information relating to the subject. Hypertext links the reader to a different page 

within the current manual, or a different manual, with information relating to the subject. For 

example, the hypertext in the Table of Contents allows a reader to go directly to the section of 

interest in the manual by clicking on the section title. 

PDF offers a variety of tools depending on the Adobe version the reader has. The newer the 

version, the more tools available. PDF documents are easily searchable for content within a 

document or within multiple documents. To learn about the variety of PDF search options: 

• Click on the “Help” tab on the top of any page in Adobe Acrobat, 

• Then click on the “Adobe Acrobat Help” bar, 

• Type the word “Search” in the “Search” box, and click on the “Search” button, 

• A series of options will become available, 

• Click on the “Access Search Features” link and follow the instructions for the type of 

search you are interested in.
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GENERAL

The SCI Division’s Quality Assurance Program (QAP) helps processing plants develop and 

implement complete or partial quality control (QC) programs that facilitate the consistent 

production of safe, wholesome, and uniformly high quality processed products to enhance their 

marketability and acceptance by consumers.

The Quality Assurance Program is a voluntary program that is based on the ongoing evaluation 

of the adequacy and effectiveness of a contracting plant’s QC program. Under the QAP, SCI 

verifies and audits the plant’s QC program and, as necessary, corrective measures. The program 

provides assurance that the plant’s QC program is reliable, effective, and capable of producing a 

sound and wholesome product of the desired quality level under sanitary conditions. 

SCI relies on the inspection results of approved QC programs, so plants may be able to reduce 

direct USDA inspection services in proportion to the QC efficacy achieved by the processing 

plant. 

In the initial stages of the program, there is an evaluation period during which SCI personnel 

determine the reliability of the plant’s QC program. During this evaluation period, certification 

will be available on lots verified by SCI personnel. Once a plant meets the plant survey 

requirements of the Regulations Governing Inspection and Certification of Processed Fruits and 

Vegetables and Related Products found in the Code of Federal Regulations (CFR), 7 CFR 52.81

(http://www.gpo.gov/fdsys/browse/collectionCfr.action?collectionCode=CFR), SCI inspectors

will be assigned to processing facilities under year-round, in-plant contracts to verify that the 

processors’ QC programs comply with the QAP.

Plants using the QAP assign quality levels to all lots produced, and record and evaluate all other 

procedures used within the specified plant using SCI in-plant inspection procedures, sampling 

plans, instructions, and acceptance and rejection criteria. Plants also may use designated grade 

marks and the “OFFICIALLY SAMPLED” stamp under QAP.
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DEFINITIONS

Quality Control (QC) - The process of establishing, securing, and maintaining a level of quality 

of a product that is satisfactory, adequate, dependable, and economical. The overall system 

involves integrating the quality aspects of several related steps, including the proper specification 

of what is wanted, production to meet the full intent of the specification, and inspection to 

determine whether the resulting product or service is in accordance with the specification.

Quality Assurance Program (QAP) - A program that provides assurance that the overall QC 

function is being performed properly and is effective. This involves an ongoing evaluation of the 

adequacy and effectiveness of the overall QC program and, as necessary, corrective measures 

initiated. The program includes verifications, audits, and evaluation of all factors that affect the 

specification, production, inspection, and use of the product or service. 

Deviations - Differences in inspection results between QC and QAP evaluations for the same lot, 

process, or procedure. (See Deviation Classification)

GUIDELINES FOR DEVELOPING A QAP PROGRAM

Elements of the QAP

A QAP program must include the following elements:

A. Effectively established controls.

B. Objective evidence showing that the controls are reliable and effective, including a 

written program.

C. A QAP manual that contains procedures, quality levels, sanitation requirements, areas of 

responsibility, and the designation of responsible individuals. SCI instructions, 

procedures, and quality levels may be used as part of the program. SCI will help set up 

guidelines for the plant’s QAP manual. 

Guidance for QAP manual development is contained in Appendix I.

D. Procedures for detecting production which does not meet acceptable levels in the 

appropriate standards and specifications. 

For QAP to be effective, the QC organization must operate independently and objectively. It 

should not be subject to pressure by plant management or other company personnel to make 

determinations based on the impact (economic or otherwise) to the company. 
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Summary of Responsibilities

Contracting party’s responsibilities after official approval of QC program:

A. Assign key individual (contact person) for each shift who will be responsible for carrying 

out the plant’s responsibilities under QAP.

B. Train and supervise all plant personnel assigned to make quality, wholesomeness, and 

other evaluations.

C. Evaluate all lots for acceptance or rejection of quality, wholesomeness, or other factors in 

accordance with SCI criteria, or criteria providing equivalent results and assurance. SCI 

notification is required on all lots exceeding wholesomeness guidelines due to the 

different tolerances, guides and other limiting factors listed and established in the AIM 

Inspection Series, Foreign Material Manual.

D. Assign individual(s) to evaluate and record sanitation in accordance with SCI 

instructions.

E. Perform all inspection duties in accordance with SCI procedures, or use approved written 

procedures that will give equivalent results.

F. Maintain records of inspection and make them available to SCI inspector(s) for 

verification or review.

G. Provide personnel to assist in SCI verification determination, case stamping, 

checkloading, condition of food container examinations, certification, or other inspection 

procedures.

SCI Responsibilities after Official Approval of QC Program:

A. Assign one or more SCI inspectors to the plant on a resident basis. 

B. Provide certification forms and certify all products produced under QAP.

C. Review inspection records, verify results, and provide management with verification 

results.

D. Monitor sanitation program, and provide suggestions for improvement to management.

E. Continually evaluate the plant for compliance with Food and Drug “Good Manufacturing 

Practice Regulations” and conduct annual USDA Plant Surveys.

F. Provide interpretation of SCI regulations and procedures.

G. Provide interpretation of the U.S. Standards for Grades, and on-site evaluation of 

proposed standard changes.
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H. Provide interpretation of requirements contained in specifications, such as State 

purchases, USDA-purchased commodities, and private buyer specifications.

I. Provide processor with all necessary SCI instructions and regulations.

J. Complete an annual review of the facility Quality Assurance Program manual and 

Verification Work Plan. (Located in Appendix III, and Appendix IV respectively)

K. Provide formal training during the off-season for QC plant personnel as requested 

through the area Officer-in-Charge (OIC).

L. Follow SCI Division Employee Rotation Policy (intranet link).

M. Assigned SCI inspector(s) will complete and submit Appendix IX Anticipated Work 

Schedule or equivalent to responsible area office.

USDA Documents Available for Use under QAP

A. U.S. standards and grading instructions for applicable products.

B. Fill weight procedures for those products where fill weights have been established.

C. Rules and regulations for on-line sampling rate for quality evaluations and verification.

D. SCI technical procedures and instructions for determination of applicable commodity 

verification factors such as Brix, Drained Weight, Count, etc. 

E. Micro-Analytical methods, analytical methods, and acceptability criteria for applicable 

products such as light filth, heavy filth, and mold determinations.

F. Technical Inspection Procedures for Foreign Material (AIM Inspection Series, Foreign 

Material Manual), including the FDA Defect Levels Handbook

Implementation of the QAP 

There are many decisions that must be made by the processor to accomplish the implementation 

of QAP. 

• What type of responsibilities is the facility able to perform? 

• Which of these responsibilities is the facility fully capable of assuming? 

• What functions would the facility prefer to postpone until personnel gain more training 

and/or experience?

It is up to the processor to determine the appropriate timeline necessary to implement the QAP, 

and demonstrate that it can assume the responsibilities. SCI role is to evaluate the 
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implementation and performance of the program. See the Stages of Implementation Table

contained in this manual for further details.

To assure that the submitted QC program is adequate in all respects, and performance of the 

system is consistently reliable, it is SCI responsibility to perform verification inspections by 

examination or testing or both.

Assessment Criteria 

SCI will:

A. Evaluate the QC program manual submitted by the contracting party for completeness, 

appropriateness, and clarity. The program must include written procedures detailing the 

corrective actions that will be implemented on program deviations.

B. Conduct a Plant Survey.

C. Through on-site evaluations, verify the performance of the sanitation program of the 

plant. Sanitation affects the wholesomeness of products being produced.

D. Through on-site evaluations, verify the performance of QC personnel in carrying out their 

duties.

E. Select and sample certain lots of production for verification. Test such lots for 

compliance with appropriate documents as specified in the QC program and/or QA 

procedures.

F. Develop verification procedures applicable to contracting plant.

Temporary Approval

Upon completion of the evaluations and Plant Survey, SCI will consider the QC program for 

approval on an interim basis. The QC program will continue to be monitored to provide a 

thorough evaluation, including working with variables that might affect consistent reliability. 

The Pack Certification - Quality Assurance Contract may be signed if the processor understands 

and agrees that inspection and certification is based on this “temporary approval” section.

To establish reliability of the contracting party’s QC program, SCI will use recognized methods 

to determine if there are significant differences between QC results furnished by the contracting 

party, and the results of SCI verification inspection on the same lot(s). The amount of 

verification inspection performed by SCI may equal the amount of inspection performed by the 

contracting party.
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Official Approval

Official approval will be granted when the following documents and data are submitted for 

evaluation and approved:

A. SCI Plant Survey;

B. Processors QAP Manual (guide for the creation of a QAP Manual is located in 

Appendix I, and an example of an acceptable QAP Manual is located in Appendix II);

C. USDA verification plan for Groups I, II, III, and optional group IV; and

D. USDA verification records and plant QC records for:

1. Ten (10) Group I verifications indicating reliable status. These verifications are 

to include each product produced during “temporary approval” with a 

representative sampling of each production shift’s reliability;

2. Seven (7) consecutive days of verifications for Group II sanitation with no 

unsatisfactory verifications. These verifications must indicate that each 

production shift is reliable; and

3. Seven (7) Group III on-site verifications. Each production shift must be 

represented.

All of the above records must validate that responsible plant personnel fully understand and are 

proficient at performing assigned task under the QAP. Appropriate personnel must also be 

capable of providing proper written responses to deviations noted on Form SC-148.

Through submission and approval of this material, SCI will determine that the contracting 

party’s QC program is capable of producing consistent, reliable results. The processor will be 

notified in writing of the approval of their QC program. Subsequently, the level of activity of 

SCI inspection personnel will be reduced as agreed upon by USDA and plant management.

Program Verification Groups

In order to provide assurance that a QC program is functioning properly, SCI will perform 

verification testing upon all phases of plant responsibility. Actual verification procedures are 

determined to some degree by a plant’s operating characteristics. 

The types of verification that may be performed are:

Group I All quality, non-quality, analyses, or any verification which can be performed on 

randomly selected sample units of predetermined sample size on the finished 

product.

Group II All sanitation verifications.
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Group III All on-site verification (except sanitation) for procedures or techniques. SCI 

inspectors will perform these verifications in the processing facility during 

production.

Group IV USDA procedures assumed under a complete QC program, such as case 

stamping, checkloading, certificate preparation, up-to-date inspection, condition 

of food container, and other similar types of USDA procedures. 

QA Verification Sampling

Product Verification - For use with Group I Verification

The processor’s QC program is subject to Group I verification on a daily basis by the random 

selection and sampling of product(s). SCI will determine the number and frequency of 

verifications according to these instructions. The number of verifications will be at least the 

minimum necessary to assure continued reliability of the processor’s QC program.

The reliability and similarity of products will be a factor in determining frequency and rate. 

Products which are similar in appearance and scoring factors may be considered one product for 

determining product rate.

Product Rate

Samples will be drawn from all product groups packed with random selection made for the lot(s) 

to be verified, provided that once a product is verified and considered reliable, it may be 

removed from the random selection until all other products are verified, except in those instances 

where Group 3 (on-site) verification indicates non-compliance with program responsibilities.

Minimum Number of Verification Lots per Number of Product Groups Packed

Number of Product Groups Packed1 Minimum Number of Lots to Verify

1 1

2 to 4 2

5 to 7 3

8 or more 4

Sampling Rates - Lot Procedures

The applicable standard sample unit size will apply to these product grade verifications.

Determine all sampling rates from Table XI through XIV (part 52.38c) of 7 CFR 52 in the 

Regulations, which may be found at the following internet address: 

http://www.gpo.gov/fdsys/browse/collectionCfr.action?collectionCode=CFR. These lot 

 1 The USDA inspector can apply this table when only one product (i.e., different styles, can size, etc.) is being packed.
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sampling rates will result in either 6 or 13 sample units, 13 samples being the maximum. 

