(B)(4)

(B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN221603 

5306N-1 

03/06/2014 03J02 Slaughter HACCP O Monitoring Records- NY Wash, Pickers, IOBW: On February 27, 2014, the EIAO 

reviewed “Process Control Sheet” records from January 13, 2014 through February 

13, 2014. The Evaluation Program states that supervision or maintenance will 

be informed if concentration is outside the target and range; and rechecks will 

be conducted if the concentration is outside the range. The range is 

ppm and the target is ppm . The following dates had values 

outside of the range with no rechecks and no notification of supervision or 

maintenance: 2/13/14 in New York Wash; and 2/11/14 in New York Wash. The 

dates had values outside the target with no notification of supervision or 

maintenance: 1/14-15/14 in New York Wash and IOBW Reprocessing, 1/16-17/14 

in New York Wash and IOBW; 1/18-19/14 in New York Wash, and IOBW Line 2; 

1/19-20/14 in IOBW Reprocessing and IOBW 1 and 2 Line A and B; 2/4-5/14 in New 

York Wash and IOBW 1 and 2 Lines A and B; and 2/13/14 in New York Wash and 

IOBW 1 and 2 Lines A and B. The establishment failed to implement their 

Evaluation Program, which is used to support that “Pathogens (example 

Salmonella)” are not reasonably likely to occur in the Slaughter hazard analysis at 

the “NY Wash”, “Inside Outside Bird Washer #1” and “Inside Outside Bird Washer 

#2” steps. This is a regulatory noncompliance under 9 CFR 417.5(a)(1) and Notice of 

Deferral Verification Plan point 7(a). 

5309 P6137A NJN291603 

2406N-1 

03/06/2014 01C01 Operational SSOP 

Record Review 

O Enterobacteriaceae: The establishment implemented the “Sanitary Operation 

Verification Program” to evaluate the effectiveness of operational sanitation 

practices by monitoring the log values of product contact surfaces with acceptable 

limits of < logs. The program indicates, 

.” The 

EIAO reviewed “Sanitary Operation Verification Program” records from 

1/15/14-2/15/14 and determined that on the date of 2/3/14, a food contact 

surface in Zone 14, Site 33, had a value of logs, however, no corrective actions 

and no re-sampling for 2 consecutive days were documented. This is a regulatory 

noncompliance under 9 CFR 416.14 and Notice of Deferral Verification Plan point 

19. 

(b) (6)
(B)(4)

(B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN441403 

4306N-1 

03/06/2014 03C02 Raw Intact HACCP O Parts SOP: The establishment’s “Parts Monitoring 

SOP" indicates, “QC will evaluate concentration and dwell times at start of 

the process, hourly and/or at the end of the process. Results will be recorded on 

® Salvaged Parts Monitoring Log”. However, on February 24, 2014 at 

approximately 1430, the EIAO observed a QC employee monitoring 

concentrations for Fillet dips. The EIAO reviewed the current monitoring 

record for the Fillet dip, which had initials and time documented for dwell time, 

however the value for dwell time was not documented. In discussion with the QC 

employee, she stated that the dwell time was monitored, however it was not 

documented. The establishment failed to implement their “Parts Monitoring 

SOP”, which is used to support that “Pathogens (example Salmonella)” are not 

reasonably likely to occur in the Raw Not Ground hazard analyses at the “ 

Dip” steps. This is a regulatory noncompliance under 9 CFR 417.5(a)(1) and Notice 

of Deferral Verification Plan point # 11. CCP 3B 

: On February 25, 2014 during night shift, the EIAO observed the 

monitoring of CCP 3B, . The critical limit for 

CCP 3B is . The EIAO 

observed a QC employee monitor the concentration of 

using a test strip on a cone located on the cone line. The test strip indicated that 

the concentration was approximately , however, 

this value was not documented and no corrective actions were taken for this 

deviation. The QC employee then monitored a conveyor belt on the cone line and 

documented this value in lieu of the previous value for the cone. The establishment 

failed to document the actual value and failed to take corrective actions in response 

to a deviation. This is a regulatory noncompliance under 9 CFR 417.5(a)(3) and 

Notice of Deferral Verification Plan point 10(b). 

(b) (6)
(B)(6)

(B)(4)

(B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5310 M6137B FFA2001031 

606N-1 

03/06/2014 01B02 Pre-Op SSOP 

Review and 

Observation 

O     On 3-5-2014, at approximately 1:45am during a 

Pre-Operational review and observation task I began my inspection in the time after 

the establishment's Quality Control personnel had finished with their inspection, I 

observed in the Raw side of production excess amounts of product left on 

numerous hanging racks(13) left from the day prior. U.S. Retain tag no.B38 937057 

was applied to the racks affected. was notified immediately of the 

discripancy and of the noncompliance. Establishment's SSOP's states in section 1; 

. This is a noncompliance with Regulatory 

Requirements of 9CFR 416.13(c) and 416.14. Corrective actions were implemented 

and the retain tag was removed at 2:30am.    A similar 

noncompliance with the same root cause was observed on 2-26-14 and 

documented on Record No. FFA0600021027 N/1. To date Plant Management has 

not provided a written response to this NR. This linkage serves to demonstrate that 

the establishment's SSOP regulatory reguirements are in need of revision to 

become effective. This document serves as written notification that failure to 

comply with regulatory requirements could result in additional regulatory or 

administrative actions as described in 9CFR Part 500.4. 

5568 M20923 XUM192203 

4206N-1 

03/06/2014 01D01 SPS Verification C On 3/6/2014, at approximately 1955 hours, while performing a routine scheduled 

Sanitation Performance Standards (SPS) inspection task on the Cook Area 

Line #2 Oven Room, I observed the following noncompliance: standing water 

flooded along the southwest portion of the oven creating insanitary conditions, a 

noncompliance per 9 CFR 416.1, 416.(b)(2), and 416.(e)(3). The water fluid was 

coming from the belt wash area and some pipe connections to the belt wash. This 

type of condition is an ideal environment for the growth and 

spreading of Listeria Monocytogenes in a Post Lethality processing environment. I 

took regulatory control by rejecting the area with US Tag # 148126. I showed and 

informed Mr. of the forthcoming 

noncompliance. After corrective actions were performed by production and sanitary 

conditions were restored, I relinquished the US Tag at 2031 hours. The 

requirement(s) of Title 9 CFR 461.1, 416.2(b)(2), and 416.2(e)(3) were not met. 

(b) (6)
(B)(6)

(B)(6) (B)(6) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5568 M20923 XUM591403 

3806N-1 

03/06/2014 03G02 Fully Cooked-Not 

Shelf Stable HACCP 

C At approximately 1115 hours while performing HACCP task (the record review 

component of procedure for fully cooked-not shelf stable process), I observed the 

following noncompliance: While review the records in the QC office dated 3/3/14 

CCP (CCP-2B), QC Verification Record review check made at 2035 QC 

auditor documented time, initial but the acc/unacc check was missing. 

Establishment HACCP Plan states- Record review indicates the specific verification 

check was made according to the HACCP plan and that the verification check was 

acceptable/ unacceptable. Records were reviewed on 3/4/14 by 

There was no corrective action documented for deficiency. Also reviewing 

the HACCP & General Temperature Monitoring Log dated 3/5/14 the records 

were reviewed by on 3/5/14 at 1746 with initial but the 

acc/unacc check was missing. I notified the about the 

non-compliance. This does not meet the requirement of 9 CFR 417.5(a)(3) which 

states: "The establishment shall maintain: Records documenting the monitoring of 

CCPs and their critical limits, including the recording of the actual times, 

temperature, or other quantifiable values, as prescribed in the establishment's 

HACCP plan; the calibration of process-monitoring instruments; corrective actions, 

including all actions taken in response to a deviation; verification procedure and 

results; product code(s), product name or identity. Each of these records shall 

include the date the record was made". This document serves as written 

notification that failure to meet these regulatory requirement(s) could result in 

additional regulatory or administrative action. 

(b) (6)
(B)(6) (B)(6) (B)(6)

(B)(7)(C)

(B)(6) (B)(7)(C)

(B)(4)

(B)(6) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH090003 

4006N-1 

03/06/2014 01C02 Operational SSOP 

Review and 

Observation 

C On the night shift that began on 03/03/2014 at approximately 2138 I was in the 

Evisceration Room at Establishment 33900  P to perform a Zero tolerance 

procedure on Evisceration line #2.  When I finished this procedure I started 

to another area of the plant.  As I walked past the final rinse cabinet I 

observed water spraying from a nozzle on the inside of the cabinet.  This 

spray was splashing on the carcass rail and turn wheels and then dripping onto the 

carcasses and shackles below.     I had Inspector

 stop the line immediately.   Approximately 25 carcasses were 

affected.  The , had the carcasses 

reconditioned with water.     I then had Inspector

 re-start the line.   The Preventive Measure given by Mr. 

was that the water pressure in the cabinet was turned down and would be 

maintained at that pressure.  Also, new plastic curtains would be installed on 

the outside of the cabinet to help keep the water inside the cabinet.   Mr.

 was informed that a Noncompliance Record would be issued documenting 

the noncompliance.   The requirements of Regulations 416.1 and 416.13(c) 

were not being met.   The Establishments SSOP plan objective is, "

   For an NR 

with the same deviation, refer to #NHH1704035104 N/ 1, dated 

03/04/2014.  The cited NR has not been answered at this time.   

5308 M6137 BXL0618034 

805N-1 

03/05/2014 01D01 SPS Verification O At approximately 1404 hours While I was walking past the Sorting/Sizing belts in 

Plant #2 Packaging Rehang area I observed the following noncompliance.  I 

observed heavy beaded condensation on the drip pan that is directly above the belt 

for Drop #4 and along the entire drip pan that runs along the back of the belts from 

Drop #1 through Drop #4.  I immediately notified of the 

noncompliance.  He immediately had the lines stopped and notified QC to 

put a hold on 2 tanks of product that were at the end of Drop #1 and Drop 

#4.   then had a 

company employee wipe down the drip pans restoring sanitary conditions by 

approximately 1415 hours.  My finding indicate a noncompliance with the 

regulatory regulations of regulations 9CFR416.1, 9CFR 416.2(d), 9CFR 416.4(b) and 

9CFR 416.4(d). 

(b) (6)
(B)(6) (B)(6)(B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1102035 

005N-1 

03/05/2014 04A06 Poultry Finished 

Product Standards 

O On 03/04/2014 at approximately 2336 hours while monitoring the Establishment's 

Reprocessing Procedures on Line in Evisceration Area 1, I observed the 

following. After taking a random 10 bird sample I found 1 split tail bird with 

airsacculitis exudates remaining inside the cavity. I informed the leadperson and at 

approximately 2345 hours I took a 10 bird sample for the recheck. I found 1 

bird with kidneys and 1 bird with airsacculitis exudates remaining inside the 

bird. I immediately took regulatory control action by stopping the line, 

and I  informed of the noncompliance 

and showed him my findings. The line was started and all birds with split 

tails or missing tails were retained while corrective actions were implemented. 

Quality Control tagged the tank of retained birds pending rework of the 

product. At approximately 0001 hours I took a 10 bird sample for my 

recheck and passed, bringing the process back into control. At approximately 0049 

hours, Quality Control performed a recheck on the retained tank of birds and 

passed, the birds were released back to production. My findings indicate a 

noncompliance with regulatory requirements of regulations 9CFR 381.76(b) and 

9CFR 381.84.  

1325 

7 

P33900 NHH460203 

4805N-1 

03/05/2014 06D02 Other Inspection 

Requirements 

C On the night of production that began on February 26, 2014 at approximately 2135 

hours a presentation check was performed on line 2.  When the no viscera 

portion of the presentation check was performed 16 carcasses with no viscera were 

observed over a 3 minute period at a line speed of carcasses per 

minute.  Mr. , was notified and stated the plant had 

not performed no viscera checks at that point in the shift.  When a second no 

viscera check was performed, 18 carcasses with no viscera were identified.  

Both checks resulted in error rates greater than the allowed at carcasses per 

minute for the evisceration system.  The line speed was reduced by 

10% to carcasses per minute and at that line speed 11 carcasses with no 

viscera were identified.  This result was within the error rate allowed for 

the evisceration system. After the establishment had completed corrective 

actions, a missing viscera check was performed at 0520 hours.  The number 

of missing viscera at line speeds of and carcasses per minute was 7 and 12, 

respectively.  These values were within the allowed error rate. 

(b) (6)
(B)(6)

(B)(6) (B)(6) (B)(6)

(B)(4)

(B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5568 M20923 XUM191203 

3704N-1 

03/04/2014 01B02 Pre-Op SSOP 

Review and 

Observation 

C At approximately 0715 hours, while performing a routine PHIS task Pre-op review 

and observation inspection task (after establishment performed their 

pre-operational inspection and prior to start of production), I observed the 

following noncompliance: Line 1, Cook side of the establishment: I found few small 

pieces of food particles on conveyor belt from the previous day of production. 

Upon continuing my inspection Line 2, I found whole piece of chicken wing stuck on

 exit belt from the last run date 2-28-14 Friday, because yesterday on 3-3-14 

they run the meatballs on line 2. I took a regulatory control action and applied 

USDA retain/rejected tag# B24829892. I informed and showed to 

, and 

and of the non-compliance. The finding described in the 

non-compliance was on the food contact surface and very close to the food contact 

areas, it is reasonable to conclude that when production began it would be under 

insanitary conditions. Immediate corrective action was performed by establishment 

on all affected areas upon notification of my finding. After sanitary conditions had 

been restored, I relinquished the regulatory control action at 0750 hours. Plant 

SSOP Section1, page1, states: " 

". 9CFR 416.13 (c) states: "All establishment shall monitor daily 

the implementation of the procedures in the sanitation SOP's". 9CFR 416.4 (a) 

states: "All food contact surfaces, including food-contact surfaces of utensils and 

equipment, must be cleaned and sanitized as frequently as necessary to prevent the 

creation of insanitary conditions and adulteration of product". This document 

serves as written notification that failure to meet these regulatory requirement(s) 

could result in additional regulatory or administrative action. 

(b) (6)
(B)(6)(B)(6) (B)(6) (B)(7)(C)

(B)(6)

(B)(6) (B)(6)

(B)(4)

(B)(7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH170403 

5104N-1 

03/04/2014 01C02 Operational SSOP 

Review and 

Observation 

C On the night shift that began on 03/03/2014 at approximately 0338 I was in the 

Evisceration Room at Establishment 33900  P to perform a Zero tolerance 

procedure on Evisceration line #2.  As I started to collect the 10 carcasses 

needed to perform the procedure a carcass hit a water nozzle on the inside of the 

rinse cabinet.  Water from this nozzle sprayed upward and outward, spraying 

the rail and the turn wheels on the shackle line.  This water then fell onto the 

carcasses below.  I had Inspector stop the line 

immediately.   Approximately 15 carcasses were affected, which the 

, chose to condemn.    

  I then had re-start the line.   The Preventive 

Measure given by Mr. was that Maintenance personnel would tighten the 

nozzle to prevent it from spraying water outside the cabinet.   Mr. 

was informed that a Noncompliance Record would be issued documenting the 

noncompliance.   The requirements of Regulations 416.1 and 416.13(c) 

were not being met.   The Establishments SSOP plan objective is, 

5112 M18909 JDD1810032 

003N-1 

03/03/2014 01C02 Operational SSOP 

Review and 

Observation 

O In Evisceration this date 03/03/2014 at 0210 H PST, I observed plant 

employee ready to place a reprocessed bird into a (Supposed To 

Be Clean Stainless Steel Vat), only the vat wasn't clean, it had a dime size 

piece of UFM, black in color, in it. This is a violation of the Establishment's 

written SSOP Program and the above 9 CFR's. Mr. 

and Ms. were shown the noncompliance and were in 

concurrence with it.Ms. paperwork did not reflect this prior to my 

notification. 

(b) (6)
(B)(6) (B)(6)(B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1808030 

703N-1 

03/03/2014 01B02 Pre-Op SSOP 

Review and 

Observation 

O On 03/03/2014 at approximately 0006 hours while performing Pre-Operational 

Sanitation procedures on the Tub Wash Machine, I observed the following. 

There was a dried residue film around the bolts located on the metal sides where 

the tubs enter the machine, that came off easily when I scratched it with my 

fingernail. I also observed fat and meat particles approximately towards the middle 

section of the machine that were located close to the top inside of the 

machine that ran from one side to the other. I applied U.S. 

Rejected/U.S. Retained tag #B31406475 to the machine and 

I informed of the noncompliance and showed 

him my findings. At approximately 0156 hours while performing a recheck on the 

tub wash machine, I observed the following. There was still some dried residue film 

around the bolts, and inside the machine were several pieces of fat between 

the metal links of the belt that are on the edges of the white plastic that runs along 

the sides of the inside of the machine. I informed and 

showed him my findings. At approximately 0324 hours after the tub wash machine 

had been washed and sanitized restoring sanitary conditions, I removed my tag and 

released the machine. My findings indicate a noncompliance with 9CFR 416.1, 9CFR 

416.13(c), and 416.4(b). 

5308 M6137 BXL5204035 

303N-1 

03/03/2014 01B02 Pre-Op SSOP 

Review and 

Observation 

O On 03/02/2014 at approximately 2129 hours while monitoring the Establishments' 

Pre-Operational Sanitation procedures in Plant 2, I observed the following. There is 

an exhaust fan directly over Scalder #3. There was a clear fluid dripping 

profusely from the opening directly into the scalder causing an insanitary condition. 

The fluid appeared to be rain water flowing from the roof. & 

was shown the noncompliance. A mechanic was called and placed a 

sheet of plastic to direct the fluid away from the scalder. The affected section 

of the scalder is located adjacent to the access door to the Stunning Area. 

The scalder  was emptied and recleaned restoring sanitary conditions by 

approximately 2230 hours. My findings indicated a noncompliance with 9 CFR 

416.1, 9 CFR 416. 2(b)(1),  9 CFR 13(c), and 9 CFR 416.14. 

(b) (6)
(B)(6) (B)(6) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH280302 

0528N-1 

02/28/2014 06D02 Other Inspection 

Requirements 

C On the night of production that began on February 26, 2014 at approximately 2145 

hours a presentation check was performed on line 2.  When the no viscera 

portion of the presentation check was performed 16 carcasses with no viscera were 

observed over a 3 minute period at a line speed of carcasses per 

minute.  Mr. , was notified and stated the plant had 

not performed no viscera checks at that point in the shift.  When a second no 

viscera check was performed, 16 carcasses with no viscera were identified.  

Both checks resulted in error rates greater than the allowed at carcasses per 

minute for the evisceration system.  The line speed was reduced by 

10% to carcasses per minute and at that line speed 11 carcasses with no 

viscera were identified.  This result was within the error rate allowed for 

the evisceration system. A presentation heck was then performed on line 1 

at 2220 hours.  When the no viscera check was performed 27 carcasses with 

no viscera were observed over a 3 minute period at a line speed of carcasses 

per minute.  Mr. , was again notified and stated the 

plant had not performed no viscera checks at that point in the shift.  A 

second no viscera check resulted in 24 carcasses no viscera.  The line speed 

was reduced by 10% to carcasses per minute and at that line speed 11 

carcasses with no viscera were identified.  This result was within the error 

rate allowed for the evisceration system. The establishment was unable to 

correct the issue on either line before the end of the night’s production; therefore, 

both lines were checked at the beginning of the shift on February 27, 2014.  

The no viscera check on line 2 at carcasses per minute resulted in 7 carcasses 

with no viscera.  This value is within the allowed error rate of so the line 

speed was increased to carcasses per minute.  Four carcasses with no 

viscera were obtained at this line speed.  No viscera checks on line 1 resulted 

in 8 and 10 carcasses with no viscera at line speeds of and carcasses per 

minute, respectively.  These results were within the error rate allowed for 

the evisceration system at the line speeds stated.The requirements of 9 CFR 

381.76(a) and 381.76(b) were not met. 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6)(B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD3622025 

727N-1 

02/27/2014 01D01 SPS Verification C On 02/27/2014 at approximately 1957 hours I observed the following 

noncompliance to 9 CFR 416.1, 9CFR 416.2(d) and 9 CFR 416.4(d) in the Weigh and 

Price Room. While doing my verification checks in the Weigh and Price room I 

observed water dripping from the ceiling next to refrigeration unit in the Weigh and 

Price Room onto a pallet of sealed cases of Turkey Breast Roast. I immediately took 

regulatory control action by applying U.S. Retain Tag # B43241090 to the pallet and 

informing of my observation 

and noncompliance. Mr. took immediate corrective action in my 

presence by removing the pallet from underneath the dripping water and 

informing maintenance. Mr. removed the cases of effected product 

and reworked the product inside. The dripping was on the outside of the 

sealed case's so no product was effected by the dripping. Regulatory control was 

relinquished at approximately 2020 hours after sanitary conditions were restored. 

5308 M6137 BXL4707024 

127N-1 

02/27/2014 01B02 Pre-Op SSOP 

Review and 

Observation 

O On 02/27/2014 at approximately 0010 hours while monitoring the Establishments' 

Pre-Operational Sanitation procedures in Packaging, I observed the following. There 

were patches of  semi-dried fat and tissue measuring to approximately 3/4" 

by 3" by 1/16" on the small cutting wheels on all three breast processors 

checked. The cutting wheels are used to make the final cut on the front halves 

before the breast halves and back bone are dropped onto the product 

belts.  There were also two large pieces of tissue to approximately 3" 

between  the chain and the upper nylon support bracket on processor 

#9.  I contacted and showed him my findings. 

Breast processors 8-10 were recleaned and returned to service by 

approximately 0020 hours.  My findings indicated a noncompliance 

with 9 CFR 416.1, 9 CFR 416.4(a) and 9 CFR 416.13(c). 

5308 M6137 BXL5203024 

027N-1 

02/27/2014 01C02 Operational SSOP 

Review and 

Observation 

O On 02/26/2014 at approximately 2307 hours while monitoring Operational 

Sanitation in the Plant 2 Paw Room, I observed the following. Water was dripping 

from an air vent above the grey plastic bin that is used to collect the paws. A 

piece of plastic had been put up under the air vent and the water that was 

dripping from the air vent was collecting in the plastic and then dripping 

directly into the bin of paws that was approximately 3/4 full.  I 

immediately tagged the bin of paws with U.S. Rejected/U.S. Retained 

tag #B31406626, and I informed of the noncompliance. The bin 

of paws were taken to the PC Plant where I removed the tag at 

approximately 2320 hours, and the paws were condemned.My findings 

indicate a noncompliance with the following regulatory requirements of regulations 

9CFR 416.1, 9CFR 416.13(c), 9CFR 416.2(b)(1), 9CFR 416.2(b)(2), 9CFR 416.4(a), and 

9CFR 416.4(d). 

(b) (6)
(B)(6)

(B)(4)

(B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5310 M6137B FFA0600021 

027N-1 

02/27/2014 01B02 Pre-Op SSOP 

Review and 

Observation 

O On 2-26-14 at approximately 01:30 hrs while performing a 

preoperational inspection, after the establishment's Quality Control personnel 

finished with their inspection I observed the following deficiencies in the Raw side 

production area(Zone A); the rework table with product left from the day 

before on the side rims around the table and underneath, including the 

framework. Product was also found on the small 

blender's dumper/crossbar(product contact), and roller guides for raising 

and lowing dumper. Excessive product left on the lid of the large blender, 

hoses,and framework of the catwalks of this machine. These are in 

noncompliance to the Establishments SSOP's.  Regulatory 

requirements of 9 CFR 416.13(2) and 416.14(2). As stated in your 

SSOP, section 1/Pre-operational Sanitation, 

ith accompanying me during my inspection, he was 

taking immediate corrective actions on all of these items mentioned and also 

notified of this N.R. This noncompliance serves as written notification that 

failure to complly with regulatory requirements listed could result in additional 

regulatory or administrative actions. 

1325 

7 

P33900 NHH040402 

0727N-1 

02/27/2014 04A06 Poultry Finished 

Product Standards 

C On the night shift that began on 02/26/2014 at approximately235 Hours, I was in 

the Evisceration room at Establishment 33900  P.  I was in the area to 

give relief breaks to the line inspectors.   At the reprocessing cut-up 

station I observed an employee pick up six carcassses that was marked with a long 

straight cut on the back of the carcass.  This cut then had a small cut across 

the long cut close to the tail of the carcass.  The plant employees had 

reprocessed these carcasses by removing part of the breast that had been 

mutilated by the picker fingers in the picking room of the establishment.  

This employee then took the carcasses to the Inflamatory Process  area and 

put them into the .  The Establishment has a cut-up reprocessing 

procedure and an Imflamatory process procedure.  Neither of these 

procedures were fully followed. Regulatory Control Action was taken by applying 

USDA Reject tag number B38075852 to the . The requirements of Regulation 

381.91(c)(2) were not being met.      

(b) (6)
(B)(6) (B)(6) (B)(6)

(B)(6)

(B)(6) (B)(7)(C)

(B)(4)

(B)(4)

(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH550302 

4527N-1 

02/27/2014 01C02 Operational SSOP 

Review and 

Observation 

C On the morning of February 26, 2014 at approximately 0540 hours while touring 

room 1 Further Processing the following noncompliance was observed.  

Approximately one-third tote of down-grade wings was observed under the catwalk 

for the breast processors.  At the time, plant employees were standing on 

the catwalk and water was dripping from the catwalk into the tote contaminating 

the product.  Mr. immediately removed the product and 

condemned it and sent the tote to be washed.  To prevent recurrence, Mr.

 stated the responsible employee would be retrained.  Mr. was 

informed the noncompliance would be documented on a noncompliance 

record.  The establishment’s SSOP plan states 

The requirements of 9 CFR 416.1 and 416.13(c) were not met.  

For a similar noncompliance refer to NR NHH0101014504N/1 dated January 4, 

2014.  The preventive measure for this noncompliance was

 These measures may have been implemented incorrectly or may have 

been ineffective at preventing recurrence.  

1326 

1 

M33901 HAY400202 

1827N-1 

02/27/2014 01D01 SPS Verification C On the calendar date of February 27, 2014 at approximately 0042 hours while 

performing the Operational SSOP Review and Observation task, the following 

facility noncompliance was observed in the RTE Clean Room: Part 2 of the 

establishment's SSOP's under "Facilities" states that 

.I, 

CSI , observed multiple beads of condensation on the underside of the 

white pipe adjacent to the oven conveyor. Beaded condensation was also located 

on the underside of the stainless conduits above the oven conveyor. At the 

time of the findings, exposed grilled chicken breast were being processed and 

conveyed from the oven into the freezer.Please be advised that no product 

contamination was observed, as the condensation was non-dripping. 

, was shown the noncompliance and she confirmed the 

findings. Production was stopped and corrective actions were immediately initiated. 

Ms. was informed that a noncompliance record would be issued. This 

noncompliance record will be discussed during the next weekly meeting.A similar 

noncompliance record was documented on February 26, 2014; please reference 

NR # HAY2413025426N-1. The establishment's response to 

NR # HAY2413025426N-1 is pending. 

(b) (6)
(B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD5606024 

726N-1 

02/26/2014 01B02 Pre-Op SSOP 

Review and 

Observation 

O EVISCERATION: 1) UFM in the Gizzard Defatter, 2) UFM in I/O Wash Line Two, 3) 

Inedible Hooks with UFM on them and RED ID TAPE loose and insanitary condition, 

4) UFM on Framework of the Quill Puller.Boning: 1) Multiple residues on the 

Tendon/Strap Puller, 2) Product Residue in Right Drive Cog on Overhead Belt 

feeding hanging, 3) Production residue on Wall/Ceiling left side of Contherms. 4) 

Sprinkler Shrouds are rust, loose paint ceiling by the MAIN BONING WASH 

STATIONS, 5) Product residue on Belts Feeding MDP and Drum machines, 6) Brown 

strips on bottom of Breast Sorter, one is badly stained and pieses have chipped out 

of it, the other has residue on it, RAW FAB: Discussed with Mr. , the 

conditions of the CASING BOXES. This is violation of the above 9 CFR's and the 

Establishment's written SSOP Program. This is Linked to NR 020-2014, Dated 

02-24-2014, JDD1608021224N/1 and its associated JDD number. 

(b) (6)
(B)(7)(C) (B)(7)(C) (B)(6) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

6036 P6164A OIJ4520025 

726N-1 

02/26/2014 03J04 Poultry Zero 

Tolerance 

Verification 

O On February 26, 2014 at 1555 I, CSI observed visible fecal 

material on one bird at the chiller exit area while performing a Post chill FPS test. 

PHV verified my finding.  The fecal material was found on 

the partial tail and on the cut surface area of the pelvic bone next to the partial tail. 

The dark brown creamy fecal material with ureate covered half of the partial tail 

and the entire cut surface of pelvic area.  A cloaca with intestine 

approximately 1 1/2” long was attached to the partial tail. All birds exiting the chill 

system were toted off and retained for rework.  QC performed Postchill fecal 

checks resulting in no fecal found. Birds exiting the chill system were allowed to 

return to the normal process flow.   A total of five totes were retained, 

reworked and reinspected by QC.  Additional checks were performed in the 

Packaging Dept on all lines receiving product from the chiller. No fecal was found. I 

verbally notified and that a NR 

would be issued.  The verbal response given was that the failure was due to 

employees failed to remove attached cloaca and intestine from the bird prior to 

entering the chiller. All Evisceration Department employees on duty at the time of 

the failure were counseled individually by the Evis Supervisor of the importance to 

remove all cloacae and intestines from the birds or hang them on the reprocess line 

for rework. The verbal preventative measure given was that all Inspector helpers 

will be retrained on the importance of removing the cloacae and intestines from the 

bird or remove the bird to the reprocess line. On December 26, 2013 

NR # OIJ4509121326N (#86) was written for fecal found while performing a prechill 

Poultry Zero Tolerance Verification test.  The cause was determined to be a 

malfunctioning spray nozzle in the New York bird wash. The written preventative 

measure given was that Maintenance will check the NY Wash at breaks and lunch. 

On December 4, 2013 NR # OIJ0908123505N (#84) was written for fecal found while 

performing a prechill Poultry Zero Tolerance Verification test.  The cause was 

determined to be a malfunctioning spray nozzle in the New York bird wash. 

 The written preventative measure given was that Production will check the 

water nozzles every half hour until 12/13/13.  The preventative measures 

given have been ineffective in preventing further occurrence of visible fecal being 

found in the chiller system. The establishment Awareness meeting notes show the 

last time fecal noncompliances were discussed was on December 26, 2013. This NR 

is linked to NR # OIJ4509121326N (#86) and NR # OIJ0908123505N (#84) for the 

same root cause of not preventing visible fecal material from entering the chiller 

system. 

(b) (6)
(B)(7)(C) (B)(7)(C) (B)(7)(C)

(B)(6)

(B)(6) (B)(6) (B)(6) (B)(4) (B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1326 

1 

M33901 HAY241302 

5426N-1 

02/26/2014 01C02 Operational SSOP 

Review and 

Observation 

C On the calendar date of February 26, 2014 (Wednesday) at approximately 0720 

hours, I received a visit from Dr. , Dr. and Dr.

 to conduct a tour through the establishment. This tour 

was conducted during scheduled operations although product was not being 

processed at the time. As we walked through the processing areas the following 

noncompliances were observed: (1) Raw processing side of lines #1 and #2, a white 

shovel that is used for edible product was hanging on the side of the large 

marinating tumbler for line #1 and was observed to have two tissue/fat particles on 

the inside surface. The particles had a brown color and ranged between 1/16” and 

2/16” in size. U.S Rejected tag B38464356 was applied to the white shovel. Also 

observed was a long trail of a white product ingredient that had been spilled onto 

the floor where the ingredients are set up at the mixing tanks. The spilled ingredient 

covered an area approximately 6’ long. (2) Raw processing side #3 and #4, three 

stacks of white barrels (four barrels in each stack) labeled for edible product were 

observed with the presence of fat particles on the outside and inside surfaces. The 

barrels were staged on a stainless steel table and were turned down on the table. 

The fat particles had a black color and ranged between 1/16” to 2/16” in size. Also 

observed on the white barrels were rough edges all around the top surfaces. U.S. 

Rejected tags B38464357, B38464358 and B38464359 were applied to white 

barrels. A stainless steel was observed to have the presence of fat 

particles/tissue on the inside surface. The particles/tissue ranged approximately 

2/16” in size. U.S. Rejected B38464360 was applied to the Mr. 

was shown the conditions and informed that there were SSOP 

noncompliances. Mr. also informed Mr. of the 

SSOP noncompliances. (3) In the middle cooler, a drip pan underneath a cooling unit 

near the entrance to the MSC department had beaded condensation present. 

Beaded condensation was also present on the ceiling of the hallway near the MSC 

department. No product was on the production lines during this time. All insanitary 

equipment was immediately removed from the raw processing areas and taken to 

the equipment wash room. As, a preventative measure, the S3 Sanitation Cleaning 

assistant site manager, Mr. , was informed of conditions and followed 

up on the cleaning of equipment. (No product was contaminated). The 

establishment’s Standard Operating Procedures for Sanitation (Part 2; section 1 

states: “ ”. Equipment 

was not maintained in a sanitary manner and ineffective SOP monitoring failed to 

prevent equipment contamination. The Regulatory requirements for 9CFR 

416.13(c), 416.1 and 416.4(d) were not met. 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5129 M210 LQN501802 

1525N-1 

02/25/2014 01D01 SPS Verification O On February 25, 2014 while performing my schedule SPS Procedure in Raw Side and 

Cook Side Coolers I observed  noncompliance with SPS regulatory 

requirement(s) 416.4(b)(1), 416.4(b), 416.2(b)(2).Raw Side Cooler Number 

Two:  Inside Cooler #2,  I observed a section of the floor that was 

damaged. Two tanks of product was stored on top of the damaged floor.  

Several loose large and small piece of the floor was scatter in different 

directions.  U.S. Reject Tag NO. B38937062 was applied to this section of the 

cooler (prduct traffic area).  Mr. ., was informed and 

showed the noncompliance.Raw Side Cooler Number One:  Inside Cooler #1, 

  I observed that behind the Ice Machine the ceiling has a couple of 

areas that has gaps and has black UFM along the gaps.  I observed that the 

Product Thawing Area has several rusty beams and rails (product staging 

area).  Mr. . was informed and showed the 

noncompliance.Cook Side Cooler #2:  I observed that the doorway as you 

enter into Cooler #2,  has rust and chip paint also at the bottom of the 

doorway I observed a hole with broken pieces of concrete.  I observed rust 

along the rail where the product is staged prior to entering Cooler #2.  I 

observed rust on the small pole before enter the hallway.  I observed prior to 

enter the handwash area for the slice pack department the overhead trim on the 

door is loose and hanging down exposing rust(product traffic areas).  Mr.

 was informed and showed the 

noncompliance.This NR is linked to NR#LQN4218025504N/1 dated 2/4/14, for a 

similar noncompliance.  This NR serves as written notification that failure to 

comply with regulatory requirement(s) may result in additional or administrative 

actions as described in 9 CFR 500.4. 

5308 M6137 BXL1813024 

725N-1 

02/25/2014 04C05 Poultry Good 

Commercial 

Practices 

O At approximately 0845 hours while monitoring the Establishments' Good 

Commercial Practices procedures, I observed the following noncompliance.  

When I walked into the Line #2 Live Hang area I observed a grey barrel 

marked Inedible on a dolly that it is used to transport DOA's from the Live 

Hang area to the USDA Condemn tank that is now kept outside.  When I 

looked inside the barrel it was approximately 3/4 full of DOA's and I observed one 

bird still breathing on the top layer of  DOA's in the barrel.  I turned on 

my flashlight to get a closer look at the bird and it lifted up it's head, was blinking 

it's eyes and was moving it's wings.  I was concerned about additional 

DOA's being placed on top of the live bird, as the bird could suffocate.  I 

immediately informed of the noncompliance.  The 

Company elected to humanely euthanize the bird.  The Establishments 

SSOP's state that grey barrels are used for Inedible product.  

 My findings indicate a noncompliance with 9 CFR 381.65(b).  

(b) (6)
(B)(6) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN510902 

4625N-1 

02/25/2014 04C05 Poultry Good 

Commercial 

Practices 

O At approximately 0700 on February 25, 2014 during the night shift at Est. P 6137A, 

I observed the following non compliance: Two carcasses, which clearly 

showed signs of having died by means other than slaugther, were found by the line 

inspector and held for the veterinarian. The carcasses were congested on one side, 

and one showed an additional 3" line of hemorrhage of the keel.  The 

viscera of both carcasses were congested and livers were friable.  This 

indicates an incomplete bleed, most often caused by dead or dying birds 

being hung on the line.  Mr. was informed and also 

inspected the carcasses.  Carcasses were subsequently condemned, and I 

informed Mr. that an NR would be issued. Poultry must be slaughtered 

in accordance with good commercial practices in a manner that will result in 

thorough bleeding of the carcasses (9 CFR 381.65(b))  and birds plainly 

showing on ante mortem inspection any disease or condition... would cause 

condemnation of their carcasses on post mortem inspection, shall be condemned. 

Birds which on ante mortem inspection are condemned shall not be dressed, nor 

shall they be conveyed into any department of the official establishment where 

poultry products are prepared or held. Poultry which has been condemned on ante 

mortem inspection and has been killed or died otherwise shall under the 

supervision of an inspector of the Inspection Service, be disposed of as provided 

in § 381.95. (9 CFR 381.71(a)). 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6)

(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5568 M20923 XUM251202 

4025N-1 

02/25/2014 01B02 Pre-Op SSOP 

Review and 

Observation 

C At approximately 620 hours, while performing a PHIS task Pre-op review and 

observation inspection task (after establishment performed their pre-operational 

inspection and prior to start of production), I observed the following 

noncompliance: Line 1, Raw side of the establishment: I found piece of chicken 

approximately 1 1⁄2 inch long stuck in chicken Flattener machine, from the previous 

day of production. Upon continuing my inspection: Line 2, I found food particles on 

one of the conveyor belt, also from the previous day of production. All finding 

described in the non-compliance were on the food contact surface, it is reasonable 

to conclude that when production began it would be under insanitary conditions. I 

took a regulatory control action and applied USDA retain/rejected tag# B24829887. 