However, when products under attributes standards are verified, the sampling rate for large 

(institutional) size containers may be reduced to 3, as outlined in the AIM Inspection Series, 

Sampling Manual. 

The number of sample units used for a particular verification factor may be increased or reduced 

depending on the testing procedure and objectivity involved in the verification. See Verification 

Work Plan Section - Group I Sampling Rate Summary. 

Selection of Lots for Verification of Each Product

A. Random selection of lots; or

B. Random selection of lots using the volume types below:

TYPE 1 - lots requiring a sample size of three (3) sample units for inspection. Refer to 

Sampling rates - Lot procedures;

TYPE 2 - lots requiring a sample size of six (6) sample units for inspection; and

TYPE 3 - lots requiring a sample size of 13 or more sample units for inspection.

For those products being verified, select the lots from the various volume types described above. 

Consider the time needed to complete the verification in addition to daily inspection 

responsibilities, and prioritize accordingly. Product rates and lot verification procedures are only 

minimum criteria. Additional verifications can be performed if verification results indicate the 

need, the processor requests additional verification data, or at the discretion of the supervisor. 

Group Verification Procedures

Group I - Sample Units of Finished Product

A. Procedure

A verification inspection consists of a review of the finished product sample units and all 

associated plant QC records covering the item selected for verification. Each numbered 

factor is considered a verification. Only one deviation will be counted in a factor when 

applying Acceptance Numbers, see Group I Deviations Verification Acceptance table. 

Once a product is selected for verification, a complete examination is made for all factors 

which can be determined on the finished product. Factors of verification for which 

reliability cannot be estimated will be based on Group III verification procedures. The 

deviations noted between SCI verification and plant generated results will be the primary 

basis for determining continued reliability of a processor’s QC program. Procedure for 

determining significant deviations is located in Appendix VI. Consideration will be 

given to the type of deviation, the severity, and their frequency, in making decisions on 

the processor’s continued reliability.
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B. Factors and rate

Below is a table of the types of factors which can be determined on a finished product 

selected for verification. The rate at which the factors should be examined is also 

included.

Factors Verification Sampling Rate

QUALITY:

Lot Evaluation

Grade Factor or Classification 

Evaluation (including flavor/odor)

All Sample Units

All Sample Units

NON-QUALITY:

Style Determination

Net Weight - Volume

Vacuum

Headspace

Drained Weight - Fill Weight

Sample Unit Count

Brix

Solids

Proportions

Condition of Container (Codes)

All Sample Units

All Sample Units

All Sample Units

Sample Units with Low Net Weights

All Sample Units

All Sample Units

All Sample Units - One lot per day

Two Sample Units

One Sample Unit

All Sample Units

ANALYSES:

Enzyme Inactivation

Mold Determination

Light Filth

Heavy Filth 

One Sample Unit or Determination per 

Verification Lot

One Sample Unit or Determination per 

Verification Lot

One Determination per Week

One Determination per Week

OTHER ANALYSES:

Foreign Material (Visual) All Sample Units
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C. Deviation classification

Deviations are classified into two categories: Minor and Major.

Deviation MINOR MAJOR

QUALITY:

QC evaluation one or more quality level(s) above verification.

QC evaluation one or more quality level(s) below verification.2

QC evaluation for individual factors or classification for grade 

deviate from verification sample units.

Inaccurate record keeping.

X

X

X

X

NON-QUALITY:

Verification(s) indicate QC evaluation or records inaccurate as to 

meeting requirements or specifications.

Verification(s) deviate somewhat from evaluation, but not to the 

point of incorrect lot assessment.

Verification(s) indicate significant deviation from QC evaluations 

for measurable factors. (Averages only)3

Verifications of QC records show incorrect procedure.

Inaccurate record keeping.

X

X

X

X

X

ANALYSES:

Verification(s) of QC records show incorrect procedure.

Verification results indicate incorrect assessment of acceptability or 

disposition of lots.

Inaccurate record keeping.

X

X

X

D. Unreliable status

The QC program for Group I verifications will be considered “unreliable” when any one 

of the following occurs:

1. No corrective action is initiated on program deviations.

2. Deviations occur in the same factor, for the same product grouping, for three (3) 

consecutive verification evaluations.

 2 This criteria does not apply to products that meet QC’s designated grade (attribute standards). 

Example: QC designates (or targets) the grade at “B” using the appropriate CuSum T&L values, and the SCI inspector determines the lot to be 

grade “A” using lot inspection procedures. 3 Significant deviations are defined as, “USDA/Plant results do not agree.”
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3. Minor deviations exceed acceptance number(s) contained in Group I Deviations 

Verification Acceptance table during three (3) out of five (5) consecutive 

verification evaluations.

4. Major deviations exceed acceptance number(s) contained in Group I Deviations 

Verification Acceptance table during two (2) out of five (5) consecutive 

verification evaluations.

E. Procedures during “Unreliable” status

Certification will no longer be based on contractor results. Certification will be available 

for those lots verified or inspected by SCI inspection personnel. Reliability will be reestablished when SCI considers that corrective measures initiated by plant management 

will prevent reoccurrence of similar deviations.

Group II - Sanitation Verification

A. Procedures

During the temporary approval period, a processor’s sanitation program, capabilities and 

reliability have been established. A plant that has gained official approval will be under a 

verification procedure, which may consist of:

1. Daily on-site verification of entire plant; or

2. Daily on-site verification of specific areas or zones, as outlined in the Verification 

Work Plan, such as:

a. Premises - receiving, dumping, garbage, and waste areas;

b. Preparation and processing areas;

c. Warehouse and shop areas, restrooms, lunchroom, and freezer facilities;

d. Personal hygiene; and

3. At minimum, a weekly sanitation verification will be conducted on those shifts 

not covered by a daily SCI on-site verification.

The combination of methods which the SCI inspector may use will depend on the 

size and complexity of a plant’s operation. SCI verification inspection procedures 

are typically elevated during the initial period after the plant is approved to 

implement QAP. If the program continues to be reliable, the level of verification 

may be reduced, at the discretion of the inspector, while still maintaining a level 

sufficient to confirm continued effective performance of program responsibilities.
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B. Unsatisfactory sanitation program

Verifications performed by the SCI inspector will be classified either satisfactory or

unsatisfactory. The processor’s sanitation program will be considered “unsatisfactory” 

when verifications indicate any one of the following occurs:

1. In a seven day period, a second occurrence of the same repeated “minor” 

sanitation deficiency that is not reported or is inaccurately reported on plant 

records; or in a thirty day period, the occurrence of a second different “minor” 

sanitation deficiency that is not reported or is inaccurately reported on plant 

records. In both instances, the verification with the first occurrence would be 

assessed as “satisfactory”. The “unsatisfactory” would be assessed to the 

verification report covering the time period of the second occurrence.

2. “Major” sanitation deficiencies not reported on plant records (incomplete 

inspection).

3. “Major” sanitation deficiencies inaccurately reported on plant records.

4. “Minor” and/or “major” sanitation deficiencies reported on plant records, but 

records do not indicate the results of follow up inspection.

5. “Critical” sanitation deficiencies.

C. Action on “Unsatisfactory” sanitation program verification

The following action will be taken when a processor’s sanitation program verification is 

found to be “Unsatisfactory”:

1. Review of deviation(s) by SCI inspector with plant management and notification 

of SCI field office.

2. Written report by plant management to SCI inspector as to the corrective action 

implemented to prevent reoccurrence of a sanitation program deviation, and if 

applicable, placing a “Hold” on all products which are affected by critical 

sanitation deviations.

If a plant’s QC has accurately reported sanitation deficiencies and has found 

sanitation “Unsatisfactory,” the SCI inspector will follow the guidelines as 

outlined in the AIM Inspection Series, Sanitation and Safety Manual.
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D. “Unreliable” sanitation program

The number of verifications indicating an “unsatisfactory” program will be limited. A 

processor’s QC program for sanitation under the QAP will be “unreliable” when:

1. Two verifications performed by a SCI inspector are “unsatisfactory” within seven 

production days; or

2. Three successive days or three days within seven production days of 

“unsatisfactory” sanitation reports as reported by the QC system within the plant.

E. Procedures during “Unreliable” period 

When the contractor’s verification is unreliable, the contractor will not be permitted to 

remain on a verification procedure for sanitation. SCI will increase the number of 

sanitation inspections, and may increase personnel if necessary during the unreliable 

period. If manpower limitations do not permit increased staffing, the QA procedures will 

apply only to those shifts where sanitation is satisfactory, as determined by on-site 

procedures.

During this period of unreliable status, all SCI and plant records pertaining to sanitation 

are to be sent to the Regional Branch Chief (RBC), the area office, and the National 

office on a daily basis.

On-site inspection and the results of corrective action initiated by plant management will 

be the determining factors in regaining reliability. With concurrence of the OIC, the 

QAP inspector will determine when reliability may be re-established. A written 

confirmation of this should then be sent to the RBC, with a copy sent to the National 

office.

Group III - On-site Verifications except Sanitation

A. Procedures

On-site verifications performed by SCI inspectors are used by the QC department to 

make program adjustments. Deviations will be recorded and discussed with designated 

plant officials. These verifications are performed during the production of an item and 

should cover all QAP program operations. A verification of the performance of each 

factor or task completed under the QAP will be performed at a frequency as determined 

applicable by responsible field office supervision. 
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B. Verification types - deviation types

QUALITY

Grade Factor Evaluation

MINOR DEVIATIONS

Inaccurate scoring/recording

Improper Technique

Procedural Errors

Improper interpretation of instructional 

material and record-keeping

or

Any other type of deviation in which the 

USDA inspector finds significant 

differences between his/her observations 

and plant generated results.

NON-QUALITY

Style Determination

Net Weight - Volume

Vacuum

Headspace

Drained Weight – Fill

Weight

Sample Unit Count

Brix

Solids

Proportions

Fruit-Sugar Ratio

Condition of Container

Sampling (verification 

samples)

Other Analyses as 

appropriate

ANALYSES

Enzyme Inactivation

Mold Determination

Light Filth

Heavy Filth

Foreign Material (visual)

Other Analyses

C. Action on “Minor” deviations

SCI inspector(s) will report and review deviations with designated plant officials. In the 

event that:

1. No corrective action is initiated on deviations, and/or

2. Two successive deviations of the same type, assignable to the same cause occur; 

the following action should be taken:

SCI inspector(s) will increase Group I type verifications to determine the extent of 

the specific deviation(s). Factors for which reliability cannot be maintained on 

the finished product must be verified through on-site procedures.
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D. Group IV - USDA procedures - verification

1. Implementation procedures

Group IV procedures are optional under this program. They must have official 

approval prior to implementation of verification procedures. During this period of 

evaluation, SCI will assist in the training and supervision of designated plant 

personnel performing the procedure. 

Reliability can be established through a sufficient number of verification 

evaluations to assure that the processor has the ability to perform the USDA 

procedure effectively and accurately. 

2. Considerations

Under a complete QAP, USDA procedures may be assumed by the processor. 

The plant size, personnel available, and desires of the plant to assume these 

functions will be the determining factors in granting approval. SCI ability to 

continue full responsibilities for these procedures will be affected by the 

minimum staffing possible under the QAP. Amount of Groups I, II, and III 

verifications during processing, and length of the processing season are prime 

considerations in determining if SCI can continue minimum staffing and carry out 

USDA procedures.

3. Types

a. Case stamping

b. Checkloading

c. Condition of food container

d. DSCP Inspection

e. Certification (preparing certificates)

f. Up-to-date inspection

g. Re-inspection

4. Verification rate

Verification rates can be developed for each type of assumed USDA procedure. 

The rate itself may depend on the processor’s capability and reliability. The 

verification rate may be reduced to one fourth of the lots produced, or to a skip lot 

rate specified for a particular type of procedure.
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E. Deviations

All deviations are considered “major.” Major deviations affecting the acceptability of a 

lot will cause the processor’s evaluation to be “unreliable.”

F. Unreliable status 

Verification(s) with deviations (major) which affect acceptability of lot, item, or 

procedures result in unreliable status.

G. Action during “Unreliable” period

SCI will not resume responsibility for procedure, but may perform verification testing on 

all lots produced. If this is necessary, SCI may elect to increase inspection personnel so 

that an accurate evaluation is determined on the acceptability of all lots, or until reliable 

status is established.

Action by Contractor on QA Verification Report, SC-148

Contractors will report corrective action for deviations from the QAP on the QA Verification 

Report. This report will be submitted to the SCI inspector for review following the contractor's 

review of the SCI deviation report.

A. Designated plant official will review the QA Verification Report of deviations issued by 

SCI inspector.

B. Designated plant official will determine cause of deviation and initiate corrective action 

necessary to prevent any reoccurrence of the deviation. The designated plant official will 

record the corrective action(s) on the QA Verification Report and return it to the SCI 

inspector for review. See the QA Verification report, SC-148.

C. The SCI inspector will be responsible for accepting or rejecting the plant’s response to 

each deviation. Acceptance of the response will be indicated by the inspector’s signature 

and date next to the signature and date of the plant official, for each deviation.
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GROUP I DEVIATION VERIFICATION ACCEPTANCE TABLE

VERIFICATION ACCEPTANCE PLAN FOR GROUP I DEVIATIONS

(Per Verification Lot)4

MINOR

NUMBER OF VERIFICATIONS

1 - 2

3 - 4

5 - 7

 8 - 10

11 - 14

15 - 17

ACCEPTANCE NUMBER

1

2

3

4

5

6

MAJOR

NUMBER OF VERIFICATIONS

1 - 7

8 - 16

ACCEPTANCE NUMBER

1

2

 4 Do not total verification factors when more than one lot is verified in a single day.
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STAGES OF IMPLEMENTATION TABLE

STAGES OF IMPLEMENTATION

Stage 1:

1. Plant develops a QAP Manual with SCI inspector's assistance.

2. Plant assigns key individuals (contact persons) for each shift who will be responsible for 

carrying out plant's responsibility under the QAP.

3. Plant assigns personnel to perform quality, non-quality, and other QC procedures.

4. Plant assigns personnel on all shifts to perform sanitation inspections and monitor procedures.

5. SCI provides inspection personnel necessary to carry out complete inspection procedures.

6. SCI trains key plant personnel in all phases of work which the plant will assume under this 

program.

7. SCI inspector develops the USDA Verification Work Plan.

Stage 2:

1. Plant QC personnel, trained by SCI, assume responsibility for:

a. On-line and finished product examination.

b. Sanitation inspection and monitoring on all shifts.

c. Supervision and training of personnel doing quality, non-quality and other evaluations.

d. Evaluation of all lots for acceptance or rejection of quality, non-quality or other factors 

in accordance with SCI criteria, and maintain records of inspection and all other 

documents.

e. Maintaining all records of inspection, including all supporting documents.

2. SCI retains responsibility for technical supervision of grading personnel and quality level 

determination, but with increased participation of plant personnel.

3. Limited verification procedures will be conducted by inspectors for any procedures and 

evaluations for which plant has assumed responsibility.

Stage 3:

1. Plant responsible for all items listed under "Contracting Plants Responsibilities."

2. SCI implements verification procedures to evaluate plant's ability to perform under QAP.
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QAP - PRODUCT VERIFICATION PLANS

This section contains instructions for product grouping, verification factors, and the minimum 

sampling rates for of verifying lot grades for plants under the SCI, QAP.

QAP Product Verification Plan Background

Procedure

The product grouping is based on similarity of evaluation and product relationship. Each 

product verification plan indicates whether the products are to be considered as one product, or 

treated individually for determining the number of products to verify. See the General section of 

this manual for additional information. The verification factors and the minimum rates remain 

constant for each product or group of products. Depending on the individual plant situation, the 

IIC may consider products within a group as individual products for verification.

Product Grouping

This section includes separate product verification plans for each product group. Similar product 

verification plans should be included with each QAP verification work plan, indicating the 

products that will be verified at that plant. The IIC may add or delete products or procedures 

from the established product grouping list by revising the verification work plan including a 

statement to cover the reason(s) for the modification. The revised product grouping list will 

become effective only upon final approval of the work plan.

The sampling rates established in each product verification plan must be tailored to meet the 

needs of that plant as well as SCI Division. In some plants it may be necessary to increase the 

rate of examination for certain factors because of their importance in buyer specifications. It 

may also be necessary to list and establish rates for additional factors.

Product Plans are located in Appendix VII.
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A. Canned products

Plan Number Canned (C) Products

1C Apricots, Sweet Cherries, Clingstone Peaches, 

 Freestone Peaches, Pears, Grapes, and Plums.

2C Fruit Cocktail, Fruits for Salad, and Fruit Mix

3C Tomatoes and Stewed Tomatoes 

(Whole, Halves, Sliced, Wedges, Diced)

4C Tomato Paste and Tomato Puree

5C Tomato Juice, Single Strength and Concentrated

6C Tomato Catsup, Chili Sauce, and Tomato Sauce

7C All other tomato products and other products which have no applicable 

grade and which are not covered by separate verification outlines.

Examples: Zucchini & Tomatoes, Tomato Juice Mixes, Vegetable 

Juices, Pizza Sauce, Spaghetti Sauce, All Purpose Sauces, Crushed 

Tomatoes, Creole Sauce, Tomato Soup, Seafood Cocktail Sauce.

8C Leafy Greens (All Types)

9C Non-Standardized Fruit Concentrates, Purees, and Nectars 

(Apple, Apricot, Peach, Pear)

10C Green Beans and Wax Beans

11C Sweet Peppers

12C Corn, Cream and Whole Kernel

13C Apples, and Applesauce

14C Canned Ripe Olives

15C Citrus Juices (Single Strength/Concentrate)

16C All other citrus products and other products which have no applicable 

grade and which are not covered by separate verification outlines.
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B. Frozen products

Plan Number Frozen (F) Products

1F Asparagus, Green Beans

2F Broccoli, Leafy Greens (All Types), and Squash (Summer Type)

3F Brussels Sprouts, Cauliflower

4F Lima Beans, Peas

5F Carrots, Sweet Peppers

6F Melon Balls

7F Apricots, Apples, Peaches, and Strawberries

8F Potatoes, French Fried Type

9F Potatoes, Hash Brown and Preformed Types

10F Whole Kernel Corn, Corn-on-the-Cob

11F Mixed Vegetables, Peas and Carrots, and Succotash

15C Frozen Orange Juice

C. Dehydrated products

Plan Number Dehydrated (D) Products

1D Tomatoes, Dried, Crystals = Powder (Nag Item)

2D Orange Juice, Dehydrated
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GUIDE FOR QAP VERIFICATION WORK PLAN

A QA verification work plan must be written so that an inspector familiar with the facility’s QA 

procedures or plant operation could function adequately by following it. An effective work plan 

is comprehensive in its scope. This section includes an outline for preparing a work plan and an 

acceptable example of one is attached as Appendix IV.

Process

Approval Procedure

The OIC is responsible for preliminary approval of the work plan. If acceptable, the work plan is 

forwarded with a cover sheet documenting dates and appropriate signatures to the RBC for final 

approval. If the work plan fails to meet the criteria established, it will be returned to the field 

office for revision. The RBC may send a copy of the proposed work plan to the Division 

Director for review and comment before granting final approval. In-plant inspectors are 

responsible for up-dating the verification work plan through-out the year as applicable. In 

addition a complete review of the verification work plan will be performed and documented on 

an annual basis to ensure continued applicability. The required certification document is located 

in Appendix III. Division operational management will perform an annual compliance review 

per Division Quality Management System. 

Distribution

Upon final approval, the work plan accompanied with the cover sheet will be forwarded to the 

OIC to replicate and distribute as follows:

A. Original to inspector in the plant,

B. One copy at the Field office (or more if needed),

C. One copy to the Regional office,

D. One copy to the National office. 

A copy of the required annual certification of the QAP manual review will be distributed no later 

than pay period two of the current year as follows:

A. Original copy to in-plant QAP manual

B. One copy to Area Office
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Guidelines - Verification Work Plan

Following is a suggested format for a verification work plan:

A. Cover page

1. Name of company and address

2. Official approval signatures

B. List management personnel

1. Executive management

2. Plant personnel

3. QAP contact person(s)

C. Products packed - groups

List all products by product groups 

D. Basic grading period

State basic grading periods for all products

E. Plant QC procedure

1. State who grades all lots

2. State grading procedures

3. State non-quality procedures

4. State other specification requirements

5. State where records are filed

6. State how records may be obtained

F. Selection of Group I verification lots

1. State sampling plan and rate

2. State how to obtain production schedule

3. State how lots are selected, and note any exceptions to normal lot selection
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4. List sampling procedure

a. State how sampling instruction is given to plant

b. State method of selecting lots for verification

c. If applicable, state how selected lots are tracked to ensure all products are 

selected for verification

5. State how and where samples are collected and taken to the laboratory

G. Group I verification - finished product

1. State procedure

2. State quality and non-quality factors and analyses evaluations

3. State finished product deviations

a. State how to compare results

b. State how to report deviations

H. Group II verification - sanitation

1. Sanitation verification areas - divide plant into areas

a. Processing areas

b. Non-processing areas

2. Plant sanitation procedure

3. USDA verification of the plant sanitation program

a. Explain random selection of areas

b. Explain auditing of plant’s sanitation report

c. If applicable, state how selected areas/zones are tracked to ensure all areas 

are selected for verification. 

I. Group III verification - on-site observations

Explain procedure, deviations, and actions to be taken
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Group III verification factors should be tracked to ensure all factors are reviewed as 

appropriate to confirm continued program effectiveness.

J. Group IV verification - USDA procedures

List procedures and contact person

Example request for Group IV verification form is located in Appendix X.

K. Reports and files

1. Quality assurance verification report SC-148

2. Audits by USDA supervisors

3. Plant QAP manual

4. USDA verification work plan

5. USDA verification summary and analysis report

6. Records and procedures for handling a foreign material or sanitation HOLD

7. Plant QC and sanitation files

8. USDA files

QAP - VERIFICATION REPORT FORM (SC-148)

This report is to be used for reporting all deviations and observations detected during verification 

inspection procedures under the QAP. This verification report form serves as the daily record of 

plant program reliability. 

Process

Procedure

This report is completed for each verification period that is a basic grading period, and 

distributed immediately to the designated plant official. This may include plant manager and 

corporate QC. The designated plant official’s response outlining the correction or explanation to 

the deviations will be one of the indicators important in the overall evaluation of the QC 

Program’s reliability. The completed SC-148 will be filed with the QAP records after the review 

and acceptance by the SCI inspector. Acceptance of the response will be indicated by the 

inspector’s signature and date directly next to the signature of the plant representative.

A. Designated plant official will draft appropriate response(s) to each deviation reported.
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B. Each response will be dated and signed by the designated plant official.

C. Acceptance of each correction or explanation will be indicated by the inspector’s 

signature and date.

D. Designated plant official and the inspector will initial and date in the appropriate block on 

the bottom of the form when all responses are accepted.

Completion Guidance for days an inspector is not on duty:

Please use the following procedure when the plant processes seven days and the inspector works 

five days - 40 hours per week:

• Prepare an SC-148 for each day that the plant worked and the inspector was not on duty. 

A day is a 24-hour period.

• List item and verification factors, and, under the deviation section of the form, state, “No 

verifications made this date. USDA inspector off duty.”

• In addition, report any other appropriate statements in this section of the form, e.g., 

reporting regulatory visit when inspector not on duty.

QA Verification Report, SC-148

Information to be included on this report should include the following: (See Example A, QA 

Verification Report SC 148, located in Appendix X.)

A. Enter all required information needed in the upper right hand corner, plant, plant address, 

date of pack, and program status.

B. Shift - Should be stated as shifts 1, 2, or 3.

C. Item and Group - Enter the verification groups that the plant is using to meet their 

requirements for their QAP Program. Some plants DO NOT participate in the Group IV. 

These may be put in any order. Group II may be first, then III, and then I. This is up to 

the inspector.
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D. Verification factor - Enter the commodities or factors being verified. See below.

GROUP I CATEGORY: 

FOR FINISHED PRODUCT CLINGSTONE PEACHES

FRUIT COCKTAIL

GROUP II CATEGORY: PREMISES

SANITATION PREPARATION

CANNING (ETC.)