I informed and of 

the non-compliance. Immediate corrective action was performed by establishment 

on all affected areas upon notification of my finding. After sanitary conditions had 

been restored, I relinquished the regulatory control action at 0655 hours. Plant 

SSOP Section1, page1, states: " 

". 9CFR 416.13 (c) states: "All establishment shall monitor daily 

the implementation of the procedures in the sanitation SOP's". 9CFR 416.4 (a) 

states: "All food contact surfaces, including food-contact surfaces of utensils and 

equipment, must be cleaned and sanitized as frequently as necessary to prevent the 

creation of insanitary conditions and adulteration of product". This document 

serves as written notification that failure to meet these regulatory requirement(s) 

could result in additional regulatory or administrative action. 

4630 M7322 AOA330502 

0424N-1 

02/24/2014 01B02 Pre-Op SSOP 

Review and 

Observation 

O At approximately 0415 hours while performing Pre-operational Sanitation Standard 

Operation Inspection in the establishment’s Raw Processing Area Freezer there 

were “2 Season Ingredient Mixing Bins” stored with a plate of whitish cloudy 

looking ice (approximately 1 1⁄2 inch thick and 2 1⁄2 square feet wide) in the inside 

bottom area of the bins. The Season Ingredient Mixing Bins have been observed in 

use to contain the season ingredients that are use in the formulation of the edible 

frank product. The condition of the Season Ingredient Mixing Bins did not meet the 

minimum requirements of 9 CFR 416.13(c), 416.4(a), 416.2(d), and 416.1. USDA 

retain tag #B40007620 was applied. and

 was notified. The area was released at 

approximately 0426 hours when the corrective actions were verified by FSIS. -This 

document serves as written notification that your failure to comply with regulatory 

requirement(s) could result in additional regulatory or administrative action(s). 

(b) (6)
(B)(6)

(B)(6)

(B)(6) (B)(6)

(B)(6)

(B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD1608021 

224N-1 

02/24/2014 01B02 Pre-Op SSOP 

Review and 

Observation 

O In Evisceration I observed the following:1)The  Gizzard Defatting Machine has 

another new crack in it one inch long in the back. This was shown to and concurred 

upon by Mr. and Mr.

 who sets the machine up, 2) I/O Wash Line Two, Red 

Rubber Hose fraying rubber off, Mr. notified of this issue, 

3)Overhead screen in ceiling in the Picking Room has feathers in it, 4) Both Knife 

Sanitizers in the OSTEO ROOM were not cleaned, they are bolted down and can't be 

easily dumped for cleaning, 5)Nails in ceiling are rusting though the paint over, 6) 

Overhead Industrial Air Moving Unit is getting rusty, 7) 

Ammonia Lines feeding GIB Chiller are rusty. Ms. 

was advised of these issues and they were not reflected in her paperwork prior to 

my notification of the same Boning: 1)Overheads holding shackles at wing trim has 

UFM on it, 2) Belt for WishBone line is peeling it's surface and was removed 

from service. 3)End chute off Breast Trim Sorting Belt is cracked again, a one 

inch crack on the interior of both sides of the Chute. Mr. 

was shown the Issue as was Mr. 4) Four 

Stainless Steel Vats with Poultry residue in them. This is a violation of the above 9 

CFR's and the Establishment's written program. This NR is Linked to the following 

NR 15-2014, Dated 02/18/2014, JDD3010025118N/1 and associated linkage. 

(b) (6)
(B)(6) (B)(6)

(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN550102 

0124N-1 

02/24/2014 03J04 Poultry Zero 

Tolerance 

Verification 

O At 2334 hrs I performed a Poultry Fecal Zero Tolerance Verification Task at the FPS 

station, a point in the process after the last intervention before carcasses enter the 

chilling system. I noted the following non compliance: On slaughter line A, I 

randomly selected 10 carcasses for visual observation.  I noted that the 

seventh of the ten carcasses exhibited a smear, approximately a 1/2 inch by 

one inch on the leaf fat inside the left side of the carcass that 

was yellow/brown in color, pasty in consistency.  This material is 

consistent with the characteristics of fecal material.  I stopped the line, 

informed and showed the finding to 

and  .  I then released control of the line so the 

establishment could initiate their corrective actions, including a recheck and 

marking the chiller with a red netted carcass.  Further corrective actions 

included increasing the chiller water by 1/4 gallon per bird.  Three post chill 

checks performed ten minutes apart indicated that there were no further findings 

of fecal material.  The red netted carcass exited the chiller at 0109 

hrs.  All corrective actions were documented by the establishment in 

accordance with the establishment's corrective action for a CCP 3B 

) failure indicating that the CCP was under control.The 

finding of fecal material on or in a carcass at this point of the production line 

constitutes a non compliance according to 9 CFR 381.65(e) which states: "Poultry 

carcasses contaminated with visible fecal material shall be prevented from 

entering the chilling tank".  

1325 

7 

P33900 NHH401602 

3124N-1 

02/24/2014 01D01 SPS Verification C At 1400 hours while touring the box storage area I also checked the outside 

premises just below the room. I observed that the inedible product dumpster near 

dock was over half filled with product that had not been denatured. 

After returning downstairs to determine why denaturant was not being applied and 

I was told that the denaturant dispensing equipment was inoperable. CFR 381.95 

states that all condemned parts of carcasses, or other condemned poultry products, 

except those condemned for biological residues shall be disposed of by either of the 

approved method listed therein. Chemical denaturing in liberal amounts, as elected 

by the plant, was not being applied at all; therefore this requirement was not 

met.Management was notified and the dumping area was rejected until denaturant 

was applied. 

(b) (6)
(B)(6) (B)(6)

(B)(4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH470002 

3224N-1 

02/24/2014 01C02 Operational SSOP 

Review and 

Observation 

C On the night shift that began on 02/23/2014 at approximately 2140 I was in the 

Evisceration Room at Establishment 33900  P to perform a finished product 

standards procedure on Evisceration line #2.  As I walked away from the 

station on my way back to the USDA office, I saw a band from the inside of the 

inside/outside bird washer that had come loose from the bracket that holds it in 

place.  A maintenance man was instructed to replace the band on the bracket 

and as he attemped to accomplish this, the sleeve of his shirt came in contact with 

the carcasses exiting the unit.   Approximately 30 carcasses were 

affected.      Regulatory Control Action was taken by stopping 

the line, removing the affected carcasses for reconditioning.  I then released 

the line to production.   The Preventive Measure given by Mr. 

was that the Maintenance personell involved would be retrained in sanitary 

operations during production.   Mr. was informed that a 

Noncompliance Record would be issued documenting the noncompliance.   

The requirements of Regulations 416.1 and 416.13(c) were not being met.   

The Establishments SSOP plan objective is, " 

(b) (6)
(B)(7)(C) (B)(6) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

4630 M7322 AOA050902 

2722N-1 

02/22/2014 01D01 SPS Verification O On Feb. 20 2014 while performing a Sanitation Standard Operation Procedure 

Inspection in the establishment cook processing areas, FSIS FLS/Dr. and I 

observed the following deficiencies: 1. At approximately 1308 hours at the #1 retail 

batter tank area of the establishment’s batter room, we observed a plastic bag that 

was partially taped to the ceiling panel. The bag contained approx. 6-8 ounces of 

clear liquid that appeared to be water. The bag was swiftly moving back and forth in 

response to the air from an air unit. We observed some clear liquid from the ceiling 

and from the swiftly moving plastic bag, dripping down (to numerous to count 

approx. 25-30 visible drops) on the cardboard spacer that were partially covering a 

pallet of approximately 9 bags of open dry batter product. Small portions of 3 bags 

of the open dry batter product were not covered by the cardboard spacer but close 

investigation reveal that there were no product contamination or adulteration. 

Official control action was taken. USDA reject tag #B40017692 was applied to the 

area and , and was notified. The area was 

released at approx. 1328 hours when corrective measures were observed. - A 

similar noncompliance was observed on 12/06/13 and documented on 

NR#AOA3014121006N/1. The preventive measure (further planned action) 

provided by the establishment that states, “The maintenance department inspected 

the attic area over the fryer room.  The attic area was found to have a water 

leak from the rain.  A panel from the roof had separated at the seam, 

creating a gap for the rain to enter the attic area and leak through, to the 

production area.  The panel in the roof was resealed and the water was 

removed from the attic area”, appears to be ineffective in preventing this 

noncompliance. -This document serves as written notification that your failure to 

comply with regulatory requirement(s) could result in additional regulatory or 

administrative action(s). -Continued failure to meet regulatory requirements can 

lead to enforcement actions described in 9 CFR 500.4. 

(b) (6)
(B)(7)(C) (B)(6)

(B)(6)

(B)(7)(C)

(B)(6)

(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

4630 M7322 AOA580902 

3322N-1 

02/22/2014 01C02 Operational SSOP 

Review and 

Observation 

C On Feb. 20 2014 while performing a Sanitation Standard Operation Procedure 

Inspection in the establishment cook processing areas, FSIS FLS/Dr. and I 

observed the following noncompliance: 1. At approximately 1315 hours while 

observing the bulk line fryer areas we observed the frank wash sinks and noticed 

that the product contact surfaces of the frank wash sinks had a heavy build up of a 

white, dry, lumpy and crusty looking substance that appeared to be an 

accumulation of previously wet batter that had dried up. The fryer #2 frank wash 

sink did not have any written information to declare the intended use (e.g. Frank 

Wash, Hand Wash, Equipment Wash). The frank wash sinks are used to rewash 

edible frank product that could be place back into the ready to eat corndog 

production process. and 

were notified. No retain tag was applied because immediate corrective 

measure were taken by the establishment. -This document serves as written 

notification that your failure to comply with regulatory requirement(s) could result 

in additional regulatory or administrative action(s). 

1326 

1 

M33901 HAY330202 

0725N-1 

02/22/2014 03G02 Fully Cooked-Not 

Shelf Stable HACCP 

C On the calendar date of February 22, 2014 at approximately 2257 hours while 

performing the Fully Cook -Not Shelf Stable HACCP task, the following 

noncompliance was observed: On, Thursday February 20, 2014 at approximately 

0114 hours I, CSI , reviewed the CCP-4 

for the date of February 19- February 20, 2014 while inside the RTE clean room. At 

the time, the log showed that the temperature of Orange Chicken was monitored at 

"9:15 pm" and that a direct observation of the monitoring was recorded at 

"9:16pm". "9:17pm" was the time recorded in the record review section of the 

record. On today's date, I reviewed the log along with the written corrective actions 

that were performed after a deviation from the critical limit occurred (please 

reference NR # HAY0118020620N/1) at CCP-4. The log now shows a line marked 

through the time of "9:16 pm" (initials included) in the direct observation section of 

the record and the time of "9:15 pm" recorded underneath the original time. No 

determination can be made as to when the entry of "9:15 pm" was recorded in the 

direct observation section of the record, as neither the date nor the time was 

recorded next to the entry. In addition, "acceptable" was recorded in the results 

column during the Records Review verification at 9:17 pm on 2/19/14. 

, was shown the noncompliance and informed that a noncompliance 

record would be issued. This noncompliance record will be discussed during the 

next weekly meeting. 

(b) (6)
(B)(6) (B)(6)

(B)(6) (B)(6)

(B)(6)

(B)(6)

(B)(6) (B)(6) (B)(6) (B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD0813025 

621N-1 

02/21/2014 01C02 Operational SSOP 

Review and 

Observation 

C On 02/21/2014 at approximately 1012 hours while performing my 

inspection duties in the Tray Pack room I observed a stainless steel tank 

containing approximately 1694 lbs of Turkey Split Half Breast with Scap being 

brought in from cooler # 3 to be packaged, I observed numerous black flakes of 

UFM on the product. I immediately took regulatory control action by applying U.S. 

Retain tag # B43241093 to the tank of Split Breast and informing 

of my observation and the noncompliance. Upon further inspection in 

cooler # 3 at approximately 1018 hours, I observed a stainless steel tank containing 

approximately 1676 lbs of Turkey Necks also with black flakes of UFM on top 

of the ice covering the necks.Regulatory control action was also enforced on the 

tank of necks by applying U.S.Retain tag # B43241094 to the tank of necks. Mr.

 was also informed of the UFM on the tank of necks. Mr. took 

immediate corrective action in my presence by having the top layers of the product 

in both tanks reconditioned  and washed with ppm water. 

Regulatory control was relinquished and product released at approximately 1130 

hours after the completion of all corrective actions. This is a noncompliance of 9 

CFR 416.1 and 9 cfr 416.4(d). 

5112 M18909 JDD1307021 

721N-1 

02/21/2014 01D03 Poultry Sanitary 

Dressing 

O In last Exit meeting dated 02/14/2014, it was brought to the attention of all parties 

in the meeting that the Establishment is not taking the rusty conditions in the 

Rosier Area seriously and no corrective action has taken place to prevent rust from 

getting in or on the unit. And on this date 02/14/2014, Mr.

 requested to Mr. . follow up and 

take care of temporary fixes. Today 02/21/2014 at 0915 H PST I went to check if 

any temporary fixes had been instituted on rusty conditions. There was 

interventions to be observed and rust observed on the the unit. Mr.

 and Ms. shown the issues. 

Mr. and Mr. were verbally on the phone. This is a 

violation of the above 9 CFR's and is LINKED to NR 014/2014, Dated 02/14/2014, 

JDD2017023014N/1 and JDD1613020406N/1 dated 02/06/2014. 

(b) (6)
(B)(6) (B)(6) (B)(6)

(B)(7)(C)

(B)(6)

(B)(4)

(B)(4) (B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0719020 

921N-1 

02/21/2014 03J02 Slaughter HACCP O While performing Pre-Chill Finished Product Standards Task, I observed a 

noncompliance with the following regulatory requirements of regulations 9CFR 

381.65 (e) and 9CFR 417.2 (c)(4).At approximately 1245 hours, I randomly removed 

a 10 bird sample from Line 1 in Evisceration Area #1. I found one out of the 

birds with visible fecal contamination inside the bird at the right side under the leaf 

fat area. The fecal material was dark green in color, pasty in texture and measured 

approximately 1/4" diameter in size. This exceed the limit of Zero 

Tolerance for the process to be in control. I informed ,

 and of the noncompliance. Dr.

 verified the fecal finding. The protocol for fecal failure was 

implemented. Quality Control performed a recheck at approximately 1315 hours 

and it passed.This is a violation of the critical limits of CCP-2B Zero Contamination 

of the Plant's HACCP Plan for Slaughter. 

5308 M6137 BXL4409024 

620N-1 

02/20/2014 01C02 Operational SSOP 

Review and 

Observation 

C On 02/18/2014 at approximately 1328 hours, while performing direct observation 

of the Second Processing Rinse at lunch break at the Rehang 2 Area, I 

observed the following. The kick outs and sorting belts had been rinsed and an 

employee had starting applying sanitizer (Quat) to that area. I observed Quality 

Control check the concentration at approximately 1332 hours. The SSOP Plan 

states in part under procedure, that 

. The 

employee that was applying the sanitizer had already begun sanitizing the 

area when Quality Control measured the concentration of the I 

informed  of the 

noncompliance.My findings indicate a noncompliance with the following regulatory 

requirements of regulations 9CFR 416.13(b) and 9CFR 416.13(c).  

(b) (6)
(B)(6)

(B)(6) (B)(6) (B)(6) (B)(4) (B)(4)

(B)(4)

(B)(4) (B)(4) (B)(4) (B)(4)(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5519022 

020N-1 

02/20/2014 01C02 Operational SSOP 

Review and 

Observation 

O At approximately 1315 hours, while monitoring the mid-shift rinse procedure at the

 Room, I observed production employees were rinsing the area with potable 

water. At approximately 1350 hours while they were rinsing the floor they 

over sprayed two stacks of clean product brown tubs, the brown tubs were located 

next to the sink on the back of the cone lines. I immediately tag the tubs with U.S. 

Retained/Rejected Tag # B31 406455 and B31 406436 and informed 

and of the noncompliance.

 sent the tubs to the tub wash room, I then removed my tags.At 

approximately 1405 hours, I observed when Quality Control finished her checks in 

the Room and sanitation personnel were also finished with the rinsed and the 

application of the sanitizer . The belt that it is over the chute by the Cone Line

 was not rinsed and sanitized with ). The belt that transfers the halves to 

the cones (line 1 to line was not rinsed and sanitized with ( either. I 

informed of the noncompliance. The SSOP Plan states 

in part under procedure 

. At 

approximately 1420 hours the belts were rinsed and sanitized, then the Area 

was released.This is a noncompliance with the following regulatory requirements of 

regulations 9CFR 416.13 (b) and 9CFR 416.13 (c). 

(b) (6)
(B)(6)

(B)(6)

(B)(6) (B)(4)

(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5568 M20923 XUM561202 

5220N-1 

02/20/2014 01B02 Pre-Op SSOP 

Review and 

Observation 

C At approximately 0650 hours, while performing a routine PHIS task Pre-op review 

and observation inspection task (after establishment performed their 

pre-operational inspection and prior to start of production), I observed the 

following noncompliance: Line 1, Cook side of the establishment: I found piece of 

chicken stuck on blue incline belt from the previous day of production. Upon 

continuing my inspection Line , I observed lots of bulid up underneath frame and 

the pipes around the C-49 blue conveyor belt also from previous day of production. 

I took a regulatory control action and applied USDA retain/rejected tag# 

B24829882. I informed sanitation and 

and of the non-compliance. The finding described in the 

non-compliance was on the food contact surface and very close to the food contact 

areas, it is reasonable to conclude that when production began it would be under 

insanitary conditions. Immediate corrective action was performed by establishment 

on all affected areas upon notification of my finding. After sanitary conditions had 

been restored, I relinquished the regulatory control action at 0730 hours. Plant 

SSOP Section1, page1, states: " 

. 9CFR 416.13 (c) states: "All establishment shall monitor daily 

the implementation of the procedures in the sanitation SOP's". 9CFR 416.4 (a) 

states: "All food contact surfaces, including food-contact surfaces of utensils and 

equipment, must be cleaned and sanitized as frequently as necessary to prevent the 

creation of insanitary conditions and adulteration of product".9CFR 416.4 (b) 

states: "Non food-contact surfaces of facilities, equipment, and utensils used in the 

operation of establishment must be cleaned and sanitized as frequently as 

necessary to prevent the creation and the adulteration of product". This document 

serves as written notification that failure to meet these regulatory requirement(s) 

could result in additional regulatory or administrative action. 

(b) (6)
(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH390002 

0720N-1 

02/20/2014 01B02 Pre-Op SSOP 

Review and 

Observation 

C On the production shift that began on 02/19/2014, I performed pre-operational 

sanitation review and observation at Est. 33900  P.   This 

Pre-Op was performed in the further processing department of the Establishment, 

in room #2(on schematics for pre-op inspection).  This was after sanitation 

had completed cleaning the equipment and the establishment had completed 

pre-operational sanitation inspection of the equipment and released the area for 

USDA inspection.  There are no additional sanitation or inspection steps prior 

to the start of production.    This procedure was completed before 

product reached the areas inspected.      The following 

non-compliance was observed on the line 1 marination injector.  Fat and a 

brown protein residue was on the under side of the unit and on product contact 

portions of the stainless steel plate that houses the injector needles.  This 

residue ranged in size from 1/8 inch to 1/2 inch in size and numbered fourteen 

pieces on the under side of the plate.  A greasy yellow to brown residue was 

on the top of the UHMW and the bottom side of the stainless steel plate that holds 

the needles in place.  The line #2 injector was then broken down and the 

same conditions were observed in the same places of this injector.   The 

units were re-cleaned by Sanitation and re-sanitized.  I then re-inspected and 

released the units to Production.     The requirements of Regulations 

416.4(a) and 416.13(c) were not being met. 

(b) (6)
(B)(7)(C) (B)(6) (B)(6) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1326 

1 

M33901 HAY011802 

0620N-1 

02/20/2014 03G02 Fully Cooked-Not 

Shelf Stable HACCP 

C On the calendar date of February 20, 2014 at approximately 0114 hours while 

performing the review and observation component of the Fully Cooked -Not Shelf 

Stable HACCP task, the following noncompliance was observed: 

Cooling finished product to <31.3F is the critical limit prescribed at CCP 4 

-after the freezer & metal detector step- in the establishment's HACCP 

plan. I, CSI , measured the temperature of Orange 

Chicken at CCP 4 by inserting the probe of the thermometer (calibrated and 

provided by the establishment) inside 2 pieces of product. After equilibrating, the 

thermometer read: 34.4F. I proceeded to take additional temperatures from 

different pieces of product from the bag and obtained temperatures 

of 33.8F, and 34.7F, respectively.  At this time, I notified 

Lernetha  , QA Technician, of my results and requested that she also 

monitor the temperature of the product from a different bag. Ms.  

monitored the temperature of the product at CCP 4 (from a different bag) in my 

presence, and once the thermometer equilibrated, the results read 33.9F. I 

reviewed the CCP 4 HACCP Record and noted that the last acceptable temperature 

was recorded at 1212 hours. Production was stopped, and all product since the last 

acceptable check (8 combos and 4 pallets of packaged and labeled product) were 

retained with U.S. RETAINED tag # B40172385. , was 

notified of the noncompliance and informed that a noncompliance record would be 

issued. This noncompliance record will be discussed during the next weekly 

meeting. . 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6) (B)(6)(B)(6) (B)(6) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2505024 

119N-1 

02/19/2014 01C02 Operational SSOP 

Review and 

Observation 

O On 02/19/2014 at approximately 0100 hours while monitoring Post-Chill Finished 

Product Standards from product exiting Chiller #3, I observed the following. After 

taking a standard 10 bird random sample, I observed two birds with medium gray 

flakes of UFM(Unidentified Foreign Material) that appeared to be paint. I 

contacted . The birds were already being hung going to 

the Weight/Check line. One of the first birds dropped at the first collection tank on 

the Weight/Check line had a similar gray flake measuring approximately 1/8" by 

1/8"on the left side exterior of the carcass near the abdominal opening. A 

partial tank of the birds collecting at the Check/Weight location was retained under 

QC hold for reinspection. I contacted , 

showed him the flakes and informed him of the noncompliance.  The 

flakes on the carcasses measured approximately 1/8"by 1/8" located 

on the outside of the carcass on the left side near the abdominal opening, 

approximately 1/8" by 1/8" located on the inside on the left leaf fat, and 

approximately 1/4" by 3/8" on the exterior of the carcass in the 

depression left by the oil gland removal. The UFM crumbled 

easily upon contact. My findings indicated a noncompliance with 9 CFR 416.1 

and 9 CFR 416.4(d).     

5308 M6137 BXL4117022 

719N-1 

02/19/2014 03J02 Slaughter HACCP O While performing Pre-Chill Finished Product Standards Task, I observed a 

noncompliance with the following regulatory requirements of regulations 9CFR 

381.65 (e) and 9CFR 417.2 (c)(4).At approximately 1053 hours, I randomly removed 

a 10 bird sample from Line 1 in Evisceration Area #1, I found one out of the 

ten birds with visible fecal contamination inside the bird at the right side under the 

leaf fat area. The fecal material was dark green in color and pasty in texture, 

measured approximately 3/16" diameter in size. This exceed the limit of Zero 

Tolerance for the process to be in control. I informed ,

 and of the noncompliance. Dr. Reza 

Hejazi verified the fecal finding. The protocol for fecal failure was implemented. 

Quality Control performed a recheck at approximately 1116 hours and it 

passed.This is a violation of the critical limits of CCP-2B 

the Plant's HACCP Plan for Slaughter. 

5112 M18909 JDD0610021 

318N-1 

02/18/2014 01D01 SPS Verification C At 0125 H PST 02/18/2014 I observed a Female Employee unroll a Tank Liner (USED 

FOR PRODUCT SURFACES) from the Master Roll, and contaminate it upon the 

Evisceration Floor. She was not aware that her action contaminated the Liner. Mr.

 and was notified of 

the Situation and of the intent of documentation. This a violation of the above 9 

CFR's. This is linked to NR 010-2014, Dated 01/24/2014, JDD2010010724N/1 and 

JDD1208013317N/1 

(b) (6)
(B)(6)

(B)(6)

(B)(6) (B)(6)

(B)(6)

(B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD3010025 

118N-1 

02/18/2014 01B02 Pre-Op SSOP 

Review and 

Observation 

O At 2245 H PST, 02/17/2013 while performing PRE-OP on CHILLERS A&B the 

following was noted: 1) Ceiling has numerous nails in it that were painted over, 

nails rusted flaked off paint and now the rusty nails readily show up, also some 

rusty electrical conduit was observed. In Evisceration in general was observed 

Electrical Boxes that are extremely rusty. These issues showed to and or discussed 

with Mr. , 

and Ms. was advised and her 

paperwork updated with my information. This also violates 9 CFR:  This is 

also a violation of this 9 

CFR::§416.4   Sanitary Operations. (a) All food-contact 

surfaces, including food-contact surfaces of utensils and equipment, must be 

cleaned and sanitized as frequently as necessary to prevent the creation of 

insanitary conditions and the adulteration of product.The following noted as 

follows BONING ROOM:: 1) Over head rails for Carcass' by the Ice/Carcass Separator 

has black UFM on it; 2) On the back side of the Contherms, the lift controls are 

extremely rusty; 3) The chute at the end of the Breast Sorter Belt has a 

3 inch crack on the product side of the chute; 4) Black UFM on long belt feeding 

MDP; 5) Seven Stainless Steel vats observed with poultry residue in them; 6) 

Off conditioned wings in Cooler 5, had to tag the product; 7) Lines 1 

& 2 Tray Pack shrink tunnels had UFM; Tape used to hold cutting board 

material Line One; Cooler Ten had blue tub with UFM in it and white tub setting 

upon a box and a lable stuck in the interior of this edible use container; 8) On 

Saddle Machine 2 on hose observed with UFM on it; 9)Fiberglass repairs on wall by 

SHOVEL HANGERS is broke and peeling paint. This all showed to and concurred 

upon by Mr. and Mr. 

no of these items were in his paperwork prior to my 

notification of the same. This is a violation of the above 9CFR's and the 

Establishments written SSOP program. This is Linked to the following NR 017-2014, 

Dated 02/10/2014, JDD5623023310N/1 and associated numbers 

JDD1405025803N/1+5 

(b) (6)
(B)(4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0218022 

118N-1 

02/18/2014 03J02 Slaughter HACCP O The establishment’s Inside Outside Bird Wash program states, “ 

” However, on multiple occasions the 

establishment did not document some of the parameters. For example, on 

December 30, 2013 at 1259 hours, and December 26, 2013 at 1539 hours, the 

Timing, Alignment, and One-Leggers checks were not documented. On December 

12, 2013 at 1455 hours, and December 26, 2013 at 0835 hours, the sprayer, 

shower heads and pumps operating check was not documented. On December 24, 

2013, at 0430 hours, and December 29, 2013, at 2339 hours, no pressure was 

documented.  On December 13, 2013, at 0629 hours, the records show that 

for the PSI “Error – wrong entry” was documented, but no other entry was made 

with the correct PSI. The establishment is not implementing CP 4 – Inside Outside 

Bird Wash Monitoring program as written. This is a regulatory noncompliance 

under Title 9 CFR 417.5(a)(1). 

(b) (6)
(B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0218022 

118N-2 

02/18/2014 03J02 Slaughter HACCP O The establishment’s CP 5 – Chlorine, pH and Peracetic Acid Monitoring program 

states, “Peracetic Acid QA will collect samples at the frequency below when utilizing 

in the following applications:  Picker Rails Operating Limits 

ppm... b. Verification of Peracetic Acid Concentration  i. Giblet Chiller, Carcass 

Chiller, Paw Chiller 1.       Rinse vial three 

times with sample solution 2. Fill vial with 30 mL of sample water  3. Add 20 

drops of Sulfuric Acid 1:1 (water color should remain clear) 4. Add 3 drops of 

Ferroin Indicator (water color will turn pale orange)  5. Add 3 drops of 

Potassium Iodide (water color will turn orange/rust) 6. Add Sodium Thiosulfate 

0.1N, one drop at a time, counting the number of drops until water turns pale 

orange. 7. Calculate the ppm of Peracetic acid by multiplying the number of drops 

by 5... Reconditioning Hose – Carcass Re-Hang Post Chill (operating limits) 

ppm (pH limits) 5.5 – 6.5...iii. pH Measurement (prior to testing for chlorine) 1. 

Press the power button to turn on the meter. Meter screen should default to pH 

measurement mode, if not press mode (enter) to display pH for pH measurement 

mode. 2. Thoroughly rinse the electrode with distilled water and place in the 

sample. 3. The meter will default to AUTO mode. Press measure (esc) and wait until 

READY appears and the “pH” stops blinking. 4. Remove the electrode from the 

sample and rinse with distilled water. To read additional samples, repeat steps 

2.b-2.d. 5. When finished measuring, place electrode in storage solution...  c. 

Corrective Actions i. Immediately notify maintenance/production. ii. Perform a 

re-check once notified by maintenance that adjustment has been made. iii. If 

re-check concentration is not within operating limits, repeat step 2.c.i” 

 However, during the on-site visit, the EIAO observed that the Picker Rails 

were below ppm of and no corrective actions were taken. According to 

management, the limits had been lowered to ppm but the program did not 

reflect this. In addition, the EIAO observed that Stannous sulfate was added to the 

Giblet Chiller, the Carcass Chiller, and the Paw Chiller. The procedure does not 

indicate that Stannous sulfate is to be added to the titration. The EIAO observed 

that during the titrations the vials were not rinsed with the sample three times and 

that the pH probe was not rinsed with distilled water in-between samples, as 

indicated in the written program. On January 28, 2013, the EIAO observed that at 

1229 hours, the concentration of the reconditioning sample was ppm and the 

pH was 6.0. At 1301 hours, a recheck sample was collected and the concentration 

was ppm, the EIAO asked the employee if she would take the pH of the sample. 

The pH of the recheck was 8.67. On February 3, 2014, the EIAO reviewed the CP 5 

records and noted that the pH of 8.67 was not documented and no recheck was 

collected. The pH was within acceptable range at the next routine check conducted 

at 1421 with a pH of 5.6 and a chlorine concentration of 27. The establishment 

cannot support that the Chlorine, pH and Peracetic Acid Monitoring program is 

(b) (6)
(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

being implemented as written. This is a regulatory noncompliance under 9 CFR 

417.5(a)(1). 

(b) (6)
(B)(6) (B)(6) (B)(6)

(B)(6)

(B)(4) (B)(4) (B)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1214023 

318N-1 

02/18/2014 04A06 Poultry Finished 

Product Standards 

C On 02/18/2014 at approximately 1046 hours while performing a Pre-Chill Finished 

Product Standards Task in the Evisceration Area on Line , I observed the 

following. After taking a standard random 10 bird sample, I accumulated 35 

noncomformance points. I informed and Quality Control 

performed a recheck. At approximately 1051 hours, the recheck failed with 36 

noncomformance points. At this point the process is judged to be out of control. I 

informed of the noncompliance. Quality Control performed a 

Post-Chill check at approximately 1102 and passed. At approximately 1108 hours, 

Quality Control performed a Pre-Chill check and passed, bringing the process back 

in control. Quality Control performed Post-Chill checks approximately every 30 

minutes until the product under process control arrived.My findings indicate a 

noncompliance with 9CFR 381.76(b). 

5308 M6137 BXL1518024 

718N-1 

02/18/2014 03C02 Raw Intact HACCP O The establishment’s records indicate that on multiple occasions the establishment 

is not collecting samples as indicated in the program. For example on December 6, 

2013, December 18, 2013,  no breast samples were collected during the AM 

shift. On December 23 and  27, 2013, and January 6 and 25, 2013, no breast 

samples were collected during the PM shift. In addition, on December 4, 2013, and 

January 4, 2014, the establishment collected two breast samples instead of an extra 

leg sample as indicated in the program. The establishment is not implementing 

their program as written. These are regulatory noncompliances under Title 9 CFR 

417.4(a)(1) and 417.5(a)(2). 

5308 M6137 BXL2707023 

118N-1 

02/18/2014 01C02 Operational SSOP 

Review and 

Observation 

O On 02/18/2014 at approximately 0315 hours while monitoring Operational 

Sanitation in Plant 2,I observed the following. ABF (Anti-Biotic Free) birds 

were entering Chiller #4 after being treated with Cetylpyridinium Chloride, 

' antimicrobial.  The antimicrobial treatment is rinsed off in the 

chiller adding an unknown amount of to the chiller water. 

  Packaging was still packing 'Organics' from before lunch and birds 

were still exiting Chiller 4. 'Organics were being exposed to the Cetylpyridinium 

Chloride which is not an authorized antimicrobial for product 

labeled 'Organic'. I contacted and stated 

that  'Organics' were still being processed. I informed him of the ' 

treated birds entering Chiller #4. The birds on the rehang belt and birds 

exiting chiller #4 until approximately 0326 hours were down 

graded from 'Organics' to ABF by production.  I informed 

of the noncompliance. My findings indicated a noncompliance with 9 CFR 

416.4(d).      

(b) (6)
(B)(6) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3908025 

618N-1 

02/18/2014 01C02 Operational SSOP 

Review and 

Observation 

O At approximately 0040 hours while monitoring Pre-Chill Finished Products 

Standards in Plant #1 on Line #1, I observed the following 

noncompliance.  After taking a random 10 bird sample, when I opened up 

the neck area to inspect it I observed a shiny piece of metal approximately 5mm x 

1mm on the fat on the left side of the neck area under the skin.  I informed

 of the noncompliance.  According to PDD, FSIS 

considers metal of any size on a carcass to be an unacceptable contaminant that 

should be addressed by the Establishments' Hazard Analysis.  The issue of 

metal contamination has been discussed at previous weekly meetings with the 

Establishment.  My findings indicate a noncompliance with 9 CFR 416.1 and 

9 CFR 416.4(d). 

1325 

7 

P33900 NHH350202 

1018N-1 

02/18/2014 01D01 SPS Verification C On the night of production which began on 02/17/2014 in est. 33900 P, Inspection 

found the Main Hallway between the QA/HACCP Office and the Drydock in an 

unsanitary condition. A dried patch of dirty water at least 6 feet in length and 1 foot 

in width was present and Power Jacks which are used in the Further Processing 

Department to move Raw Edible Product were being driven through it and into the 

Further Processing Area where Floor Salvage is conducted. Inspection took 

Regulatory Control Action by taping off the Area and placing Us Reject Tags 

#B38075672 at 0039 Hours and #B38075667 at 0041 respectively. Sanitary 

conditions were restored to the Hallway at 0122 Hours at which the two tags were 

removed. The requirements of 9CFR 416.1, 416.2(b)(1) and 416.2(b)(2) were not 

being met and Night-shift Plant Superintendant Mr was advised that a 

Non-compliance record would be generated. Refer to NR 

#NHH0503105231N/1 dated 10/30/2013 for a similar noncompliance. 

(b) (6)
(B)(6)

(B)(6)

(B)(6)

(B)(6)

(B)(4) (B)(4) (B)(4)

(B)(4)

(b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1326 

1 

M33901 HAY040802 

3718N-1 

02/18/2014 01B02 Pre-Op SSOP 

Review and 

Observation 

C On calendar date February 18, 2014 (Tuesday) at approximately 0655 hours while 

performing Pre-Op SSOP Review and Observation task in the IF Department (zone 

10), the following noncompliance was observed: I, , observed a 

brown, dusty residue all along the top surface of 2 two overhead Verifeeder pipes. 

These pipes are insulated with a white covering and are used to pump cold water to 

the Tanks on Line These pipes are approximately 35’ in length. I also 

observed that the overhead ammonia pipes had a similar brown, dusty residue 

present on the top surfaces. I showed Mr. 

) and Ms. of the conditions and informed them that there 

was Sanitation Performance Standards noncompliance. The establishment’s SSOP, 

states that 

” According to the S3 Sanitation Cleaning 

company schedule, the overhead equipment will be cleaned on a weekly basis. The 

establishment failed to meet the requirements for 9CFR 416.4(b) and 416.1. 

5308 M6137 BXL1116023 

715N-1 

02/15/2014 04A06 Poultry Finished 

Product Standards 

O At approximately 1301 hours, I randomly removed a 10 bird sample from Line A in 

Evisceration Area #2 for Pre-Chill Finished Product Standard Check, I documented 

39 points in the Processing Nonconformances from the 10 bird sample. This exceed 

the subgroup absolute limit of points for the Processing Nonconformances to be 

in control. I informed Quality Control of the failure and at approximately 1310 

hours she performed a recheck. Quality Control documented 27 points on the 

Processing Nonconformances, this exceed the limit of the points allowed for the 

recheck, at this point the process is considered out of control. I informed 

of the noncompliance. Corrective actions were implemented. 

Quality Control performed rechecks at Pre-Chill and Post-Chill. At 

approximately 1505 hours the process was back in control.This is a 

noncompliance with the following regulatory requirements of regulation 9CFR 

381.76 (b). 