GROUP III CATEGORY:

ON-SITE NET WEIGHTS

FILL WEIGHTS (ETC.)

GROUP IV CATEGORY: CHECKLOADING

THIS CATEGORY IS NOT USED BY ALL PLANTS. CHECK 

VERIFICATION WORK PLANS.

E. Number of verification - The number entered in this column represents the factors being 

verified under the plan used for that commodity (QAP Product Verification Plans section 

of this manual).

Example:

Plan number 1C has 12 factors. If the plant runs other commodities, the inspector may 

only have completed 11 factors, Brix may have been done on the other commodity 

packed. At the bottom of this column is an area for a total; when only one lot is verified, 

enter the number of the factors completed. Do not total verification factors when more 

than one lot is verified in a single day, leave blank.

F. S/U/M/m columns

S = Satisfactory

U = Unsatisfactory

M = Major Deficiency

m = Minor Deficiency

Enter an X next to the deficiency in the correct column indicating if it is major, minor, 

satisfactory, or unsatisfactory. Total the number of major or minor deficiencies in the 

boxes at the end of those columns.

G. Deviations and/or deficiencies-Quality corrections - Enter all deficiencies noted for 

each/all verification factors. Leave room under each deficiency for any needed response 

from the contact person. The contact person and the inspector will sign and date under 

each response. The USDA inspector will sign and date each acceptable response next to 

the contact person’s signature and date.

H. Inspector's signature
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I. Date - (To left of inspector's signature). The correct date will be the date that the form is 

issued.

J. Initials of plant official - After the inspector has reviewed the form, the plant official will 

initial this box.

K. Date - this date will be the date the plant contact person completes all responses and the 

responses have been accepted by the USDA inspector.

Examples of completed SC-148 forms are located in Appendix X. The individual plant 

needs will determine whether Groups 1, 2, 3, and 4 need to be issued on separate sheets 

or whether combining the groups is possible.

Group I - Finished Product Verifications

Group II - Sanitation Verifications (Satisfactory)

Group II - Sanitation Verifications (Unsatisfactory)

Group III - On-Site Verifications

Group IV - USDA Procedures/Verifications

Group I - Finished Product Verification

The primary purpose of this verification is to document all deviations. Example F of a 

completed SC-148 is located in Appendix X – Quality Assurance Verification Report Examples. 

List the deviations in a concise manner. Plant responses to all deviations should indicate:

• What caused the deviations, if possible?

• What action was taken to correct the deviation?

Do not accept plant responses that are vague or that indicate that the corrective action will only 

temporarily correct the deviation. The primary strength of this program is related to accurate 

documentation of deviations and their immediate correction within the QC system.

Group II - Sanitation Verifications

The primary purpose of sanitation verification is to determine the on-going capabilities and 

reliability of the processor. Verifications are performed to assess the sanitarian’s ability to 

recognize, classify, and record sanitation deficiencies; the processor’s capabilities to correct 

deficiencies and to keep plant management informed on the overall reliability of their sanitation 

program.

Verifications performed by the USDA inspector are recorded on the official sanitation 

scoresheet. “USDA Group I Verification” should be recorded in the title block. Example G, 

located in Appendix X – Quality Assurance Verification Report Examples, is an example of a 
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completed sanitation scoresheet. This scoresheet is used for comparing verification findings 

with the plant sanitation scoresheets to determine whether the verification is “satisfactory” or 

“unsatisfactory.” 

If the verifications indicate a “satisfactory” status, the SC-148 need only indicate this fact.

If the verifications indicate an “unsatisfactory” status, the SC-148 should indicate the types of 

deficiencies and area within the plant causing this status.

The form used to record deficiencies found in the verification inspection is not distributed to the 

plant. It is used only by USDA as a supporting document for SC-148. It must NOT be used as 

an additional checklist for plant personnel.

Two examples of completed SC-148s illustrating the type of information needed under 

“satisfactory” and “unsatisfactory” situations are located in Appendix X – Quality Assurance 

Verification Report Examples. Example C shows a “satisfactory” report. Example D shows an 

“unsatisfactory” report, listing the deviations in the program which may be used to show reasons 

for “unsatisfactory.” If the actual deficiencies are listed on the SC-148, show only general types 

and/or areas. The primary purpose of the verifications is to alert the processor to a breakdown of 

their sanitation program, and to have them respond with corrective measures to prevent 

reoccurrences of similar deviations incomplete inspections, inaccurate reporting, incomplete 

follow-up inspections or failure to prevent “critical” conditions from occurring. 

Responses to “unsatisfactory” verifications are outlined in the General Section of this manual.

Group III - On-Site Verifications

While Group III - On-site verifications are performed during production, and involve direct 

observation of the performance of assumed responsibilities. Verifications of this type are used 

by the plant to make immediate corrections of program deviations. Since the designated plant 

individual is responsible for the training and supervision of plant personnel, this type of 

verification gives plant management information concerning the effectiveness of this phase of 

their operation.

Since these verifications are random and of short duration, they are not used to establish 

“reliable” or “unreliable” status. They are used as a basis for increasing Group I type 

verifications. All deviations are minor, but do not enter (X) in the “m” column.

The SCI inspector will record all on-site observations on Form SC-148 whether or not deviations 

are found. Only by accurate and timely documentation by the SCI inspector can plant 

management measure the effectiveness of the QAP and their own areas of responsibility.

Group III On-Site Verification, Example E, located in Appendix X, is an example of a completed 

SC-148 for on-sites. List the deviations in a concise manner. Plant responses to all deviations 

should indicate:
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• What caused the deviations, if possible?

• What action was taken to correct the deviation?

Do not accept plant responses that are vague, or that indicate that the corrective action will only 

temporarily correct the deviation. The primary strength of this program is related to accurate 

documentation of deviations and their immediate correction within the QC system.

Group IV - USDA Procedures/Verifications

This group of procedures are optional under the program, and must have official approval prior 

to implementation of a verification procedure.

Verification procedures must be developed for each type of USDA procedure being assumed by 

the processor, and being included in the USDA verification work plan for each plant. 

Verifications for Group IV are directed toward deviations which affect acceptability of the lot, 

item, or procedures. Any verification which indicates nonconformance requires verification on a 

lot by lot basis until reliability is reestablished.

All deviations are considered “major” and those affecting lot acceptability cause the status to be 

“unreliable.”

Any deviations found by the USDA inspector during verifications will be listed on Form SC148, "Quality Assurance Verification Report", and will require the designated contact person to 

indicate what caused the deviation and what action was taken to correct it. The USDA inspector 

will be responsible for accepting or rejecting the plant’s response to each deviation. Acceptance 

of the response will be indicated by their signature and date next to the signature and date of the 

plant representative for each deviation.

Example F: Group IV – USDA Procedures Verifications is located in Appendix X – Quality 

Assurance Verification Report Examples.

VERIFICATION SUMMARY AND ANALYSIS - QAP PLANTS

The verification summary report is intended to provide information to the company’s top 

management on how well the plant’s QC program is working. This report should cover 

verification deviations in Groups I, II, III, and IV, the causes of the deviations, and the plant’s 

responses and corrective actions taken for each deviation.

The verification summary and analysis report is to be completed by October 31st each year. The 

report should cover the prior fiscal year and be submitted to the appropriate Regional office. 

Verification deviations must be tracked throughout the year for verification summary reporting

purposes and to assist in identify potential trends or opportunities for improvement. Example 

verification deviation tracking form are located in Appendix IIX.
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Format

Group I, Finished Product Deviations

A. Frequent or common general deviations occurring in most products, (vacuum, Brix, 

sampling procedures, etc.). Include general discussion on cause, response, and corrective 

action, as applicable.

B. Deviations by product

1. Insert a recap of total deviations along with the narrative.

2. Discuss cause, response, and corrective action as applicable.

3. Relate to Group III, if appropriate.

Group II, Sanitation Deviations

A. Insert a recap of total unsatisfactory verifications.

B. Discuss cause, response, and corrective action(s).

C. Discuss reason and length of any periods of unreliable status, if applicable.

Group III - On-Site Verifications

A. Insert a recap of total deviations.

B. Discuss cause, response, and corrective action(s).

C. Relate to Group I if applicable.

Group IV - USDA Procedure Deviations

A. Insert recap of total deviations.

B. Discuss cause, response, and corrective action for each applicable procedure.

Summary of Analysis

A. Discuss effectiveness of the QAP.

B. Discuss main problem areas.

C. Discuss problem areas per shift.
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REFERENCE LINKS Version Date

(Printed for distribution)

7 CFR 52.38c, 52.81: __________

http://www.gpo.gov/fdsys/browse/collectionCfr.action?collectionCode=CFR

AIM Inspection Series, Foreign Material Manual __________

https://originedit.ams.usda.gov/sites/default/files/media/Foreign_Material_Manual%5B1%5D.pdf

FDA Defect Levels Handbook __________

http://www.fda.gov/Food/GuidanceRegulation/GuidanceDocumentsRegulatoryInformation/Sanit

ationTransportation/ucm056174.htm

 

Form SC-148, Quality Assurance Verification Report: __________

https://ems-team.usda.gov/sites/AMS/AMSFormsCatalog/Forms/AllItems.aspx

SCI Division Employee Rotation Policy __________

\\usda.net\ams\SCSCI\SCIAIM\Management\FieldOfficeManagement\SCIDivisionEmployeeRotationPolicy.pdf

Checked Materials have been printed from the links in this manual and included for 

reference.
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APPENDIX I – GUIDE FOR THE QAP MANUAL

This section provides guidance for any processing plant to develop a QAP manual in accordance 

with Division policy that is concise and tailor-made for their QC program. Areas of interest 

include:

• Guidelines for the QAP Manual;

• Example of an acceptable QAP Manual; and 

• Specific USDA procedures (Group IV).

Responsibility

In-plant inspectors are responsible for monitoring and up-dating the manual as applicable 

through-out the year. In addition a complete review of the plant’s approved QAP manual should 

be performed and documented on an annual basis to ensure continued applicability. The 

required certification document is located in Appendix III. Division operational management 

will perform an annual compliance review per Division Quality Management System. The 

manual should contain current publications, and the QC procedures referenced in the manual 

should coincide with the actual methods used. The inspector should assist the processor in the 

maintenance of the manual by providing all applicable Division instructional materials and U.S. 

Standards.

Distribution

A copy of the plant’s QAP manual and revisions to the manual must be distributed as follows:

1. One copy to Officer-in-Charge;

2. One copy to RBC; and

3. One copy to National office 

A copy of the required annual certification of the QAP manual review will be distributed no later 

than pay period two of the current year as follows:

1. Original copy to in-plant QAP manual

2. One copy to Area Office
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Guidelines – QAP Manual

The following is a suggested format for compiling a QAP manual. Contractors may use this 

format or any similar format which will coincide with the actual procedures and methods used by 

the quality control staff.

Cover page

Name of company and address

Introduction

A. Purpose

B. Products

C. Group verifications

D. Procedure implementation

1. Implementation

2. List of all USDA materials and revisions needed by the plant.

E. Maintenance of the QAP manual

Organization

A. Chart relating to lines of communication

B. Responsibilities – general

C. Responsibilities of individuals (Titles only)

Quality assurance program

A. General program

B. QA responsibilities

C. Quality factors, non-quality factors, analysis (Group I)

1. USDA standards and procedures

a. Sample grade sheet

b. Standard sample size
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2. Hold lots

3. Product segregation - recalls

D. Sanitation (Group II)

1. General policy

a. Intent

b. Major laws and regulations

2. Management responsibilities

a. Plant manager

b. Supervisors

c. Sanitarians

d. QC Director

3. Plant sanitation regulations

a. Housekeeping

4. Sanitation program for QA

a. Daily sanitation inspection record

b. Classification of deficiencies

c. Recording deficiencies

E. On-site verification (Group III)

Daily on-site observations are performed by the USDA inspector and plant. These are 

part of the QAP and are important in making program adjustments. If deviations are 

found, they will be recorded and discussed with the USDA contact person and the plant. 