(b) (6)
(B)(6)

(B)(6) (B)(6) (B)(6)

(B)(6)

(B)(6) (B)(6) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD2017023 

014N-1 

02/14/2014 01D03 Poultry Sanitary 

Dressing 

C     On 02/14/2014 I observed the following 

non-compliance's to 9 CFR 416.1, 9CFR 416.2(b)(2) and 9CFR 416.2(d). At 

approximately 0950 hours while passing through the hallway between the old 

Loading dock and Bagging Area I observed heavy beaded condensation on the drip 

pan above hallway in the Rosier Room. I immediately  informed 

of my observation and non-compliance. Ms took 

immediate corrective action by having the condensation wiped off to restore 

sanitary conditions. No product was involved.At approximately 1312 hours 

while performing my inspection duties in the Boning Room I observed 

condensation dripping from between the ceiling panels next to the exhaust vent, I 

immediately took regulatory control action by applying U.S. Reject tag # B39554636 

to the area underneath the drip and informing of the drip 

and non-compliance and that the area underneath had been tagged and 

rejected. Regulatory control was relinquished at approximately 1410 hours after 

sanitary conditions were restored. No product was involved. This NR is being linked 

to NR # JDD1613020406N dated 02/06/2014 

5308 M6137 BXL0504024 

715N-1 

02/14/2014 01C02 Operational SSOP 

Review and 

Observation 

O At approximately 1737 to 1855 hours on February 14, 2014, while monitoring the 

establishment’s Operational sanitation Standards in the Packaging, Room, 

and Rehang areas, I observed the following deficiencies: 

a)      Plant 1 Rehang Conveyor Areas:  

Personnel still hanging product coming directly out of Chiller # 1 & 2 at 1735 

hours. I observed Sanitation Personnel spraying down the Chillers while product 

was still in the chilling processing mode and be directly dumped onto the Rehang 

Conveyors to be sorted and re-hung for the further processing and packaging 

process.  Retain Tag # B 31407539 issued to affected one bin of product. 

 All above discrepancies were creating a food safety noncompliance. I 

informed , 

, of the noncompliance. Corrective actions 

were implemented immediately.  Sanitation personnel  was stopped 

from further cross contaminating remaining product and from raising temperature 

levels of the water that is chilling the product in Chiller # 1. Rehang Conveyors and 

Rehang Production was ceased for the day and product was condenmed by 1811 

hours per . My findings indicate a non compliance 

with the regulatory regulations CFR 416.1 and 416.4(d).     

(b) (6)
(B)(6)

(B)(6)

(B)(6) (B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5806023 

815N-1 

02/14/2014 01C02 Operational SSOP 

Review and 

Observation 

O At approximately 1805 to 1855 hours on February 14, 2014, while 

monitoring the establishment’s Operational Sanitation Standards in the Packaging, 

Room, and Rehang areas, I observed the following deficiencies: 

     Room & Packaging Department Areas 

:  a)     Establishment’s employee hygiene 

cleanliness issues with correct method of sanitizing personal equipment (gloves, 

aprons, boots) and direct handling of unsanitized contaminated areas prior to direct 

product contact. Establisments personnel are cleaning their personal equipment 

(boots, aprons, gloves) from dirty to clean (boots to apron and gloves)without 

resanitizing their gloves prior to going back to their production duty lines and 

handling product. b)      Personnel 

are also handling unsanitized areas(wheeled dollies which hold stacked racks of 

product) (the actual wheel portion which is in direct contact with the filth of 

contaminated areas of the establishment) with their green gloves and not 

resanitizing their gloves prior to handling unsealed bulk product.Direct cross 

contamination issues creating a faliure of preventing adulterated product being 

processed. All above discrepancies were creating adultered food safety 

noncompliance. I informed ; 

; and  of the 

noncompliance. Corrective actions were implemented 

immediately.  All personnal involved was stopped from working with 

product; resanitized their equipment; and product involved was condemned per 

establishment. All affected areas were restored to correct sanitary conditions by 

1855 hours. My findings indicate a non compliance with the regulatory regulations 

9 CFR 416.1; 416.13(c);416.4(d); and 416.5(a). 

(b) (6)
(B)(7)(C)(B)(6)

(B)(6)

(B)(6) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

6036 P6164A OIJ3517025 

714N-1 

02/14/2014 04A06 Poultry Finished 

Product Standards 

O On February 14, 2014 I, CSI performed a scheduled Finished 

Product Standard test at the Prechill area.  This test is applied to permit FSIS 

to estimate when the production process is in control for ready-to-cook 

poultry.  The test consists of two parts, trim and processing 

nonconformances.  The absolute limit allowed for trim nonconformances is

 points. My test at 1444 resulted in 27 points.   At approximately 

1504 a retest was performed by using a tighten criteria 

of 12 points which failed with 17 points.  I verbally notified 

of the noncompliance and that I would be issuing a NR.  The 

plant implemented the required procedures for FPS failure.  Two passing 

Prechill tests were achieved at 1531.  No failing tests at Postchill are 

documented. The Prechill nonconformances I observed at 1444 were: 

  3 bruises > 1” (6 pts), 8 scabs/IP < 1/2” (16 pts), and 1 IP > 

1/2” (5 pts). On January 17, 2014, NR # OIJ4601011718N (#2) was issued for 

processing noncompliance which is the second part of FPS Prechill 

requirements.  The written response given that Maintenance made 

adjustments to bring the process under control was not effective to prevent 

recurrence of Prechill FPS noncompliance.   This noncompliance is 

linked to NR # OIJ4601011718N (#2) for the same root cause of Prechill FPS 

noncompliance.  The Establishment Awareness Meeting notes show that FPS 

NRs were last discussed at the January 23, 2014 meeting. 

5308 M6137 BXL0816025 02/13/2014 01C02 Operational SSOP O On February 6th 

913N-1 Review and 

Observation 

5308 M6137 BXL3222022 

413N-1 

02/13/2014 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 02/12/2014 at approximately 2200 hours while monitoring the establishments' 

Pre-Operational Sanitation procedures in Plant #2, I observed the following. There 

was heavy beaded condensation above Chiller #3 middle section near the 

giblet chillers. The condensation was on the PVC, metal and 

vinyl covered pipes, and concrete ceiling surfaces directly above the 

chiller. The ceiling and piping are treated as non-product contact surfaces. I 

informed of the noncompliance. I moved to the center walkway 

between the chillers to monitor the drying of the affected surfaces and observed 

the same beaded condensation condition on the pipes and ceiling 

surfaces over large areas above both Chillers 3 & 4.  

The condensation was removed restoring sanitary conditions by approximately 

2210 hours. My findings indicated a noncompliance with 9 CFR 416.1, 416.2(d), 9 

CFR 416.4(d), 9 CFR 416.13(c) and 9 CFR 416.14.   

(b) (6)
(B)(6) (B)(6)

(B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5568 M20923 XUM412202 

4713N-1 

02/13/2014 01D01 SPS Verification C On 02/13/2014, at approximately 2000 hours, while performing a directed 

Sanitation Performance Standards (SPS) inspection task in response to a deficiency 

on the Cook Area Line Oven Room, I observed the following noncompliance: 

beaded and dripping condensation coming from a hanging gray electrical 

wire and electrical box to a panel cover sensor above the belt wash to the 

oven creating insanitary conditions, a noncompliance per 9 CFR 416.1 and 416.2(d). 

The condensation was dripping in close proximity to the oven belt. Also, the screw 

brackets to the electrical box were pitted and worn. I took regulatory control by 

rejecting the area with US Tag # 24829911. I showed and informed Mr. 

of the forthcoming noncompliance. Corrective actions 

were immediate performed by production restoring sanitary conditions, I 

relinquished the US Tag at 2010 hours. The requirements of Title 9 CFR 416.1 and 

416.2(d) were not met. 

5308 M6137 BXL2814025 

712N-1 

02/12/2014 03J02 Slaughter HACCP O On 02/12/2013, at approximately 0840 hours, I observed how the Establishment's 

employee performed the Salvage Parts Treatment Procedure on the evisceration 

parts in Plant #2. The procedure was acceptable. At approximately 0844 

hours, I observed Quality Control performed CCP-1B ). At 

approximately 0930 hours, I went  to reviewed the records  for

 Monitoring Log Plant #2" for Evis Parts. I noticed that the concentration 

was ppm) at 0812 hours, ppm) at 0843 hours and at 0904 hours the recheck 

passed with ppm). On the Product Hold and Release Form it was written Hold 

Tag # 58393, hoses retained released when in compliance. The hose of was 

retained at 0817 hours and released at 0904 hours. The Salvage Parts 

procedure was performed with concentration of ppm of HACCP Plan 

-Slaughter Plant 2- under step #36 states in part: Parts Salvage (B) Pathogens, i,e. 

Salmonella. Is the Hazard significant? No. Justification for decision

 Supplements 2,7,17,18,56. HACCP 

Supplement #56, Salvage Parts Treatment: CP-19 under procedure #2 states in part 

". " 

water ( ) ppm and concentration ( ) ppm".

 was informed of the noncompliance. 

(b) (6)
(B)(6)

(B)(6) (B)(6)

(B)(7)(C) (B)(4) (B)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1013023 

711N-1 

02/11/2014 03J02 Slaughter HACCP O While performing Pre-Chill Finished Product Standards Task, I observed a 

noncompliance with the following regulatory requirements of regulation 9CFR 

381.65 (e) and 9CFR 417.2 (c)(4).At approximately 0852 hours, I randomly removed 

a 10 bird sample from Evisceration Area #2, Line , I found one out of the ten 

birds with visible fecal contamination inside of the bird between the tail and 

the kidneys, the bird had side cut tail. The Establishment marking system 

used the side cut tail to identify possible fecal contamination from the The 

fecal material was dark green in color and pasty in texture measured approximately 

1/4" long by 3/8" wide in size. This exceed the limit of Zero Tolerance for the 

Process to be in control. I informed of the 

noncompliance. The protocol for fecal failure was implemented. Quality Control 

performed a recheck at approximately 0920 hours and it passed.This is a violation 

of the critical limits of CCP-2B of the Plant's HACCP Plan 

for Slaughter. 

5309 P6137A NJN101802 

3811N-1 

02/11/2014 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 1422 hours, while performing PHIS finished product standards 

task in the evisceration department on the reprocessing off-line, prior to the birds 

entering the chiller, I observed one carcass, out of the ten (10) carcasses random 

sample, contaminated with visible fecal material. The fecal material was 

approximately half inch long and quarter of inch wide, brown in color, pasty 

in consistency, and located on a broken back bone close to the tail of the carcass. I 

took regulatory control action by stopping the reprocessing line and applied a US 

retain tag, # B43303968, on the affected carcass. The finding was shown to Mr. 

, and 

.  SPHV, Dr. , confirmed that my finding was indeed fecal 

material. The reprocessing line and the affected carcasses were released to the 

establishment, allowing QC representative to perform a re-check and the 

plant procedures for fecal failure. The findings of fecal material on a carcass 

passed the final wash cabinet en-route to the chilling system represents a zero 

tolerance failure, as outlined in the establishment’s HACCP and in accordance with 

the regulations 9 CFR 381.65(e) which states: "poultry carcasses contaminated with 

visible fecal material shall be prevented from entering the chilling tank." 9 CFR 

417.2(c) (4) states: "List the procedures, and the frequency with which those 

procedures will be performed, that will be used to monitor each of the critical 

control points to ensure compliance with the critical limits."A PHIS slaughter HACCP 

task was performed to verify that all corrective and preventative measures were 

completed.The plant took action to control CCP1B and turned up the chiller 

overflow to 1/4 of gallon per bird, marked the chiller to identify the end of the 

affected lot, and post chill checks were performed until the mark came out of the 

chiller.  

(b) (6)
(B)(6)(B)(6)

(B)(6) (B)(6) (B)(6) (B)(6) (B)(6)

(B)(6)

(B)(6) (B)(4) (B)(4) (B)(4) (B)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN481102 

2812N-1 

02/11/2014 04A06 Poultry Finished 

Product Standards 

C While performing a finished product standards check on the reprocessing line, at 

approximately 1422 hours, prior to the birds entering the chiller, I 

observed the following noncompliance. In a sample of ten carcasses, 

there were five carcasses with split tail, which identifies that vacuuming is 

required to remove all affected tissues including the kidneys. One carcass had 

yellow gelatinous tissue on one side of the rib cage and a bruised wing, and another 

carcass had large amounts of yellow flacks and gelatinous tissue on the flap area as 

well as a bruised mutilated thigh. In addition, I found two other carcasses with 

cellulitis on the breast muscle and the stomach still inside the carcasses. Another 

three carcasses had partial crops; one of them had injesta on the crop area and the 

stomach inside the carcass. I immediately took regulatory control action by 

stopping the re-processing line and showed Mr. 

, my findings and informed him of the 

forthcoming noncompliance. The presence of all these deviations and affected 

tissues in ten carcasses indicates that the re-processing line was not under 

control. The plant failed to effectively apply their procedures and comply with the 

federal regulations 9 CFR 381.84, 381.86, 381.89. 

5112 M18909 JDD5623023 

310N-1 

02/10/2014 01B02 Pre-Op SSOP 

Review and 

Observation 

O On 02/10/2014 in Evisceration I observed the Gizzard Defatter Machine, interior 

product contact area to have a three inch crack. Mr.

 and Mr. , in charge of setting up the 

Machine. Was to be welded prior to start up. Picking room had numerous feathers 

on overheads. Ms. . was also advised of the issues. In room 

the floor is breaking up. Ms. and Mr. was 

advised This is a violation of the above CFR's and the Establishment's written 

program. This is linked to  012-2014, Dated 02/03/2014, 

JDD1405025803N/1 and Five other associated JDD Numbers. 

5308 M6137 BXL1618025 

410N-1 

02/10/2014 01D01 SPS Verification O While walking through Plant #2 between evisceration lines at approximately 1500 

hours, I observed numerous beads of condensation formed on the ceiling 

above the automatic drawers machines for Line and Line . The condensation 

also was along the ceiling from the entrance of the condemned room 

through station #10, Line . I informed and 

of the noncompliance. immediately started 

wiping down the condensation. I walked through the body opener area and 

observed more condensation above the back up body opener Area for the

 lines and the drip pan, also in the paw room was condensation on the ceiling. 

Establishment personnel wiped down the condensation. This is a 

noncompliance with the following regulatory requirements of regulations 9CFR 

416.1 and 9CFR 416.2 (d). 

(b) (6)
(B)(6)

(B)(6)

(B)(6) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3320020 

610N-1 

02/10/2014 03J04 Poultry Zero 

Tolerance 

Verification 

O On 02/10/2014 at approximately 1040 hours, while performing a Zero Tolerance 

Task on Line #1 in Evisceration, I observed the following. After talking a random 10 

bird sample, I found 2 birds with visible fecal cotamination. The fecal on the first 

bird was located inside on the left under the leaf fat. The fecal material measured 

approximately 3/16" in size, olive green in color and slightly watery in texture. The 

fecal on the second bird was located inside on the right under the leaf fat. The fecal 

material measured approximately 5/16" in size, olive green in color and pasty in 

texture. This exceeds the limit of Zero Tolerance for the process to be in control. I 

informed after I had found the first bird with fecal, of 

the noncompliance and the protocol for fecal failure was implemented. Quality 

Control performed the recheck at approximately 1055 hours and passed, bringing 

the process back into control. Quality Control performed post chill checks on the 

suspect lot, and all checks passed.My findings indicate a noncompliance with 9CFR 

381.65(e) and 9CFR 417.(c)(4). 

5308 M6137 BXL4520020 

610N-1 

02/10/2014 01C02 Operational SSOP 

Review and 

Observation 

O On 02/10/2014 at approximately 1315 hours, Line #1 in Plant 1 was stopped and 

there were no birds on the line. Maintenance was working on the plastic that was 

covering the leaks in the ceiling observed by plant personnel. I was 

informed by one of the USDA Inspectors that there was water dripping from the 

ceiling in another location. I shone my flashlight at the ceiling located towards the 

front and to the right side of  the Inspectors Station #3. I observed the 

droplets of water that was falling from the ceiling and I informed 

. Another USDA Inspector that was on Station #4, informed me that 

drops of water were falling on her at the Inspectors Station. I again shone my 

flashlight up at the ceiling and I observed that water was dripping from 2 bolts that 

were in the ceiling to the right side and towards the front of the station. I informed

 and I placed a U.S. Rejected/Retained tag #B31406631 on 

Line #1. I informed of the 

noncompliance. Maintenance placed plastic under the leaks and the line was 

washed restoring sanitary conditions. I removed the tag and released the line at 

approximately 1341 hours.The previous corrective actions were insufficient to 

prevent the reoccurrence. My findings indicate a noncompliance with 9CFR 416.1, 

9CFR 416.13(c), 9CFR 416.2(b)(1), 9CFR 416.2(b)(2), 9CFR 416.4(a), and 9CFR 

416.4(d). 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6) (B)(7)(C) (B)(6) (B)(6) (B)(6) (B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4919021 

410N-1 

02/10/2014 01B02 Pre-Op SSOP 

Review and 

Observation 

O On 02/10/2014 at approximately 0740 hours while monitoring Pre-Operational 

Sanitation Procedures in Plant 1, I observed the following. On the Inspectors 

station #2, I shone my flashlight up at the ceiling and saw beaded water on a 

seam running along the ceiling. I informed and an 

employee came with a sponge mop and wiped the water off the ceiling. Upon 

further inspection I saw that there was more water, along the same seam on 

the ceiling in the middle of Line 1 and Line 2 that was dripping directly above the 

product area. While maintenance was taking corrective action by putting up 

plastic under the leaks in the ceiling, I continued with the pre-op in the evisceration 

department. At Chiller #2 I observed beaded condensation on a pipe 

directly over the chiller at approximately the middle section. I informed the 

, and a sanitation employee wiped off the 

pipe. I informed of the 

noncompliance. I tagged both Line 1 and Line 2 with U.S. Rejected/Retained tags 

#B31406636 and #31406641. After maintenance had finished putting up plastic 

and after the lines were washed restoring sanitary conditions, SCSI 

removed the tags and released the area at approximately 0910 hours.At 

approximately 0900 hours while performing Pre-Operational Sanitation Procedures 

in Packaging, I observed the following. A drip pan directly over Line was covered 

with heavy beaded condensation. I informed , and 

a sanitation employee wiped off the drip pan.  I continued to Line and I 

observed a drip pan directly over the line was also covered with heavy 

condensation. As I observed the employee wiping off the drip pan, drops of 

condensation fell onto the product belt. I informed and the 

belt was washed and sanitized restoring sanitary conditions.I informed

 and of the noncompliance.The 

previous corrective actions were insufficient to prevent the reoccurrence. My 

findings indicate a noncompliance with 9CFR 416.1, 9CFR 416.13(c), 9CFR 

416.2(b)(1), 9CFR 416.2(b)(2), 9CFR 416.4(a), and 9CFR 416.4(b) 

(b) (6)
(B)(7)(C)

(B)(6)

(B)(6) (B)(6)

(B)(6)

(B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4)

(B)(4)

(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN272102 

5110N-1 

02/10/2014 01C02 Operational SSOP 

Review and 

Observation 

C On February 10, 2014 while walking through the Packaging department I, CSI 

observed the following noncompliance.  The drip pan directly above the 

 product exit rollers was overflowing due to a clogged 

drain.  The water was falling from the drip pan at a rapid and steady rate. The

 releases front halves of chickens by weight into a brown tub 

and an employee puts a clean lid on the tub as it exits the machine.  I 

observed one tub with front halves in it exit the and water from 

the drip pan fell on to the product inside the brown tub.  At 

approximately 1841 hours I took a regulatory action by tagging the 

affected product in the tub and informed 

 of the 

forthcoming noncompliance.  stopped production and 

restored sanitary conditions by unclogging the drip pan and removing all 

water from the overhead drip pan, as well as sanitizing the exit 

rollers.  The affected product was reworked by the establishment and 

reinspect and released at approximately 1910 hours.These findings represent 

a noncompliance with the regulatory requirement of 9CFR 416.4(d) which 

states: Product must be protected from adulteration during processing, handling, 

storage, loading, and unloading at and during transportation from 

official establishments.        

5308 M6137 BXL0210023 

507N-1 

02/07/2014 03J02 Slaughter HACCP C On 02/05/2014 at approximately 0946 hours while observing Quality Control 

performing a CP-1 Vent and Body Opening check in Plant 2, I observed the 

following. Line check was performed and documented, Line was 

documented as "No Product Available" even though there were birds on the line 

and the line was running, and Line check was performed and 

documented. This is a noncompliance with not verifing the operation of the 

and body opener on each line. The establishments' HACCP Plan-Slaughter Plant 2-

Vent/Body Opener Step 12, under Potential Hazards Introduced, Controlled, or 

Reduced at this step, Is the hazard significant? No. Under 'Justification for Decision' 

it states in part, " 

". This is a 

noncompliance with 9CFR 417.5(a)(1). I informed 

of the noncompliance. 

(b) (6)
(B)(6) (B)(6) (B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0610025 

407N-1 

02/07/2014 01D01 SPS Verification O While going to performed Post-Chill Finished Product Standards Task, at 

approximately 0948 hours, I observed numerous beads of condensation formed on 

the ceiling above the dumper for Chiller #1, cabinet, the drip pan for the

 cabinet and the water rinse cabinet. These last areas are product 

contact surfaces, the dumper in front of Chiller #1 transfers the birds 

from stainless steel tanks to the rehang conveyors belts. I immediately informed

 of the noncompliance. He took immediate corrective 

action by wiping down the condensation.This is a noncompliance with the 

following regulatory requirements of regulations 9CFR 416.1 and 9CFR 416.2(d). 

5308 M6137 BXL5102025 

407N-1 

02/07/2014 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 02/06/2014 at approximately 2222 hours while monitoring Pre-Operational 

Sanitation procedures in Plant 1, I observed the following. There was a heavy 

layer of brown rust on the top chain driven sprocket for the Oil 

Gland Cutter for line 1. The rust coating had migrated down the shaft 

from the upper sprocket and was pooling on the lower sprocket that 

does the oil gland removal.  Mechanics were called and the upper 

rusted chain was replaced on both lines with a stainless steel 

chain. After grinding and buffing was 

completed  was called to remove the 

numerous specks and metal shards to approximately 1" left on the oil gland 

cutter, PMT machine and rehang belts. The items were rewashed restoring sanitary 

conditions by approximately 0115 hours.  At approximately 2228 hours 

there was heavy beaded condensation on the ceiling above the Heart and Lung 

Remover on line 2. The condensation covered the ceiling from the wall on the 

 line 2 side near station 8 to inspection station #4 on line 1, and 

from inspection station 8 to the line 2 Cropper. The 

condensation that was mopped with sponge mops and blown down with air. 

The use of air on the ceiling caused the entire area to be contaminated 

with specks and pieces of black and brown UFM (Unidentified Foreign 

Material) to approximately 1/2". Stations 4 & 8, Line 2 Liver 

Harvesting and the Giblet sorting belt were all rewashed to restore sanitary 

conditions by approximately 2300 hours. My findings indicated a noncompliance 

with 9 CFR 416.1, 9 CFR 416.2(b)(1),  9 CFR 416.4(a) & (b) and 9 CFR 

416.13(c).  

(b) (6)
(B)(6)

(B)(6)

(B)(6) (B)(6) (B)(6)

(B)(4)

(B)(4) (B)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5404021 

607N-1 

02/07/2014 01B02 Pre-Op SSOP 

Review and 

Observation 

O At approximately 2414 hours on February 7, 2014, while monitoring the 

establishments Pre-Operational Sanitation Standards in the Packaging Department 

area, the Room, I observed the following deficiency: 

a)       Wishbone Conveyor  - grey 

and white support bars (entire length) – greyish to black coloring from mold growth 

on excessive yellowish product and thick slimy, textured fat buildup left under rim 

of support and on the guide bars.  Black pipe running parallel to the conveyor 

had a buildup of sticky yellowish fat/residue full  length of pipe 

area.   b)        Back 

Conveyor – stainless steel bar and white guide bar – full length of 

conveyor – excessive buildup of yellowish product and thickish slimy textured fat 

left under rims, guide bars, and the conveyor belting.    

 All above discrepancies were creating food safety noncompliances.  I 

informed ;   

;  and of the non compliances. Areas 

recleaned, sanitatized and released at 2435 hours.  My findings indicate a 

non compliance with the regulatory regulations  9 CFR 416.1, 9 CFR 416. 

13(a), 9 CFR 416.4(a) and (b). 

5568 M20923 XUM001402 

5707N-1 

02/07/2014 03G02 Fully Cooked-Not 

Shelf Stable HACCP 

C At approximately 1125 hours while performing HACCP task (the record review 

component of procedure for fully cooked-not shelf stable process), I observed the 

following noncompliance: While review the records in the QC office dated 2/6/14 

Line 1 CCP-2B product Grilled chicken strips the check made at 21:57 

temperature # 5 recorded . Establishment HACCP Plan statesRecords were reviewed on 2/7/14 at 

7:29 am by . There was no corrective action and deviation 

documented at temperature deficiency. I notified the 

about the non-compliance. This does not meet the requirement of 9 CFR 417.5(a)(3) 

which states: "The establishment shall maintain: Records documenting the 

monitoring of CCPs and their critical limits, including the recording of the actual 

times, temperature, or other quantifiable values, as prescribed in the 

establishment’s HACCP plan; the calibration of process-monitoring instruments; 

corrective actions, including all actions taken in response to a deviation; verification 

procedure and results; product code(s), product name or identity. Each of these 

records shall include the date the record was made". This document serves as 

written notification that failure to meet these regulatory requirement(s) could 

result in additional regulatory or administrative action. 

(b) (6)
(B)(6) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

4630 M7322 AOA462102 

1206N-1 

02/06/2014 01C02 Operational SSOP 

Review and 

Observation 

C At 2120 hours regulatory control action was taken when the following non 

compliances were observed as while performing an observation and review of the 

establishments operational sanitation and santiary performance standards within 

the packaging department of Foster Farms in 

Demopolis Alabama. I observed water dripping from the end of 

a valve on a 3/4 inch water pipe along north east wall of the department, as the 

dripping was splatter off a concrete side extension of the wall and in the same 

vacinity next to employees packaging corn dogs along the conveyor line. No product 

was affected yet an insanitary condition was more than likely than not at all.Upon 

further observation I observed product boxes, plastic, gloves, 

wood sticks (used for the corn dogs), standing water, water in pans over flowing 

with grease and or oil on the department floor. In addition, product 

over flow on the conveyor belt had corn dogs flowing onto the catch pans when 

packaging was backing up. Plant employees immediately removed in excess of 50 

pounds of corn dogs to be discarded.Multiple trash recepticles and trash gondolas 

were over flowing.After corrective actions were taken and all sanitary requirements 

were met, the area was released officially back to the establishment for control of 

operations   

5112 M18909 JDD1613020 

406N-1 

02/06/2014 01D01 SPS Verification C On 02/06/14 at approximately 0940 hours  while performing my 

presentation check in evisceration I observed the following noncompliance to 9 CFR 

416.1 and 9 CFR 417.2(d). I observed heavy beaded condensation on the main 

overhead water pipe crossing over Line 1 and Line 2 evisceration lines. 

I immediately informed of my observation and 

noncompliance. Mr. immediately took corrective action by having the 

condensation wiped off to restore sanitary conditions. No product was involved. 

(b) (6)
(B)(6)

(B)(6)

(B)(6)

(B)(6) (B)(6) (B)(6) (B)(6) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5310 M6137B FFA2816024 

910N-1 

02/06/2014 03G02 Fully Cooked-Not 

Shelf Stable HACCP 

C During a routine patrol of the Cook Pack Department, I observed noncompliance 

with HACCP regulatory requirements 417.2(a)(1), 417.2(a)(2) and 417.4(a).On 

February 6, 2014 at approximately 1420 hrs. in the New Corndog Fryer Room I 

observed as 3 employees removed casing from cooked (RTE) franks that were 

located on the top of one stainless steel table. This table was located adjacent to 

one wall and in close proximity of Fryer #5. The Corndog Supervisor, Ms. 

, was notified and asked if it was customary for this RTE frank product to be 

'reworked' at this particular location. stated that she was unsure. 

accompanied me as I proceeded to the QA office in order to review 

the establishment's written 'Deli Plant Frank HACCP Fully Cooked - Not Shelf 

Stable Program'. Documentation in the Flow Chart demonstrated that the 'Rework' 

process step is only performed in the Raw Product Processing Department and is 

then incorporated into the 'Batching' process step. Documentation in the Hazard 

Analysis identified one biological food safety hazard, Listeria monocytogenes, 

as reasonably likely to occur at the 'Rework' process step. 

However, justification defined the probability of this biological food safety 

hazard occurring as 'low risk' as the process is designed through programs of 

product inspection and temperature control to reduce risk associated with the 

hazard. While reviewing the HACCP Program, Superintendent, Mr. 

nbsp;joined us who was notified of IPP's concern with food safety 

for the RTE product taken out of the defined frank processing product 

flow. We returned to the New Corndog Fryer Room where the 

3 employees were still in the process of removing the casing from the 

exposed RTE franks. Mr. confirmed that the RTE product was, 

in fact, undergoing the "Rework' process at this alternate location in the post 

lethality environment. I asked Mr. to take random internal product 

temperatures of the franks on the table top as well as in the one edible product 

barrel that the 'Rework' product was being transferred to. The average 

RTE product temperature was F. As the 'Rework' process step was being 

performed in an alternate location and one that was not included in the Flow Chart 

of the above cited written HACCP Program is noncompliance with 417.2(a)(2). 

Also, a hazard analysis had not been performed for the alternate 'Rework' 

process step which is noncompliance with 417.2(a)(1) and 417.4(a). Official 

regulatory control action was taken and U.S. Retain Tag No. B31408287 was 

collectively used to retain the RTE post lethality exposed frank 

product located on the table top and in the edible product barrel. Mr.

 elected to condemn the U.S. Retained product and proceeded to transfer 

this product from the two sites into one condemn barrel (81 lbs). 

Upon appropriate product disposition official regulatory control action 

was relinquished and the above cited U.S. Retain Tag was removed (1445 

(b) (6)
(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

hrs).This document serves as written notification that failure to comply with the 

regulatory requirements in 9 CFR Part 417 could result in adulteration of 

product and could result in additional regulatory or administrative actions as 

described in 9 CFR Part 500.4.   

(b) (6)
(B)(6) (B)(6)

(B)(6)

(B)(6) (B)(6) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

6036 P6164A OIJ2115025 

607N-1 

02/06/2014 01C02 Operational SSOP 

Review and 

Observation 

C On February 6th 2014 at approximately 0826 hours I entered the packaging floor 

coming from the chiller area and as I passed rotisserie at the area of the thigh and 

leg belt lines along the outer perimeter I stumbled upon a scene where two tan 

totes of whole birds had fallen and spilled onto the floor and establishment 

employees were picking whole birds off of the floor and placing them back into the 

tan totes of which they originally spilled out. Whole potentially insanitary birds 

from the floor were being comingled with whole clean birds that did not spill out of 

the tan totes. In the immediate area where whole birds spilled onto the floor there 

was a grated floor trough style drain system, a pallet jack and a large black wheeled 

refuse container. It is reasonable to assume that establishment employees involved 

did not have a working understanding of the establishment’s floor salvage program 

since comingling of sanitary product with insanitary product is unacceptable. It is 

further reasonable to assume that whole birds may have been rendered 

permanently insanitary and not eligible for the floor salvage program after coming 

in contact with an employee boot, the grate covering the trough style drain, the 

pallet jack or the refuse bin. I identified and asked 

her where those birds were being taken. She informed me they were going to a 

rinsing table in the chiller area to undergo floor salvage reprocessing. I immediately 

walked back to the chiller area and observed multiple tan totes with whole birds. 

The tan totes were not labeled with orange establishment hold tags. There was no 

way to visually distinguish the birds that had fallen onto the floor and been 

comingled with clean birds from another tan tote in the immediate vicinity 

containing whole birds which may or may not have been involved in the incident. I 

took a regulatory control action and I informed that I was retaining all the 

tan totes with whole birds in the chiller area near the reprocessing table until I 

could unequivocally determine their wholesomeness. 

became involved and I explained what I had observed 

and my concern that there was unaccounted and unidentifiable potentially 

permanently insanitary product present and comingling had occurred. He checked 

and counted birds in the red condemn barrel just to the side of the reprocessing 

table in the chiller area and the number of birds could not account for the total 

number of birds that spilled onto the floor.   Mr. and I walked 

back to the scene where the initial incident had occurred and stumbled upon a 

second identical incident occurring where another two tan totes containing whole 

birds had spilled onto the floor and multiple establishment employees were again 

picking birds off of the floor and comingling them with clean whole birds that 

remained in their tan totes. None of the tan toes were labeled or marked in any way 

to distinguish them from the multiple covered tan totes containing wholesome 

product. Mr. immediately stepped in and told establishment 

employees to stop what they were doing and walk away from the scene. Mr. 

(b) (6)
(B)(6)(B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(7)(C) (B)(7)(C) (B)(6)

(B)(6) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

enlisted the assistance of other and to gain control of 

the scene and collect all whole birds involved. I observed all whole birds involved or 

potentially involved consolidated into four tan totes, labeled with orange 

establishment retain for disposition tags and placed in a labeled product hold area 

next to rotisserie. I verbally informed Mr. that I would be issuing a 

noncompliance report. became 

involved and informed me that she wished to review the establishment’s written 

floor salvage program and inform of the 

situation and she would get back with me shortly as to the establishment’s 

disposition of the birds. I verbally informed Mrs. that I was unlikely to 

accept any disposition other than condemnation. At approximately 0910 hours 

Mrs. informed me that the establishment had decided to render all product 

involved or potentially involved. I accompanied Mrs. and Mr. out 

onto the packaging floor and observed all four totes of consolidated whole birds be 

placed into a red establishment condemn barrel. All whole birds from both 

instances that were involved or potentially involved were rendered and no 

unwholesome or potentially insanitary product entered commerce. 

     

1326 

1 

M33901 HAY030002 

1608N-1 

02/06/2014 01C01 Operational SSOP 

Record Review 

C On the calendar date of February 6, 2014 at approximately 1855 hours while 

performing the Operational SSOP Record Review task, the following 

noncompliance was observed: The Implementation and Monitoring section of the 

establishment's Sanitation SOP's states that 

. I, CSI , 

reviewed the operational records from the previous day's operations, February 5, 

2014. The record showed that all procedures were monitored and were found 

acceptable and included the initials of the QA technicians who performed the 

procedures. However, while performing the Operational SSOP Review and 

Observation task on the previous day, I, along with Dr. , observed 

water dripping from an overhead pipe onto bagged dry ingredients near processing 

line # 2. At the time of the observation, the line leader had notified maintenance of 

the leak and the dry ingredients were being removed from the area to prevent 

product contamination. The establishment failed to document the deficiency on the 

official SSOP record as well as the corrective actions that were taken to restore 

sanitary conditions. , and 

, were notified of the noncompliance and informed that a noncompliance 

record would be issued. This noncompliance record will be discussed during the 

next weekly meeting. 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6)

(B)(6)

(B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3803022 

005N-1 

02/05/2014 01C02 Operational SSOP 

Review and 

Observation 

C On 02/05/2014 at approximately 0022 hours while monitoring Operational 

Sanitation in Packaging Area 1, I observed the following. There was black 

UFM(Unidentified Foreign Material) specks and smears to approximately 

1/2" by 2" on the whole body carcasses on line . The birds had received 

their final trim, final antimicrobial intervention and the giblets were being 

added back into the 'Organic' birds at the location where I was making my 

observations. After taking off several birds in a row the line 

was stopped and was called. An 

additional employee was placed at the final trim location to 

removed the affected birds. Approximately 30 carcasses were removed and 

held for reconditioning. The UFM was located on the drumstick and at the 

joint area with the thigh on the carcasses.  held 2 partial 

racks of packaged product for reinspection. My findings indicated a 

noncompliance with 9 CFR 416.1 and 9 CFR 416.4(d). 

5308 M6137 BXL4619020 

805N-1 

02/05/2014 03J04 Poultry Zero 

Tolerance 

Verification 

O While performing Zero Tolerance Task, I observed a noncompliance with the 

following regulatory requirements of regulations 9CFR 381.65 (e) and 9CFR 417.2 

(c)(4).At approximately 1452 hours, randomly removed 

a 10 bird sample from Line #2 in Plant #1, I found one out the ten birds with visible 

fecal contamination, inside of the bird at the right side between the tail and the leaf 

fat area. The fecal material was dark green in color and pasty in texture, measuring 

approximately 1/4" diameter in size. This exceed the limit of Zero Tolerance for the 

process to be in control. I informed and 

of the noncompliance. The protocol for fecal failure was implemented. 

Quality Control performed a recheck at approximately 1545 hours and it 

passed.This is a violation of the critical limits of CCP-2B of 

the Plant's HACCP Plan for Slaughter. 

(b) (6)
(B)(6)

(B)(6) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4723023 

805N-1 

02/05/2014 01C02 Operational SSOP 

Review and 

Observation 

O At approximately 1815 hours to 1840 hours on February 5, 2014, while monitoring 

the establishments Operational Sanitation Standards in the Packaging Department 

and Rehang areas, I observed the following deficiencies: 

a)      Plant 2 – Sanitation Personnel was washing 

down during production time at the Pre-chill/FPS tables, drip pans, pipes, and floor 

area. They were directly spraying the day’s slaughter production debris from a 

non-product contact surfaces into Chiller # 3, a direct product contact surface and 

onto product while passing on shackles. b)      

Plant 1 – Sanitation Personnel was washing down during production time by the 

Chillers and washing the day’s slaughter production debris from a non-product 

contact surface directly into the Chillers, which is a product contact surface and a 

hold orifice for the product while chilling. Plus they were washing down into the 

Chiller while the product was still in there chilling down to the correct temperature. 

c)       Rotisserie Room – Sanitation 

Personnel was washing down before the completion of the task that was being 

performed. The wash down was creating heavy fog moisture which settles on pipes 

and ceiling, which are insanitary, non- product contact surfaces. The fog creates 

heavy moisture droplets coming from these insanitary areas, which falls onto the 

product and the boxes with the packing blue liners (ready for product and packing). 