The corrective action will then be initiated by the plant. On-site observations will vary 

from day to day and will include every part of the program. 
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F. USDA procedures (Group IV)

1. General policy

2. Responsibilities (General)

3. Responsibilities of individuals

4. Specific procedures

a. Condition of food container

b. Case stamping

c. Checkloading

d. DPSC inspection

e. Certification (preparing certificates)

f. Update inspection

g. Re-inspection

Appendix II is an example of an acceptable QAP Manual
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APPENDIX II – EXAMPLE OF AN ACCEPTABLE QAP MANUAL

Electronic version of Acceptable QAP Manual (intranet link)
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APPENDIX III – ANNUAL CERTIFICATION OF QUALITY ASSURANCE PROGRAM

REVIEW 

Electronic version of Annual Certification of Quality Assurance Program Review (intranet link)
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APPENDIX IV – SAMPLE VERIFICATION WORK PLAN

Electronic version of Sample Verification Work Plan (intranet link)
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APPENDIX V – PROCEDURES FOR DETERMINING SIGNIFICANT DEVIATIONS

This procedure provides a statistical test for use when verifying a plant’s results on inspections 

by variables (i.e. net weight, Brix, etc.). It is not applicable to quality factors which are 

inspected on an attribute basis, or which are assigned score points. In addition, at the discretion 

of SCI supervision, analytical deviant ranges may be used to determine USDA and plant result 

agreement of applicable verification factors.

For a given factor, the test compares the sample average value obtained by plant personnel with 

the sample average value obtained independently by the USDA inspector. The test comparison 

of these two averages will indicate whether USDA and plant results agree or disagree. 

Agreement means that the two results are not significantly different. Disagreement means that 

the two results are significantly different, and that any existing difference cannot be attributed 

solely to chance. Typical applications of this variables verification procedure will be illustrated 

with examples.

When the range(s) and average(s) of the data being compared are close, this procedure does not 

have to be applied. It is most useful when there are extreme values in the data.

Procedure

1. Designate the factor and the lot or portion of production (e.g., shift) for which variables 

verification will be conducted,

2. Obtain a random sample of size 3, 6, or 13 from this production as required.

3. For each sample unit, determine and record the factor value.

4. Obtain the results of plant personnel for this same quality factor and production. A 

maximum of 21 plant results will be used for verification purposes even though many 

more might be recorded. In those instances where more than 21 results are recorded, 

obtain a random sample of 21 results. (Select one from each subgroup).

5. Calculate the average value of the USDA results (XX�uu) and of the plant results (XX�pp). 

6. Determine the range of the USDA results (Ru) and of the plant results (Rp). (The range 

is the largest value minus the smallest value.)

7. Calculate the value of the test statistic, T, as shown below. Disregard any minus sign 

from the difference of the two averages.

T = 

XX�uu - XX�pp

 Ru + Rp

8. From the table on the following page, find the value of C which corresponds to the 

USDA and plant sample sizes.
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9. Determine agreement or disagreement between USDA and plant results as follows:

a. Results agree if T is less than or equal to C.

b. Results disagree if T is greater than C.
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Table of Values of C for Variables Verification Procedure

Plant Sample Size USDA Sample Size

3 6 13

2 0.980 0.549 0.382

3 0.639 0.391 0.279

4 0.506 0.319 0.228

5 0.435 0.277 0.198

6 0.391 0.250 0.178

7 0.360 0.231 0.163

8 0.338 0.217 0.152

9 0.321 0.206 0.143

10 0.307 0.197 0.136

11 0.296 0.189 0.131

12 0.287 0.183 0.126

13 0.279 0.178 0.121

14 0.272 0.173 0.118

15 0.266 0.169 0.115

16 0.261 0.166 0.112

17 0.256 0.163 0.109

18 0.252 0.160 0.107

19 0.248 0.157 0.105

20 0.245 0.155 0.103

21 0.241 0.153 0.102

1. Results agree if T is less than or equal to C.

T = XX�uu - XX�pp

 Ru + Rp

2. Results disagree if T is greater than C.

Examples

The following examples follow the procedure described in part A of QAP - Procedure for 

determining significant deviations in the beginning of this section on a step-by-step basis.
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Example 1

A lot of canned peaches has been sampled and inspected by plant personnel. The USDA 

inspector decides to verify the plant’s Brix determinations.

1. Lot as described above. Factor is Brix.

2. USDA inspector obtains a random sample size of 13.

3. The Brix for each of the 13 sample units is:

18.9 24.0 25.5 27.9 24.0

18.6 23.6 21.2 23.2

20.0 21.4 23.6 25.9

4. There are 16 plant results:

20.8 22.4 25.4 25.0

21.2 22.2 22.0 23.2

22.8 23.0 24.2 22.4

25.6 25.3 25.4 25.2

5. XX�uu= 22.91 and XX�pp = 23.51

6. Ru = 27.9 - 18.6 = 9.3 and Rp = 25.6 - 20.8 = 4.8

7.

8. From table on page 48, for sample sizes 13 and 16, we find that C = 0.112.

9. Since T (0.043) is less than C (0.112), the USDA and plant results agree.

Example 2

The day shift has just completed its production of canned peaches. Plant personnel have sampled 

and inspected the product and have recorded their data on control chart forms. The USDA 

inspector decides to verify the plant’s net weight determinations.

1. Verification for net weight will be conducted on the day shift’s production.

2. USDA inspector obtains a random sample size of 6.

(disregarding minus sign) 22.91 – 23.51 0.60

9.3 + 4.8 14.1 T = = 0.043 =
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3. The net weight of each of the six cans is:

4. The plant results for each of the nine sampling periods during the day are (as read off of 

the control chart from highest to lowest value):

1 2 3 4 5 6 7 8 9

18.0 18.0 18.0 18.2 17.7

17.6 17.9 18.0 17.6 17.8

17.8 18.0 17.9 17.7

17.7 17.8 17.9 17.7

17.7 17.5 17.7 17.6 17.5

There are a total of 45 plant values but only 21 values are needed for verification 

purposes. A recommended way of obtaining a random sample of 21 values is as follows:

a. Randomly select a sampling period to start with, e.g., period 6.

b. Mentally number the first value in period 6 as 1 and so on down the column until 

the last number is designated as 5. Randomly select a number from 1 to 5, e.g., 4.

c. Select the 4th value from period 6 as the first sample value. Then go to the 5th 

value from period 7; then the 1st value of period 8; then the 2nd value of period 9; 

then the 3rd value of period 1; and so on until 21 values are obtained.

The random start and subsequent “cycling” through the plant control chart values 

helps to spread the selected plant values over the entire shift’s production. If 

during the “cycling” process, a column position (i.e., 1 through 5) is selected 

which has already been chosen for the sample, take the value of the next lower 

position and continue on from that point.

5. XX�uu = 16.90 and XX�pp = 17.71

6. Ru = 17.1 - 16.7 = 0.4 and Rp = 18.0 - 17.5 = 0.5

17.1 16.8 17.0

16.7 16.9 16.9

18.

17. 17.

17. 17.

17.

5

17.

6

18. 18.

17.9 17.

17.

17.6

17.

17.

17.

17.

17.

17.5

17.

17.8

17.7

End

Start
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7. (disregarding minus sign).

8. From the Table of Values of C for Variables Verification Procedure, for sample sizes 6 

and 21, we find that C = 0.153.

9. Since T (0.900) is greater than C (0.153), the USDA and plant results disagree.

10. Because the verification samples and the plant results disagree, this is considered a Group 

I major significant deviation for the factor that was compared.

T = −

+ = = 16 90 17 71

0 4 0 5

0 81

0 9

0 900 . .

. .

.

. .
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APPENDIX VI – PRODUCT PLANS

Plan numbers - Canned products

Plan Number 1C: Canned Apricots, Cherries, Peaches, Pears, Plums, Grapes

Canned Products: Apricots, Sweet Cherries, Clingstone Peaches, Freestone Peaches, Pears, 

Plums, and Grapes.

Verification Plan: These products considered as one product for verification when processed 

during the same basic grading period.

Sampling Rate: Lot sampling plan up to thirteen (13) sample units.

Verification Factors:

1. Lot Evaluation

2. Grade Factor Evaluation5

a. Color

b. Uniformity of Size 

& Symmetry

c. Absence of Defects

d. Character

e. Flavor & Odor

3. Style

4. Net Weight

5. Vacuum

6. Headspace

7. Drained/Fill Weight

8. Sample Unit Count6

9. Brix

10. Condition of Container

11. Coding

12. Foreign Material (Visual)

Minimum Sample Units to Examine

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

Sample Units with Low Net Weight

All Sample Units

All Sample Units

All Sample Units - One Lot Per Day

All Sample Units

All Sample Units

All Sample Units

 5 Products graded on the Cumulative Sum Sampling Plan (CuSum). Verify the prerequisites and classified defects as the grade factor evaluation 6 Applies only to products have count criteria.
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Plan Number 2C: Canned Fruits

Canned Products: Fruit Cocktail, Fruits for Salad, Fruit Mix.

Verification Plan: These products considered as one product for verification when processed 

during the same basic grading period.

Sampling Rate: Lot sampling plan up to thirteen (13) sample units.

Verification Factors:

1. Lot Evaluation

2. Grade Factor Evaluation

a. Clearness of Liquor

b. Color

c. Uniformity of Size 

& Symmetry

d. Absence of Defects

e. Character

f. Flavor & Odor

3. Style (Fruit & Forms)

4. Net Weight

5. Vacuum

6. Headspace

7. Drained/Fill Weight

8. Sample Unit Count7

9. Brix

10. Fruit Proportions

11. Condition of Container

12. Coding

13. Foreign Material (Visual)

Minimum Sample Units to Examine

All Sample Units

All Sample Units (Fruit Cocktail only)

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units (Fruits for Salad only)

All Sample Units

All Sample Units

Sample Units with Low Net Weight

All Sample Units

All Sample Units

All Sample Units - One Lot Per Day

Random Sample, 1 Minimum

All Sample Units

All Sample Units

All Sample Units

 7 Fruit Cocktail (Cherry and Pineapple Count) Fruits for Salad (Count all Units in Sample Unit)
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Plan Number 3C: Canned Tomatoes

Canned Products: Tomatoes, Stewed Tomatoes (Whole, Halves, Sliced, Wedges, Diced).

Verification Plan: These products considered as one product for verification when processed 

during the same basic grading period.

Sampling Rate: Lot sampling plan up to thirteen (13) sample units.

Verification Factors:

1. Lot Evaluation

2. Grade Factor Evaluation

a. Drained Weight

b. Character8

c. Color

d. Wholeness9

e. Flavor/Odor

f. Absence of Defects

3. Net Weight

4. Vacuum

5. Headspace

6. Style

7. Sample Unit Count10

8. Condition of Container

9. Coding

10. Mold Determination

11. Heavy Filth11

12. Foreign Material (Visual)

Minimum Sample Units to Examine

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

Sample Units with Low Net Weight

All Sample Units

All Sample Units

All Sample Units

All Sample Units

One Determination

One Determination (per week)

All Sample Units

 8 Diced style by weight, all other styles by count.

9 Applicable to whole style only.

10 Refers only to products having count criteria. 11 One determination and one complete on-site (Group III) per week.
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Plan Number 4C: Canned Tomato Paste and Puree

Canned Products: Tomato Paste, Tomato Puree.

Verification Plan: These products considered as one product for verification when processed 

during the same basic grading period.

Sampling Rate: Lot sampling plan up to thirteen (13) sample units.

Verification Factors:

1. Lot Evaluation

2. Grade Factor Evaluation

a. Color (Visually)12

b. Defects

c. Consistency

d. Flavor/Odor

3. Concentration (Solids)

4. Texture - Finish

5. Net Weight

6. Vacuum

7. Headspace

8. Condition of Container

9. Coding

10. Heavy Filth13

11. Mold Determination

12. Foreign Material (Visual)

Minimum Sample Units to Examine

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

Two Sample Units

All Sample Units

All Sample Units

All Sample Units

Sample Units with Low Net Weight

All Sample Units

All Sample Units

One Determination (Per Week)

One Determination

All Sample Units

 12 Products for which colorimeter is used for evaluation – two sample units, one from each half of the basic grading period. 13 One determination and one complete on-site (Group III) per week.
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Plan Number 5C: Canned Tomato Juice

Canned Products: Tomato Juice, Single Strength and Concentrated.

Verification Plan: These products considered as one product for verification when processed 

during the same basic grading period.

Sampling Rate: Lot sampling plan up to thirteen (13) sample units.