Contaminating all product contact surfaces. All above discrepancies were creating 

food safety noncompliances.  I informed 

and , and of the non 

compliances. Corrective actions were implemented immediately. Inappropriate 

sanitation cleaning ceased until completion of production, product was removed, 

boxes and liners all condemned, and all the affected areas were restored to correct 

sanitary conditions by 1916 hours. My findings indicate a non compliance with the 

regulatory regulations 9 CFR 416.4(d) and 416.13(c).     

(b) (6)
(B)(6) (B)(7)(C) (B)(6) (B)(6)

(B)(4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN210302 

0105N-1 

02/05/2014 01B02 Pre-Op SSOP 

Review and 

Observation 

C After QC had performed pre-operational sanitation and the area was released for 

USDA inspection,  the following non compliances where noted in the 

respective areas:  Food Service Area at approximately 0035 

hrs. - The white product transfer belt of multi-cut #2 had black grease 

like material on the surface.  This belt is a product contact surface 

used to convey the cut up pieces of chicken to the red mesh net 

hopper. Packaging Area at approximately 0047 hrs. - Leg 

Processor #1 had multiple pieces of fat and product residue on the frame 

along with numerous pieces of fat on the cutting board and frame of the 

cutting board located on the east side of the machine.  The cutting board is 

also a product contact surface.  I informed and 

showed  these findings as he was 

present during the inspection and I informed him of the issuance of the non 

compliance report.  A USDA retain tag was not issued since the areas where 

in control with the lock-out/tag out procedures.  After the units where 

washed and sanitized the areas where released for production.These finding 

represent a non compliance with 9 CFR 416.4(a) and 416.13(c).  

On 12/16/2013, Non Compliance report NJN3103121817N/1 was issued 

for similar findings on leg processor #2 in the packaging area.  

1326 

1 

M33901 HAY341602 

5706N-1 

02/05/2014 03G02 Fully Cooked-Not 

Shelf Stable HACCP 

C On the calendar date of February 5, 2014 at approximately 1543 hours while 

performing the recordkeeping component of the Fully Cooked -Not Shelf 

Stable HACCP task, the following noncompliance was observed: I, CSI 

, reviewed the HACCP record (CCP 3) from the previous day's operations; 

2/4/2014. The record shows that the recorded temperatures met the critical limit 

prescribed in the HACCP plan, and that all monitoring and verification procedures 

were performed at the frequencies prescribed in the HACCP plan. "2/4/14" is the 

only date recorded in the "DATE" section of the record which indicates that all 

entries were made on 2/4/14. The record also shows that product temperatures 

were monitored and recorded past midnight on 2/4/14; however, the 

entries made after midnight do not include the date of 2/5/2014.   

, was shown the noncompliance and she confirmed the 

findings. Ms. was informed that a noncompliance record would be issued. 

This noncompliance record will be discussed during the next weekly meeting. A 

similar noncompliance record was documented on January 8, 2014; please 

reference NR # HAY0703013909N/1. The establishments response to 

NR # HAY0703013909N/1 of -

- failed to prevent recurrence. 

(b) (6)
(B)(7)(C)(B)(6) (B)(7)(C) (B)(6) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5129 M210 LQN421802 

5504N-1 

02/04/2014 01D01 SPS Verification C On February 4, 2014 while performing a routine patrol of the cook side 

departments I and FLS Dr. observed noncompliance with SPS 

regulatory requirement(s) 416.4(d); 416.4(b) and 416.2(b)(1). At 15:35 hours I 

observed the east wall to have a hole in the white panel under the refrigeration unit 

above the pipe in the cook pack shipping dock; as well the metal frame of the door 

to the cook pack shipping dock cooler was broken;exposed wood and 

caulking was visible. As well on the east wall a white metal panel was broken and 

bent as well there was a large exposed gap on both sides of the ceiling 

refrigeration unit and black unidentifiable black material on the seams from the 

ceiling to the walls in the same cook pack shipping dock storage cooler.Also there 

were three sections on the ceiling in the hallway between the coolers and the

 chillers where loose caulking or sections of metal ceining material were 

hanging down. Mr. was notified and shown the 

noncompliances. This NR serves as written notification of SPS noncompliance; as 

well as notification that failure to comply with regulatory requirement(s) may lead 

to additional regulatory or administrative actions as described in 9 CFR 500.4. 

5129 M210 LQN421802 

5504N-2 

02/04/2014 01D01 SPS Verification C On February 4, 2014 while performing a routine patrol of the establishment's raw 

production areas I and FLS Dr observed noncompliance with SPS 

regulatory requirement(s) 416.4(d), 416.4(b) and 416.2(b)(1). At 16:10 hours I 

observed in the raw cooler to the left of the scale a gap between the stainless steel 

guard and the floor, the gap had pieces of concrete coming loose and on the floor as 

well the wall area behind the stainless steel water system tank had loose caulking 

and rust between the white wall panels and stainless steel guard in several 

locations on the west wall. As well the oven loading area had a CIP monitoring 

equiptment machine that had a severly rusted motor on the bottom side as well as 

rusted conduit attachments and componets all over the machine parts and yellow 

gauges. Mr. was notified and shown the areas. This NR 

serves as written notification that failure to comply with regulatory requirement(s) 

may result in additional regulatory or administrative actions as described in 9 CFR 

500.4. 

5308 M6137 BXL5305022 02/04/2014 01B02 Pre-Op SSOP O At approximately 2400 hours 

404N-1 Review and 

Observation 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5568 M20923 XUM581502 

4804N-1 

02/04/2014 01D01 SPS Verification C This morning approximately at 1040 hours, while performing PHIS routine SPS task 

(Other Inspection Requirements/ Facilities and Equipment Standard), the following 

noncompliance was observed: Cook side of the establishment Line North side 

wall of the fryer room hand pallet jack charger has peeling paint and very rusty. I 

informed and of the 

non-compliance. Poorly maintained facilities and equipment can and do harbor 

food borne pathogens, which can then multiply and be dispersed throughout the 

food processing environment increasing the chances of product contamination 

which can render product adulterated. 9 CFR 416.1 states: "Each official 

establishment must be operated and maintained in a manner sufficient to prevent 

the creation of insanitary conditions and to ensure that the product is not 

adulterated". This document serves as written notification that failure to meet 

these regulatory requirement(s) could result in additional regulatory or 

administrative action. 

5112 M18909 JDD1405025 

803N-1 

02/03/2014 01B02 Pre-Op SSOP 

Review and 

Observation 

C On PRE-OP this date 02/03/2014 in Evisceration was noted the following: 1) 11/2 

inch crack in the interior of the Gizzard Defatter by the Final Wash. 2) Above final 

wash, line two, the Overhead Fan is insanitary with Black UFM 

on Blades and supports for Fan are rusty. 3) I/O Wash Line Two has a 

Frayed Hose, 4) Picker Three has a Four Inch Weld that is Cracked. 5) Overheads in 

Picking Room has Feathers too numerous to count. 6) Plastic Strips insanitary with 

numerous Feathers from blood tunnel into first wash. 7) First Wash Spray Nozzles 

has UFM on both of them. 8) Pipes on Wall, Line One, near Head Pulling are black 

with UFM. 9) Evisceration Mens Restroom, the wall dividers between Urinals 

are insanitary and rusty. Mr. . had been 

notified of this issue last week. Mr. , Ms. Mr. were 

notified of their respective issues. Issues were not previously documented in QC 

paperwork prior to notification of the same.In TRAY PACK, LINE ONE, SHRINK 

TUNNEL, the Exhaust Hose and related Piping has Black Grimy UFM inside 

them. Mr. and QC notified and it was not documented in 

 paperwork prior to my notification of the same. These 

are violations of the Establishment written SSOP program and the above 9 CFRs. 

This is linked to NR 011-2014, Dated 01/31/2014, JDD1407012031N/1 and Six 

other related JDD numbers. 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(4) (B)(4) (B)(4)

(B)(4)

(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD1407012 

031N-1 

01/31/2014 01B02 Pre-Op SSOP 

Review and 

Observation 

C Pre-op this date 01/31/2014 at 0500 H PST in the Room off of Rosier Area, 

the Computer and Electrical Panel so dusty as to write your name in dust. This is a 

violation of the Establishment's written SSOP program and the above 9 CFRs. This is 

linked to NR 009-2014, Dated 01/23/2014, JDD3611015623N/1 and Five other 

associated JDD Numbers. Mr. was shown 

the Noncompliance and Q.C. Paperwork had no documentation of this prior to my 

notification of the same. 

5568 M20923 XUM301101 

4531N-1 

01/31/2014 01B02 Pre-Op SSOP 

Review and 

Observation 

C At approximately 0645 hours, while performing a routine PHIS task Pre-op review 

and observation inspection task (after establishment performed their 

pre-operational inspection and prior to start of production), I observed the 

following noncompliance: Line , Cook side of the establishment: I found lots of 

pieces of food particles on UHMW guide incline conveyor belt, few food particles 

under chute and also found food particles above belt bars from the previous 

day of production. Upon continuing my inspection Line some of the batter pipes 

have food particles also from previous day of production. Found one of the batter 

mixer pipe rusty. I took a regulatory control action and applied USDA 

retain/rejected tag# B24829877. I informed and

 and of the non-compliance. The finding described in the 

non-compliance was on the food contact surface, it is reasonable to conclude that 

when production began it would be under insanitary conditions. Immediate 

corrective action was performed by establishment on all affected areas upon 

notification of my finding. After sanitary conditions had been restored, I 

relinquished the regulatory control action at 0735 hours. Plant SSOP Section1, 

page1, states: 

". 9CFR 416.13 (c) states: "All establishment shall monitor daily the 

implementation of the procedures in the sanitation SOP's". 9CFR 416.4 (a) states: 

"All food contact surfaces, including food-contact surfaces of utensils and 

equipment, must be cleaned and sanitized as frequently as necessary to prevent the 

creation of insanitary conditions and adulteration of product". This document 

serves as written notification that failure to meet these regulatory requirement(s) 

could result in additional regulatory or administrative action. 

(b) (6)
(B)(6)

(B)(6) (B)(6)

(B)(6)

(B)(6)

(B)(4) (B)(4)

(b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH050901 

3531N-1 

01/31/2014 03J02 Slaughter HACCP C On Friday, January 31, 2014, at approximately 0801 hours, while performing 

Poultry Finished Product Standards (Prechill) on Evisceration Line #2, I observed 

fecal contamination on the outside of the first carcass randomly selected for the ten 

bird sample.  The fecal material was located below the oil gland area.  

the fecal was approximately 1/4 inch in size and light brown in color.  It had a 

watery texture to the touch.  There were no plant employees between me 

and the chilling tanks when I performed this check.  Therefore, It is 

reasonable to assume that the feces would have entered the chilling tanks in 

violation of Regulation 9 CFR 381.65(e).  Mr.

 was notified of the deviation for the Critical Control Point CCP-1, 

at CCP-1, and he was shown the carcass.  He immediately 

implemented the establishment's corrective action for visible feces at CCP-1.At 

0815 hours, Mr. notified me that the cause of the noncompliance wa 

equipment malfunction.  Mr. stated, 

".  The 

preventative measure that was given was that a supervisor or leadperson will check 

the Bird Brush rotation everyday at start up.A similar noncompliance was 

documented on NR NHH0801014321N/1 dated 01-21-2014.  The further 

planned action may not have been implemented or was ineffective in preventing 

the reoccurrence of this similar noncompliance. 

5308 M6137 BXL4318010 

429N-1 

01/29/2014 04A06 Poultry Finished 

Product Standards 

C On 01/29/2014 at approximately 1517 hours while performing a Pre-Chill Finished 

Product Standards Task on Line #2 in Plant #1, I observed the following. After taking 

a standard random 10 bird sample, I accumlated 32 nonconformance points. There 

were 3 cloacas, 1 intestine, 3 whole lungs, 1 pin-feather, 1 feather, and 2 long 

hocks.This exceeds the subgroup absolute limit of points. I informed 

of the failure and Quality Control performed a recheck. At approximately 

1527 hours, the recheck failed with 34 nonconformance points. At this point the 

process is judged to be out of control. I informed of the 

noncompliance. There were no other rechecks at pre-chill due to the shift finishing. 

Post-Chill checks were performed every 30 minutes until the birds finished coming 

out of the chiller. My findings indicate a noncompliance with 9CFR 381.76(b). 

(b) (6)
(B)(6) (B)(6) (B)(4) (B)(4) (B)(4) B)(4) (B)(4)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4716014 

729N-1 

01/29/2014 03C02 Raw Intact HACCP C At approximately 1725 hours on 01/28/2014, while monitoring the dip on 

Line in Packaging, I observed the following noncompliance. There was one spray 

nozzle  that was not working on the spray rinse that is required after 

the thighs go through the dip. The spray nozzle that was not working 

was located on the end of the spraying unit and I noticed that the thighs 

going under it were not being rinsed. The establishments' HACCP Plan -Raw IntactPackaging Step 16 Parts Dip, under Potential Hazards Introduced, Controlled or 

Reduced at the step lists (C) Cetylpryridinium Chloride and Is the hazard significant? 

No. Under ' Justification for Decision' it states 

. A review of FSIS Directive 7120.1 Rev 16 dated 08/13/2013 under 

'Antimicrobial lists "Cetylpyridinium Chloride used 'To treat the surface of raw 

poultry carcasses or parts (skin-on or skinless) and then 'Dip tank application' to 

treat poultry carcasses/parts "When application of the additive is not followed by 

immersion in a chiller, the treatment will be followed by a potable water rinse. I 

informed and she informed the employee that was 

dumping a tub of thighs into the dip to stop. The line was stopped and I 

informed  of the noncompliance. Quality 

Control retained the racks of packaged thighs from the last acceptable check. On 

01/29/2014, the packages of thighs were opened and the thighs were rinsed with 

potable water.My findings indicate a noncompliance with 9CFR 417.2(a)(1) and 

9CFR 416.4(d). 

(b) (6)
(B)(6)

(B)(6) (B)(6) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH271301 

4029N-1 

01/29/2014 06D02 Other Inspection 

Requirements 

C On Wednesday, January 29, 2014, while performing an Other Inspection 

Requirement Task (Paw Diverter Check), on Evisceration Line #2 Station #2, I 

observed the following noncompliance.  I asked the establishment to 

perform a Paw Diverter Verification Test; maintenance and production personnel 

performed the test.  I observed when the paw diverter button for Inspection 

Station #2 was pushed, the paws did not divert into the condemn container; 

instead, they went into the paw chilling system where they were mixed with 

inspected paws.  I immediately notified Mr. 

, of the noncompliance and applied USDA Reject Tag # B 29 699848 to 

the system at 1134 hours.  I checked the paw diverter paperwork that the 

establishment documents their checks on and the last acceptable check was made 

at 0930 hours.  Mr. , tagged and 

condemned 32 cases of Grade A paws and 2 cases of B Grade paws and 10 cases of 

C Grade paws that were produced between 0930 hours and 1134 hours.After lunch 

Mr. notified me that maintenance was ready for me to perform a 

retest.  I performed a retest with production personnel on Evisceration Line 

#2 Station #2 and it failed at 1238 hours.  I performed another retest 

with them at 1245 hours on Evisceration Line #2 Station #2 and it passed.  I 

notified Mr. that he could resume saving paws; he had restored sanitary 

conditions to the chilling system during the lunch break.  At this time the 

tagged was removed.There was a similar noncompliance documented on 

noncompliance report #NHH5500125412N/1 dated 12-12-2013. There was no 

further planned action given. 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6)

(B)(6)

(B)(6) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5129 M210 LQN421101 

4128N-1 

01/27/2014 03G02 Fully Cooked-Not 

Shelf Stable HACCP 

C On January 27, 2014 at approximately 1220 hours, while performing records review 

on HACCP records. I observed that the Pre-Shipment Review Log for Further 

Processed  Product cook log CCP-1B was not verified for 

production date January 25, 2014. The Pre-Shipment page was filed with no 

signiture a deviation was in the works for an oven failure but there was no 

exception report or other documentation filed along with the 

log. This is a Noncompliance of the verification activities of the HACCP Plan. 

This does not comply with establishment Verification Activities for CCP-1B and 

CCP-2B to be met prior to shipment. This does not comply with 9CFR 417.5(c) 

which states in part "Review prior to shipment", and 9CFR 417.4(a)(2)(iii) which 

states in part: Records review". was informed 

of the Noncompliance and was shown and informed 

of the noncompliance.This document serves as written notification that failure to 

comply with regulatory requirement(s) could result in additional regulatory or 

administrative actions. 

5308 M6137 BXL3109015 

226N-1 

01/26/2014 03J02 Slaughter HACCP C On 01/25/2014 at approximately 2350 hours while monitoring Pre-Chill Finished 

Product Standards on Line in Plant #2, I observed the following. After 

taking a standard 10 bird sample, I observed one carcass with visible fecal 

contamination. I contacted and an employee was stationed at the 

end of the line to wash carcasses per the establishments' protocol for fecal 

failure, however hanging was not stopped. The fecal material was on the 

inside of the carcass on the tissue under the left side fat flap. The fecal material was 

olive green in color, pasty in texture and measured approximately 1/2" by 1/4" by 

1/8".  directed to perform a 

recheck as it was near break time. The  recheck passed at 0013 hours. 

The cause of the failure was determined to be the Inside Outside Bird 

Washer. A QC check of the Inside Outside Bird Washer on line at 2342 hours 

documented that the bird washer was working satisfactorily including timing, 

alignment, one leggers, spray valves, and  pump with the water pressure at 

77psi. The Pickup Sheet for the shift had the average bird weight at 7.0 pounds. The 

line was running at birds per minute at the time of the failure. The tail of 

the bird had been marked by the Establishments' procedure to identify birds 

that do not pass through the  or Body Opener correctly. 

 Issues with the  fecal failure protocol (not stopping hanging), line 

speed, marked tail and bird size were all discussed with 

. The production line was moved to line after break. My 

findings indicated a noncompliance with 9 CFR 381.65(e), 9 CFR 417.2(c)(4) and the 

critical limit of CCP-2B of the Plant's HACCP Plan for 

Slaughter.  

(b) (6)
(B)(6)(B)(6) (B)(7)(C) (B)(6)

(B)(6)

(B)(6)(B)(6)

(B)(6) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5223012 

926N-1 

01/26/2014 01D01 SPS Verification C On 01/24/2013 at approximately 0300 hours while monitoring line functions at 

startup after lunch break, I observed the following. A pipe had split at a point just 

before where the rubber hose is attached. The hose supplies water to the shower 

heads located just before the (IOBW) Inside Outside Bird Washer on 

line . The stream of water was spraying onto the chain, 

rail, the corner wheel that supports the chain and the supporting 

assembly for the blue corner wheel. These surfaces are treated as 

non-product contact surfaces. The fluids were dripping from the non-product 

contact surfaces onto the shackles, creating an insanitary condition. I 

contacted who was at the Rehang Area starting up 

line nbsp; Upon returning a few birds had passed through the 

area before  line  was stopped and a mechanic was called. 

The pipe was replaced and the line was returned to service by approximate 0315 

hours. I discussed the current water pressure which on occasion 

exceeds 100psi and the various types of piping installed 

with  . My findings indicated a 

noncompliance with 9 CFR 416.1 and 9 CFR 416.2(b)(1).     

5309 P6137A NJN421301 

4425N-1 

01/25/2014 03J04 Poultry Zero 

Tolerance 

Verification 

C On 1/25/14 in the Evisceration department on "A" line at 

approximately 1120 hours I, CSI , randomly selected ten carcasses for a 

zero-tolerance fecal check.  One of the ten carcass sampled had a brownish 

green fecal smear on the center of the back of the carcass in the shape of a 

circle.  The smear was approximately 1/4 of an inch in it's greatest 

diameter.  I took a regulatory control action by retaining evisceration 

"A" line with the application of U.S.retain tag B38495207 and showed my 

findings to .  I released "A" line to 

who immediately 

implemented the establishment's corrective actions by conducting a 

ten bird recheck that passed. Both and 

  were informed of the forthcoming 

noncompliance.     

5112 M18909 JDD2010010 

724N-1 

01/24/2014 01D01 SPS Verification O On 01/23/2014 in the Old Shipping Dock Area near the Q.C. Inspection Station I 

observed a large floor patch loose. In the Rosier Area I observed OVERHEAD 

ELECTRICAL CONDUITS extremely rusty and this is direct over the open Rosier. Also 

observed a tool marked Inedible inside the Rosier and in solution. No notes of 

this in Q.C. Paperwork. This violates the above 9 CFR's and is linked to NR 

003-2014, Dated 01/17/2014, JDDD1208013317N/1 Note: Kudos to the 

Establishment!!! The floor already repaired. 

(b) (6)
(B)(7)(C) (B)(7)(C) (B)(6) (B)(6) (B)(7)(C)

(B)(6)

(B)(6) (B)(6) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1304010 

924N-1 

01/24/2014 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 01/23/2014 at approximately 2230 hours while performing 

Pre-Operational Sanitation verification after the establishments Pre-Operational 

checks, CSI observed the following noncompliance to 9 CFR 416.4(b) in 

Plant 1 area 4 unit 13 line 2 liver harvester. CSI observed blood and fat on 

the frame and sides of the liver harvester from the previous days production. 

Liver Harvester was cleaned and sanitized in my presence and 

and were notified of the noncompliance.In Plant 2 at approximately 

2232 hours CSI observed pasty fat on the inside 

of Chiller #3 above the water line covering an area measuring 

approximately 3 feet long to 6" wide and up to 1/4" thick. There was also 

numerous pieces of fat and tissue to approximately 1/2" splattered on 

approximately a 6' long section of a brace at the same location. There was 

also pasty fat covering approximately a 6" by 2" section of 

a bracket attached to the base of the kick out mechanism. The chiller was 

cleaned and released at approximately 2236 hours. At approximately 

2233 hours the inside of the Finishing Chiller for line had numerous pieces 

of  fat and tissue to approximately 1/2". There was also a heavy layer 

of grease on the paddle associated with the unit that was at the top of its 

cycle and out of the water.  The Finishing Chiller was 

dumped, recleaned  and released by approximately 2239 hours. My 

findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.4(a), 9 CFR 

416.13(c) and 9 CFR 416.14.     

5309 P6137A NJN560201 

0724N-1 

01/24/2014 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 00:10, the following noncompliance was noted.   During 

the performance of a zero tolerance verification procedure on “B” line, I noted 

visible fecal material on the exterior of a poultry carcass. The affected area was 

located on the hock joint area of the right leg.  The fecal matter measured 

approximately one eighth of an inch in diameter, was brown in color and of a paste 

like consistency.   Upon noticing the affected carcass, I stopped the 

processing line and showed the fecal matter on the affected bird to Ms. 

 and Mr. .   After 

notification, the establishment implemented corrective actions which included a 

subsequent recheck on “B” line. The recheck was conducted, completed and passed 

by Ms. at 00:18.  The establishment did not meet the requirements 

of 9 CFR 381.65(e) which requires that the establishment prevent poultry carcasses 

contaminated with visible fecal material from entering the chilling system. In 

addition, the finding of visible fecal on a carcass after the final wash 

does not meet the establishment's critical limit for CCP 1B of "no visible fecal". 

Consequently, there is also noncompliance with 9 CFR 417.2(c)4. 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(4)

(B)(4)

(b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD3611015 01/23/2014 01B02 Pre-Op SSOP O Floor in OSD, Rosier OH, Inedible Hook 

823N-1 Review and 

Observation 

5112 M18909 JDD3611015 

823N-2 

01/23/2014 01B02 Pre-Op SSOP 

Review and 

Observation 

O In Tray Pack Shrink Tunnels Line one and were observed to be insanitary 

condition, Line One had a piece of styrofoam in it 1" x 6", feeding belt to tunnel is 

cracked and frayed and Line had UFM in the bottom Pan. This is a 

violation of the Establishment SSOP Program and the above 9 CFR's. Quality Control 

paperwork did not reflect these issues. This is linked to NR 002-2014, Dated 

01/07/2014, JDD3010012407N/1 and four other associated JDD Numbers. 

5308 M6137 BXL2804013 

223N-1 

01/23/2014 03J02 Slaughter HACCP C On 01/23/2014 at approximately 0000 hours while monitoring Pre-Chill Finished 

Product Standards on Line in Plant 2, I observed the following. After 

taking a standard 10 bird random  sample I observed one carcass with visible 

fecal contamination. I contacted and the protocol for fecal failure 

was implemented. The fecal material was on the inside of the carcass on the tissue 

under the left side fat flap. The fecal material was olive green in color, pasty in 

texture and  measured approximately 3/8" by 1/8" by 1/8". A QC recheck 

passed at 0035 hours. My findings indicated a noncompliance with 9 CFR 

 381.65(e), 9 CFR 417.2(c)(4) and the critical limit of CCP-2B 

of the Plant's HACCP Plan  for Slaughter. 

5308 M6137 BXL4514011 

323N-1 

01/23/2014 01C02 Operational SSOP 

Review and 

Observation 

O At approximately 1050 hours while performing Post Chill Finished Products 

Standards task in Plant #1, I was walking past Drop #3 in the Plant #1 Packaging 

Rehang Area when I observed the following noncompliance.  I stopped next 

to the bin staged for product at Drop #3 and observed a carcass on top of the pile 

already in the bin with black UFM (unidentified foreign material) on one of it's 

hocks.  On further investigation I found 1 more carcass with black UFM on 

the hocks.  I immediately informed of the 

noncompliance, as QC was walking past the area I informed QC of my 

findings and she applied a QC hold tag to the bin pending rework.  I 

continued on to perform my Post Chill task on Chiller #2 where I took a random 10 

bird sample and found 3 out of the 10 birds with black UFM on the hocks.  I 

immediately informed and QC of my 

findings,  and were also 

informed of the findings as well as .  My 

findings indicate a noncompliance with the regulatory regulations of 

regulations 9CFR 416.1 and 9CFR 416.4(d).  

(b) (6)
(B)(6) (B)(6) (B)(7)(C) (B)(7)(C) (B)(7)(C) (B)(7)(C) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5508014 

823N-1 

01/23/2014 06D02 Other Inspection 

Requirements 

C On 01/23/2014 after receiving complaints from inspectors on line concerning 

Presentation I reviewed the Presentation Log for the shift and found no 

documentation concerning 'Parts" inside the birds. I conducted a Presentation 

procedure on line with the line running at birds per 

minute) and  on the first station observed (1) viscera on shackle, (1) 

membrane, (3) not reflective (2) parts inside and (1) contamination for a total of 24 

nonconformance points. This exceeded the limit of points or occurrences for 

one error for the process to be in control. The third station had (1) viscera on 

shackle, (2) not reflective, (6) parts inside for a total of 18 nonconformance points.

 was informed of the failure. QC rechecks at 0401 hours 

failed. At this point the process is judged to be out of control. The line was slowed 

to A recheck at 0427 hours at passed at which time 

the evisceration process was moved to Line My findings indicated a 

noncompliance with 9 CFR 381.76(b).   

5308 M6137 BXL4208012 

922N-1 

01/22/2014 01C02 Operational SSOP 

Review and 

Observation 

O On 01/21/2014 at approximately 2240 hours in Plant 1, Line # 2 , Inspection station 

7, Inspector observed a piece of shiny metal measuring approximately 

2 inches by 1 inch and 1 cm thick attached to the viscera of a chicken 

on the evisceration line . Inspector immediately stopped  evisceration 

line # 2 and informed CSI of the metal on the chicken viscera. CSI 

notified of the metal . Production on line 2 was stopped 

and corrective action was done to find the source of the metal. Production was 

resumed at approximately 2330 hours after corrective actions were completed. 

According to PDD, FSIS considers metal of any size on a carcass to be an 

unacceptable contaminate that should be addressed by establishments Hazard 

Analysis. The issue of metal contamination has been discussed at previous weekly 

meets with the establishment. This noncompliance is being linked to NR 

BXL5704014912N dated 1/12/2014. 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(4)

(B)(4)

(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5568 M20923 XUM061101 

1222N-1 

01/22/2014 01B02 Pre-Op SSOP 

Review and 

Observation 

C At approximately 625 hours, while performing a routine PHIS task Pre-op review 

and observation inspection task (after establishment performed their 

pre-operational inspection and prior to start of production), I observed the 

following noncompliance: Line 2, Raw side of the establishment: I found few food 

particles on from the previous day of production. Upon continuing my 

inspection: Line , I found food particles on hopper 3A, also GCO in feed conveyor 

belt has lots of food particles and some build up on the bars, also from the previous 

day of production. All finding described in the non-compliance were on the food 

contact surface, it is reasonable to conclude that when production began it would 

be under insanitary conditions. I took a regulatory control action and applied USDA 

retain/rejected tag# B24829888. I informed and

 and of the non-compliance. Immediate 

corrective action was performed by establishment on all affected areas upon 

notification of my finding. After sanitary conditions had been restored, I 

relinquished the regulatory control action at 0700 hours. Plant SSOP Section1, 

page1, states: " 

". 9CFR 416.13 (c) states: "All establishment shall monitor daily the 

implementation of the procedures in the sanitation SOP's". 9CFR 416.4 (a) states: 

"All food contact surfaces, including food-contact surfaces of utensils and 

equipment, must be cleaned and sanitized as frequently as necessary to prevent the 

creation of insanitary conditions and adulteration of product". This document 

serves as written notification that failure to meet these regulatory requirement(s) 

could result in additional regulatory or administrative action. 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6) (B)(6)

(B)(4)

(B)(4) (B)(4) (B)(4)

(B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH440501 

3522N-1 

01/22/2014 01C02 Operational SSOP 

Review and 

Observation 

C On the night shift that began on 01/22/2014 at approximately 0225 I was in the 

Further Processing Room #1 at Establishment 33900  P.  I was in the 

area to perform a scheduled SSOP Operational Sanitation tour.  As I walked 

through the room I observed a card board combo that contained inedible wing 

tips.   The combo was not identified as containing inedible 

product.  The requirements of 9CFR 416.3(c) were not being met.   I 

walked approximately 20 feet further and saw a combo of back portions that were 

also inedible.  This combo also did not display anything that would identify 

the product as inedible.  The 2 combos were retained with USDA Retain tags 

#B38075849 and B38075850 respectively.    Approximately 10 feet 

from this combo was a pallet of boxes with blue plastic liners that had been over 

sprayed during the floor wash down.  These liners are product contact. 

  Regulatory Control Action was taken by applying USDA Reject Tag 

#B38075851to the pallet of boxes. Mr. and Mrs. 

were in the area and were shown the noncompliance.   The Preventive 

Measure given by Mrs. was, “disciplinary action was taken against 

employee”.   and Mrs. were informed that a 

Noncompliance Record would be issued documenting the noncompliance.   

For similar noncompliance refer to NR # NHH5705015821N / 1, dated 1/21/2014. 

  The requirements of Regulations 416.3(c) and 416.13(c) were not being 

met.   The Establishments SSOP plan objective is 

" 

5129 M210 LQN461901 

4821N-1 

01/21/2014 04B01 Labeling - Product 

Standards 

C On January 21, 2014 at 1500 hours while observing the operation in the Cook Side 

Dicing Department, I observed a Labeling/ Product Standard Noncompliance.  

I observed five barrels of edible product staged at the dicer ready to be diced 

without labels to identify the product.  U.S. Retain Tag NO. B38937059 was 

applied to the five barrels of edible product.  I informed and showed Ms.

 the noncompliance.  This does not comply with 

Regulatory Requirement 381.117; which states in part: 

, 381.122; which states in part:  

", and 381.123; which states in part:  

".Immediate corrective 

actions was implemented by management: U.S. Retain Tag was removed 

after  Product was Identified with the proper label in my presence.  

This document serves as written notification that failure to comply with regulatory 

requirement(s) could result in additional regulatory or administrative actions. 

(b) (6)
(B)(6) (B)(6)

(B)(6)

(B)(6) (B)(6)

(B)(6)

(B)(6)

(B)(4)

(B)(4) (B)(4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN402101 

0421N-1 

01/21/2014 01D01 SPS Verification O While performing an anti-mortem and humane handling check, I noticed that the 

cage washer machine was not operating at all. The cages were passing through the 

washing machine and coming out the same, dry as well as dirty. I immediately 

informed Mr. , of my observation and 

notified him of the forthcoming noncompliance. Mr. assigned an employee to 

manually wash all the cages that were not washed. The cages were soiled with 

heavy lodes of fecal material 

1325 

7 

P33900 NHH080101 

4321N-1 

01/21/2014 03J04 Poultry Zero 

Tolerance 

Verification 

C At 2140 hours on the night of production which began on 01/20/2014, while 

performing required PHIS Poultry Zero-Tolerance task at the designated Line #2 

Pre-chill station at est. 33900 P, after randomly selecting 10 slaughtered and 

eviscerated and chilled chicken carcasses for the subgroup test and having begun 

the test at 2139 hours, Inspection found fecal material on the 3rd bird in the set. 

The fecal material was a dark green color and of a pasty consistency which would 

easily smear to the touch. It consisted of one piece 1/4” in diameter and 1/8” in 

thickness, located on the inside of the breast area.

 was shown the carcass and he concurred that the 

material in question was indeed feces. Upon investigation, it was found that the 

cause of the fecal find was 

” Plant Management’s Measure to prevent recurrence was 

.” The requirements of 

9CFR381.65(e) and 417.2(c)(4) were not met and Mr. was advised that the 

incident would be documented on a Noncompliance Record. Refer to NR 

#NHH5405010808N/1 dated 01/08/2014 for a similar Noncompliance. Plant 

Management’s measure to prevent recurrence was: 

.” To date all preventive measures may not have been 

implemented as described or were ineffective in preventing recurrence. 

1325 

7 

P33900 NHH570501 

5821N-1 

01/21/2014 01D01 SPS Verification C On the night of production which began on 01/20/201 in est. 33900 P, Inspection 

was in Room 1 of Further Processing in est. 33900-P and found this 

Noncompliance: At 0359 Hours a 1/2-full Cardboard Combo of Wing Tips was found 

by the Leg Processor Machine with no identifying Label. The 

said that it was Inedible Product and was to be 

rendered. Inspection took Regulatory Control Action by applying US Retain Tag 

#B38075676 to the Combo until an Inedible Sticker was affixed. Inspection then 

released the Combo at 0407 Hours. Mr. was advised that a 

Non-compliance Record would be generated. The requirements of 9CFR416.3© 

were not met. Refer to NR #NHH2910114712N/1 dated 11/12/2013 for a similar 

noncompliance. 

(b) (6)
 

 

 

 

 

 

(B)(6) (B)(7)(C) (B)(6) (B)(6) (B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH580001 

4121N-1 

01/21/2014 01B02 Pre-Op SSOP 

Review and 

Observation 

C On the production shift that began on 01/20/2014, I performed pre-operational 

sanitation review and observation at Est. 33900  P.   This 

Pre-Op was performed in the further processing department of the Establishment, 

in room #1(on schematics for pre-op inspection).  This was after sanitation 

had completed cleaning the equipment and the establishment had completed 

pre-operational sanitation inspection of the equipment and released the area for 

USDA inspection.  There are no additional sanitation or inspection steps prior 

to the start of production.  This procedure was completed before product 

reached the areas inspected.    The following non-compliance 

was observed on the line 1 breast conveyor that brings the breast portions to the 

breast skinners.  Fat and a brown protein residue was on the under side of 

the unit and on product contact portions of the belt.  This residue ranged in 

size from 1/8 inch to 1/2 inch in size and numbered four pieces on the belt. 

 A greasy yellow to brown residue was on the rails on the under side of the 

belt. Regulatory Control Action was taken by applying USDA Reject Tag 

#B38075848 to the belt until it was re-cleaned by Sanitation and 

re-sanitized.  The drip pans on the line were dripping water on the product 

contact portions of the belt.  Maintenance personnel straightened the drip 

pans as a temporary measure.  I then re-inspected and released the units to 

Production.   The requirements of Regulations 416.4(a) and 416.13(c) were 

not being met.       The noncompliance was shown to 

Mr. and he was informed that it would be documented on a 

NR.    For similar noncompliance refer to 

NR # NHH0303124510N / 1, dated 12/09/2013.   

1326 

1 

M33901 HAY500001 

5325N-1 

01/21/2014 04B04 General Labeling C On the calendar date of January 22, 2013 at approximately 1657 hours while 

performing the Operational SSOP Review and Observation task, the following 

labeling noncompliances were observed: I, CSI , observed 2 combos of 

blocked product staged in front of lines . At the time of the findings, there 

were no labels on or inside the combos to identify the contents within. The combos 

were retained with U.S. RETAINED tag #'s B43134431 & B43134432. At 

approximately 1701 hours I observed another combo, containing ground product, 

staged along side the wall adjacent to line The product could not be identified as 

there was no label to describe the contents within. The combo was retained with 

U.S. RETAINED tag # B43134434. , was shown the 

noncompliance and he confirmed the findings. Once the product was correctly 

identified, the regulatory control action was relinquished. Mr. was informed 

that a noncompliance record would be issued. This noncompliance record will be 

discussed during the next weekly meeting. 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD1823015 

920N-1 

01/20/2014 03J02 Slaughter HACCP C On 01/20/2014 at approximately 1254Hrs, I observed that the establishment failed 

to perform the required 10 bird WIP (work in process) sample check per container 

prior to putting the reprocessed birds into the chilling tank. I observed a 

plant employee taking reprocessed whole body turkeys from the tank when the 

plants HACCP monitor and I were at the Quality Control table documenting our 

task. He was putting the birds onto the incline conveyor which was taking 

the turkeys into the chilling tank. I had observed the attatched WIP 

red tag prior going to the Quality Control table. The WIP tag had now been removed 

from the tank.   when ask her if 

she had performed the CCP 1B check and released the birds she said she had not.

 also had not performed the task. U.S. Retain Tag 

NO:B43241031 was applied to the tank of whole body turkeys which had not 

been inspected per HACCP Plan. was notified of the 

noncompliance. She questioned the employee and found that the employee had 

misunderstood instruction regarding the WIP birds. She took immediate corrective 

actions. She had all of the birds in the tank reconditioned bird by bird with

 water spraying. The whole body reprocessed birds were 

released back to production flow at approximately 1450Hrs after verifying the 

plants appropriate corrective actions and reinspection by Ms. . This 

observed incident of personnel not following the establishment's "Reprocessing 

Whole body Turkey's" WIP procedure is in violation to the Reprocessing Whole 

body turkeys HACCP Plan monitoring for CCP 1B. The in place CCP 1B is to comply 

with 9 CFR 381.65(e) zero tolerance for feces entering the chilling tank and 

also the plant's in place monitoring 9 CFR 417.2(c)(4). This noncompliance is being 

linked to noncompliance (#146) JDD4201114502N/1 dated 11/1/2013 for the same 

cause respectively.  

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(4) (B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5568 M20923 XUM001601 

3220N-1 

01/20/2014 03G02 Fully Cooked-Not 

Shelf Stable HACCP 

C At approximately 1342 hours while performing HACCP task (the record review 

component of procedure for fully cooked-not shelf stable process), I observed the 

following noncompliance: Line while review the records of CCP-2B last check was 

made at 1338 hour all the entries were documented beside product description. I 

notified the and about the 

non-compliance. This does not meet the requirement of 9 CFR 417.5(a)(3) which 

states: "The establishment shall maintain: Records documenting the monitoring of 

CCPs and their critical limits, including the recording of the actual times, 

temperature, or other quantifiable values, as prescribed in the establishment's 

HACCP plan; the calibration of process-monitoring instruments; corrective actions, 

including all actions taken in response to a deviation; verification procedure and 

results; product code(s), product name or identity. Each of these records shall 

include the date the record was made". This document serves as written 

notification that failure to meet these regulatory requirement(s) could result in 

additional regulatory or administrative action. 

5568 M20923 XUM302201 

3820N-1 

01/20/2014 03G02 Fully Cooked-Not 

Shelf Stable HACCP 

C On 01/20/2014, at approximately 19:02 hours while performing a directed HACCP 

Review in response to a deficiency on the Palletizing Dept. Line , I observed the 

following noncompliance: the metal detector kick out was overfilled causing the 

kick out platform to be stuck and remain in the open position. This condition 

caused all product to flow over the metal detector and product could not be 

rejected for possible metal contamination. The palletizing line operator 

failed to monitor the kick out box that was overfilled and caused the "Metal 

Detection Verification Procedure" to fail, a noncompliance per 9 CFR 

417.5(a)(1). The establishment identifies metal contamination as 

reasonably not likely occur and controls metal hazards with the 

"Metal Detection Verification Procedure", however this prerequisite program 

failed to identify possible metal detection due to the condition of the metal 

detectors kick out platform. This identified that the program is not 

effectively controlling the hazard and the establishment may not have 

adequate support for the decision made in its hazard analysis for that production 

lot. I took regulatory control by retaining two combo bins and 42 

cases of Mini Corn Dogs product code 95038 with US Tag # 24829878. I showed 

and informed Mrs. of the forthcoming 

noncompliance. After corrective actions were performed by production, I 

relinquished the US Tag at 01:25 hours on 1/21/14. The requirements of 9 CFR 

417.5(a)(1) and the establishment's Metal Detection Verification Procedure were 

not met. 

(b) (6)
(B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN162101 

4918N-1 

01/18/2014 01D01 SPS Verification C On January 13, 2014, and January 16, 2014, during a recent follow-up visit, an EIAO 

observed insanitary conditions in the picking room. The drain below the paw 

cleaning/brush machine was clogged with skin and water was unable to drain. At 

the time of the observations, a pool of water filled with paw skins, bits of tissue and 

other debris was observed to be approximately 5’ -6’ in diameter and from 2-4” 

deep. At both occurrences, plant management was notified and corrective actions 

were immediately implemented. This is noncompliance with Title 9 CFR 416.1, 

416.2(e)(4). QC was present at time of the observation and implemented 

immediate corrective actions. was informed of 

the noncompliance. 

(b) (6)
(B)(4)(b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN222201 

0318N-1 

01/18/2014 01B02 Pre-Op SSOP 

Review and 

Observation 

O An EIAO observed the establishment Quality Assurance employees conduct 

pre-operational inspection as per the establishments written SSOP. After the QC 

had completed their pre-operational inspection and released the area for product, 

the EIAO observed the following: Evisceration January 16, 2014 Fat on the door to 

the control panel where the QC applies their lock out tag out locks. Non food 

contact. A feather inside the control panel where the QC applies their lock out tag 

out locks. Non food contact  A large piece of fat on the drain cover by the 

PAC machine. Non food contact Unidentifiable foreign material brownish green 

with the appearance of fecal on a small gray hose above the steps into Inspection 

station 1 (non food contact) and blood on the hydraulic hose to the station lift 

(incidental food contact) Unidentifiable foreign material small black and flaky in 

appearance on the A&B line evisceration machine drain pan Non food contact 

Feather, skin and cartilage on the paw conveyor (after the paw chiller) Food contact 

Fat and feathers on the Line B IOBW Food Contact Packaging January 16, 2014 Fat 

on the side of the dip tank. Non food contact. Pipe tape hanging from the 

junction of the hose to the tank non food contact. Tissue adhered to the plastic 

belt guide food contact. Fat on the tank exit frame non food contact. Fat and 

meat residue on the control panel/ electrical box non food contact A piece of fat on 

the roth line dark meat non food contact Fillet January 17, 2014 Fat and 

tissue dried to the side of the East Ice hopper non food contact. Meat residue on 

the bottom of the conveyor non food contact. Fat inside the Westside Incline 

Coveyor food contact Large piece of fat on the chute adjacent to the Westside 

Incline Conveyor Hard dark round piece of unidentifiable foreign material with the 

appearance of metal on Breast Processor 16, non food contact A piece of meat and 

fat on the Organic incline conveyor that is adjacent to the  Front Half Delivery 

System Establishment had not run Organic material for “several months” according 

to plant manager. Fat on plastic ‘cog’ food contact. Large piece of meat in white 

buckets, food contact Unidentifiable Foreign Material with the appearance of black 

grease and fat on removable cutting boards. food contact. This describes 

noncompliance with Title 9 CFR 416.4(a), 416.4(b) and 416.13(c). The establishment 

took immediate corrective actions. 

(b) (6)
(B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN262101 

4418N-1 

01/18/2014 01D01 SPS Verification O On January 16, 2014, during a recent follow-up visit, an EIAO observed floors 

throughout the establishment in both production and non production areas exhibit 

pits, divots, holes, exposed aggregate, scratches and areas where steel rods are 

inserted through the floor, but are not readily cleanable. Holes range from 

approximately 1” to 2’ in diameter and approximately1/2” to 2” deep and contain 

dark water and solids at all times, including at pre-op. Sections of the floor in Fillet 

and Packaging have holes running under a layer of sealant, that when stepped on 

allow fluid that was trapped under the sealant to come out. The floor wall junctions 

throughout the facility exhibit cracks, standing water and are not readily cleanable. 

The walls throughout the establishment appear to have dirt and product residue 

adhered to the surface. The sections of wall constructed of white FRP are beige in 

appearance, and some areas exhibit black residue that is removable with gentle 

hand pressure. Further, there are numerous areas of the wall that exhibit rust. 

Throughout the establishment, there are areas of caulking that are peeling away 

from the wall, creating potential for pest harborage, and creating conditions that 

are not readily cleanable. Further, there is a section of the floor in evisceration that 

exhibits unidentified foreign material green in color with the appearance of 

algae.  This is noncompliant with Title 9 CFR 416.2(b)(2). EIAO notified

 of the findings. 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN452201 

2818N-1 

01/18/2014 01D01 SPS Verification O On January 16, 2014, and January 17, 2014, an EIAO performed 

Employee / Employee Equipment Inspection (all items listed are food contact) with 

the QC representative present. 3 steels taken out of production due to rust, rough 

welds that are not readily cleanable with  holes in the handles. 8 steels had 

loose blue plastic stuck at the point where the metal of the steel is encased on the 

plastic of the handle. Production Supervisor and QCs removed the plastic prior to 

production. 4 knives had tissue adhered to the blade, or between the blade and the 

pommel. 2 knives had loose blue plastic adhered between the blade and the 

pommel. 3 cut gloves had tissue and fat stuck in between the links. Additionally, 

the floor of the evisceration, Packaging and Fillet areas was littered with several 

pieces of fat, meat and sinew.  This describes noncompliance with Title 9 

CFR 416.1, 416.3(a). During a recent follow up visit from January 13, 2014, 

through January 18, 2014, an EIAO observed the following: A gap approximately 

2-3” at the maintenance door Gaps at the base of the roll up door from 2-4” in the 

Picker room Gaps at the base of the doors leading into Live hang The doors to the 

outside in the auxiliary rooms off of the Fillet room are not maintained to prevent 

the entrance of vermin as they are locked open with a gap at the base of the doors 

Gaps at the base of the air vent in the boiler room ranging from 1” to 4” high and 

2” to 1’ long. This is noncompliant with Title 9 CFR 416.2(a) and 416.2(b)(3). Plant 

management was notified of the findings. On January 16, 2014, EIAO and FLS 

entered into the New Product Rooms and noted a foul putrid odor. The odor was 

identified as coming from the floor drain near the exit side of the Rotisserie area. 

Plant management including the Plant Manager, were present and observed the 

odor. Further, on January 15, 2014, EIAO entered into the Picking room to observe 

a QC check. The Picking room had a strong foul odor and was filled with steam to 

the extent that visibility was severely limited, creating potential safety concerns. 

Your establishment failed to provide ventilation adequate to control odors and 

vapors. This is noncompliant with Title 9 CFR 416.2(d). Plant management took 

immediate corrective actions. 

5112 M18909 JDD1208013 

317N-1 

01/17/2014 01D01 SPS Verification C In Evisceration 01/09/2014, around 0845 I stopped both lines due to the water 

refuse drainage canal under the lines was full and oveflowing into traffic pattern 

areas. Downtime about six minutes on the canal to drain and 

resanitize areas on both sides of the line. Ms. ., Mr.

 , , and Mr. 

were notified of the noncompliance. This is a violation of the abvove 9 CFR's. 

(b) (6)
(B)(6) (B)(6)(B)(6) (B)(7)(C)

(B)(4)

(B)(4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD2414012 

218N-1 

01/17/2014 03J02 Slaughter HACCP C On 01/17/2014 at approximately 2013Hrs, I found the plant failed to meet the 

established Boning Room CCP 5B requirement of 

. Using a company calibrated thermometer, I performed a physical 

verification check of the Heavy Tom Turkey Breast meat which was on the New 

Shipping dock. My findings were 50F, 48F, 50F & 48F, 46F, 40F. U.S. Retain Tag 

NO's:B43241029 & B43241030 were attatchted to the two tank's, containing 

Tom Turkey Brst 1, boneless, skinless without flt, with temperatures above 45F. The 

plant's Boning Room scan tags# T001913263 & T001912937 showed 

the tanks leaving the Boning Room at 14:01Hrs and 12:00Hrs on kill date 

01/17/2014. was notified of the noncompliance and showed 

the temperatures above 45F. Mr. chose to add more C02 and put the affected 

breast meat into the P-157 blast. . was notified and verified the 

temperatures above 45F. He also applied his Quality Control retain tags. The total 

affected product was 2918 pounds. , CSI verified all sites of the 

product was below 45F at 0842Hrs on 01/18/2014. The establishment chose to run 

the University of Wisconsin PMP calclation and it showed no Salmonella outgrowth 

using the 1401Hrs & 1200Hrs found on 01/17/14 to 0030Hrs on 01/18/14 

when product was 39F, per plant Q.C. record. The product was released back 

to shipping at 1620Hrs on 01/20/2014 after verifying the plant's corrective actions. 

The establishment has Salmonella Initiative Program (SIP), a waiver to 9 CFR 

381.66(b). This waiver allowes the establishment chill whole birds/parts to 45F in 

8Hrs from slaughter. This observed incident of product temperatures above 45F 

exceeding the 8Hrs from slaughter is in violation to the plant's HACCP Plan at the 

Boning Department monitoring of CCP 5B which states in part; " 

". The plants CCP 5B established company 

critical limit which states; " 

, was not sufficient in preventing temperatures above 45F. This 

noncompliance is being linked to noncompliance (#150) JDD5910114705N/1 dated 

11/4/2013 for the same cause respectively. 

(b) (6)
(B)(6) (B)(6) (B)(7)(C) (B)(7)(C) (B)(6) (B)(6) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD4508012 

717N-1 

01/17/2014 01D01 SPS Verification C On 01/14/2014 in the Old Shipping Dock around 0130HPST, I observed a stainless 

steel tank with a 1/2 inch crack in the corner with readily visible product residue in 

it. I informed Mr. , of this issue. He indicated 

one of his people would take care of it. I waited until after PRE-OP was over and 

rechecked on it. It was missed and I tagged it, U.S. Reject Tag # B43241104. I then 

notified Ms. .of it and it was taken to shop for repair. Later in 

the day, Ms. , C.S.I. released the Tag. This is a violation of the above 9 

CFR's. 

6036 P6164A OIJ4601011 

718N-1 

01/17/2014 04A06 Poultry Finished 

Product Standards 

C On January 17, 2014 I, CSI performed a scheduled Finished 

Product Standard test at the Prechill area.  This test is applied to permit FSIS 

to estimate when the production process is in control for ready-to-cook 

poultry.  The test consists of two parts, trim and processing 

nonconformances.  The absolute limit allowed for processing 

nonconformances is points. My test at 2251 resulted in 42 points.   

At approximately 2320 a retest was performed by using 

a tighten criteria of 25 points which failed with 30 points.  I verbally notified

 of the noncompliance and that I would be issuing a 

NR.  The plant implemented the required procedures for FPS failure.  

The Prechill nonconformances I observed at 2251 were:  3 ingesta < 1/16” 

(3 pts),  5 partial oil glands (5 pts),  4 partial lungs (4 pts),  8 

whole lungs (16 pts),  1 partial crop (2 pts), 1 trachea > 1” (2 pts), 2 small 

feathers (2 pts),  4 large feathers (4 pts), and 2 long hocks (4 pts). On 

December 12, 2013, NR # OIJ3913124612N (#85) was issued for processing 

noncompliance.  The written response given that Maintenance made 

adjustments to bring the process under control were not effective to prevent 

recurrence.  This noncompliance is linked to NR # OIJ3913124612N (#85) for 

the same root cause.  The Establishment Awareness Meeting notes show 

that FPS NRs were last discussed at the December 19, 2013 meeting. 

(b) (6)
(B)(6) (B)(6) (B)(6)

(B)(6)

(B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5129 M210 LQN042201 

3016N-1 

01/16/2014 01D01 SPS Verification C On January 16, 2014 at approximately 1550 hours while walking through Raw Side 

Cooler #2, I observed noncompliance with SPS Regulatory Requirement(s) 416.1 and 

416.4(d).Raw Side Cooler #2:  I observed beaded condensation along the 

overhead stainless steel strip next to the overhead refrigeration unit and also on 

the overhead entrance door to cooler #2 (product traffic area).  I informed 

and showed Mr. and Mr. ., the 

noncompliance.  At the time of my observation I did not see any 

condensation dripping and the product staged in the cooler was completely 

covered.Immediate corrective action was implemented by Mr. by having the 

overhead structures wiped down and monitoring the condensation for the rest of 

the shift.  Sanitary conditions was restored at 1605 hours.  This does 

not comply with Regulatory Requirement(s) 416.1 which states in part: Each 

official establishment must be operated and maintained in a manner sufficient to 

prevent the creation of insanitary conditions and to ensure product is not 

adulterated", and 416.4(d) which states in part: "Product must be protected during 

storage".This noncompliance is linked to NR#LQN4803115908N/1 dated 11/8/13, 

for a similar noncompliance on condensation in the coolers. This document serves 

as written notification that continue failure to comply with regulatory 

requirement(s) 9 CFR Part 416 could result in additional regulatory or 

administrative actions as described in 9 CFR Part 500.4. 

5112 M18909 JDD5722013 

015N-1 

01/15/2014 01D01 SPS Verification C On 01/15/2014 at approximately 1300Hrs while performing ante-mortem 

inspection task, I observed a noncompliance to 9 CFR 381.95(c). I observed 4 clean; 

edible, clear plastic lined combo bins containing edible foods products. The product 

filled the combo bins and no red color consistent with an application of 

visible denaturant was present on any of the food products in the combo bins. The 

chicken and turkey food products (breasts, paws, fillets, thigh, whole body birds 

and ground products) were outside near the plants condemn dump truck. All of the 

bins plastic liner were open with the food products exposed. The exposed food 

products had written on the bins PC- 1/13/14. The products appeared to 

have been frozen in boxes prior to being put into the combo bins. 

was notified of the noncompliance and shown the edible food products 

with no denaturant. Ms. found a plant employee who had noticed the 

bins of food product at approximately 0200Hrs. At approximately 1312Hrs 

the product was released after verifying the plants implemented corrective 

actions and the liberal denaturizing which was applied in my 

presence.  

(b) (6)
(B)(6) (B)(6)

(B)(6) (B)(6) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5568 M20923 XUM571401 

2415N-1 

01/15/2014 01D01 SPS Verification C This morning approximately at 0745 hours, while performing PHIS routine SPS task 

(Other Inspection Requirements/ Facilities and Equipment Standard), the following 

noncompliance was observed: Line 1, Cook side of the establishment 

transfer belt metal cover has crack on one of the corner. I informed 

of the non-compliance. Immediately the part was revoved and sends it 

to the maintenance shop for repair. Poorly maintained facilities and equipment can 

and do harbor food borne pathogens, which can then multiply and be dispersed 

throughout the food processing environment increasing the chances of product 

contamination which can render product adulterated. 9 CFR 416.1 states: "Each 

official establishment must be operated and maintained in a manner sufficient to 

prevent the creation of insanitary conditions and to ensure that the product is not 

adulterated". This document serves as written notification that failure to meet 

these regulatory requirement(s) could result in additional regulatory or 

administrative action. 

5129 M210 LQN240201 

0814N-1 

01/14/2014 01D01 SPS Verification C On January 13, 2014 at approximately 1440 hours, I observed noncompliance with 

SPS regulatory requirement(s) 416.1, 416.4(d).Cook Side Film Room:  I 

observed one roll of tan color plastic liners (food contact) with part of the 

roll laying directly on the floor. The tan color plastic is used to line the 

bins and tanks that edible product comes in contact with.  U.S. Reject Tag 

NO. B38934386 was applied to the roll of plastic liners.  Ms.

 was informed and showed the noncompliance. Ms. . 

was also informed.   Immediate corrective action was implemented by 

management :  Ms. removed all of the plastic liners 

that was in contact with the floor and disposed into the trash.  The rest of 

the plastic liners was properly wrap up.  After sanitary conditions were 

restored U.S. Reject Tag NO. B38934386 was removed.This does not comply with 

Regulation 416.1; which states in part:  "Each official establishment must be 

operated and maintained in a manner sufficient to prevent the 

creation of insanitary conditions and to ensure that product is not 

adulterated".This document serves as written notification that failure to comply 

with regulatory requirement(s) could result in additional regulatory or 

administrative actions as described in 9 CFR Part 500.4. 

(b) (6)
(B)(6) (B)(6)

(B)(6)

(B)(7)(C) (B)(7)(C)

(B)(6)

(B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD3123010 

513N-1 

01/13/2014 01D01 SPS Verification C On 01/13/2014 at approximately1315Hrs, I was notified by Dr. 

, SPHV that Ms. and Ms. , food 

inspectors, had just observed a live cock roach inside the U.S.D.A. break 

room. They saw the roach moving on the wall above the break table. 

The wall is connected to the plant's entry hallway. They called out as they 

tried to terminate the roach using a paper towel roll. Dr. was near by and he 

was able to terminated the live cock roach when it landed on the table.

 was notified of the noncompliance and showed the terminated 

cock roach. The roach was removed and the table was sanitized. She notified plant 

management. This observed incident of a live cock roach inside the establishment's 

break room is in violation to 9 CFR 416.2(a) Grounds and Pest Control and 9 CFR 

416.2(b)(3) walls/floors/ceilings constructed to prevent entrance of vermin. The 

establishment does have in place a outside pest management service. 

5568 M20923 XUM251601 

4013N-1 

01/13/2014 01D01 SPS Verification C This morning approximately at 1410 hours, while performing PHIS rotine SPS task 

(Other Inspection Requirements/ Facilities and Equipment Standard), the following 

noncompliance was observed: Line 2, Cook side of the establishment one of the 

electrical motor of MFG conveyor belt is very rusty. I informed 

and of the non-compliance. Poorly maintained 

facilities and equipment can and do harbor food borne pathogens, which can then 

multiply and be dispersed throughout the food processing environment increasing 

the chances of product contamination which can render product adulterated. 9 CFR 

416.1 states: "Each official establishment must be operated and maintained in a 

manner sufficient to prevent the creation of insanitary conditions and to ensure 

that the product is not adulterated". This document serves as written notification 

that failure to meet these regulatory requirement(s) could result in additional 

regulatory or administrative action. 

(b) (6)
(B)(6)

(B)(6) (B)(4) (B)(4)

(B)(4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5568 M20923 XUM302301 

4613N-1 

01/13/2014 01C01 Operational SSOP 

Record Review 

C On 1/13/2104, at approximately 2025 hours, while performing a directed SSOP 

Record Review inspection task in response to a deficiency in the QC Lab, I observed 

the following noncompliance: while reviewing the SSOP Monitoring Log dated 

1/10/14 Shift 1, Part 2 Operational Sanitation, Section 1 Raw Products, there 

was a response in the Comments Corrective portion of the Monitoring Log 

complete by QC employee with the initial's NX. The response stated, 

. I noticed that there was no condemn report 

attached to the SSOP form. This is a procedure that the establishment performs to 

show when product has been condemned for various reasons at the plant. I 

inquired with the night shift QC Dept. and the Production Management on the 

status of the 40 lbs of QC retained product. I was informed that no condemn 

report had been completed for the 40 lbs of exposed 95507  Turkey 

Ground Meat product identified on the SSOP Monitoring Log and the status of the 

retained product was unknown, a noncompliance per 9 CFR 416.15(b) 

and 416.16(a). I showed and informed Mr.

 of the forthcoming noncompliance. The requirement of 9 CFR 

416.15(b), 416.16(a) and the establishment's SSOP Plan Part 2, Section 1, 

Implementation and Monitoring #3 were not met. 

5308 M6137 BXL3104010 

912N-1 

01/12/2014 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 01/10/2014 at approximately 2230 hours while monitoring Pre-Operational 

Sanitation standards in Plant 2, I observed the following. There was varying 

amounts of black UFM(Unidentified Foreign Material) that smeared like grease 

 on the shackles and  guide bars above the inflow section of the 

scalders for kill line The shackles were cleaned with green pads and paper 

towels. The area was released by approximately 2257 hours. My 

findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.4(a) and 9 CFR 

416.13(c).   

5308 M6137 BXL5704014 

912N-1 

01/12/2014 01C02 Operational SSOP 

Review and 

Observation 

C On 01/08/2014 at approximately 0115 hours whole monitoring Pre-Chill Finished 

Product Standards on line in Plant 2, I observed the following. After taking a 

standard 10 bird sample there was a piece of shiny metal measuring approximately 

5mm by 3mm by 2mm attached to the connective tissue in the neck area of a 

carcass. I informed . According to PDD, 

FSIS considers metal of any size on a carcass to be an unacceptable 

contaminant that should be addressed by the establishments' Hazard 

Analysis. The establishment has no metal detectors. The issue of metal 

contamination has been discussed at previous morning meetings with the 

establishment. My findings indicated a noncompliance with 9 CFR 416.1 and 9 CFR 

416.4(d). 

(b) (6)
(B)(6)

(B)(6) (B)(7)(C) (B)(7)(C) (B)(6)(B)(4) (B)(4) (B)(4)

(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1815010 

511N-1 

01/11/2014 01B02 Pre-Op SSOP 

Review and 

Observation 

O On 01/11/14 at approximately 0840 Hours while performing pre-operational 

sanitation verification in the Packaging Department with CSI , Dr. 

observed the stainless steel product shoot lid at the end line having a 

cracked and broken hinge on one end. Regulatory control action was taken by 

applying U.S. Reject tag #B 39930856 to Line and informing 

and of the noncompliance to 

9CFR 416.2(b)(1) regulatory control was relinquished at approximately 0920 Hours 

after lid and hinge were removed and area was cleaned and sanitized. 

5308 M6137 BXL2517010 

111N-1 

01/11/2014 03J04 Poultry Zero 

Tolerance 

C On 01/11/2014 at approximately 1444 hours, while performing the Zero Tolerance 

Task on Line , I found visible fecal contamination on one of the ten birds I 

Verification randomly removed. The fecal was located on the top side of the tail by the 

vent area. The fecal material measured approximately 1/8" in diameter in 

size, olive green in color and pasty in texture. This exceeds the limit of Zero 

Tolerance for the process to be in control. I informed of the 

noncompliance and the protocol for fecal failure was implemented. Quality Control 

performed the recheck at approximately 1513 hours and passed, bringing the 

process back into control.My findings indicate a noncompliance with 9CFR 

381.65(e), 9CFR 417.2(c)(4), and the critical limit of CCP2B, 

of the Plant's HACCP Plan for Slaughter. 

(b) (6)
(B)(6)

(B)(6)

(B)(6) (B)(7)(C) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4)

(B)(4)

(b)(4) (b)(4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

6036 P6164A OIJ0218014 

611N-1 

01/11/2014 06D02 Other Inspection 

Requirements 

C At approximately 2148 on 01-10-14, I, CSI performed the missing viscera 

test component of the regularly scheduled Other Inspection Requirements task. The 

maximum allowed missing viscera at the line speed of is and I 

observed 14. witnessed the test 

and I verbally informed her of the failed test results. At approximately 2210, I 

performed the retest for missing viscera and I observed 17.

 Swing Shift witnessed the retest. I immediately notified him 

of the failed test results, that I was taking the regulatory control action of slowing 

the line to as per requirements, and that a NR would be issued to 

document the noncompliance. At approximately 2216, I performed a missing 

viscera retest requested by to verify process control at the line 

speed of The maximum allowed missing viscera at the line speed of 

is and I observed 6. The line speed was increased to . At 

approximately 2258, I performed the missing viscera test to verify process control 

at the line speed of and I observed 8.    This NR is linked to 

NR # OIJ401114109N issued on swing shift, 11-08-13. Including this NR, there have 

been four linked Other Inspection Requirements NRs issued in the last 90 days for 

the same root cause. Maintenance adjustments in response to previous Other 

Inspection Requirements NRs were not effective in preventing this NR. Other 

Inspection Requirements NRs were most recently discussed and documented during 

a weekly Establishment Awareness Meeting on 11-21-13.    

(b) (6)
(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5568 M20923 XUM372301 

2910N-1 

01/10/2014 03G02 Fully Cooked-Not 

Shelf Stable HACCP 

C On 1/10/2014, at approximately 1600 hours, while performing a routine scheduled 

HACCP Record Review inspection task in the QC Managers Office, I observed the 

following noncompliance: In the Fully Cooked Shelf Stable Whole Muscle / Diced 

Stripped Product hazard analysis the establishment identifies "Allergens" as a 

chemical hazard not reasonably likely to occur at the following steps in the hazard 

analysis; "Glaze Mix and Pre-Mixed" and "Glaze Mixing". The 

establishment implements a "Corporate Allergen Control 

Program" prerequisite program, which maintains that allergenic ingredients 

are identified and controlled were they are introduced into the 

process that the hazard is not reasonably likely to occur. However, the 

establishment does not identify "Allergens" as a hazard, at all applicable steps in 

the hazard analysis. The establishment failed to identify "Allergens" at the following 

steps; "Pro Grill", "Cooking", "Dicing / Slicing", "Cooling and Freezing", "Scaling and 

Packaging", and "WIP product in combo / labeling". Allergenic ingredients are 

utilized at these steps in the process. Failing to identify all hazards at those steps 

does not comply with 417.2(a)(1) and also the failure to document the prerequisite 

program that prevents the hazard of undeclared allergens through cross 

contamination or mislabeling at the steps described does not comply with 

417.5(a)(1) by not supporting the decisions that allergens are not reasonably likely 

to occur at those steps. The requirements of Title 9 CFR 417.2(a)(1), 417.5(a)(1) and 

the establishment's "Corporate Allergen Control Program" were not met.   

(b) (6)
(B)(6)

(B)(6) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

4630 M7322 AOA300901 

0809N-1 

01/09/2014 01D01 SPS Verification O While performing a Sanitation Performance Standard Inspection in the 

establishment’s Raw processing department the following noncompliance were 

observed: 1. At approximately 0426 hours in the raw/cook side transfer holding 

cooler there were 2 full pallets of cheddar cheese product stored slightly under the 

overhead air unit. The top row of boxes were observed with some heavily covered 

unidentifiable black gradual looking material and drip of clear liquid randomly 

scattered over the top portion of all the boxes in areas to numerous to count. The 

liquid and unidentifiable material appeared to have come from the air unit. Some 

(approx. 5) of the boxes of product were slightly opened. The palletized containers 

of product did not have any cardboard box slips protector or other materials on the 

top of the boxes to protect the containers from foreign elements. Further 

investigation confirmed that no product contamination was involved.

 was immediately notified. No retain tag was applied because immediate 

corrective actions were taken by the establishment. 2. At approximately 0431 hours 

in the raw storage cooler I observed 4 combos of “Low fat Chicken Product “with 

the date 01/04/14 stored directly under the 2 air units (2 combos under each unit). 

I observed some clear liquid (that appeared to be condensate) that was falling from 

the each air units directly onto the blue plastic cover that was over the product. 

Further investigation confirmed that no product contamination was involved. The 

ceiling of the raw storage cooler had heavy liquid condensation build up over 

approximately 1/3 of the area. was immediately notified. 

No retain tag was applied because immediate corrective actions were taken by the 

establishment. -Raw  was later notified 

of all the noncompliance and he assisted with the corrective measures. -The 

observed conditions did not meet the requirements of 9 CFR 416.1/Sanitation 

Performance Standards General Rule, 9 CFR 416.4(d)/Preventing insanitary 

conditions where  product is storage, 9CFR 416.4(b)/Non food 

contact surfaces cleaning and 9 CFR 416.2(d)/Ventilation. -This document 

serves as written notification that your failure to comply with regulatory 

requirement(s) could result in additional regulatory or administrative action(s). 

5112 M18909 JDD3206015 

313N-1 

01/09/2014 01D01 SPS Verification O bygf76y 

(b) (6)
(B)(6) (B)(6) (B)(6)

(B)(4)

(b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5568 M20923 XUM061201 

0209N-1 

01/09/2014 01B02 Pre-Op SSOP 

Review and 

Observation 

C At approximately 0705 hours, while performing a routine PHIS task Pre-op review 

and observation inspection task (after establishment performed their 

pre-operational inspection and prior to start of production), I observed the 

following noncompliance: Line 1, Cook side of the establishment: I found piece of 

chicken stuck on ishida scale bracket from the previous day of production. Upon 

continuing my inspection Line 1 transfer blue belt one of the bar 

underneath has few food particles also from the previous day of production. I took 

a regulatory control action and applied USDA retain/rejected tag# B24829883. I 

informed and and of the 

non-compliance. The finding described in the non-compliance was on the food 

contact surface, it is reasonable to conclude that when production began it would 

be under insanitary conditions. Immediate corrective action was performed by 

establishment on all affected areas upon notification of my finding. After sanitary 

conditions had been restored, I relinquished the regulatory control action at 0745 

hours. Plant SSOP Section1, page1, states: 

. 9CFR 416.13 (c) states: "All establishment 

shall monitor daily the implementation of the procedures in the sanitation SOP's". 

9CFR 416.4 (a) states: "All food contact surfaces, including food-contact surfaces of 

utensils and equipment, must be cleaned and sanitized as frequently as necessary 

to prevent the creation of insanitary conditions and adulteration of product". This 

document serves as written notification that failure to meet these regulatory 

requirement(s) could result in additional regulatory or administrative action. 

5568 M20923 XUM322201 

2709N-1 

01/09/2014 01D01 SPS Verification C On 1/09/2014, at approximately 1928 hours, while performing a directed 

Sanitation Performance Standards (SPS) inspection task in response to a deficiency, 

I observed the following noncompliance: several cobb webs on the ceiling overhead 

exhaust fan cover in the Compacter Room of the Raw Area creating insanitary 

conditions, a noncompliance per 9 CFR 416.1 and 416.2(b)(3). I took regulatory 

control by rejecting the area with US Tag # 24829912. I showed and informed Mr.

 of the forthcoming noncompliance. After 

corrective actions were performed by production and sanitary conditions were 

concerned, I relinquished the US Tag at 2005 hours. The requirements of 9 

CFR 416.1 and 416.2(b)(3) were not met. 

(b) (6)
(B)(6) (B)(6)

(B)(4)

(b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

4630 M7322 AOA121401 

0508N-1 

01/08/2014 01C02 Operational SSOP 

Review and 

Observation 

O On 01/08/14, while performing a Sanitation Performance Standard Inspection of 

the box rooms and shipping department to assure all product, equipment and 

product package containers were properly stored, I found the following 

noncompliance. 1. At approximately 0845 hours, I observed a pallet of partially 

covered and unprotected premade brown boxes, stacked approximately 7 rows high 

(to numerous to count) of the same unassembled box containers. These premade 

box containers have been observed in use in the packing area for direct 

handling/contact by the packing employees immediately before packing the ready 

to eat product. The pallet of premade boxes were partially (approx. 15-20) 

uncovered (exposed) with the possibility of being affected by foreign materials in 

the box room/shipping area (e.g. dust, fumes, hair, wood chips and etc.). The box 

room area is not required by the establishment GMPs for employees to wear hair 

covers/nets, or special footwear. The box room area is also used for continuous 

transporting of garbage/trash, chemicals, maintenance equipment, wood pallets, 

and pallet jacks and etc. The box room is an entrance point for the some employees 

from the outside (before covering the hair or changing footwear or garments). The 

conditions that the premade boxes were being handled and stored did not meet the 

requirements of 9 CFR 416.4(d). Employees was initially notified 

and was later notified and observed the pallet of boxes. No 

product contamination was observed. No regulatory control tag was applied 

because Employee took immediate corrective actions as instructed 

by the supervisor. 2. At approximately 0851 hours while inspecting the cook side 

dry ingredient storage cooler, I observed a pallet of dry ingredients (whole grain 

batter) that had one busted bag of product that had spilled onto the floor and 

frame of the storage shelf. The opening in the bag of product appeared to be 

approx. 4 to 5 inches in circumference and the opening in the bag left the product 

exposed. was notified. No tag was applied because I 

observed as immediate corrective action was taken by the establishment. -A similar 

noncompliance was observed on 09/17/13 and documented on NR 

#AOA3213091217N/1. The previous written further planned action that was 

provided by the establishment on 11/13/13 that states, 

”, 

appeared to be ineffective in preventing this noncompliance. -Continued failure to 

meet regulatory requirements can lead to enforcement actions described in 9 CFR 

500.4. 

(b) (6)
(B)(6) (B)(6) (B)(7)(C) (B)(7)(C) (B)(6) (B)(6) (b) (7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2008014 

008N-1 

01/08/2014 01D01 SPS Verification O On 01/08/2014 at approximately 0350 hours, Line Food Inspector 

observed a live cockroach when he was washing his gloves in the sink that it's 

located in Line 2 behind station #7 in Plant #1 during his USDA break time. The 

cockroach was running away from the sink. Food Inspector caught the 

cockroach and contacted CSI I informed and

 his finding. Cockroaches are carriers of bacterial 

contamination and disease which can spread to exposed product, and creats an 

insanitary condition.The sink was washed with potable water. This is a 

noncompliance with the following regulatory requirements of regulations 9CFR 

416.1 and 9CFR 416.2 (a). 

5310 M6137B FFA2122010 

908N-1 

01/08/2014 01C02 Operational SSOP 

Review and 

Observation 

C On January 8, 2014 at approximately 1855 hours while performing my operational 

sanitation inspection in the Raw Side Blending/Rework area I observed 

noncompliance with SSOP Regulatory Requirement 416.13(c), and SPS 416.1, 

416.4(d).  I observed several small pieces of blue plastic casing on the 

re-work chicken franks product code 11005 dated 01/07/14.  The 

chicken franks had already been cleaned and put into a clean 

cardboard bin ready to be used.  U.S. Retain Tag NO. B34377425 was applied 

to this bin of Chicken Franks.  Mr. was informed 

and showed the noncompliance and Ms. was also informed.  

At 2105 hours after the Re-work product was re-cleaned, and re-inspected U.S. 

Retain Tag NO. B34377425 was removed and product was released.This does not 

comply with Regulatory Requirement 416.1; which states in part: "Each official 

establishment must be operated and maintained in a manner sufficient to prevent 

the creation of insanitary conditions and to ensure that product is not adulterated", 

416.4(d); which states in part:  "Product must be protected from 

adulteration during processing, handling, storage, loading, and unloading", and 

416.13(c), which states in part:  "Each official establishment shall monitor 

daily the implementation of the procedures in the sanitation SOP's".This 

noncompliance report serves as written notification that failure to comply with 

regulatory requirement(s) of 9 CFR 416 could result in additional regulatory or 

administrative actions. 