Verification Factors:

1. Lot Evaluation

2. Grade Factor Evaluation

a. Color (Visually)14

b. Defects

c. Consistency

d. Flavor/Odor

3. Refractive Indexes or 

Solids

4. Volume and Net Weight

5. Vacuum

6. Headspace

7. Condition of Container

8. Coding

9. Mold Determination

10. Heavy Filth15

11. Foreign Material (Visual)

Minimum Sample Units to Examine

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

Two Sample Units

All Sample Units

All Sample Units

All Sample Units

Sample Units with Low Net Weight

All Sample Units

All Sample Units

One Determination

One Determination (Per Week)

All Sample Units

 14 Products for which colorimeter is used for evaluation – two sample units, one from each half of the basic grading period. 15 One determination and one complete on-site (Group III) per week.
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Plan Number 6C: Tomato Catsup, Chili Sause, Tomato Sauce

Canned Products: Tomato Catsup, Chili Sauce, and Tomato Sauce.

Verification Plan: These products considered as one product for verification when processed 

during the same basic grading period.

Sampling Rate: Lot sampling plan up to thirteen (13) sample units.

Verification Factors:

1. Lot Evaluation

2. Grade Factor Evaluation

a. Color (Visually)16

b. Consistency

c. Character17

d. Defects

e. Flavor/Odor

f. Finish18

3. Concentration (Solids)

4. Net Weight

5. Vacuum

6. Headspace

7. Condition of Container

8. Coding

9. Mold Determination

10. Heavy Filth19

11. Foreign Material (Visual)

Minimum Sample Units to Examine

All Sample Units

All Sample Units

One Sample Unit

All Sample Units

All Sample Units

All Sample Units

All Sample Units

Two Sample Units

All Sample Units

All Sample Units

Sample Units with Low Net Weight

All Sample Units

All Sample Units

One Determination

One Determination (Per Week)

All Sample Units

 16 Products for which colorimeter is used for evaluation – two sample units, one from each half of the basic grading 

period

17 Applicable to Chili Sauce only 18 Applicable to Tomato Catsup and Tomato Sauce only

19 One determination and one complete on-site (Group III) per week.
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Plan Number 7C: Canned Other Tomato Products and NAGs

Canned Products: All other tomato products and other products which have no applicable 

grade and which are not covered by separate verification outlines. 

Examples: Zucchini & Tomatoes, Tomato Juice Mixes, Vegetable Juices, 

Pizza Sauce, Spaghetti Sauce, All Purpose Sauces, Crushed Tomatoes, 

Salsa, Creole Sauce, Tomato Soup, and Seafood Cocktail Sauce.

Verification Plan: These products considered as one product for verification when processed 

during the same basic grading period.

Sampling Rate: Lot sampling plan up to thirteen (13) sample units.

Sampling: Products which are packed for short durations should be sampled and 

verified during the beginning of each production period.

Verification Factors: Minimum Sample Units to Examine

1. Rate: As established in the USDA Verification Plan for each plant.

 The factors and rate will follow the general outline contained in 

 this manual.
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Plan Number 8C: Canned Leafy Greens

Canned Products: Leafy Greens (All Types).

Verification Plan: These products considered as one product for verification when processed 

during the same basic grading period.

Sampling Rate: Lot sampling plan up to thirteen (13) sample units.

Verification Factors:

1. Lot Evaluation

2. Grade Factor Evaluation

a. Color

b. Character

c. Damage

d. Harmless Ext. 

Material

e. Stem Material

f. Flavor and Odor

3. Style

4. Vacuum

5. Headspace

6. Net Weight

7. Drained Weight

8. Condition of Container

9. Coding

10. Heavy Filth

11. Foreign Material (Visual)

Minimum Sample Units to Examine

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

One (1) Determination

All Sample Units

All Sample Units

All Sample Units

Sample Units with Low Net Weight

All Sample Units

All Sample Units

All Sample Units

All Sample Units

One (1) Determination (Rapid Jar 

Method)

All Sample Units
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Plan Number 9C: Canned Non-Standardized Fruit Products

Canned Products: Non-Standardized Fruit Products - Concentrates, Purees, Nectars (Apple, 

Apricot, Peach and Pear).

Verification Plan: These products considered as one product for verification when processed 

during the same basic grading period.

Sampling Rate: Lot sampling plan up to thirteen (13) sample units.

Verification Factors:

1. Lot Evaluation

2. Grade Factor Evaluation

a. Color

b. Absence of Defects

c. Flavor and Odor

3. Net Weights

4. Vacuum Readings

5. Headspace Measurement

6. Solids Determination (Brix)

7. Analysis (pH, Total Acidity)

8. Foreign Material (Visual)

9. Condition of Container

10. Coding

11. Mold Determination

12. Light Filth

13. Heavy Filth

Minimum Sample Units to Examine

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

Sample Units with Low Net Weight

Two (2) Sample Units

One (1) Sample Unit

All Sample Units

All Sample Units

All Sample Units

One (1) Determination

As Necessary to Verify Wholesomeness

As Necessary to Verify Wholesomeness
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Plan Number 10C: Canned Green Beans, Wax Beans

Canned Products: Green Beans, Wax Beans.

Verification Plan: These products are considered as one product for verification when 

processing during the same basic grading period.

Sampling Rate: Lot sampling plan up to thirteen (13) sample units.

Verification Factors:

1. Lot Evaluation

2. Grade Factor Evaluation

a. Clearness of Liquor

b. Color

c. Absence of Defects

d. Character

e. Flavor and Odor

3. Net Weight

4. Vacuum

5. Headspace

6. Drained Weight

7. Type

8. Style

9. Sieve Size20

10. Length of Cut21

11. Condition of Container

12. Coding

13. Foreign Material (Visual)

Minimum Sample Units to Examine

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

Sample Units with Low Net Weight

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

 20 Not Applicable to sliced lengthwise style 21 Not applicable to whole and sliced lengthwise style
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Plan Number 11C: Canned Sweet Peppers

Canned Products: Sweet Peppers. 

Verification Plan: This product is considered as one product for verification when processed 

during the same basic grading period.

Sampling Rate: Lot sampling plan up to thirteen (13) sample units.

Verification Factors:

1. Lot Evaluation

2. Style Determination

3. Grade Factor Evaluation

a. Color

b. Size

c. Absence of Defects

d. Character

e. Flavor and Odor

4. Net Weight

5. Vacuum

6. Headspace

7. pH

8. Drained Weight

9. Foreign Material (Visual)

10. Condition of Container

11. Coding

Minimum Sample Units to Examine

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

Sample Units with Low Net Weight

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units
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Plan Number 12C: Canned Corn

Canned Products: Corn - Cream and Whole Kernel.

Verification Plan: This product is considered as one product for verification when processed 

during the same basic grading period.

Sampling Rate: Lot sampling plan up to thirteen (13) sample units.

Verification Factors:

1. Lot Evaluation

2. Grade Factor Evaluation

a. Color

b. Consistency22

c. Absence of Defects

d. Tenderness and 

Maturity

e. Flavor and Odor

3. Net Weight

4. Vacuum

5. Headspace

6. Drained Weight

7. Type

8. Style/Varietal Type

9. Length of Cut23

10. Condition of Container

11. Coding

12. Foreign Material (Visual)

Minimum Sample Units to Examine

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

Sample Units with Low Net Weight

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

 22 Cream style only 23 Whole Kernel style only
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Plan Number 13C: Canned Apples, Applesauce

Canned Products: Apples, Applesauce.

Verification Plan: These products considered as one product for verification when processed 

during the same basic grading period.

Sampling Rate: Lot sampling plan up to thirteen (13) sample units.

Verification Factors:24

1. Lot Evaluation

2. Grade Factor Evaluation

a. Consistency

b. Color

c. Uniformity of Size

d. Absence of Defects

e. Character/Finish

f. Flavor & Odor

3. Type

4. Style

5. Net Weight

6. Vacuum

7. Headspace

8. Drained Weight

9. Sample Unit Count

10. Brix

11. Condition of Container

12. Coding

13. Foreign Material (Visual)

Minimum Sample Units to Examine

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

Sample Units with Low Net Weight

All Sample Units

All Sample Units

All Sample Units - One Lot Per Day

All Sample Units

All Sample Units

All Sample Units

 24 Verify factors applicable to product graded
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Plan Number 14C: Canned Ripe Olives

Canned Products: Canned Ripe Olives.

Verification Plan: This product is considered as one product for verification when processed 

during the same basic grading period.

Sampling Rate: Lot sampling plan up to thirteen (13) sample units.

Verification Factors:

1. Lot Evaluation

2. Grade Factor Evaluation

a. Color

b. Uniformity of Size25

c. Absence of Defects

d. Character

e. Flavor

3. Type

4. Style

5. Size Designation(Average 

Count or Diameter)25

6. Vacuum

7. Head Space

8. Net Drained Weights

9. Salt (Salometer Readings)

10. Condition of Container

11. Coding

12. Foreign Material (Visual)

Minimum Sample Units to Examine

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

Sample Units with Low Volume

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

 25 Applies to whole and pitted styles
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Plan Number 15C: Canned/Frozen Citrus Juice

Citrus Juice Canned/Frozen: Orange, Grapefruit, Tangerine, Lemon, Beverage Base Products, 

Orange Products with Calcium/Vitamin C, Citrus Sections, and 

Sugar Added products. (See next page for products and 

abbreviations)

Verification Plan: These products are considered as one product for verification when 

processed during the same basic grading period.

Sampling Rate: Lot sampling plan up to thirteen (13) sample units. 
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 26 Acronyms are defined on following page.

27 FCOJ, RAFCOJ, CCOJ, POJ, OJFC, FCBGJ&OJ, POJwCAL, OJ, OJFM, CCOJwVITc, FCOJwCAL

28 FCOJ, RAFCOJ, OM, CCOJ, TM, FCBGJ&OJ, LM, FCLJ, CCOJwVITc, FCOJwCAL 29 COJ, POJ, OJFC, GJ & OJ, POJwCAL, OJ, OJFM, CTJ 30 POJ, OJFC, OJ, OJFM 31 Canned Products only 32 FCC requirement: One sample - On-line product packed in cans. 33 All products except: OM, GM, LM 34 GJ, FCGJ, GM, GJFC, CTJ, GJ & OJ, FCBGJ&OJ

Verification Factors:26

1. Lot Evaluation

2. Grade Factor Evaluation

 a. Color

 b. Defects

 c. Flavor (and Odor for Sections)

 d. Wholeness (Sections)

 e. Character (Sections)

3. Count (Sections)

4. Packing Media (Sections)

3. Appearance27

4. Reconstitution28

5. Coagulation29

6. Separation30

7. Style 

8. Net Weight 

9. Drained Weight

10. Vacuum31

11. Temperature (Frozen Retail) &32

12. Brix

13. Acid

14. Ratio

15. Recoverable Oil33

16. Suspended Pulp34

17. Floating Pulp

18. Vitamin C (Ascorbic Acid)

19. Calcium Analysis

20. Condition of Container

21. Coding

22. Mold Determination

23. Foreign Material

Minimum Sample Units to Examine

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

One

One

One

One

One

One

All Sample Units

All Sample Units

All Sample Units

All Sample Units

One

All Sample Units

All Sample Units

All Sample Units

One

One

One

One

One

All Sample Units

All Sample Units

One

One
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Citrus Juices Canned/Frozen Product Names:

FCOJ: Frozen Concentrated Orange Juice

FCOJwCAl: Frozen Concentrated Orange Juice with Calcium Added

RAFCOJ: Reduced Acid Frozen Concentrated Orange Juice

CCOJ: Canned Concentrated Orange Juice

CCOJwVITC: Canned Concentrated Orange Juice with Vitamin C Added

OM: Concentrated Orange Juice for Manufacturing

POJ: Pasteurized Orange Juice

POJwCAL: Pasteurized Orange Juice with Calcium Added

COJ: Canned Orange Juice

OJFC: Orange Juice from Concentrate

OJ: Orange Juice

OJFM: Orange Juice for Manufacturing

GJ: Grapefruit Juice

GJFC: Grapefruit Juice from Concentrate

FCGJ: Frozen Concentrated Grapefruit Juice

GM: Concentrated Grapefruit Juice for Manufacturing

CTJ: Canned Tangerine Juice

TJ: Tangerine Juice

TM: Concentrated Tangerine Juice for Manufacturing

GJ & OJ: Grapefruit Juice and Orange Juice

FCBGJ&OJ: Frozen Concentrated Blended Grapefruit Juice and Orange Juice

LM: Concentrated Lemon Juice for Manufacturing

FCLJ: Frozen Concentrate for Lemonade

GBB: Grapefruit Beverage Base

OBB: Orange Beverage Base

Citrus Sections:

Canned Grapefruit

Canned Grapefruit and Orange for Salad

Chilled Citrus Salad 
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Plan Number 16C: Other Citrus Products

Canned Citrus Product: All other Citrus Products and other products that have no 

applicable grade and which are not covered by separate 

verification outlines.