(b) (6)
(B)(6)

(B)(7)(C)

(B)(6)

(B)(6)

(B)(4)

(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH540501 

0808N-1 

01/08/2014 03J02 Slaughter HACCP C  On the night shift that began on 01/07/2014, at approximately 0401 Hours, 

I was in the Evisceration Department, line #2, to perform Finish product Standards 

Verification for pre-chill standards.    I randomly selected 10 

carcasses at a collection point after the inside/outside rinse cabinet, designated by 

the Establishment as the point to collect carcasses for this procedure.  There 

are no further interventions by the Establishment beyond this point.  

  On the first carcass that I inspected, I observed a substance inside carcass, 

in the kidney area that appeared to be fecal material.  I summoned Mr. 

and he agreed that the material was feces.  The feces was 

approximately 1/16 inch in diameter to 1/8 inch in diameter and numbered 3 

specks. The feces was brownish tan to dark brown in color and greasy to the 

touch.  The material smeared easily to the touch.   At approximately 

0000 Hours I was informed that the cause of the deviation was investigated and 

found to be, ”   The 

preventive measure given was, 

  The requirements of Regulations 381.65(e) and 417.2(c)(4) were 

not being met.   Refer to NR#NHH3204011807N / 1, dated 07/07/2014, for 

similar non – compliance.   All measures taken by the establishment to 

prevent recurrence to date have been ineffective or may not have been 

implemented properly.    

1326 

1 

M33901 HAY070301 

3909N-1 

01/08/2014 03G02 Fully Cooked-Not 

Shelf Stable HACCP 

C On the calendar date of January 8, 2014 at approximately 2210 hours while 

performing the Fully Cooked, Not Shelf Stable HACCP task, the following 

noncompliance was observed: I, CSI , reviewed the HACCP records 

generated on the previous days operations, 1/7/2014. The records included the 

results of the monitoring and verification procedures at the CCP's, the initials of the 

person who made the entries, and the time in which the entries were made. The 

records also show that product temperatures were monitored after midnight and 

the results are acceptable, as the temperatures met the critical limits prescribed in 

the HACCP plan. The results recorded after midnight were actually entered on 

1/8/14. However, the "DATE" section of the record only contains "1/7/14, which 

indicates that all entries were made on the date of 1/7/14. Please be advised that 

records generated under the Raw, Intact HACCP Plan for the date of 1/7/14, 

which are recorded on the Individually Frozen In-Process Temperature Monitoring 

Log, also show entries made after midnight but the person(s) making the entries 

failed to record the date of 1/8/14 next to the entries. 

, was shown the noncompliance and she confirmed the findings. 

Ms. was informed that a noncompliance record would be issued. This 

noncompliance record will be discussed during the next weekly meeting. 

(b) (6)
(B)(6)

(B)(6)

(B)(6) (B)(6)

(B)(7)(C)

(B)(7)(C) (B)(7)(C)

(B)(6)

(B)(6) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD3010012 

407N-1 

01/07/2014 01B02 Pre-Op SSOP 

Review and 

Observation 

C In Tray Pack 01/07/2014 during PRE-OP I observed poultry residue on center line 

product contact zone and the Pink UFM noted in the Q. C. Leaker Check Apparatus. 

This was pointed out to Mr. and Mr. 

This a violation of the Establishment's written SSOP program and the 

folowing above 9 CFR's.. This is linked to NR 176-2013,Dated 12/14/2013, 

JDD0310124414N/1 and its Three Associated Links. 

5308 M6137 BXL3808015 

307N-1 

01/07/2014 01D01 SPS Verification O On 01/07/2014 at approximately 0458 hours, Line Food Inspector

 observed a live juvenile cockroach when she was working on Line 

1 on station #4 in Plant #1. The cockroach was crawling on the gray plastic 

tub that the company used to save the wings from the trimming. The tub 

was empty and turned upside down because it was almost company break 

time. Food Inspector caught the cockroach and contacted CSI 

. I informed and of 

her finding. Cockroaches are carriers of bacterialcontamination and disease which 

can spread to exposed product, and creats an insanitary condition.The area was 

washed with potable water.  This is a noncompliance with the following 

regulatory requirements of regulations 9CFR 416.1 and 9CFR 416.2 (a). 

5310 M6137B FFA0416013 

507N-1 

01/07/2014 01D01 SPS Verification C  On January 7, 2014 while walking through the cooking area, I observed 

noncompliance with SPS regulatory requirement(s) 416.1,416.2(d) and 416.4(b). At 

approximately 11:35 hours I observed beaded dripping condensation on the 

bottom side of the gray beams and iron rails between oven #3 and the chiller 

area no product was affected. I informed and showed 

and the noncompliance. They had an employee wipe down the 

condensation in my presence.This NR represents SPS noncompliance of the 

regulations cited above; as well as written notification that failure to comply with 

regulatory requirement(s) may result in additional regulatory or administrative 

action as described in 9 CFR 500.4. This NR is link to NR #FFA0216125111 Dated 

12/11/2013 for a similar noncompliance. 

(b) (6)
(B)(6)

(B)(6) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH211301 

3607N-1 

01/07/2014 01D01 SPS Verification C On 01/07/2014 at appoximately 1145 hours while performing an SPS task in the 

paw room/giblet chiller area, I observed that water from the top of the ice machine 

chute was splashing onto the ceiling and other overhead structures 

and dripping onto covered  plastic totes used for product; water was 

also dripping from overhead structures onto the floor adjacent 

to an ice bin containing potable ice.  The outside surface of the exit end of 

the neck chiller was also insanitary and contained numerous fat particles and 

brown grease; a section of the outside surface of the neck chiller 

contained an area of rust approximately 10-12 inches in diameter.  

Adjacent glycol pipes attached to the neck chiller had extensive rust and a brown 

greasy substance along 24 and 30 inch sections of the pipes.  

Additionally, there was a 12-18 inch crack in the plastic insulation around a 

large pipe at the end of the neck chiller; the exposed surface of the 

pipe contained extensive rust and a brown/black greasy substance.  

USDA Reject/Retain tag # B38075651 was assigned to these deficiencies.  I 

advised  Mr. , of these issues and that a 

Non-compliance Record would be issued.  There was no product 

contamination involved with this non-compliance.  The establishment did 

not meet the regulation requirements of CFR9 416.1, CFR9 416.2(b)(1), and CFR9 

416.2(b)(2), which states that the establishment will operate in a manner to 

prevent insanitary conditions and in good repair. 

1325 

7 

P33900 NHH320401 

1807N-1 

01/07/2014 03J04 Poultry Zero 

Tolerance 

Verification 

C On the night of production that began on January 6, 2014, at approximately 0345 

hours while performing a Poultry Zero Tolerance task at the evisceration line 2 

pre-chill station, I found feces inside the third bird of a ten bird set.  The feces 

was located on the inner ventral surface of the bird's abdominal cavity at the level 

of the keel.  The feces was approximately 1/8 inch by 1/8 inch, was pasty in 

texture, and was dark green in color.  

 was shown the carcass.  

 informed me that the cause of the fecal failure was a broken 

shackle guide in the inside-outside bird washer.  The 

establishment's measure to prevent recurrence was to replace the broken 

shackle guide.  The establishment did not meet the regulatory requirements 

of 9 CFR 381.65(e) and 9 CFR 417.2(c)(4).  Refer to NR 

#NHH0200014502N written on December 31, 2013, for a similar 

noncompliance.      

(b) (6)
(B)(6)

(B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH240801 

0006N-1 

01/06/2014 01C02 Operational SSOP 

Review and 

Observation 

C #3-14 At approximately 0718 while performing an operational sanitation 

observation and review task in the further processing areas I observed insanitary 

conditions in the thigh deboning/rotisserie department of room two. I observed 

whole thighs, fat and debris, and thigh trimmings along the wall, along the thigh 

deboning line and in the traffic area between thigh and rotisserie pack out 

conveyors. There was a massive pile of bones in the area thigh bones exit the 

deboning machine. The work area was totally congested with hardly any space to 

allow for wash down or cleanup of any sort while employees are working on the 

line. The requirements of 416.11 and the establishment’s SSOP plan which requires 

. The line lead was notified and US tag #B38075641 was assigned to 

the noncompliance. The employees were removed from the line so that the floor 

area and stands could be washed to an area where the water and debris could drain 

properly. The line was released after sanitary conditions were restored. The same 

noncompliance was cited on 12/12/2013 and Management’s response was that 

floor man will rinse the floor before leaving the production area. Employees were 

informed to push debris that is under the line to the wall and maneuver into a 

larger drain. Any efforts to do so either were unaccomplished or have been 

ineffective.Another noncompliance observed were insanitary conditions while 

wearing and storing aprons. In room one I observed two plastic 

hanging on the floor rack with the ties touching the floor. was 

notified. In room two the was one plastic smock hanging with the ties touching the 

floor. Another employee was observed walking to her work area with the garment 

untied allowing the ties drag over the floor. The establishment SSOP states that

 These requirements are not being 

met.The same noncompliance was cited on 12/19/2013 and efforts to prevent the 

recurrence of this noncompliance has been unsuccessful. 

(b) (6)
(B)(6)

(B)(6) (B)(6) (B)(6) (B)(6) (B)(6)

(B)(6) (B)(6)

(B)(6) (B)(6)

(B)(4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH450201 

0006N-1 

01/06/2014 04A06 Poultry Finished 

Product Standards 

C 2335 hours-01/05/2014-04C04-Chiller room, Line #2 exit end of chill system. 

  On the night shift that began on 01/05/2014, at approximately 2318 

hours, I monitored Procedure 04C04 (Finished Product standards for carcasses 

exiting the chill system).   The test was being performed by

 on production line #2. On the initial test a score of 27 was 

obtained.  This is 17 points above what is allowed for this test.  Mr. 

performed a Verification check at 2326 hours with a result of 22.  

Action test at 2329 received a score of 11.    Mr. informed the

 that the line was not in compliance 

and that the product needed to be retained for rework.  For approximately 

four minutes Mr. and I observed product entering the room from the 

non-compliant line and being hung on the production line along with product from 

line #1.  Mr. attempted to have the noncompliant product diverted 

from this line for approximately four and a half minutes before being 

successful.  During this time product that was not eligible for production was 

being mixed with eligible product.    

was informed of the noncompliance, and he over saw the collection and 

retention of the product.     

1325 

7 

P33900 NHH010101 

4504N-1 

01/04/2014 01C02 Operational SSOP 

Review and 

Observation 

C On the night shift that began on 01/03/2014 I was in the Evisceration Room at 

Establishment 33900  P to perform a finished product standards procedure 

on Evisceration line #2.  As I walked through the room on my way to the 

pre-chill station, I saw oily, black colored water dripping from the rail and the turn 

wheels on the #2 carcass line.  This oily water was dripping from the greasy 

rail onto the carcasses below.      Regulatory Control Action 

was taken by stopping the line and since the 

was present, he had the lines and turn wheels dried in a timely manner so 

On the production shift that began on 01/03/2014, at approximately 2140, I was in 

the no other action was taken at this time.  I then released the line to 

production.   The Preventive Measure given by Mr. was that the 

line leads would inspect the shackle line before production begins.   Mr.

 was informed that a Noncompliance Record would be issued documenting 

the noncompliance.   For similar noncompliance refer to 

NR # NHH2204122803N / 1, dated 12/02/2013.   The requirements of 

Regulations 416.1 and 416.13(c) were not being met.   The Establishments 

SSOP plan objective is 

" 

(b) (6)
(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3808012 

403N-1 

01/03/2014 01B02 Pre-Op SSOP 

Review and 

Observation 

O On 01/03/2014 at approximately 0100 hours while monitoring Pre-Operational 

sanitation in Packaging Area #1, I observed the following. There was a layer 

of pasty fat and tissue on a cutting wheel on the out flow side of Breast Processor 

#9. The wing section collection belt that runs under the breast processors had 

numerous specks and smears of black UFM(Unidentified Foreign Material) that 

smeared like grease. The area was recleaned and released by approximately 0115 

hours. In  Packaging Area #2, the the red fire fighting 

piping is severely deteriorated. The rust and peeling/flaking paint is extensive. At 

several locations the flaking rust and paint is in granular size pieces that 

easily falls off the tops of the pipes with the slightest contact. In many 

locations the fire fighting  piping is directly over the lines creating an 

insanitary condition.  At approximately 0130 hours in Plant #1 there 

was pasty fat and tissue on the metal support brackets  and semi-dried 

yellowish UFM on the rubber fingers on Picker #2 on Line 2. The 

area was released by approximately 0135 hours. My findings indicated a 

noncompliance with 9 CFR 416.1, 9 CFR 416.2(b)(1), 9 CFR 416.4(a) & (b) and 9 

CFR 416.13(c). 

(b) (6)
(B)(6)

(B)(6) (B)(6) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4)

(B)(4)

(B)(4) (B)(4)

(B)(4)

(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD2922014 

302N-1 

01/02/2014 03C02 Raw Intact HACCP C On 01/02/2014 at approximately 1248Hrs, I performed a physical 

verification check of the Raw Not Ground Turkey Breast and Turkey Unsorted Skins 

which were weighed/scanned/loaded in a trailer for shipping to the establishment's 

Plant # 2. Using a company calibrated thermometer, I took the temperature of one 

Turkey 1 Brst, boneless, skinless, W/O FLT (3.50 - 5.00 weight) and 

one Turkey Unsorted skins container. The temperatures of the Breast were

 & and the Skins were & . U.S. Retain Tag 

NO's:B39554882 & B39554881 were applied to the loaded affected Turkey 

Breast and Skins for temperatures above at shipping. 

, was notified of the noncompliance and verified my temperature 

findings at shipping. The Ice appeared not to be evenly dispersed over the 

turkey breast and skins. Mr. notified the plant Q.C. The establishment chose 

to add more to the affected (1912 pounds) of turkey breast and (1773 pounds) 

of turkey skins with kill date 1/2/2014 and with time 1217Hrs & 1225Hrs 

leaving the boning room. At approximately1505Hrs the turkey breast and skins 

were released back to shipping after verifying all of the food products temperature 

readings which were performed by were below This 

observed incident of turkey products being shipped above is in violation to 9 

CFR 381.66(b) and 417.2(c)(4) monitoring at the critical limit. The establishment's 

supporting documentation for Salmonella Initiative Program (SIP) states; "

 The establishment's HACCP Plan at 

shipping states: " 

Since the supporting documentation for your SIP 

waiver states that 

and the SIP is used as justification in your HACCP Plan, a violation of 

417.5(a)(2) also exists. This noncompliance is being linked to noncompliance 

(#156) JDD5604112312N/1 dated 11/11/2013 for the same cause respectively. 

(b) (6)
(B)(6)

(B)(6) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0311011 

602N-1 

01/02/2014 04A06 Poultry Finished 

Product Standards 

C On 01/02/2014 while monitoring the Establishment's Reprocessing Procedures on 

Line in Plant #1, I observed the following noncompliance. At approximately 0825 

hours I randomly removed a 10 bird sample and found one split tail bird with 

airsacculitis exudates remaining in the bird. I informed 

of my findings and at approximately 0829 hours I took a 10 bird 

sample for my recheck. Out of the 10 bird recheck I found four birds with 

airsacculitis exudates remaining in the bird. I immediately took regulatory control 

action by stopping the line, and I informed of the 

noncompliance. The line was started and all missing tail and split tail 

birds were retained while corrective actions were implemented. I 

tagged the tank of retained birds with U.S. Retained/Reject Tag #B31406693, 

pending rework of the product. Quality Control performed a recheck at 

approximately 0839 hours and passed, bringing the process back into control. I 

removed my tag and released the product to Quality Control and she applied her 

"Hold" tag to the retained tank of birds. At approximately 0957 hours Quality 

Control performed a recheck on the retained tank of birds and passed, the birds 

were released back to production.My findings indicate a noncompliance with 

regulatory requirements of regulations 9CFR 381.84 and 9CFR 381.76(b). 

(b) (6)
(B)(6)

(B)(4)

(B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (b)(4)

(b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5308012 

202N-1 

01/02/2014 01C02 Operational SSOP 

Review and 

Observation 

C On 01/02/2014 at approximately 0425 hours while performing a direct 

observation function under Step 14 CCP-3B of the 

establishments' Notice of Deferral Verification Plan dated October 13, 2013, I 

observed the following. In the Rotisserie Room, I observed 

the injection  process of the birds  through packaging 

and labeling. While observing the Gas Flush part of the process, I observed 

that the stainless probes that are inserted into the plastic product bags to extract 

the air prior to sealing were coming into contact with the injected carcasses in the 

product bags. At approximately 0430 hours the injection process was 

completed and the establishment started to boxout bulk packed 

product 00626 breast meat using the same Gas Flush machines. In the main 

Packaging Area the bulk product is packaged in to blue plastic 10 

pound bags, placed into gray product baskets, crusted(chilled to 40'F or 

below) then held for the boxing process. The gray baskets that the bulk 

product is placed in are not treated as product contact surfaces. As the 

baskets of bulk product were being emptied in Rotisserie at approximately 

0430 hours during boxing process I observed varying amounts of black and 

brown UFM(Unidentified Foreign Material) on the bottoms and sides of the 

baskets.  The exterior of the blue plastic bags that the  

bulk product is packaged in that was in contact with the gray baskets 

 was not being decontaminated in any way before being placed into the 

plastic liner before gas flushing. Again I observed the Gas Flush process and the 

stainless probes were coming into contact with the contaminated blue plastic bags 

that the bulk product is packaged in. As soon as the boxing of the bulk was finished 

the Second Processing Rinse began.     During the 

Second Processing Rinse I observed packaging materials (boxes with plastic liners) 

were not covered/protected from over spray during the wash down.  The 

establishments Second Process Rinse Procedure states under step (1) " 

. "I contact 

and the affected liners in boxes on the conveyor belt behind 

the brown packaging belt area were discarded. I also observed 

that the sanitizer  was not applied to the product contact 

surfaces, stainless probes,  of the Gas Flush Machines 1-4. The Second 

Rinse Procedure states under step 5(a)  and under 

(b) .  was 

contacted and an employee applied to the working surfaces on the 4 

units.   My findings indicated a noncompliance with 9 CFR 416.1, 9 

CFR 416.13(b), 9 CFR 416.13(c) and 9 CFR 416.15(b). 

(b) (6)
(B)(6)

(B)(4) (B)(4) (B)(4) (B)(6) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (b)(4) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5708010 

502N-1 

01/02/2014 04A06 Poultry Finished 

Product Standards 

C On 01/02/2014 at approximately 0620 hours while performing the weekly 

 monitoring of Reprocessing Line  processes in Plant 1, I observed the 

following. After taking a standard 10 bird sample, I observed three birds with 

airsacculitis exudates. The exudates were inside the carcass on the keel bone near 

the interclavicular area.  Of the random 10 bird sample 5 of the birds had 

split tails including the three with the visible exudates. The establishment has the 

tails split before the birds are placed on to line as an indicator that the 

carcass needs to be vacuumed for what ever reason.  At this point the 

process is judged to be out of control. The line was stopped and Department

 was called. Adjustments were made to 

personnel and training was conducted. The line was restated and a recheck passed 

at approximately 0633 hours. The line was running at approximately (birds 

per minute) and there were two house inspection and three 

employees vacuuming at the time of the failure. My findings indicated a 

noncompliance with 9 CFR 381.84. 

5308 M6137 BXL0717124 

531N-1 

12/31/2013 06D02 Other Inspection 

Requirements 

C At approximately 1238 hours while performing a presentation check on Line in 

Plant #2 I observed the following noncompliance.  The first station on Line

 had (3) viscera on shackle and (1) contamination inside for a total of 30 

nonconformance points.  This exceeds the limit of points or 2 occurances 

for one error for the process to be in control.  I informed

 of the failure.  QC did a recheck at approximately 1247 

hours which also failed with (2) viscera on shackle and (3) not reflected, which 

exceeds the limit of occurances for one error.  The line speed was 

immediately reduced as per protocol ( nbsp;to .  QC 

performed a rechek at 1307 hours that passed at , the line speed was then 

raised to .  QC did another recheck at which passed, bringing 

the process back in control.  My findings indicate a noncompliance with the 

regulatory regulations of regulation 9CFR 381.76(b).  

(b) (6)
(B)(6) (B)(6) (B)(6)

(B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2013121 

331N-1 

12/31/2013 04A06 Poultry Finished 

Product Standards 

C At approximately1040 hours while monitoring the Establishments On Line 

Reprocessing procedure on Line , I observed the following noncompliance.  

After taking a random 10 bird sample of split tails from Line I found 2 of the 10 

birds had airsacculitis exudates remaining.  The exudates were found on the 

inside of one carcass in the airsac on the left side and in the 

second carcass there was a large piece on the left flap that measured 

approximately 1/2" in diameter.  I immediately informed 

of the noncompliance. &

 immediately went and instructed personnel on the vacuuming 

procedure, as there were already 2 people vaccuming and the line was at 

.  I performed a recheck at 1050 hours which passed bringing 

the process back on control.  My findings indicate a noncompliance with the 

regulatory regulations of regulations 9CFR 381.76(b) and 9CFR 

381.84.      

5308 M6137 BXL3208123 

831N-1 

12/31/2013 03J02 Slaughter HACCP C On 12/31/2013, while performing a HACCP Slaughter Review and Observation Task 

in Plant #2, Reprocessing Line I found a noncompliance with the following 

regulatory requirements of regulations of 9CFR 381.65 (e) and 9CFR 417.2 (c)(4).At 

approximately 0438 hours, I randomly removed a 10 bird sample from 

Reprocessing Line after the final house inspector station, I found one out of the 

ten birds with visible fecal contamination outside of the bird, on the 

right side by the tail area. The fecal material was green in color, pasty in 

texture and measured approximately 1/4" diameter in size. I 

immediately stopped the line and informed the Lead Person and 

 of the noncompliance. The protocol for fecal failure was implemented. 

Quality Control performed a recheck at approximately 0444 hours and it passed. 

This is a violation of the critical limits of CCP-1B of the 

Plant's HACCP Plan for Slaughter. 

(b) (6)
(B)(6) (B)(6)

(B)(6) (B)(4) (B)(4)

(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH020001 

4502N-1 

12/31/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C On the night of production that began on December 30, 2013 at approximately 

2136 hours while performing the Poultry Zero Tolerance task at the designated line 

1 prechill station at establishment P33900 after randomly selecting 10 carcasses, 

fecal material was observed on the seventh carcass inspected.  The fecal 

material was green in color, pasty in texture and easily smeared when 

touched.  The three smears observed each measured approximately one 

eighth inch by one eighth inch and were located in the tail area.  Mr. 

, was notified of the finding and informed the noncompliance 

would be documented on a noncompliance record.  According to the plant’s 

investigation the cause of the noncompliance was the IOBW was not properly 

adjusted for the size of bird.  The measure to prevent recurrence was 

“ The 

requirements of 9 CFR 381.65(e) and 417.2(c)(4) were not met.   

Refer to NR NHH2408125816N/1 dated December 16, 2013 for similar 

noncompliance.  The measure to prevent recurrence for this noncompliance 

was maintenance will monitor the I/O wash height 2 times more during the 

shift.  These measures may have been implemented incorrectly or may have 

been ineffective at preventing recurrence. 

5308 M6137 BXL2918124 

830N-1 

12/30/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 1537 hours while performing a Zero Tolerance task on Line in 

Plant #2, I observed the following noncompliance.  After&

 removed a standard 10 bird sample from the line,I observed 1 bird 

with visible fecal contamination.  The fecal material was inside the carcass on 

the left side.  It measured approximately 1/2" x 1 1/2" and extended from 

the left leaf fat to the kidney area above the tail.  The 

fecal material was brownish green in color and thick and pasty in 

texture.  This exceeds the limit of Zero Tolerance for the process to be 

in control.  I informed of the noncompliance.  

The protocol for fecal failure was implemented.  Quality Control did a recheck 

after the line gap and it passed at approximately 1610 hours.  My findings 

indicate a noncompliance with the critical limits of CCP-2B 

of the Plant's HACCP Plan for Slaughter, regulations 9CFR 381.65(e) 

and 9CFR 417.2(c)(4). 

(b) (6)
(B)(6) (B)(6)

(B)(6)

(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5108125 

630N-1 

12/30/2013 04A06 Poultry Finished 

Product Standards 

C On 12/30/2013, while performing Pre-Chill Finished Product Standards Task, 

I observed a noncompliance with the following regulatory requirements of 

regulation 9CFR 381.84.At approximately 0548 hours, I randomly removed a 

10 bird sample from Line in Plant #2 for my FPS check. I found one out of the ten 

birds with visible airsacculitis exudates, the bird had split tail. The 

establishment marking system uses a split tail to mark the birds requiring 

vacuuming. At approximately 0553 hours, Quality Control performed a recheck and 

failed.  found two out of ten birds with split tail containing 

airsacculitis exudates. QC informed the Line Supervisor and birds from that line 

were retained. At approximately 0600 hours QC performed another recheck and it 

passed. The retained product was reworked. was 

informed about the noncompliance. 

5309 P6137A NJN191212 

4031N-1 

12/30/2013 04A06 Poultry Finished 

Product Standards 

O While performing a finished product standards check at approximately 1130 hours, 

on the reprocessing line prior to the birds entering the chiller, I observed a 

noncompliance. In a sample of ten carcasses, there were eight carcasses with split 

tail (which identifies that vacuuming is required to remove all affected tissues 

including the kidneys). Three out of the eight carcasses had yellow gelatinous tissue 

inside, located beside the pelvic bone and on the flap area, and another two 

carcasses had parts of the affected kidneys not vacuumed. I immediately took 

regulatory control action by stopping the re-processing line and showed Mr. 

, my findings and informed him 

of the forthcoming noncompliance. The presence of five carcasses with airsacculitis 

affected tissues out of eight carcasses indicates that the re-processing line was not 

under control. The plant failed to effectively apply their procedures for air-sac and 

comply with federal regulation 9 CFR 381.84. 

(b) (6)
(B)(6) (B)(6) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5708125 

428N-1 

12/28/2013 03J02 Slaughter HACCP O On 12/28/2013 at approximately 0555 hours while monitoring Post-Chill Finished 

Product Standards from product exiting Chiller #4, I observed the following. 

After collecting a standard 10 bird sample I found one bird with visible fecal 

contamination. There was a gizzard with approximately 6" of intestine attached 

inside the carcass. The cut end of the intestine was visible at the opening to the 

abdominal cavity. There was fecal material leaking from the cut end of the intestine 

onto the left exterior side of the carcass on to the thigh area approximately 1" from 

the base of the tail. was observing so I 

immediately showed him the carcass and the fecal contamination. The fecal 

material was a smear,  medium brown in color and measured approximately 

3/8" by 1/8" in size. The hanging of carcasses going into packaging was 

stopped. A recheck passed at approximately 0558 hours. A partial tank of carcasses 

was placed under QC hold pending reinspection. was 

informed of the noncompliance.  My findings indicated a noncompliance 

with 9 CFR  381.65(e) and 9 CFR 417.2(c)(4).  

5308 M6137 BXL5901124 

528N-1 

12/28/2013 01D01 SPS Verification C On 12/27/13 at approximately 2319 hours I was giving an Inspector a break in Plant 

one, line #2, Station #7, when I noticed a juvenile cock roach sitting on the left side 

faucet. I stop the line, took a piece of paper towel and killed the roach.I then started 

the line and turn on my call light, answered my light and I 

informed him of the cock roach. My findings indicate a non compliance with 

CFR 416.2(a). 

(b) (6)
(B)(6) (B)(6)

(B)(4)

(B)(4)

(b)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5129 M210 LQN091412 

5927N-1 

12/27/2013 01D01 SPS Verification C While performing the review and observation component of one Sanitation 

Performance Standard (SPS) task, I observed noncompliance with SPS regulatory 

requirement 416.1 and 416.4(d).At approximately 0857 hrs in the Raw 

Product Processing Department/Injection Area, I observed numerous flakes 

(approximately 20 count </= 1/16") of black unidentifiable foreign material 

(UFM) lying on the top surface of one large plastic bag which 

served to line one edible product stainless steel tank (# 562) and to protect the raw 

product contained within. I observed that the protective plastic material was 

partially draped back leaving a portion of the raw product contained within the tank 

exposed. Upon further investigation, additional black flakes of UFM (approximately 

10 count < 1/16") were observed lying on top of and in direct contact 

with random surfaces of the exposed raw product. Official regulatory control 

action was taken and U.S. Retain Tag No. B39554792 was used to retain the 

contaminated product (Turkey Breast Meat-Est. 157). , was 

promptly notified who immediately implemented corrective action. I asked 

where the U.S Retained tank of raw product had been stored prior to being staged 

in the Injection Area.  stated that the tank had been retrieved from 

Raw Product Cooler #4.Upon appropriate product disposition, official regulatory 

control action was relinquished and the above cited U.S. Retain 

Tag was removed (1225 hrs.).A review of the establishment's written 

SSOP Program was performed. Section II. Operational Objective states, 

."A similar noncompliance with the same 

root cause (black UFM on raw exposed product and protective 

plastic covering in Cooler #4) was observed and documented on 

NRLQN3923085210N/1 dated 8/10/2013. Plant Management's elected 

written response states,

 This linkage serves to demonstrate that the 

preventive measures were either not implemented or were ineffective 

in preventing recurrence of SPS regulatory noncompliance (cross 

contamination of raw product). Note: To date Plant Management has proffered that 

the source of the black UFM has not yet been identified.This document serves as 

written notification that failure to comply with regulatory requirements in 9 CFR 

Part 416 could result in contamination or adulteration of product and 

insanitary conditions and could result in additional regulatory or 

administrative actions as described in 9 CFR Part 500.4.    

(b) (6)
(B)(6) (B)(4) (B)(4) (B)(4) (B)(4) (b)(4) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0409121 

927N-1 

12/27/2013 06D02 Other Inspection 

Requirements 

C On 12/27/2013 at approximately 0003 hours the inspectors on line were 

complaining about the way the carcasses were arriving at the inspection 

station. After checking the Presentation Log for the shift and finding no 

issues documented I performed the task and observed the following. The first 

station on line had (1) viscera not uniform, (5) viscera on shackle, (1) membrane, 

(3) not reflected, (3) parts inside for a total on 59 nonconformance points. This 

exceeded the limits of points or occurrences for one error for the process to be 

in control. A total of over 40 nonconformance points requires an immediate 

reduction in line speed. I contacted and 

informed him that the process was out of control. The line was slowed to birds 

per minute. The second station had (1) viscera not uniform, (2) viscera on shackle, 

(3) not reflected and (2) parts inside for a total of 32 nonconformance points. The 

third station had (1) viscera on shackle, (1) membrane, (2) not reflected and (4) 

parts inside for a total of 18 nonconformance points. A Quality Control recheck 

passed at 0010 hours at (birds per minute) and a second recheck at 0040 

hours passed at bringing the process back into control. My findings 

indicated a noncompliance with 9 CFR 381.76(b). 

(b) (6)
(B)(6)

(B)(6) (B)(6) (B)(6)

(B)(6)

(B)(7)(C) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

6036 P6164A OIJ1021122 

026N-1 

12/26/2013 04B01 Labeling - Product 

Standards 

C On 12-24-13 at approximately 1434, I, CSI , was performing the regularly 

scheduled Labeling-Product Standards PHIS Task in the packaging area. I observed a 

pallet of twenty two cases of product  # 090201 Frying Chicken Whole Breast 

located at the east end of the Rotis Area. I observed that some of the case’s box end 

labels had a slaughter date of 12-23-13 and a Julian date of 357. According to the 

establishment’s labeling procedure, the correct Julian date for 12-24-13 is 358. I 

did not know when this product had been packaged. To answer this question, at 

approximately 1438, I discussed the issue with 

, and showed him what I observed in the Rotis Area.  Mr.

 explained the product was part of an order of two hundred and thirty cases 

and had been slaughtered 12-23-12 and packaged 12-24-13. Mr. explained 

that two hundred cases were already on a trailer located at the shipping dock. At 

approximately 1439, I verbally informed Mr. that I was issuing a 

noncompliance record for the mislabeled cases with the wrong Julian date and 

applied US Rejected/US Retained Tag # B37852272 to one of the cases on the pallet. 

At approximately 1448, with the assistance of 

, the two cases of product that had been mislabeled were relabeled with 

labels with the correct slaughter date and Julian date. At approximately 1449, I 

removed the US Rejected/Us Retained Tag from the cases and released the product 

back into the establishment’s control.   At approximately 1452, with the 

assistance of , the two hundred cases of product # 090201 were 

located on five pallets inside trailer # 285 at bay # 3 at the shipping dock. I visually 

verified the labels on the cases had the correct slaughter date and Julian date. This 

NR is not linked to any recently issued NR for the same root cause. 

(b) (6)
(B)(6) (B)(6) (B)(7)(C) (B)(4) (B)(4)

(B)(4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

6036 P6164A OIJ4509121 

326N-1 

12/26/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C On December 26, 2013 at 0705 I, CSI performed a routine 

scheduled Poultry Zero Tolerance task.  I observed visible fecal material on 

one of the ten randomly selected carcasses. The 1/2” by 1/8” strip of dark olive 

green fecal material was found on the interior of the bird located along the right 

thigh/hip.  Adjacent to the green fecal material was white urate 

approximately 1/8” in diameter. I verbally notified and

 of the failure and that a NR would be issued.  The plant 

implemented their fecal failure program.  The verbal response given as to the 

cause was a nozzle in the New York wash cabinet was not working.  The 

nozzle was repaired.  A retest by QC found no further incidence of visible 

fecal present.  The verbal preventative measure given was that the New York 

bird wash cabinet nozzles will be added to the Maintence machine checks required 

to be performed at every plant break. Records show that on December 4, 2013, 

NR# OIJ0908123505N (#84) was written for fecal found on a wing.  The 

written response states the cause was the New York bird wash cabinet had a 

malfunctioning spray nozzle.  The preventative action was that the New York 

bird wash cabinet was to be monitored every half hour until December 13, 2013. 

 This NR is linked to NR# OIJ0908123505N (#84).   The 

Establishment Awareness Meeting notes show the last time fecal noncompliances 

were discussed was on December 5, 2013. 

5308 M6137 BXL2807120 

924N-1 

12/24/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 12/23/2013 at approximately 2223 hours while monitoring the establishments 

Pre-Operational Sanitation standards in Plant 2, I observed the following. The 

Scalders at the end of line were being drained for cleaning. As 

discussed at the morning meeting with management on 12/18 the establishments' 

SSOP Pre-Operational Sanitation procedure states in part 

 A review of the SSOP Pre-Operational sanitation Implementation and 

Monitoring Log for the shift revealed that Plant 2 was released at 2213 hours by 

the SSOP for 'operations' although cleaning of the Scalders was not completed until 

approximately 2238 hours.  At approximately 2226 hours there was a 

heavy yellowish pasty UFM(Unidentified Foreign Material) on the top of the guide 

bar associated with second Picker on line . The unit was recleaned and released by 

approximately 2232 hours. At approximately 2250 hours there were 3 hoses that 

each had several feet coated with a pink slimy UFM. The hoses are 

 associated with the chiller aeration system. The hoses were disconnected 

and flushed restoring sanitary conditions by approximately 2256 hours. My 

findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.4(a) & (b), 9 

CFR 416.13(c) and 9 CFR 416.14.  

(b) (6)
(B)(6)

(B)(6)

(B)(6) (B)(6) (B)(6) (B)(7)(C) (B)(7)(C) (B)(4)

(B)(4)

(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2114125 

923N-1 

12/23/2013 03J02 Slaughter HACCP C While performing Pre-Chill Finished Products Standards Task, I observed a 

noncompliance with the following regulatory requirements of regulations 9CFR 

381.65 (e) and 9CFR 417.2 (c)(4).At approximately 0957 hours, I randomly removed 

a 10 bird sample from Line in Plant #2, I found one out of the ten birds with 

visible fecal contamination inside of the bird, on the right leaf fat area. The 

fecal material was brownish in color, creamy in texture and measured 

approximately 1/8" diameter in size. This exceed the limit of Zero Tolerance 

for the process to be in control. I informed and 

of the noncompliance. The protocol for fecal failure was implemented. 

Quality Control performed a recheck at approximately 1027 hours and it 

passed.This is a violation of the critical limits of CCP-2B of 

the Plant's HACCP Plan for Slaughter. 

5112 M18909 JDD5907121 

420N-1 

12/20/2013 01D03 Poultry Sanitary 

Dressing 

C On 12/16/2013, Dr. , at about 0230 H PST observed a bird from 

Tanked Off Birds being returned to line without washing off the 

Fecal Contamination. They were adding the affected carcass to the 

community vat, this is at the Hock Cutter/Rehang Station. Dr. took 

control of the Carcass and had it reconditioned by Mr. prior to 

him putting it back on the line. Mr. and Ms.

 were notified of this issue and of our intent to document.The 

birds were tanked off because of the size (birds were abnormally small) and 

condition of the birds, Contamination with Fecal before and after opening the 

cavity. This in turn caused the Establishment to stop the kill line for while, tank off 

birds while getting caught up on the reprocessing of birds with Fecal Contamination 

that had been removed at the Two Inspection Stations. Noted: Later this Lot the 

Establishment stationed one employee on each line spaying fecal 

contamination off the carcass prior to opening. The contamination rate was 

25%>. This is a violation of of the Establishment written SSOP Program stating in 

" and the above 9 CFR's. 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(6)

(B)(4)

(B)(4)

(B)(4) (B)(4) (B)(4) (B)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1323120 

020N-1 

12/20/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 12/19/2013 at approximately 0400 hours while performing a direct observation 

function under Step 10 CCP-3B of the establishments' Notice of 

Deferral Verification Plan dated October 13,2013, I observed the 

following. At Rehang 1 at approximately 0400 hours I monitored 

the mid-shift Second Processing Rinse Procedure. At approximately 0440 

hours according to the requirements of the process were 

met and packaging production resumed. I had monitored the area the entire 

time and the 'kickers' for the Check/Weight lines and the parts of the drip trays that 

drain back into the spray cabinets that are treated as product contact 

surfaces had not been rinsed or treated with I informed 

who called , and and I 

repeated my observations. I was informed by that he was not 

aware of the requirement to the kickers or the drip pans so he would not do 

so today. I informed him that a noncompliance would be issued. A 

review of the Establishments' HACCP Plan - Raw Intact - Packaging Step 6 

Sort/Size under Potential Hazard lists (B) Salmonella and then Is the Hazard 

Significant? YES. Under Justification for Decision it states 

. Supplement 53 is listed as a supporting document. Supplement 53 

states under procedure Step 4 

The procedures in Supplement 53 regarding 

application were not implemented as written.  My findings indicated a 

noncompliance with 9 CFR 416.13(b) & (c), and 9 CFR 416.15(a) & 

(b).   

(b) (6)
(B)(6) (B)(6) (B)(4) (B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN401812 

1420N-1 

12/20/2013 01D01 SPS Verification C At approximately 0918 hours, while performing an operational sanitation task in 

area 2-packaging section (B), I observed plant employees washing down the 

Marination line, over head conveyors, deboning table, deboning 

machine, and the associated conveyors. The plant employees had over sprayed four 

boxes containing trays and labels, which were placed beside the hopper prior to 

polar massager. Damper # 1 contained a combo bin filled with product and had the 

sides of the plastic liner tied over it which had been over sprayed from the outside. 

Also, I observed an ice combo bin placed beside the delivery system # 1 and drop 

chutes. The ice bin was improperly covered with a plastic bag and had debris due to 

the wash down of the lines. Farther more, there was cardboard combo bins with 

plastic liner without labels to indicate the intended use. I immediately informed Mr. 

, of the forthcoming 

noncompliance. The plant failed to comply with the regulations cited 

above.   

5308 M6137 BXL1805125 

719N-1 

12/19/2013 03J02 Slaughter HACCP C On 12/19/2013 while performing a Pre-Chill Finished Products Standards Task, I 

observed a noncompliance with the following regulatory requirements of 

regulations 9CFR 381.65(a) and 9CFR 417.2(c)(4).At approximately 0159 hours, I 

randomly removed a 10 bird sample from Line in Plant #2. I found one out of 

the ten birds with visible fecal contamination on the right hock. The fecal material 

was approximately 3/16" in diameter in size, olive green in color and pasty in 

texture. I informed of the noncompliance and the protocol 

for fecal failure was implemented. Live hang had already stopped hanging birds for 

the lunch break and at approximately 0307, after the lunch break, Quality 

Control performed a recheck and passed. This is a violation of the critical limits of 

CCP2B,  of the Plant's HACCP Plan for Slaughter. 

(b) (6)
(B)(6)(B)(4) (B)(4)

(B)(4)

(B)(4)

(B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2504120 

519N-1 

12/19/2013 01C02 Operational SSOP 

Review and 

Observation 

O On 12/18/2013 at approximately 2220 hours after the area had been released from 

Pre-Operational Sanitation and while monitoring Operational Sanitation in 

the Rotisserie Room, I observed the following. There was an employee standing on 

the top of the Tank for the Injection Machine assisting with the assembly of 

the Injector Machine. The establishments' SSOP Section II - Operational 

sanitation under Implementation  '

 There was no plastic or other protective measure in use 

as the employee boots were in direct contact with the top of the tank.  The 

SSOP - Operational Sanitation under Corrective Action a Plant 

Management Team Member  under Restoration of Sanitary Conditions: 

." A review of the 

SSOP Daily Implementation and Monitoring log for the shift under Operational 

SSOP found everything acceptable for the shift. The lack of access to 

reassemble the machine was discussed with management previously  at a 

weekly meeting. My findings indicated  indicated a noncompliance with 9 

CFR 416.1, 9 CFR 416.2(b)(1), 9 CFR 416.3(a), 9 CFR 416.12(a), 9 CFR 416.14 and 9 

CFR 4156.15(b).        

5308 M6137 BXL3617124 

719N-1 

12/19/2013 03B02 Raw Non-Intact 

HACCP 

C On 12/18/2013, at approximately 1800 hours, while performing HACCP Raw 

Non-Intact Record Review Task, I found a noncompliance with the following 

regulatory requirements of regulation 9CFR 417.5 (a)(3).The day before 

(12/17/2013) while performing direct observation on Raw Non-Intact task in the 

Rotisserie Room, I observed the following. During the mid-shift (lunch break) 

rinse, the HACCP monitor or designee measured the sanitizer concentration 

on five contact surfaces. The first check Quality Control had two failures, 

(each of of and the third recheck passed  ppm of 

The second and the third regular checks passed. The fourth check had again two 

failures, (each of ppm of  and the third recheck passed ppm of 

. The fifth regular check passed. When I review the records, the HACCP 

Monitoring Log -CCP 3B- , Raw 

Non-Intact, dated on 12/17/2013, PM shift, did not have any 

Corrective Action Log. I observed that the corrective actions were performed 

but not documented in the Corrective Action Log. I informed Quality Control

 about the noncompliance. 

(b) (6)
(B)(6)

(B)(6)

(B)(4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5310 M6137B FFA1304124 

619N-1 

12/19/2013 01D01 SPS Verification C On December 19, 2013 at approximately 0145 hours, after the establishment had 

finished their pre-operational sanitation inspection and prior to the start of 

operation, I observed noncompliance with SPS 416.1; 416.2(b)(1), and 

416.4(b). While performing my pre-operational sanitation inspection on 

Oven #1 and Oven #2, I observed that at the exit end of oven 1 and 2 the overhead 

exhaust drip pans and supports have an excessive amount of what appears to be 

Rust and Smoke build up.  I informed and showed 

the noncompliance.  Ms. ., was also 

informed.This does not comply with Regulatory Requirements: 416.1; which states 

in part, "Each official establishment must operate in a manner to prevent insanitary 

conditions", 416.2(b)(1); "Establishment buildings, compartments must be kept in 

good repair", 416.4(b);  "Non-food contact surfaces of facilities must 

be cleaned and sanitized as frequently as necessary to prevent the creation of 

insanitary conditions and the adulteration of product".This document serves as 

written notification that failure to comply with regulatory requirement(s) could 

result in additional regulatory or administrative actions as described in 9 CFR Part 

500.4. 

1325 

7 

P33900 NHH501212 

3119N-1 

12/19/2013 01C02 Operational SSOP 

Review and 

Observation 

C #200 At 0638 hours while walking down the hall to enter the evisceration area I 

observed two sleeved aprons hanging on the rack along the hallway were resting on 

the floor. The ties on these aprons are extremely long and measures need to be 

taken to prevent the ties from dragging on the floor hanging or wearing them. The 

rack in the further processing hallway also had three aprons hanging that were in 

contact with the floor. US tag numbers B38075647 and B38075646 were applied to 

the aprons. Management was notified and all the aprons that were contacting the 

floor were thrown away. The SSOP plan states that 

” This requirement and the requirements of requirements of 416.11 were 

not met. 

(b) (6)
(B)(6) (B)(6) (B)(6)

(B)(6) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1231 

11 

V210A 000061912 

3519N-1 

12/19/2013 04B05 General Labeling 

(V) 

C On December 19, 2013 while performing a visual inspection of "Chicken Paws" to 

be exported to Hong Kong I observed noncompliance with 9 CFR part 381.96 & 

381.123 of the Meat & Poultry Regulations. At 16:45 hours I observed four 

pallets of product stamped with export MPJ#567367; the plant number on the 

label; P6137A was printed directly into the inspection bug and unclear to read; as 

well there were several cases of product where the plant number was tore off of the 

label all togather, I was unable to determine the plant number. Mr. 

& Mr. were both verbally notified and shown the 

noncompliance. A regulatory control action; (RCA) was taken on the four pallets 

with U.S. Retain tags# B43241946, 47, 48, 49. At 18:30 hours when the plant 

implemented corrective action I relinquished the (RCA). This document serves as 

written notification that failure to comply with regulatory requirement(s) could 

result in additional regulatory or administrative actions as described in 9 CFR 500.4. 

1231 

11 

V210A 000430112 

2319N-1 

12/19/2013 01D04 SPS Verification (V) C On December 18, 2013, at approximately 1645 hours I was performing my export 

inspection on the boxes of product staged in the shipping dock at V210A.  I 

observed that the lighting near door #5 where some of the product was staged to 

be inspected was not acceptable making it difficult to check the plant number, 

exports stamp number, use by dates, and labels on each box of product. I informed

 who accompany me when I performed my export 

inspection.  Mr. informed me that he would notify his boss Mr. 

.This is a violation of Regulation 416.2(c); which states in part:  

"Lighting of good quality and sufficient intensity is required in areas where product 

is stored or examined".This document serves as written notification that failure to 

comply with regulatory requirement(s) in 9 CFR 416 could result in additional 

regulatory or administrative actions as described in 9 CFR Part 500.4. 

(b) (6)
(B)(6) (B)(6) (B)(4) (B)(4)

(B)(4)

(B)(4) (B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3505123 

318N-1 

12/18/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 12/17/2013 at approximately 2200 hours while monitoring the Establishments' 

Pre-Operational Sanitation standards in Plant #1, I observed the following. 

There was a heavy layer of pasty yellowish UFM(Unidentified Foreign Material) on 

the stainless guide bar above the third Picker for line #2. The unit was cleaned and 

released by approximately 2210 hours.  At approximately 2330 

hours Packaging Area 1 in the Plant #1 Rehang area there was a thick coating 

of dried black and brown UFM on the guide bars for the Check /Weight line. 

An area approximately 6 feet long of the guide bars on the return side of line 

1 & 2 and the spray assemblies at the same location were recleaned and 

released by approximately 0000 hours.  At approximately 2340 

hours there were several pieces of fat and tissue to approximately 1/4" on 

the inside surfaces of a stainless steel tank covered with blue plastic and 

staged for use near the outflow conveyor for Chiller 2.  The blue 

plastic is used by the Establishment to identify tanks that are clean and ready for 

use. The tank was rinsed with potable water restoring sanitary conditions. At 

approximately 2335 hours there were numerous pieces of tissue to approximately 

1" inside of the unit filter. The filter was rinsed with potable water and 

returned to service by approximately 2345 hours. was informed 

of the noncompliance. At approximately 0004 hours in Packaging Area #1 

along line on the blue product belt for the  Dip system there 

was black UFM(Unidentified Foreign Material) that smeared like grease 

contaminating an area of the belt measuring approximately 1 square foot. There 

was also several pieces of tissue to approximately 1/4" on the stainless under the 

belt at the same location. There were several pieces of fat and tissue measuring to 

approximately 2" on the sprocket for the tray belt at the head of line The area 

was cleaned and released. At approximately 0010 hours there was fat and 

tissue to approximately 2" on the chain of Leg Processors 1-3. The machines were 

released by approximately 0015 hours. At approximately 0025 hours in Packaging 

Area 2, the , there was black UFM (Unidentified Foreign Material) that 

appeared to be mold along the ceiling support beam near the vertical belt 

that transports breast fillets from the final trim table to Packaging Area 1. The area 

will be cleaned after production. was informed of the 

noncompliance. As discussed in the morning meeting on 12/18 the establishments' 

SSOP Pre-Operational Sanitation procedure under Monitoring states in part 

Yet for each area even with the SSOP log completed certifying that 

the area is 'released for operations' the USDA inspector is told by the area 

Sanitation Supervisor that the area is not ready with cleaning still in progress. The 

SSOP Pre-Operational Sanitation 'Implementation' daily procedure steps should 

(b) (6)
(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

routinely be completed before the 'Monitoring' step is performed.  This issue 

was discussed with management at the morning meeting on 12/18/2013. My 

findings indicated a noncompliance with 9 CFR 416.1,  9 CFR 

416.4(a) & (b), 9 CFR 416.13(c) and 9 CFR 416.14. 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(4) (B)(4)

(B)(4)

(B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3805124 

018N-1 

12/18/2013 01D01 SPS Verification O On 12/17/2013 at approximately 2000 hours while monitoring the establishments' 

Operational Sanitation Standards in the Plant #1 Cooler, I observed the following.

 Refrigeration Unit W-1 mounted from the ceiling near the Staging 

Cooler door was in the defrost cycle. Thawing condensates were dripping from the 

bottom the the drip pan onto three pallets of brown product tubs of giblets 

staged directly below the cooler unit. The condensates were adding an 

untold number and variety of contaminants on the exterior of the brown 

product tubs that are handled during dumping by employees wearing  there 

green product contact gloves. The condensates were creating an insanitary 

condition.  I contacted and showed him the 

noncompliance.  A mechanic was called and after checking the computer 

he said that the unit was defrosting. The drip pan that should be collecting 

the condensates and directing them to a drain was leaking. I got a ladder and inside 

the drip pan was a large area of a blackened slimy mass of UFM (Identified Foreign 

Material). I collected some of the UFM and it consisted of plastics coated with a 

blackened grease like substance. The defrosting  fluids were passing through 

the blackened mass before dripping from the leaking catch tray onto the 

brown product tubs. The tubs were moved and reconditioned with 

water. My findings indicated a noncompliance with 9 CFR 416.1 and 9 CFR 

416.2(b)(1).    

5308 M6137 BXL3817120 

318N-1 

12/18/2013 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 0858 hours while monitoring the shift change rinse procedure 

and application at the Plant #2 Post Chill Rehang area, I observed the following 

noncompliance.  Production employees were rinsing and applying sanitizer 

( to the product contact surfaces as prescribed in the SSOP Plan.  A 

company employee was still rinsing Line #2 at Rehang 2 when he was asked to 

hurry up so could be applied at which time he stopped rinsing the line, 

without rinsing inside the drop chutes for carcasses to reach the lower belt.  I 

then observed company personnel applying the sanitizer ) to Line the Bag 

Fryer line.  When the employee was through with the line, I had observed 

that he had not sprayed inside the drop chutes that take birds to the lower belt, 

which is a product contact surface.  I immediately informed QC and

 of the noncompliance.  The SSOP Plan states in 

part under Second Processing Rinse Procedure that 

".  had a 

sanitation employee rinse the inside of the drop chutes on Line #2 and then 

had sanitizer applied to the inside of the drop chutes on Line #2 

and the Bag Fryer Line as well, restoring sanitary conditions.  

(b) (6)
(B)(6) (B)(6)

(B)(6)

(B)(6) (B)(4) (B)(4) )(4) (B)(4) (B)(4)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2621120 

817N-1 

12/17/2013 01C02 Operational SSOP 

Review and 

Observation 

O On 12/16/2013 at approximately 1935 hours while monitoring Operational 

Sanitation in Packaging, I observed the following. There were employees deboning 

leg meat on line 1 and at the salvaged parts table adjacent to line 1 and 

placing the meat in blue plastic bags. The establishments' Notice of Deferral 

Verification Plan dated October 13, 2013 step 17 had the establishment 

install Acidified sprays on all lines. The HACCP Plan - Raw 

Intact - Packaging step 7. Cut/Deboning/Trim under (C) Chlorine  and (B) 

Pathogens states ' The process is designed to reduce the risk associated with the 

hazard. 

. Supplement 59  has the 

sprayers monitored 

."  The SSOP Daily Implementation and Monitoring 

Log - Packaging for the shift  showed that the last sprayer check in Packaging 

was performed at 1612 hours. The sprayers were not on as required 

by the establishments' Verification Plan. I contacted and a 

partial rack of leg meat was placed into 3  brown tubs to be treated and 

repacked. My findings indicated a noncompliance with 9 CFR 416.13(b) & (c) 

and the establishments' Verification Plan. 

5308 M6137 BXL2710125 

717N-1 

12/17/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C While performing Zero Tolerance Task, I observed a noncompliance with the 

following regulatory requirements of regulations 9CFR 381.65 (e) and 9CFR 417.2 

(c)(4).On 12/16/2013, at approximately 1243 hours, removed 

a 10 bird sample from Line #1 in Plant #1, I found one out the ten birds with visible 

fecal contamination, inside of the bird at the left side, close to the tail. The 

fecal material was brownish in color, creamy in texture and measured 

approximately 1/4" diameter in size. This exceed the limit of Zero Tolerance for the 

process to be in control. I informed and 

of the noncompliance. The protocol for fecal failure was implemented. Quality 

Control performed a recheck at approximately 1312 hours and it passed.This is a 

violation of the critical limits of CCP-2B of the Plant's 

HACCP Plan for Slaughter. 

(b) (6)
(B)(6)

(B)(6)

(B)(6)(B)(6)

(B)(6) (B)(7)(C) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5568 M20923 XUM580212 

3617N-1 

12/17/2013 03G02 Fully Cooked-Not 

Shelf Stable HACCP 

C On 12/16/2013, at approximately 2020 hours, while performing a routine 

scheduled HACCP Records Review inspection task in the QC Managers Office, I 

observed the following noncompliance: while reviewing the Fully Cooked Shelf 

Stable Whole Muscle / Diced Stripped HACCP Program's Hazard Analysis 

dated 12/16/13, several process steps from the Refrigerated Storage Step to 

the Shipping WIP Product to FTP2 Plant or approved Co-Packer for High Pressure 

Pasteurization Step were missing the hazard of concern, a noncompliance per 9 CFR 

417.5(a)(1). The hazard analysis did document the hazard as not likely to 

occur and establishment's reasoning / prerequisite program 

used, thus there were no food safety hazards 

identified with the establishment shipping adulterated product into 

commerce during that production. I showed and informed Mr. , 

Production Superintendent of the forthcoming noncompliance. The requirement of 

9 CFR 417.5(a)(1) was not met. 

5112 M18909 JDD1523125 

816N-1 

12/16/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On PRE-OP  this date 12/16/2013 I observed the following: 1) Black 

Piece of Plastic 1/2 in long, on the End Chute off the Breast Sorting Belt. 2) Grease 

Zirk missing on bearing at Spiral Belt, this has been gone several days. 3) Product 

Residue on both side of the door between Cooler Five and Raw Fab. 4) In little Dry 

Storage Room off of Raw Fab, the racks there had Product Residue on them. 5) 

Broken Air Lines on bottom of Chiller B.  Mr. 

, Mr. and Ms 

were advised of these issues and no note of these were seen in Q.C. 

POaperwork. This is a violation of the Establishments SSOP program and the above 

listed 9 CFR's. This linked to NR 176-2013, Dated 12/14/2013, JDD0310124414N/1 

and its associated JDD Numbers. 

5112 M18909 JDD5119121 

417N-1 

12/16/2013 03J02 Slaughter HACCP C On 12/16/2013 at approximately 1824Hrs while reviewing the establishments 

12/14/2013 records in the Quality Control Lab as part of my Slaughter records task, 

I found the following noncompliance to the relevent regulations cited above. The

 (CCP 2B) -Gib Temperature Monitoring and 

Documentation Log dated 12/14/2013 showed that the shift B HACCP 

Monitor performed her temperature check at 1812Hrs. The record did not show the 

second required hourly temperature check for the 1800Hrs. The 

pre-shipment review at 0600Hrs on 12/16/2013 to ensure completeness was 

performed by plant management also the HACCP record was reviewed and verified 

on 12/16/2013 by Quality Control. was notified of the 

noncompliance by e-mail. Dr. SPHV was also notified of the noncompliance. 

(b) (6)
(B)(6)

(B)(6)

(B)(6) (B)(6) (B)(6) (B)(6)

(B)(6) (B)(6)

(B)(4)

(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD5907125 

616N-1 

12/16/2013 01C02 Operational SSOP 

Review and 

Observation 

C Observed Boning Supervisor Ms. employee doing operational 

tasks of putting liners in tanks. I then checked the tanks and the employee had 

liners in five tanks that had product residue in them. Mr. 

was witness to the events. The tanks were 

then recleaned by Sanitation. Ms. was advised of the 

operational noncompliance as was Ms. There was not any previous 

documentation of this issue,  prior to my notification of the same. Along the 

same issue Mr. , employee is putting equipment into 

a dry storage area and the equipment has pieces of poultry residue too numerous 

to readily count. This was put in there, " not cleaned". This is a grinder and it 

is the office and Mr. 

 is witness as to the condition of the grinder. This is a violation of 

the Establishment's written SSOP program, stating in part: " 

" This 

is also a violation of the above 9 CFR's. This is linked 152-2013, 

JDD1623115706N/1, Dated 11/06/2013 and 158-2013, JDD3803110513N/1, Dated 

11/13/2013 and both NR's associated JDD Numbers. 

5309 P6137A NJN310312 

1817N-1 

12/16/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C At approximately 0049 hours, after the QC Technicians had performed Pre 

Operational Sanitation and released the area for production, I proceeded to perform 

Pre Operational Sanitation in Area 2-Packaging/ Section C: Segment Line & 

. While doing so, I observed numerous pieces of fat and skin on and 

around Leg Processor # 2 as well as conveyors directly below LP #2. On a supporting 

structure above there was grease and fat build up from the previous day’s 

production. I took immediate regulatory control action by applying US Rejected 

Tag # B 43303634 to the affected area and informed Mr. 

of the forthcoming Non Compliance Record. At 0103 hours, after the 

restoration of sanitary conditions, I reinspected and released the area. The 

establishment failed to adequately monitor the implementation of the sanitation 

SOP, which in turn created an insanitary condition. The findings represent a 

non-compliance with 9 CFR 416.4a, 416.4b and 416.13c. 

(b) (6)
(B)(6)

(B)(6) (B)(6)

(B)(6)

(B)(6) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH240812 

5816N-1 

12/16/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C #199At approximately 0803 hours while performing a zero tolerance task 

on eviscerating line two I observed feces inside the lower keel 

area of the first sample bird. It was approximately 3/16” in 

diameter, olive green in color with a pasty consistency. The bird 

was shown to QA, maintenance personnel, and Management.   

The establishment failed to comply with the requirements of CFR 381.65(e). After 

investigating the incident, according to the report,Maintenance found that 

the I/O wash was too low for the smaller birds and the probe not entering the 

cavity of the bird. It also stated that Maintenance will monitor the I/O wash height 

2 more times during the shift. 

5310 M6137B FFA2100121 

815N-1 

12/15/2013 01D01 SPS Verification C On December 14, 2013 at 1510 hours while monitoring the operation in the Frank 

Peeling Area I observed insanitary conditions.  I observed an excessive 

amount of product on the floor in front and underneath the Frank Peelers numbers 

1, 2, and 3.  I observed excessive amount of product on the floor underneath 

the Hoppers/Convery Belts to numbers 1, 2, and 3.  At the time of 

my observation I did not see anyone cleaning up in this area.  Mr. 

and Ms. , was informed.  Immediate 

Corrective Action was implemented by Management:  Product was condemn 

and the floor was cleaned and sanitized.This does not comply with Regulation 416.1 

which states:  "Each official establishment must be operated and maintained 

in a manner sufficient to prevent the creation of insanitary conditions and to ensure 

that product is not adulterated", and Regulation 416.2(b)(2); which states in 

part:  "Floors within the establishment must be cleaned and sanitized as 

necessary to prevent adulteration of product or the creation of insanitary 

conditions".This NR is Linked to NR#FFA5818120006N/1 dated 12/06/13, for a 

similar noncompliance.  As of today 12/14/2013, Management has not given 

a written response to this NR.This document serves as written notification that 

continue failure to comply with regulatory requirement(s0 could result in 

additional regulatory or administrative actions as described in 9 CFR Part 500.4. 

5112 M18909 JDD0310124 

414N-1 

12/14/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C 1) Water Reuse Tank off of Chiller B had Poultry Residue in it. 2) Product Discharge 

Belt into Chiller A had Poultry Residue on it. 3) Product Residue and Rust in 

the Final Wash. 4) Hoses in I/O Wash One are frayed. 5) Overheads by Picker Three 

with Feathers > 10. Mr. , Mr. 

and Mr. were notified of these 

issues. No documentation of these issues was observed in QC Paperwork. The is a 

violation of the Establishment's written SSOP program and the above listed 9 CFR's. 

This is linked to NR 172-2013, Dated 12/09/2013; 171-2013, dated 12/07/2013; 

168-20132, Dated 12/02/2013 and their associated JDD Numbers. 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(7)(C) (B)(7)(C) (B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD0423125 

514N-1 

12/14/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C On 12/14/2014 at approximately 1730Hrs while performing my PHIS Zero 

Tolerance fecal check, I observed visible fecal material on the 10th bird sampled out 

of the ten whole body Light Hen Turkeys sampling test from line one. The feces was 

found on the left side of the distal pelvic cavity at the cavity opening. The 

fecal material was non granular; uniformly green in color, moist and pasty 

consistency with the distinct odor consistent with fecal material. The two 

fecal material pieces were at the same site one in front of the other. They 

were approximately 10mm x 3mm and 8mm x 3 mm in size. U.S. Retain Tag 

NO:B39554629 was applied to the affected carcass. ; 

, and Dr. , SPHV were 

notified of the noncompliance and shown the affected carcass. Dr. 

concurred that it was fecal material. Ms. immediately implemented the 

establishment's corrective actions. The had the affected turkey reconditioned by 

trimming and spraying and reinspection. At 

approximately 1836Hrs the turkey was released back to production after 

verifying the plant's corrective actions and reinspection. Ms. conducted 

her rechecks after the final wash and they passed. This observed incident of visible 

fecal material is a noncompliance to 9 CFR 381.65(e). Also is a violation to 9 CFR 

417.2(c)(4) monitoring at the critical control point to ensure compliance to the 

established CCP 4B ) after the final wash and before 

entering the chiller. At approximately 2055Hrs the plants implemented corrective 

actions at the post chill were completed and passed by Ms. Ms. verified 

the checks per HACCP Plan. This noncompliance is a repeated noncompliance and is 

being linked to noncompliance (#173) JDD5422121809N/1 dated 12/9/2013; 

(#170) JDD2423120405N/1 dated 12/5/2013, (#167) JDD 1623110427N/1 dated 

11/27/2013 and (#134) JDD5821101818 dated 10/17/2013 for the same cause 

respectively. 

(b) (6)
(B)(6) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5008124 

214N-1 

12/14/2013 04B03 Labeling - Net 

Weights 

C On 12/14/2013 at approximately 0540 hours while monitoring 

Weigh & Price, I observed the following. As the Night Shift was 

finished in Weigh & Price Production Supervisors and Quality Control were 

leaving for the Day. I left Weigh & Price to ensure other production 

areas were finished.  I again passed  through the Weigh & Price 

area at approximately 0550 hours on my way home when I observed 

establishment personnel boxing out product in Weigh & 

Price. I went to the Production Supervisors office and the Quality Control 

office but everyone was gone. I went to NCDC to see if  a QC person 

was monitoring the Net Weight process. An  employee placing the 

cases onto a pallet said QC already went home. I asked for a Supervisor and found

 in the NCDC loading area. I asked if he frequently operated 

without Quality Control personnel monitoring the Weigh & Price 

function. He said that Weigh & Price personnel  normally do not 

go home so early. The employee palletizing the product said they  

were expecting approximately 40 cases. I checked a case of  

wings and a case of B/S breast for Net Weight compliance using a nearby  QC 

Scale and found that none of the packages were incompliance ( 

net or better).  I explained   at the 

scale that the weight on the consumer packaging label should be the weight 

of the product plus the tare. The product including 3 cases of 00510 wings for order 

704201, 22 cases of b/s breast for order 708001 and 8 cases of 00510 wings for 

order 702500  were placed under USDA retained until being released for 

rework at 1719 hours on 12/16/2013. A review  of the establishments 

computer showed that the last entries in Weigh & Price  by Quality 

Control were made at 0512 hours and 0531 hours. No checks were made of 

the wings and B/S Breast packed at 0550 hours. A review of the establishments' 

Master Container Net Content Compliance Testing Program - RTC Plants under 

responsibility states ' It is the responsibility of QC personnel to follow this 

procedure when sampling product for net weight compliance purposes.  

There were no QC personnel available. The product was for a Sunday order and with 

the day shift coming in at 0930 hours until orders were filled there was no 

reason to by pass normal  Quality Control Net weight procedures. 

 My findings indicated a noncompliance with 9 CFR 442.1,  9 CFR 

442.2 and NIST Handbook 133..        

(b) (6)
(B)(6)(B)(6) (B)(6) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD2423123 

713N-1 

12/13/2013 01D01 SPS Verification C On 12/13/2013 at approximately 1323Hrs, I observed standing water/fluid 

approximately 3" deep at the Cooler #3 drain and extended outwards 

from the drain approximaely 3' x 3'. The drain runs across the entire hallway. The 

floor drain appeared to be backing up in the cooler #3 hallway. At this time the 

Boning Room was performing a shift washdown. The wheels of three tanks which 

contained edible food products and 2 tanks of clean ice were staged in the standing 

water/fluids. was notified and observed the 

overflowing drain. Ms. called to the personnel in the Boning 

Room to check their drains. She had the cooler #3 traffic stopped. The affected 

area was cleared of the water/fluids (fat, skin, meat) debris. The area 

was cleaned and sanitized. All of the wheels were sanitized. The food 

traffic area resumed at approximately 1329Hrs. I observed the restored sanitary 

conditions no U.S. retain tag was applied. I did not observe any direct food product 

contact adulteration at this time of my observation. The standing water at the drain 

was creating insanitary conditions that may lead to product contamination and/or 

a potential cross contamination when the tanks are moved to production areas. 

This observation is in violation to the relevent regulation cited above. Joe Lemos, 

Supervisor was notified of the noncompliance. 

5129 M210 LQN301812 

3513N-1 

12/13/2013 01D01 SPS Verification C On December 13, 2013 while performing a routine patrol of the oven control room I 

observed noncompliance with SPS regulatory requirement(s) 416.2(b)(1) & 

416.2(b)(2). At 16:11 hours I observed three large cracks running down the east, 

white painted wall located at the end of chiller #3 and oven #7; two of the 

cracks had areas of paint beginning to chip away from the wall, the cracks run from 

the ceiling to the base of the wall. Mr. was verbally notified 

and shown the noncompliance. This NR serves as written notification of a SPS 

noncompliance; as well as notification that failure to comply with regulatory 

requirement(s) may lead to additional regulatory or administrative actions as 

described in 9 CFR 500.4. 

(b) (6)
(B)(6)

(B)(6)

(B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5310 M6137B FFA0817122 

613N-1 

12/13/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On December 12, 2013 at approximately 0130 hours, after the establishment had 

finished their pre-operational sanitation inspection and prior to the start of 

operation, I observed noncompliance with SSOP Regulatory Requirement(s) 

416.13(c), SPS 416.4(a), and 416.4(b).While performing my pre-operational 

sanitation inspection in the Raw Side Department I observed Rust on the inside of 

the Large Spice Bin (product contact).  I observed one small piece of meat on 

the inside surface of the stainless steel bucket that is used to measure and 

weigh ingredient (product contact).  I observed several pieces of meat 

on the bottom side of the small dumper platform (non-product contact).  

U.S. Reject Tag NO. B38937058 was applied to the Bin and Bucket.  Mr. 

, Ms. , and Ms. 

, was informed and showed the noncompliance.  Immediate 

corrective action was implemented by management:  The Spice Bin, Stainless 

Steel Bucket, and Dumper was Re-washed, Sanitized, and Re-inspected.  

 After sanitary conditions was restored U.S. Reject Tag NO. B38937058 was 

removed.This does not comply with Regulatory Requirement(s) 416.13(c); which 

states in part:  "Each official establishment shall monitor daily the 

implementation of the procedures in the Sanitation SOP's, 416.4(a); which states in 

part:  All  food -contact surfaces must be cleaned and sanitized 

as frequently as necessary to prevent the creation of insanitary conditions and the 

adulteration of product", 416.4(b); which states in part:  "Non-food-contact 

surfaces must be cleaned and sanitized as frequently as necessary to prevent the 

creation of insanitary conditions".This NR is lined to NR#FFA5203122903N/1 dated 

12/03/13 for a similar noncompliance on Pre-op Product Contact Surface.  

This document serves as written notification that continue failure to comply with 

regulatory requirement(s) of 9 CFR Part 416 could result in additional regulatory or 

administrative actions as described in 9 CFR Part 500.4. 

(b) (6)
(B)(6) (B)(6)

(B)(4) (B)(4)

(B)(4)

(B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH391312 

5713N-1 

12/13/2013 01C02 Operational SSOP 

Review and 

Observation 

C #198At approximately 0842 while performing an operational sanitation observation 

and review task shortly after the beginning of the shift I observed insanitary 

conditions in the thigh deboning/rotisserie department of room two. I observed fat 

and debris, puddled water, thigh trimmings, and a pile of bones along the thigh 

deboning line and in the traffic area between thigh and rotisserie pack out 

conveyors. The work area was totally congested with hardly any space to allow for 

wash down or cleanup of any sort while employees are working on the line. There is 

also a problem with proper drainage in the area.  The requirements of 416.11 

and the establishment’s SSOP plan which requires that 

. 

was notified and US tag #B38075645 was assigned to the noncompliance. The 

employees were removed from the line so that the floor area and stands could be 

washed to an area where the water and debris could drain properly. The line was 

released after sanitary conditions were restored. 

5308 M6137 BXL0418122 

312N-1 

12/12/2013 03J02 Slaughter HACCP C While reviewing the company computer records for CP's, I found a 

noncompliance with the following regulatory requirements of regulation 9CFR 

417.5 (a)(1).The Salvage Parts Treatment (CP-19) for 12/11/2013, AM shift 

-Plant #1- had only three checks, at 0002 hours,  0254 hours and 0356 

hours. The last check between the hours of 0500 and 0700 for that day was not 

performed. HACCP Plan -Slaughter Plant 1- under step #37 states in part:

 The process is designed to reduce the risk associated with the hazard. 

Parts are washed with water or to reduce bacterial contamination. 

Supplements 2,7,17,18,56. HACCP Supplement #56, Salvage Parts Treatment: CP-19 

under procedure #4 states in part " 

". was 

informed about the noncompliance. 

(b) (6)
(B)(6)

(B)(6)

(B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3804125 

712N-1 

12/12/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 12/11/2013 at approximately 2137 hours while monitoring the Establishments' 

Pre-Operational Sanitation standards in Plant #2, I observed the following. 

There was a yellowish pasty UFM (Unidentified Foreign Material) on the 

fingers of  the second Picker on Line . The fingers on the half 

of the unit randomly selected were scrubbed then rinsed with potable water 

restoring sanitary conditions by approximately 2145 hours. There was a 

heavy laver of a yellowish pasty UFM on the fingers of the third Picker 

on line . There were numerous pieces to approximately 1/8"of tissue and feathers 

on the guide bars associated with the picker. The guide bar and 

the fingers on the half of the picker randomly selected were scrubbed then 

rinsed with potable water restoring sanitary conditions by approximately 2230 

hours. was informed of the noncompliance. This is a recurring 

issue that has been discussed with the Establishment at previous morning meetings 

and has yet to be resolved.  My findings indicated a 

noncompliance with 9 CFR 416.1, 9 CFR 416.4(a), 9 CFR 416.13(c) and 9 CFR 

416.14.  

5568 M20923 XUM582012 

1912N-1 

12/12/2013 01D01 SPS Verification C On 12/12/13, at approximately 1811 hours, while performing a directed Sanitation 

Performance Standards (SPS) inspection task on the Cooked Area by the entrance to 

Line I observed the following noncompliance: an overhead dome 

light CL-4-18 with chipping paint directly over exposed product being 

further processed on the transfer conveyor 

belt creating insanitary conditions, a noncompliance per 9 CFR 416.1 

and 416.4(b). This condition could cross contaminate/adulterate exposed 

Pop Dog product being ran on the transfer belt in a post lethality processing 

environment. I took regulatory control by stopping the Line production and 

rejecting the area with US Tag # 24829894. I showed and informed Mr. 

of the forthcoming noncompliance. After corrective 

action were performed by production and sanitary conditions were restored, I 

relinquished the US Tag at 1832 hours. The requirements of 9 CFR 416.1 and 

416.4(b) were not met. 

(b) (6)
(B)(6)

(B)(6)

(B)(7)(C) (B)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

6036 P6164A OIJ3913124 

612N-1 

12/12/2013 04A06 Poultry Finished 

Product Standards 

C On December 12, 2013 I, CSI performed a scheduled Finished 

Product Standard test at the Prechill area.  This test is applied to permit FSIS 

to estimate when the production process is in control for ready-to-cook 

poultry.  The test consists of two parts, trim and processing 

nonconformances.  The absolute limit allowed for processing 

nonconformances is points. My test at 0942 resulted in 43 points.   

At 0950 a retest was performed by using a tighten criteria 

of 25 points which failed with 32 points.  I verbally notified 

of the noncompliance and that I would be issuing a NR.  The 

plant implemented the required procedures for FPs failure.  The Prechill 

nonconformances I observed at 0942 were:  3 ingesta < 1/16” (3 pts), 

 6 partial oil glands (6 pts),  2 whole oil glands (4 pts),  4 whole 

lungs (8 pts),  1 trachea < 1” (1 pt), 6 trachea > 1” (12 pts), 6 small 

feathers (6 pts), and 3 large feathers (3 pts). On October 18, 2013, 

NR # OIJ2416101418N (#80) was issued for processing noncompliance.  The 

written response given is that Maintenance made adjustments to bring the process 

under control.  This noncompliance is linked to NR # OIJ2416101418N (#80) 

for the same root cause.  The Establishment Awareness Meeting notes show 

that FPS NRs were last discussed at the October 24, 2013 meeting. 

1325 

7 

P33900 NHH411112 

2912N-1 

12/12/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C #197At approximately 0837 hours while performing a zero tolerance task 

on eviscerating line one I observed feces inside the lower keel area of 

the ninth sample bird. It was approximately 3/16” in diameter, olive 

green in color with a pasty consistency. The bird was shown to QA, 

maintenance personnel, and Management.   The establishment failed to 

comply with the requirements of CFR 381.65(e). After investigating the 

incident, Maintenance found that the bottom cam was too high. 

causing the opener arm to push intestines to the front of the birds. The cam 

was lowered so it would not lift the bird to high.  