Examples: Water Extracted Soluble Fruit Solids, 

Fruit Pulp Cells

Verification Plan: These products are considered as one product for verification when 

processed during the same basic grading period.

Sampling Rate: Lot sampling plan up to thirteen (13) sample units.

Sampling: Products which are packed for short durations should be sampled 

and verified during the beginning of each production period.

Verification Factors Minimum Sample Units to Examine

1. Rate: As established in the USDA Verification Plan for each plant. 

The factors and rate will follow the general outline contained in 

this manual.
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Plan Numbers - Frozen Products

Plan Number 1F: Frozen Asparagus, Green Beans

Frozen Products: Asparagus, Green Beans.

Verification Plan: These products are considered as one product for verification when 

processed during the same basic grading period.

Sampling Rate: Lot sampling plan up to thirteen (13) sample units.

Verification Factors:35

1. Lot Evaluation

2. Grade Factor Evaluation

a. Color

b. Uniformity of 

Length

c. Character

d. Damage

e. Harmless 

Extraneous 

Material

f. Flavor & Odor

3. Type and Style

4. Size

5. Net Weight

6. Condition of Container

7. Coding

8. Enzyme Inactivation

9. Light Filth (Asparagus)

Light Filth (Green Beans)

(Visual)

10. Foreign Material (Visual)

11. Finished Product 

Temperature

Minimum Sample Units to Examine

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

One Determination

One Determination

All Sample Units

All Sample Units

Two Per Day

 35 Verify factors applicable to product graded
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Plan Number 2F: Frozen Broccoli, Leafy Greens, Squash

Frozen Products: Broccoli, Leafy Greens (All Types), 

Squash (Summer Type).

Verification Plan: These products are considered as one product for verification when 

processed during the same basic grading period.

Sampling Rate: Lot sampling plan up to thirteen (13) sample units.

Verification Factors:36

l. Lot Evaluation

2. Grade Factor Evaluation

a. Color

b. Defects

c. Character/Development

d. Flavor/Odor

3. Style

4. Net Weight

5. Condition of Container

6. Coding

7. Enzyme Inactivation

8. Foreign Material (Visual)

9. Light Filth (Broccoli, and 

Leafy Greens only)

10. Finished Product 

Temperature

Minimum Sample Units to Examine

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

One Determination

All Sample Units

One Determination

Two Per Day

 36 Verify factors applicable to product graded
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Plan Number 3F: Frozen Brussel Sprouts, Cauliflower

Frozen Products: Brussels Sprouts, Cauliflower.

Verification Plan: These products are considered as one product for verification when 

processing during the same basic grading period.

Sampling Rate: Lot sampling plan up to thirteen (13) sample units.

Verification Factors:

1. Lot Evaluation

2. Grade Factor Evaluation

a. Color

b. Defects

c. Character

d. Flavor/Odor

3. Net Weight

4. Count (Brussels Sprouts only)

5. Condition of Container

6. Coding

7. Enzyme Inactivation

8. Foreign Material (Visual)

9. Light Filth37

10. Finished Product 

Temperature

Minimum Sample Units to Examine

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

One Determination

All Sample Units

One Determination

Two Per Day

 37 Brussel Sprouts only
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Plan Number 4F: Frozen Lima Beans, Peas

Frozen Products: Lima Beans, Peas.

Verification Plan: These products are considered as one product for verification when 

processed during the same basic grading period.

Sampling Rate: Lot sampling plan up to thirteen (13) sample units.

Verification Factors:

1. Lot Evaluation

2. Grade Factor Evaluation

a. Color

b. Defects

c. Tenderness and 

Maturity

d. Flavor and Odor

3. Types (Lima Beans Only)

4. Size (Frozen Peas)

5. Net Weight

6. Count38

7. Condition of Container

8. Coding

9. Enzyme Inactivation

10. Foreign Material (Visual)

11. Finished Product 

Temperature

Minimum Sample Units to Examine

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

Two Sample Units per Verification Lot

All Sample Units

All Sample Units

All Sample Units

All Sample Units

One Determination

All Sample Units

Two Per Day

 38 Count lima beans every sixth sample only
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Plan Number 5F: Frozen Carrots, Sweet Peppers

Frozen Products: Carrots, Sweet Peppers.

Verification Plan: These products are considered as one product for verification when 

processed during the same basic grading period.

Sampling Rate: Lot sampling plan up to thirteen (13) sample units.

Verification Factors:

1. Lot Evaluation

2. Grade Factor Evaluation

a. Color

b. Size

c. Defects

d. Character/Texture

e. Flavor and Odor

3. Style and Types (Sweet Peppers)

Style (Carrots)

4. Net Weight

5. Condition of Container

6. Coding

7. Enzyme Inactivation

8. Foreign Material (Visual)

9. Finished Product Temperature

Minimum Sample Units to Examine

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

One Determination

All Sample Units

Two Per Day
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Plan Number 6F: Frozen Melon Balls

Frozen Products: Melon Balls.

Verification Plan: This product is considered as one product for verification when processed 

during the same basic grading period.

Sampling Rate: Lot sampling plan up to thirteen (13) sample units.

Verification Factors:

1. Lot Evaluation

2. Grade Factor Evaluation

a. Color

b. Uniformity of Size 

and Shape

c. Absence of Defects

d. Character

e. Flavor and Odor

3. Style

4. Net Weight

5. Condition of Container

6. Coding

7. Foreign Material (Visual)

8. Finished Product 

Temperature

Minimum Sample Units to Examine

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

Two Per Day
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Plan Number 7F: Frozen Apricots, Apples, Peaches, Strawberries

Frozen Products: Apricots, Apples, Peaches, and Strawberries.

Verification Plan: These products are considered as one product for verification when 

processing during the same basic grading period.

Sampling Rate: Lot sampling plan up to thirteen (13) sample units.

Verification Factors:39

1. Lot Evaluation

2. Grade Factor Evaluation

a. Color

b. Uniformity of Size 

and Symmetry

c. Absence of Defects

d. Character

e. Flavor and Odor

3. Style/Similar Variety

4. Net Weight

5. Drained Weight

6. Sample Unit Count

7. Brix

8. Condition of Container

9. Coding

10. Foreign Material (Visual)

11. Mold Determination

12. Finished Product 

Temperature

Minimum Sample Units to Examine

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

Two Sample Units -One Lot Per Day

All Sample Units

All Sample Units

All Sample Units

One (1) Determination

Two Per Day

 39 Verify the factors applicable to the product graded.
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Plan Number 8F: Frozen French Fried Potatoes

Frozen Products: Potatoes, French Fried Type (any style cut from the potato, whole, slice, 

dice, etc.).

Verification Plan: These products are considered as one product for verification when 

processed during the same basic grading period.

Sampling Rate: Lot sampling plan up to thirteen (13) sample units.

Verification Factors:40

1. Lot Evaluation

2. Grade Factor Evaluation

a. Uniformity of Size 

and Shape

b. Absence of Defects

c. Color

d. Texture

e. Flavor and Odor

3. Net Weight

4. Condition of Container

5. Coding

6. Finish Product Temperature

7. Style

8. Length Designation

9. Cut Size

10. Color Designation

11. Foreign Material (Visual)

Minimum Sample Units to Examine

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

Two Per Day

All Sample Units

Two Sample Units

All Sample Units

1

3 Sample Units

All Sample Units

All Sample Units

All Sample Units

 40 As applicable to style graded.
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Plan Number 9F: Frozen Preformed and Hash Brown Potatoes

Frozen Products: Potatoes, Preformed and Hash Brown Types (any style shredded, diced or 

chopped from the potato and machine formed or used in hash browns).

Verification Plan: These products are considered as one product for verification when 

processed during the same basic grading period.

Sampling Rate: Lot sampling plan up to thirteen (13) sample units.

Verification Factors:41

1. Lot Evaluation

2. Grade Factor Evaluation

a. Uniformity of Size and 

Shape

b. Absence of Defects

c. Color

d. Texture

e. Flavor and Odor

3. Net Weights

4. Condition of Container

5. Coding

6. Finished Product Temperature

7. Style

8. Size/Count

9. Cut Size

10. Color Designation

11. Foreign Material (Visual)

12. Peroxidase Test

Minimum Sample Units to Examine

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

Two Per Day

All Sample Units

Two Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

One Determination

 41 As applicable to type or style graded.
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Plan Number 10F: Frozen Corn

Frozen Products: Whole Kernel Corn, Corn-on-the-Cob.

Verification Plan: These products are considered as one product for verification when 

processed during the same basic grading period.

Sampling Rate: Lot sampling plan up to thirteen (13) sample units.

Verification Factors:42

 l. Lot Evaluation

2. Grade Factor Evaluation

a. Color

b. Uniformity of Size43

c. Development43

d. Defects

e. Tenderness and 

 Maturity

f. Flavor/Odor

3. Color Designation

4. Style43

5. Net Weight44

6. Length43

7. Condition of Container

8. Coding

9. Enzyme Inactivation

10. Foreign Material (Visual)

11. Finished Product 

 Temperature

Minimum Sample Units to Examine

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

One Determination

All Sample Units

Two Per Day

 42 Verify the factors applicable to the product graded 43 Corn-on-the-Cob 44 Whole Kernel Corn
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Plan Number 11F: Frozen Mixed Vegetables, Peas and Carrots, Succotash

Frozen Products: Mixed Vegetables, Peas and Carrots, Succotash.

Verification Plan: These products are considered as one product for verification when 

processed during the same basic grading period.

Sampling Rate: Lot sampling plan up to thirteen (13) sample units.

Verification Factors:45

 l. Lot Evaluation

2. Grade Factor Evaluation

a. Color

b. Defects

c. Character/Tenderness

d. Flavor/Odor

3. Style (2, 3, 4, or 5-way)46

4. Ratio (Proportion of 

 Ingredients)

5. Net Weight 

6. Composite Grade of each 

Ingredient

7. Brine Test (Pea Maturity)

8. Condition of Container

9. Coding

10. Enzyme Inactivation

11. Foreign Material (Visual)

12. Finished Product 

 Temperature

Minimum Sample Units to Examine

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

One Determination

All Sample Units

Two Per Day

 45 Verify the factors applicable to the product graded. 46 Mixed vegetables.
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Plan Numbers – Dehydrated Products

Plan Number 1D: Dehydrated Tomatoes

Dehydrated Products: Tomatoes, Dried, Crystals - Powder (NAG Item).

Verification Plan: This product is considered as one product for verification when processed 

during the same basic grading period.

Sampling Rate: Lot sampling plan up to thirteen (13) sample units.

Verification Factors:

1. Lot Evaluation

2. Grade Factor Evaluation

a. Color

b. Defects

c. Moisture

d. Consistency 

 (Lamb & Lewis)

e. Flavor and Odor

3. Total Acid

4. Mold

5. Foreign Material (Visual)

6. Condition of Container

7. Coding

Minimum Sample Units to Examine

All Sample Units

All Sample Units

All Sample Units

Two Sample Units

Two Sample Units

All Sample Units

Two Sample Units

One Sample Unit

All Sample Units

All Sample Units

All Sample Units
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Plan Number 2D: Dehydrated Orange Juice

Dehydrated Products: Orange Juice, Dehydrated

Verification Plan: This product is considered as one product for verification when processed 

during the same basic grading period.

Sampling Rate: Lot sampling plan up to thirteen (13) sample units.

Verification Factors:

1. Lot Evaluation

2. Grade Factor Evaluation

 a. Color

 b. Defects

 c. Flavor

3. Appearance

4. Reconstitution

5. Style

6. Net Weight

7. Vacuum

8. Brix

9. Acid

10. Ratio

11. Recoverable Oil

12. Condition of Container

13. Coding

14. Mold Determination

15. Foreign Material 

Minimum Sample Units to Examine

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

All Sample Units

One Sample Unit

One Sample Unit
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APPENDIX VII – REQUEST FOR GROUP IV VERIFICATION

The following is an example of a request for Group IV Verification. Use Current approved SCI 

Division letterhead (intranet link) to submit request.

REQUEST FOR GROUP IV VERIFICATION

TO: _______________________________

THRU: _______________________________

FROM: _______________________________

Official Approval is hereby requested for __________________________________under 

Group IV procedures.

Fairway Packing Company has designated a plant individual to perform this function. 

This individual has been trained by the USDA inspector assigned to the plant, and also by the plant.

The USDA inspector assigned to this plant has verified the capability of this company to handle this 

function. This was done through on-site verifications.

Enclosed is the necessary paperwork covering _____________________________ Verifications.

Official approval for _____________________________________is requested.

The USDA inspector’s verification work plan for the___________________________ is attached.

Official approval for the plant to assume the_____________________________ Group IV function 

is requested.

Submitted by:

_____________________________ ______________________

USDA Inspector-in-Charge Date

_____________________________ ________________________

Officer-in-Charge Date

_____________________________ ________________________

Regional Branch Chief Date

21
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APPENDIX IIX – VERIFICATION DEVIATION TRACKING FORM

Electronic version of Verification Deviation Tracking Form (intranet link)
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APPENDIX IX – QAP PLANT ANTICIPATED WORK SCHEDULE

Electronic version of Anticipated Work Schedule Form (intranet link)
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APPENDIX X – QUALITY ASSURANCE VERIFICATION REPORT EXAMPLES
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Example G
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APPENDIX XI – FILL WEIGHT VERIFICATION GUIDE: PEARS

This procedure provides an inspection guide for use when verifying that a plant’s fill weight 

control for pears is reasonable, based on 24-hour drained weights obtained by the USDA 

inspector. It is applicable for all types of pear styles and syrups.

For a given production period (i.e., shift, day, etc.), the sample average value of 24-hour drained 

weights obtained by the USDA inspector is used to determine a tolerance interval for the plant’s 

final average fill weight value, as read directly from the plant’s fill weight control forms. The 

verification status of the plant’s fill weight control is determined by use of this tolerance interval.

Procedure

1. Designate the production period (i.e., shift, day, etc.) and can size for which the plant’s 

fill weight control is to be checked.

2. Obtain a random sample of size 3, 6, or 13 from this production as required. This

sampling should be spread out as much as possible over the designated production period.

3. For each sample unit, determine and record the 24-hour drained weight.

4. Calculate the average value of these drained weights.

5. Obtain the plant’s fill weight control forms for this production period. From the forms, 

obtain the plant’s final average fill weight value. This value is usually recorded as XX�. If 

XX� is not designated, the average median value, MM�ii for that production period may be 

used.

6. Select the appropriate graph for the designated can size. Three lines are shown on each 

graph - an upper and lower tolerance interval limit line, and a line which shows the 

midpoint of the intervals.

7. Enter the graph along the horizontal axis with the USDA 24-hour average drained weight 

value calculated in Step 4 above. Proceed vertically from the point and intersect each of 

the three lines. The average fill weight value on the vertical axis corresponding to the 

intersection with the lowest, middle, and upper line represents the lower limit, midpoint, 

and upper limit, respectively, of the tolerance interval.

8. Compare the plant’s final average fill weight from Step 5 with the lower and upper 

tolerance interval limits from Step 7 above. The verification status of the plant’s fill 

weight control is determined as follows:

a. Control is reasonable if the plant’s final average fill weight is on or between the 

lower and upper tolerance interval limits.

b. If the plant’s final average fill weight is outside the lower and upper tolerance 
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interval limits, the USDA inspector should thoroughly review the plant’s fill 

weight control forms and procedures for the production period in order to 

determine why the plant’s value did not fall within the tolerance interval. 

Accuracy of any numerical computations should be one of the first factors to be 

checked.

Note: Over a long period of time, the plant’s result should cluster around the midpoint 

of the tolerance intervals and approximately one out of every one hundred results 

should fall outside the intervals, even though the plant has good fill weight 

control.

Example

The night shift completed production of pear halves in heavy syrup in #300 cans. The USDA 

inspector decides to verify the plant’s fill weight control for that shift. The following examples 

follows the procedure described above in Part II on a step-by-step basis.

1. Production period is the night shift. Can size is #300.

2. USDA inspector obtains a random sample of 13 cans from the night shift production.

3. The 24-hour drained weights (in ounces) for these cans are:

6.0 7.7 6.5 6.8 6.1

6.0 6.0 6.4 7.1

6.0 7.6 5.7 7.3

4. Twenty-four hour drained weight average is 6.55 ounces.

5. From the plant’s fill weight control forms for the night shift we obtain

MM�ii = 9.9 ounces.

6. The graph for #300 can size is selected.

7. From this graph we can obtain the following average fill weight values corresponding to 

the 24-hour drained weight average of 6.55 ounces:

Lower Tolerance Interval Limit = 5.65 ounces

Tolerance Interval Midpoint = 7.35 ounces

Upper Tolerance Interval Limit = 9.05 ounces

8. Since the plant’s final average fill weight (9.9) exceeds the upper tolerance interval; limit 

(9.05), the USDA inspector should conduct a thorough review as discussed in Procedure 

portion of this section.
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24 HOUR DRAINED WEIGHT AVERAGE (OUNCES)

AVERAGE 

FILL 

WEIGHT (OUNCES)

53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69

54

55

56

57

58

59

60

61

62

63

64

65

66

67

68

69

70

71

72

73

74

75

76

77

78

79

80

FILL WEIGHT VERIFICATION GRAPH PRODUCT: PEARS CAN SIZE: #10

Upper 

Limit Line

Midpoint 

Line

Lower 

Limit Line
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Effective Date: April 2018 Page 91 of 99

24 HOUR AVERAGE DRAINED WEIGHT (OUNCES)

AVERAGE 

FILL 

WEIGHT 

(OUNCES)

13 14 15 16 17 18 19 20

12

13

14

15

16

17

18

19

20

21

22

23

24

FILL WEIGHT VERIFICATION GRAPH PRODUCT: PEARS CAN SIZE: #2 1/2

Upper 

Limit Line

Midpoint 

Line

Lower 

Limit Line
SCI Division Inspection Series Quality Assurance Program (QAP) Manual

Effective Date: April 2018 Page 92 of 99

24 HOUR AVERAGE DRAINED WEIGHT (OUNCES)

AVERAGE 

FILL 

WEIGHT 

(OUNCES)

5 6 7 8 9 10 11 12 13 14 15 16

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

FILL WEIGHT VERIFICATION GRAPH PRODUCT: PEARS CAN SIZE: #300

Upper 

Limit Line

Midpoint 

Line

Lower 

Limit Line
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Effective Date: April 2018 Page 93 of 99

24 HOUR DRAINED WEIGHT (OUNCES)

AVERAGE 

FILL WEIGHT 

(OUNCES)

3 4 5 6 7 8 9 10

2

3

4

5

6

7

8

9

10

FILL WEIGHT VERIFICATION GRAPH PRODUCT: PEARS CAN SIZE: 8 OUNCES

Upper 

Limit Line

Midpoint 

Line

Lower 

Limit Line
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Effective Date: April 2018 Page 94 of 99

APPENDIX XII – FILL WEIGHT VERIFICATION GUIDE: PEACHES 

This procedure provides an inspection guide for use when verifying that a plant’s fill weight 

control for Clingstone Peaches is reasonable, based on 24-hour drained weights obtained by the 

USDA inspector. It is applicable for various can sizes, styles, and syrups.

For a given production period (i.e., shift, day, etc.), the sample average value of 24-hours drained 

weight obtained by the USDA inspector is used to determine a tolerance interval for the plant’s 

final average fill weight value, as read directly from the plant’s fill weight control forms. The 

verification status of the plant’s fill weight control is determined by use of this tolerance interval.

Procedure

1. Designate the production period (i.e., shift, day, etc.) and item for which the plants fill 

weight control is to be checked.

2. Obtain a random sample of size 3, 6 or 13 from this production, as required. This 

sampling should be spread out as much as possible over the designated production period.

3. For each sample unit, determine and record the 24-hour drained weight.

4. Calculate the average value of these drained weights.

5. Obtain the plant’s fill weight control forms for this production period. From the forms, 

obtain the plant’s final average fill weight value. This value is usually recorded as XX�. If 

XX� is not designated, the average median value, MM�ii, for that production period may be 

used.

6. Select the appropriate graph for the designated item. Three lines are shown on each 

graph - an upper and lower tolerance interval limit line and a line which shows the 

midpoint of the intervals.

7. Enter on the graph along the vertical axis the USDA 24-hour average drained weight 

value calculated in Step A4 above. Proceed horizontally from the point and intersect 

each of the three lines. The average fill weight value on the horizontal axis 

corresponding to the intersection with the lowest, middle, and upper line represent the 

lower limit, midpoint, and upper limit, respectively, of the tolerance interval.

8. Compare the plant’s final average fill weight with the lower and upper tolerance interval 

limits. The verification status of the plant’s fill weight control is determined as follows:

a. Control is reasonable if the plant’s final average fill weight is on or between the 

lower and upper tolerance interval limits.

b. If the plant’s final average fill weight is outside the lower and upper tolerance 

interval limits, the USDA inspector should thoroughly review the plant’s fill 
SCI Division Inspection Series Quality Assurance Program (QAP) Manual

Effective Date: April 2018 Page 95 of 99

weight control forms and procedures for the production period in order to 

determine why the plant’s value did not fall within the tolerance interval. 

Accuracy of any numerical computations should be one of the first factors to be 

checked.

Note: Over a long period of time, the plant’s result should cluster around the midpoint of 

the tolerance intervals and approximately one out of every one hundred results 

should fall outside the intervals, even though the plant has good fill weight 

control.
SCI Division Inspection Series Quality Assurance Program (QAP) Manual

Effective Date: April 2018 Page 96 of 99

24 HOUR AVERAGE DRAINED WEIGHT (OUNCES)

AVERAGE 

FILL 

WEIGHT 

(OUNCES)

68 69 70 71 72 73 74 75 76 77 78 79 80

56

57

58

59

60

61

62

63

64

65

66

67

68

69

70

71

72

73

74

75

76

FILL WEIGHT VERIFICATION GRAPH-PRODUCT: PEACHES(SLICED) CAN SIZE: #10

Upper 

Limit Line

Midpoint 

Line

Lower 

Limit Line
SCI Division Inspection Series Quality Assurance Program (QAP) Manual

Effective Date: April 2018 Page 97 of 99

24 HOUR AVERAGE DRAINED WEIGHT (OUNCES)

AVERAGE FILL WEIGHT (OUNCES)

17 18 19 20 21 22 23 24

13

14

15

16

17

18

19

20

21

FILL WEIGHT VERIFICATION GRAPH PRODUCT: PEACHES (HALVES) CAN SIZE: #2.5

Upper 

Limit Line

Midpoint 

Line

Lower 

Limit Line
SCI Division Inspection Series Quality Assurance Program (QAP) Manual

Effective Date: April 2018 Page 98 of 99

24 HOUR AVERAGE DRAINED WEIGHT (OUNCES)

AVERAGE FILL WEIGHT (OUNCES)

9 10 11 12 13

7

8

9

10

11

12

FILL WEIGHT VERIFICATION GRAPH PRODUCT: PEACHES (HALVES) CAN SIZE: #300

Upper 

Limit Line

Midpoint 

Line

Lower 

Limit Line
SCI Division Inspection Series Quality Assurance Program (QAP) Manual

Effective Date: April 2018 Page 99 of 99

24 HOUR AVERAGE DRAINED WEIGHT (OUNCES)

AVERAGE 

FILL 

WEIGHT (OUNCES)

4 5 6 7 8

2

3

4

5

6

7

FILL WEIGHT VERIFICATION GRAPH PRODUCT: PEACHES (HALVES) CAN SIZE: 8 OUNCE

Upper 

Limit Line

Midpoint 

Line

Lower 

Limit Line