(b) (6)
 

 

 

 

(B)(7)(C) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH550012 

5412N-1 

12/12/2013 06D02 Other Inspection 

Requirements 

C On the night shift that began on 12/11/2013, at approximately 2125 hours I was in 

the picking room of Establishment 33900  P.  This Establishment uses 

a batching system of inspection, if the carcass is condemned or hung back for 

re-inspection the paw condemn button is pressed and a batch of paws are 

condemned.  This insures that all paws from condemned carcasses are also 

condemned.  I asked a picking room employee to block the electronic eye on 

both lines for a second.  If the paws were put into the drain, this would prove 

the establishment could segregate and discard the affected paws. The result of 

the test was that the establishment could not collect any of the paws that are used 

to show that all condemned paws would be captured and condemned. I talked to 

Dr. the IIC on night shift and explained what I had observed and informed 

him that I was going to reject the paw system.  Regulatory Control Action 

was taken by applying USDA Reject Tag #B38075846 to the system.  

 After repairs to the system, at approximately 2130, another test was 

performed on the line #1 system and the results allowed the Establishment to begin 

collecting paws at 2230 Hours, after the system had been rinsed with 

water.  The requirements of Regulation 381.76(b) were not being met. 

Refer to NR NHH2504123402N / 1 dated 12/02/2013 for similar 

noncompliance.        

(b) (6)
(B)(6)

(B)(6)

(B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4420120 

511N-1 

12/11/2013 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 0915 hours while monitoring the Establishment's Second 

Processing Rinse procedure, I observed the following noncompliance.  

While observing the shift change rinse in the Rotisserie Room, I was watching a 

sanitation employee rinsing near the tank, which had been covered 

prior to the rinse procedure with blue plastic.  I noticed the end of the 

tank has a bracket attached to it that the large screen sits in while in use and the 

plastic covering the tank had not completely covered the end of the tank where the 

bracket attaches to it.  There was a gap appoximately 1" wide x the 

width of the tank. While the employee was rinsing, overspray from water hitting 

the outside of the injection machine went into the in the tank in the form of 

spray and from dripping off of the plastic covering the tank.  As the 

outside of the injection machine is not considered a product contact surface and is 

not cleaned as such, the overspray water contaminated the   I 

immediately took regulatory control action and attached USDA Retain tag # B31 

407354 to the tank.  I immediately notified 

of the noncompliance.  immediately had the 

employee drain the tank and rinse it, she then had them apply to 

the tank to ensure it was clean.  The tank was then tested for the 

test strip read , restoring sanitary conditions.  I then 

released the tank back to production and removed my tag at 

approximately 0935 hours.  My findings indicate a noncompliance with the 

regulatory regulations of regulations 9CFR 416.1, 9CFR 416.4(a) and 9CFR 416.4(d). 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5617122 

811N-1 

12/11/2013 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 0900 hours while walking past the Post Chill Rehang area in Plant 

#1, I observed the following noncompliance.  As I was walking by Drop 

# 3  I observed a bird on the top of an almost full cardboard bin with 

black UFM (unidentified foreign material) on the hock.  Upon further 

investigation I found 3 more birds on the top with black UFM on the hocks.  I 

immediately took regulatory control action and attached USDA Retain 

tag #B31 407355 to the bin and notified of the 

noncompliance.  had the bin of birds covered and removed 

for rework.  He then notified the company employees working the line 

at rehang to watch for birds with the black UFM on the hocks and put them 

in stainless steel carts for rework as well.  The bin of birds was 

reworked and I performed a recheck which passed at approximately 1721 

hours, at which time I removed my tag.USDA was 

advised of the noncompliance.  on further investigation 

found numerous birds exiting Chiller #1 with black UFM on the hocks.  

 immediately advised Quality Control personnel of 

his findings so that they could take corrective actions.  The company took 

corrective action by reducing the line speed and having employees trim the 

contaminated parts for the rest of the day. At approximately 1010 hours 

while performing a Finished Products Standards task on Line in Plant #1, I 

collected a random 10 bird sample from the line and found 4 out of the 10 birds 

with black UFM on the hocks.  I immediately stopped the line and 

informed QC and of my findings.  They 

immediately started checking the birds that were on the line for UFM and 

pulled them off for rework.  They then notified the employees to 

watch for UFM on the hocks and clean them.  At approximately 1022 hours 

QC did a recheck on the line and it passed, bringing the process back in 

control.  My findings as well as findings indicate 

a noncompliance with the regulatory regulations of regulations 9CFR 416.1, 9CFR 

416.4(a) and 9CFR 416.4(d).   

(b) (6)
(B)(6)

(B)(6) (B)(6) (B)(6)

(B)(6)

(B)(7)(C) (B)(4) (B)(4)

(B)(4)

(B)(4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5310 M6137B FFA0216125 

111N-1 

12/11/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 12/11/2013 at approximately 1330 hours while performing my Operational 

Sanitation Inspection. I observed the following noncompliance.In the oven area 

between the chiller and ovens 3 and 4 there was numerous beads of 

condensation dripping from the over head beams. I informed and showed 

and the noncompliance. At the time of my observation I did not 

see any condensation dripping into the Frank racks. Mr immediately 

moved any racks that were close to the affected area and began to wipe down the 

condensation in my presence.This does not comply with the establishment written 

SSOP program which states in part: Objective; 

.This is also a violation of Regulatory Requirement(s) 

which states in part: 416.1; "Operate in a manner to prevent insanitary conditions", 

416.4(d); "Product must be protected during processing", and 416.13(c); "Plant 

monitors implementation of SSOP Procedures".This noncompliance report serves as 

written notification that failure to comply with regulatory requirement(s) of CFR 

416 could result in additional regulatory or administrative action. 

1326 

1 

M33901 HAY120912 

4211N-1 

12/11/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On the calendar date December 11, 2013 (Wednesday) at approximately 0715 

hours while performing the Pre-Op SSOP Review and Observation task in zone 4 the 

following noncompliance was observed: I, CSI observed two pieces 

of fat/meat present on the product belt of the Injector machine that’s set up on the 

Individually Wrapped Individually Frozen, Line The pieces fat/meat had a 

brownish color and ranged from 4/16” to 7/16” in size. This belt is a product 

contact surface. The Injector Machine was rejected with U.S. Rejected tag 

#B39506491. Mr. and Ms. 

were informed and shown the insanitary conditions. I informed Mr. 

Blanch that the conditions present on the equipment was from previous 

operations, he immediately had sanitation workers to reclean the Injector 

Machine. At 0730, zone 4 was released after equipment had been cleaned and 

sanitized. The establishment’s SSOP, states that 

” Regulatory requirements were not met for 9 CFR 416.13(c) 

and 416.11. For similar noncompliance record with the same cause, refer to NR 

HAY1116095219N/1 dated 9/19/13 where the Plant Management Response states 

“the affected pieces of equipment were recleaned, rinsed, re-inspected, passed and 

sanitized.” 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6)

(B)(4) (B)(4) (B)(4)

(B)(4) (B)(4) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3814124 

510N-1 

12/10/2013 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 0850 hours, while monitoring the change-shift rinse procedure at 

the rehang area #2, I observed the following; 

Two carts and a table that the USDA Graders used to inspected the birds 

 for Grade A, located at the beginning  of the sorting lines were not 

sanitized with ( . The table that USDA  used to performed the FPS 

post-chill check and is located between the chillers was also not 

sanitized with ). The SSOP Plan states in part under Second Processing Rinse 

Procedure that " 

. was nearby 

and I asked her if the area was finished, she had all her checks done and sanitation 

personnel were also finished. I informed   about the 

noncompliance. She informed of the 

deviation.   and sanitation employees, 

rinsed and sanitized the carts and the tables. At approximately 0915 hours the area 

was released. This is a noncompliance with the following regulatory requirements of 

regulations 9CFR 416.13 (b) and 9CFR 416.13 (c). 

5308 M6137 BXL5317123 

410N-1 

12/10/2013 03J02 Slaughter HACCP C At approximately 1400 hours while performing HACCP Slaughter Record Review 

Task, I found a noncompliance with the following regulatory requirements of 

regulation 9CFR 417.4 (a)(2)(iii). The HACCP Monitoring Log-CCP 1B-Salvage Parts 

Inspection dated on 12/06/2013, Plant #2 AM shift "Records Review" was 

not performed by Quality Control or designee. The HACCP Plan Slaughter 

Plant #1, States in part under Verification Procedures that 

". I informed

 of the noncompliance. 

(b) (6)
 

 

 

 

 

(B)(6) (B)(6) (B)(6)(B)(6) (B)(6)

(B)(4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH200112 

5710N-1 

12/10/2013 01C02 Operational SSOP 

Review and 

Observation 

C On the production shift that began on 12/09/2013, at approximately 2330 Hours I 

was in Room #2 at Establishment 33900  P.  I was in the marination 

line area to perform operational sanitation inspection on product contact surfaces 

of the fryer marination line.  Production personnel were stationed on the line 

awaiting the start of operations.  As the line started and the belts and 

marination cones began making the first full rotation, I observed pieces of fat, skin 

and kidneys on the belts and cones.  This material numbered more than 20 

pieces and was approximately 1/8 inch in size.  There was also a greasy 

residue on the product contact portion of the belt.    Regulatory 

Control Action was taken by applying USDA Reject Tag numbered B38075843 to the 

Start/Stop switch of the marination machine. The non-compliance was shown to 

Ms. and and Mr. had the sanitation department 

reclean and sanitize the equipment.  Mr. was informed that a 

non-compliance record would be issued. The requirements of Regulations 

416.4(d) and 416.13(c) were not being met.    The preventive 

measure given by Mr. was that the sanitation personnel would start the line 

after cleaning and before the beginning of production to insure the cleanliness of 

the line.</P> <P><SPAN><SPAN><SPAN></SPAN></SPAN></SPAN></P> 

<P><SPAN><SPAN><SPAN>Refer to NR #NHH2522113213N/1, dated 11/13/2013 

for similar non-compliance of an adulterant on product contact surfaces. 

</SPAN></SPAN></SPAN></P> 

<P><SPAN><SPAN><SPAN></SPAN></SPAN></SPAN></P> 

<P><SPAN><SPAN><SPAN><SPAN>      & 

nbsp;      

           & 

nbsp;          & 

nbsp;          & 

nbsp;          & 

nbsp;  </SPAN></SPAN></SPAN></SPAN></P> 

<P><SPAN><SPAN><SPAN><SPAN>The Establishment’s SSOP plan objective is 

" 

</SPAN></SPAN></SPAN></SPAN></P> 

<P><SPAN><SPAN><SPAN><SPAN> </SPAN></SPAN></SPAN></SPAN></P> 

<P><SPAN><SPAN>  </SPAN></SPAN></P> 

<P><SPAN><SPAN> </SPAN></SPAN></P> <P><SPAN></SPAN></P> 

<P><SPAN></SPAN></P> <P><SPAN></SPAN></P> <P> </P> 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(7)(C) (B)(6)

(B)(6)

(B)(6) (B)(6) (B)(4) (B)(4) (B)(4) (B)(4)(B)(4) (B)(4) (B)(4) (B)(4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD2123123 

409N-1 

12/09/2013 04B01 Labeling - Product 

Standards 

C On 12/09/2013 at approximately 1552Hrs, I observed a noncompliance to 9 CFR 

381,129(6)(i) in that "Raw poultry product whose internal temperature has ever 

been below may not bear a label declaration of "FRESH".  Raw poultry 

product bearing a label declaration of "fresh" but whose internal temperature has 

ever been below is misleading. In the Bagging Department, I observed plant 

personnel taking Fresh Young Organic Turkey out of their bag. They 

took two birds to the line and put the birds into Fresh Young Turkey bags 

(Foster Farms) at the Bag Line. Using a company calibrated thermometer, I took the 

temperature of the two turkeys which were bagged on the line. My temperatures 

were and . I notified and showed him my 

findings. and Dr. SPHV were notified of the 

noncompliance. U.S. Retain Tag NO:B39554627 was applied to the birds found with 

temperatures below Ms. took temperature of the 

Fresh Turkey's. She found ten more birds with temperatures & She 

had all 12 birds with temperatures below put into a tank. She will notified 

Boning Room Supervision of the issue. The retain tag will remain pending plant 

decision. 

5112 M18909 JDD3707124 

809N-1 

12/09/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C At 0200 H PST I was asked to do PRE-OP in Boning Room and I observed the 

following issues: 1) By wing belt, the overheads had black UFM on it., 2) 2nd grinder 

for MDP had  poultry residue on  it., 3) Conveyor off of Drum 

Machine had peeling surfaces coming off of the Cutting Board Type Material., 4) In 

Raw Fab the Switch on the Stand for large grinder had poultry residue on it.  

Mr. , Mr. 

, and Mr. were notified of 

the noncompliances. No documentation of these was observed. Mr. was also 

advised of missing wear guides on conveyor feeding the MDP PRE-GRINDER. This is 

a violation of the Establishment's written SSOP program and the above 9 CFR's. This 

is linked to the following NR 171-2013, Dated 12/07/2013, JDD3907120807N/1 

and it's associated JDD numbers. 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6) (B)(7)(C) (B)(7)(C) (B)(6) (B)(6) (B)(6) (B)(6) (B)(4) (B)(4) (B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD5422121 

809N-1 

12/09/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C On 12/09/2013 at approximately 1825Hrs while performing my PHIS Zero 

Tolerance fecal check, I observed visible fecal material on the first bird sampled out 

of the ten whole body Consumer Tom Turkeys sampling test. The feces was found 

on the upper third of the right thigh in front of the longitudinal axis of the 

thigh bone or femur. The fecal material was non granular; uniformly green in color; 

moist and pasty consistency with the distinct odor consistent with fecal material. 

The fecal material was approximately 10mm x 3.5mm in size. U.S. Retain Tag 

NO:B39554628 was applied to the affected carcass. ; 

, and Dr. , SPHV were 

notified of the noncompliance and shown the affected carcass. Dr. 

concurred that it was fecal material. Ms. immediately implemented the 

establishment's corrective actions. She had the affected turkey reconditioned by 

trimming and spraying and reinspection. At 

approximately1913Hrs the turkey was released back to production after verifying 

the plant's corrective actions and reinspection. Ms. conducted her 

rechecks after the final wash and they passed. This observed incident of visible fecal 

material is a noncompliance to 9 CFR 381.65(e). Also it is in violation to 9 CFR 

417.2(c)(4) monitoring at the critical control point to ensure compliance to the 

established CCP 4B ) after the final wash and before 

entering the chiller. At approximately 2138Hrs the plant's implemented corrective 

actions at the post chill were completed and passed by Ms. . Ms. verified 

the checks. This noncompliance is being linked to noncompliance (#170) 

JDD2423120405N/1 dated 12/5/2013; (#167) JDD1623110427N/1 dated 

11/27/2013 and (#134) JDD5821101818 dated 10/17/2013 for the same cause 

respectively. 

5308 M6137 BXL1018121 

509N-1 

12/09/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C While monitoring the Establishments' Pre-operational Sanitation Procedures in 

Plant #2 (Evisceration), I observed a noncompliance with the following 

regulatory requirements of regulations 9CFR 416.1, 9CFR 416.4 (b) and 9CFR 

416.13 (c).At approximately 0658 hours while inspecting Area #2, picker 1- Line I 

found in the scalder (unit #5) that it is next to the picker,  white/cream 

color residue in the water covering the entire scalder. The residue appeared 

to be melted fat. I went to check the scalder for Line (unit #8) and found 

the same issue. was informed. He immediately 

drained the water from both scalders and had sanitation personnel 

rinsed and scrubbed both scalders. At approximately 0723 hours, I 

reinspected and found them to be clean, I then released the area.  

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3417120 

109N-1 

12/09/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C At approximately 0855 hours while performing Pre-Op SSOP review and 

observation task in the room I observed the following noncompliance.  

While inspecting the Breast Tender Harvester conveyor belts I observed a 

large piece of dried breast meat left over from the previous shifts production, which 

was 2 days prior.  The piece of breast meat was approximately 1 1/2" 

x 1/2"  in size, it was located on the small belt that dumps the tenders into 

bins and tanks, it was on the side of the bracket, the bracket is in continuous 

contact with the belt.  I also found ground up breast meat on the ends of the 

brackets and multiple tiny pieces along the edge of one of  the brackets 

holding the belt, between the belt and the bracket.  I immediately informed

 of the noncompliance.  

immediately had a sanitation employee clean and rinse the belt and brackets, 

restoring sanitary conditions by approximately 0905 hours.  My findings 

indicate a noncompliance with the regulatory regulations of regulations 9CFR 416.1, 

9CFR 416.4(a) and 9CFR 416.4(d). 

1325 

7 

P33900 NHH030312 

4510N-1 

12/09/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On the night of production which began on 12/09/2013, Inspection performed 

scheduled PHIS procedure Pre-op SSOP Review and Observation in the Further 

Processing Department of 33900 P. This was after Sanitation had finished cleaning 

the equipment and QA had finished their Pre-operational inspection of the 

equipment and released the area for USDA inspection. There are no additional 

Sanitation or Pre-operational steps prior to the start of production. The following 

noncompliances were observed: At 2328 hours while checking the Truss Conveyor 

(Zone #13-Unit #11), Inspection found the Conveyor (Product contact surface) in an 

unsanitary condition: Weld Spots and tiny gritty and grainy particles. Inspection 

took Regulatory Control Action by applying US Reject Tag #B3075666 to the Unit 

until it could be recleaned and reinspected, and was released at 0046 Hours. At 

2338 Hours while checking the Case Scale Infeed Conveyor (Zone #15-Unit #17) and 

also a Product Contace Surface, Inspection found the surface of the Belt in an 

unsanitary condition with a thin layer of grease that appeared to be several days 

old and could be scraped off with the fingernail. Inspection took Regulatory Control 

Action by applying US Reject Tag #B38075671 to the Unit until it could be restored 

to a sanitary condition and released at 0000 Hours. The Requirements of 9CFR 

416.13(c) were not being met and  was 

shown the noncompliance and advised that a Noncompliance Record would be 

issued. The items of Equipment cited were Stumble-on Finds. For a similar 

noncompliance refer to NR #NHH2522113213N/1 dated 11/13/2013. To 

date, all Preventive Measures may not have been implemented as described or 

were ineffective in preventing recurrence. 

(b) (6)
(B)(6)

(B)(6)

(B)(6)

(B)(6) (B)(6) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH291712 

3709N-1 

12/09/2013 01D01 SPS Verification C On 12/09/2013 while performing an export task on the front dock at appoximately 

1650 hours, I observed rain water dripping excessively from the overhead bay doors 

of bay # 3, # 4, and # 5.  Bay # 3 was the loading bay for the export load, 

bay # 4 was partially loaded with other product and bay # 5 did not have a trailer in 

it at that time.  There were no precautions being administered that I could 

see or was told they were using to prevent the dripping water from contaminating 

the boxes containing the product.   The rain water was 

contaminated  and it was dripping from an unsanitized area.  I tagged 

the affected bays with U. S. Retain/Reject tag #'s B38075968 for bay's # 3 and # 4 as 

they were being utilized and U. S. Retain/Reject tag # B38075655 for bay # 5 that 

was not in use at the moment.  I advised Mr. 

, that they were tagged and a noncompliance would be 

issued.  Mr. had maintnance hang plastic to divert the dripping water 

and I removed my tags allowing the establishment to resume loading product on 

the trailers.  No product was contaminated.  This clearly violates CFR9 

416.1; CFR9 416.2(b); CFR9 416.4(d) which states the establishment must operate 

in a manner to prevent insanitary conditions, maintain sound construction, good 

repair, and sufficent size, and protect the product during processing, handling, 

storage, loading, unloading, and  transportation. 

5112 M18909 JDD3907120 

807N-1 

12/07/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C At 0450 H PST in evisceration I observed the following 1): In final gizzard defatter 

was a rock and poultry residue. 2):Five pieces of poultry residue in the cross over 

belt to Chiller A. 3): Numerous feathers in picking room. 4)Rosier had dripping 

condensation from overheads in to unit and one bagged bird with bag torn open 

found in the Rosier. The carcass was condemned. This a violation of the 

Establishments written SSOP Program and the above 9 CFR's. Mr.

 Mr. , 

Mr. and Mr. were all 

advised or shown the Noncompliances. No note of these issues were in Q.C. 

Documentation. This is linked to NR #165-2013, Dated 11/19/2013 

JDD3504114321N/1 and it's associated Linking JDD # and NR # 168-2013, Dated 

12/03/2013, JDD22001218031N/1 and it's associated linkages. 

(b) (6)
(B)(6) (B)(4) (B)(4) (B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1007123 

807N-1 

12/07/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 12/07/2013 at approximately 0225 hours while monitoring the Establishments' 

Sanitation Performance Standards in Plant 1, I observed the following. There was a 

clear fluid dripping from the side of a ceiling mounted ventilation duct 

above the Check/Weight lines near the final trim station access to line The fluid 

was dripping on to a blue wheel that supports the chain for line and the 

dripping onto the carcasses passing down Reprocessing line  just prior to 

entering the Chilling System. The fluid dripping from a leaking ceiling on to 

carcasses was creating an insanitary condition. I contacted

 who was nearby and showed him the 

noncompliance. The line was stopped. Carcasses on Line were tanked off and 

placed on hold pending reconditioning. Plastic was affixed at the location to 

direct the fluid to a drip pan. A QC red tag was placed on a partial tank of 

birds for reconditioning. A steady rain was observed falling during a Good 

Commercial Practices procedure conducted at approximately 0200 hours. 

My findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.2(b)(1) 

and 9 CFR 416.4(a) .   

(b) (6)
(B)(6)

(B)(6)

(B)(6) (B)(6) (B)(4)

(B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (b) (4) (b) (4)

(b) (4)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1407123 

607N-1 

12/07/2013 04B04 General Labeling C On 12/05/2013 at approximately 2000 hours while performing a 

Labeling procedure in the Weigh & Price Cooler (Finished Product A 

& B) I observed racks of product in the general storage area as old as 

11/29/2013. An employee was conducting an inventory at the time. I returned at 

approximately 2010 hours on 12/06/2013 to see if the old product had been culled. 

The cooler seemed to be colder then normal and my pocket 

thermometer registered temperatures between 22 to 

 Production was done so I waited until  

arrived at approximately 2145 hours. helped me with a 

company calibrated thermometer in the QC Office. In the Weigh & Price Cooler 

using the company calibrated thermometer I showed QC& 

 the temperature of a couple of packages of Boneless Skinless 

Thighs that registered to . I told her I would take up the issue 

with the Weigh & Price Supervisor. At 2245 hours again 

using the company calibrated thermometer I showed Weigh & 

the temperatures of several packages of boneless skinless product. 

The product below  was confined to racks with dates of 

12/04/2013 to 11/29/2013  except for 5 racks of Organics located on the 'B' 

side of the cooler that were dated 12/05/2013. 12 racks of 

and Foster Farms boneless skinless product and two racks of 

thighs labeled 'Fresh" were culled and placed on hold for being to cold to be 

labeled as fresh. A printout from Refrigeration indicated that the Weigh & 

Price Cooler temperature was below the monitoring station for the 

entire day. A review of the HACCP Plan -Raw Intact -Packaging Step 12 (Shipping) 

states in part " ." 

Supplement 35 under 'Crust Tunnel' states

 is < .' and Note: 

' The 

Establishments' Weigh & Price procedure does not include monitoring 

of  Shipping temperatures.  A check of Foster Farms Refrigerated 

Status Report for 12/6/2013 lists a target temperature for Finished Product 'A 

& B' Coolers as . While the log registers temperatures every 4 

hours for PLT1,PLT2, NCDC,Deli and DC 2 Coolers there is no documentation for the 

actual monitoring of Finished Product Coolers "A & B". A 

computer printout from Refrigeration from 11/30/2013 thru 

12/06/2013  indicated that temperatures in the Weigh & Price 

Coolers varied between approximately 20'F 

and 25'F  at the monitoring station.  The product was 

released on 12/09/ 2013 and 12/10/2013 for down grading to 

(b) (6)
(B)(6)

(B)(4)

(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

'Sunland'.  My findings indicated a noncompliance with 9 CFR 

381.129. 

5308 M6137 BXL3908125 

307N-1 

12/07/2013 03J02 Slaughter HACCP C While reviewing the company computer records for CP-19, Salvage Parts Treatment, 

for night shift 12/06/2013, I observed the following. In Plant #2 the first Salvage 

Parts Treatment check was at 1148 and the next check was at 0416. The HACCP 

Plan, Slaughter Plant 2, under step #36 states in part

 HACCP Supplement #56, Salvage Parts Treatment, CP-19 under procedure 

#4 states in part " 

". I informed of the 

noncompliance.This is a noncompliance with the following regulatory requirements 

of regulation 9CFR 417.5(a)(1). 

(b) (6)
(B)(6)

(B)(6)

(B)(6) (B)(6) (B)(6) (B)(7)(C)

(B)(4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

4630 M7322 AOA301412 

1006N-1 

12/06/2013 01D01 SPS Verification C On Friday 12/06/13 at approximately 1350 hours while performing Sanitation 

Performance Standard Inspection in the Retail Fryer room area, I observed the 

extended space in the fryer room that is located to the left side of Fryer #8. In the 

open space beside fryer #8 I notice there was evidence or a liquid substance 

that had run down the wall in two area and there was some clear liquid dripping 

from the edge of the ceiling close to the beam that separated the open space from 

product fryer # 8. There were rainy weather conditions at the time of my 

observance. There were 3 unopened boxes of sticks that are used in the edible 

product process stored in the open space area. The unopened boxes of sticks were 

not affected by the unsanitary condition of the liquid substance. Production 

employee traffic was observed in the effected area however I did not observe any 

employees being affected by the falling liquid. and

 was notified. I observed as the unopened boxes of sticks were 

removed from the area and the maintenance department immediately closed the 

area off to stop any further production employees traffic until the process was 

under control. I observed as instructed the employees not to 

enter the effected area until corrective action were complete. No FSIS 

regulatory control tag was provided because I observed as 

took immediate took corrective action. No product or product contact surfaces 

were affected. came by the FSIS office at 

approximately 1425 hours to inform me that the maintenance department had 

taken action in the ceiling to prevent any further leaking conditions in that area. He 

also said that maintenance would continue to monitor the area to assure sanitary 

conditions were maintained. -A similar noncompliance was observed on 08/22/13 

and documented by Inspector on NR#AOA1222081022N/1 dated 

08/22/13. The preventive measure (further planned action) provided by the 

establishment that states, 

”, appears to be ineffective in preventing this 

noncompliance. -This document serves as written notification that your failure to 

comply with regulatory requirement(s) could result in additional regulatory or 

administrative action(s). -Continued failure to meet regulatory requirements can 

lead to enforcement actions described in 9 CFR 500.4. 

(b) (6)
(B)(6)

(B)(6) (B)(6) (B)(6) (B)(6) (B)(6)

(B)(6)

(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0518121 

806N-1 

12/06/2013 01D01 SPS Verification C At approximately 1020 hours while walking through the packaging area, I walked 

by Line (the Leg Processors) and observed the following 

noncompliance.  While walking by the leg processors I observed the bottom 

of the drip pan directly above Leg Processors #11,12,13 and 14 had what appeared 

to be heavy beaded condensation the full length of the drip 

pan.   I was informed by the Line lead person that it was over spray 

from the shift change wash down that had not been cleaned.  The over spray 

was dripping all around the line.  I immediately informed 

of the noncompliance.  immediately had 

a plant employee stop the line and remove the product from the 

line.   then had sanitation wipe down the 

drip pan, restoring sanitary conditions.  My findings indicate a 

noncompliance with the regulatory requirements of regulations 9CFR 416.1, 9CFR 

416.2(d), 9CFR 416.4(b) and 9CFR 416.4(d). 

5310 M6137B FFA5818120 

006N-1 

12/06/2013 01D01 SPS Verification C On December 06, 2013 at 1520 hours while walking to the oven room I observed 

insanitary conditions.   I observed franks all over the floor in front of 

Oven #1 and Oven #2.  At the time of my observation I did not see any 

supervisor in the area nor did I see anyone cleaning up in this area.  Ms. 

., and Mr. was informed.  Immediate 

Corrective Action was implemented by Management:  Product was condemn 

and the floor was cleaned and sanitized.At approximately 1533 hours after 

performing my product temperature check on product in oven number #3, I 

observed rust on the overhead beams in front of Oven #4 and Oven #3, I also 

observed on the overhead unit in front of Oven #4 Rust on the bottom of the unit 

drip pan (product traffic areas).  This unit was brought to management 

attention in the weekly meeting dated 10/08/13.  I left a voice mail 

for Mr. and also informed Ms. 

about the noncompliance.This does not comply with Regulation 416.1 

which states in part: "Each official establishment must operate in a manner to 

prevent insanitary conditions", 416.2(b)(1) which states in part:  

"Establishment buildings, compartments must be kept in good repair", and 

416.4(b) which states in part: "Non-food contact surfaces of facilities, equipment, 

and utensils must be cleaned and sanitized as frequently as necessary to prevent 

the creation of insanitary conditions and the adulteration of product".This 

document serves as written notification that failure to comply regulatory 

requirement(s) could result in additional regulatory or administrative actions as 

described in 9 CFR Part 500.4. 

(b) (6)
(B)(6) (B)(6) (B)(4)

(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5568 M20923 XUM451312 

3106N-1 

12/06/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C At approximately 645 hours, while performing a routine Pre-op review and 

observation inspection task (after establishment performed their pre-operational 

inspection and prior to start of production), I observed the following 

noncompliance: Line 1, Raw side of the establishment: I found few pieces of food 

particles on hopper pipe, from the previous day of production. Upon continuing my 

inspection: Line I found small piece of food particles on hopper A , hopper B and 

C4 conveyor belt, also from the previous day of production. All finding described in 

the non-compliance were on the food contact surface, it is reasonable to conclude 

that when production began it would be under insanitary conditions. I took a 

regulatory control action and applied USDA retain/rejected tag# B24829889. I 

informed and of 

the non-compliance. Immediate corrective action was performed by establishment 

on all affected areas upon notification of my finding. After sanitary conditions had 

been restored, I relinquished the regulatory control action at 0720 hours. Plant 

SSOP Section1, page1, states: 

". 9CFR 416.13 (c) states: "All establishment shall monitor daily 

the implementation of the procedures in the sanitation SOP's". 9CFR 416.4 (a) 

states: "All food contact surfaces, including food-contact surfaces of utensils and 

equipment, must be cleaned and sanitized as frequently as necessary to prevent the 

creation of insanitary conditions and adulteration of product". This document 

serves as written notification that failure to meet these regulatory requirement(s) 

could result in additional regulatory or administrative action. 

(b) (6)
(B)(6) (B)(6)

(B)(6)

(B)(7)(C) (B)(7)(C) (B)(7)(C) (B)(6) (B)(6) (B)(6) (B)(6) (B)(6)

(B)(6)

(B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD2423120 

405N-1 

12/05/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C On 12/5/2013 at approximately 1645Hrs while performing my PHIS Zero Tolerance 

fecal check, I observed visible fecal materials on the 7th. bird sampled out of the ten 

whole body light hen turkey sampling test. The fecal material was inside the 

turkey's pelvic and kidney area. U.S. retain Tag NO:B39554890 was 

applied to the affected carcass. The size of the fecal materials were approximately 

1/2" x 1/4" on the turkeys pelvic cavity and approximately 1/4" x 1/8" in size 

on the kidney. The fecal was greenish in color, semi-solid in nature 

with the distinct odor consistent with fecal material. The line two ten bird random 

sample was collected after the final wash and before entrance into the chiller by the 

establishment's . I notified and showed the fecal 

materials to Dr. , SPHV; and 

  Dr. concurred that it was fecal material. Dr. and I watched 

as  using a knife removed the feces from the turkey. She put it 

on the top side of her left gloved hand. She moved the fecal around with the knife 

and smelled it. She then put the fecal back into the turkey (not in the 

site found and the fecal was not the amount that I had found). I hung the 

turkey inside the product wash cabinet for reconditioning and requested to 

be present for the reconditioning. Ms. nbsp;conducted her 

required fecal checks after the final wash and they passed.  At approximately 

1730Hrs I watched put the affected turkey on the USDA table and 

then she took a picture of the fecal inside the turkey. She had the turkey 

reconditioned by and trimmed. The turkey 

was released back to production at approximately 1734Hrs after verifying the 

reconditioning and reinspection. This observed incident of visible-fecal material is a 

noncompliance to 9 CFR 381.65(e). Also is in violation to 9 CFR 417.2(c)(4) 

monitoring at the critical control point to ensure compliance to the established CCP 

4B ( ) after the final wash and before entering the chiller. At 

approximately 2005Hrs the plant's implemented corrective action at the post chill 

were completed and passed by Ms. . Ms. verified the checks.

 was notified of the noncompliance. This noncompliance is being linked to 

noncompliance (#167) JDD1623110427N/1 dated 11/27/2013; (#134) 

JDD5821101818N/1 dated 10/17/2013 and (#112) JDD1623092204N/1 dated 

9/4/2013 for the same cause respectively. 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6)(B)(6) (B)(6) (B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0916121 

505N-1 

12/05/2013 04A06 Poultry Finished 

Product Standards 

C At approximately 1248 hours while performing a Poultry Finished Products 

Standards check on Line# in Plant 2, I observed the following 

noncompliance.  After removing a 10 bird sample from Line I found 3 

birds with split tails with airsacculitis exudates remaining.  I immediately 

informed and of the 

noncompliance.   asked me to do a recheck 

immediately, at which time I found 1 more bird with airsacculitis exudates 

remaining.  immediately started tanking birds, with all 

split tail and missing tail birds being retained. Another person was added to 

vacuum and I performed another recheck at approximately 1316 hours that passed, 

bringing the process back in control.  QC put their hold tag on the tank 

for rework.  QC rechecked the tank of birds and released it back to 

production at 1404 hours.  My findings indicate a noncompliance with the 

regulatory requirements of regulations 9CFR 381.76(b) and 381.84. 

5308 M6137 BXL2104124 

805N-1 

12/05/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 12/05/2013 at approximately 0055 hours in the MV Cooler there was a partial 

stack of brown product tubs with a few specks of black UFM (Unidentified Foreign 

Material) on the outside. I separated several of the tubs and found more 

black specks inside. I observed the area for several minutes and  

production personnel were using the brown product tubs 

from another pallet closer to the door. The tubs were on a wooden pallet 

covered with blue plastic. A second stack of brown product tubs on 

the same pallet still had a lid on top and was partly wrapped with clear 

plastic. The plastic wrap is used by the establishment to identify clean 

product tubs. I contacted and showed him the noncompliance. 

 The tubs were taken to the tub wash room. In the tub wash room, I 

checked several more of the tubs from the affected stack and found two 

pieces of wood measuring approximately 1/2" by 1/8" in two separate tubs. There 

were also numerous specks of black and brown UFM to approximately 1/4"on 

several of the tubs. Approximately half of the tubs in the stack were dirty. A 

check of the Establishments' 12-05-2013 SSOP Daily Implementation and 

Monitoring Log for the shift in the MV Cooler at 2341 hours found 

everything in the cooler to be acceptable.  My findings indicated a 

noncompliance with 9 CFR 416.1 and 9 CFR 416.4(a).  

(b) (6)
(B)(6)

(B)(6)

(B)(6) (B)(6)

(B)(4)

(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH010312 

5705N-1 

12/05/2013 01C02 Operational SSOP 

Review and 

Observation 

C On the night of production that began on December 3, 2013 at approximately 0408 

hours while performing Sanitation Performance Standards verification activities in 

room 1 Further Processing, a plant employee was observed using a floor hose with 

his gloved hands to spray off his boots.  The employee then went to the 

breast processor line and began putting product into the machine without washing 

or sanitizing his gloves.  The line was rejected and the product retained with 

US tag B38075664.  Mr. , and Mr. 

, were notified of the noncompliance.  Inspection 

observed as sanitary conditions were restored to the breast processor and 

belts.  The product, approximately 150 pounds of breast meat, was taken to 

the wash station and washed with water.  Mr. stated 

“The employee would be retrained” as a preventive measure.  The regulatory 

control action was then released.  Mr. was informed the 

noncompliance would be documented on a noncompliance record and that due the 

staffing shortage and the associated time constraints the NR would not be issued to 

the plant until the following shift. Refer to NR NHH2202094917N/1 dated 

September 17, 2013 for a similar noncompliance.  The preventive measure 

for this noncompliance was “ 

.”  These measures may have been implemented incorrectly 

or may have been ineffective at preventing recurrence. 

(b) (6)
(B)(6) (B)(7)(C) (B)(7)(C) (B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(6)

(B)(4) (B)(4)

(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD0623123 

204N-1 

12/04/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 12/4/2013 1745Hrs Dr. , SPHV and  went to the 

Quality Control Lab during our record review as part of my Operation Sanitation 

(SSOP) records review task for 12/2 & 12/3/13 dates. I found 

the establishment failed to make available the SSOP monitoring verification 

record performed by the plant Quality Control on 12/3/2013 for the "A" shift's 

Evisceration production. The shift "A" was scheduled for 7.87Hrs and was in 

operation for approximately 8Hrs. This production time of approximately 8Hrs with 

no available SOP monitoring verification record is a violation to 9 CFR 416.16(a) 

which states in part; "each official establishment shall maintain daily records 

sufficient to document the implementation and monitoring of the Sanitation 

SOP's..." This is also in violation to the plant's page one: Personnel Responsibility 

Monitoring and Sanitation SOP's which states in part; " 

" 

."  pulled the records out of the plant's file 

for us. Dr. verified that the record was missing from the 12/3/13 filed SOP's. 

was notified of the missing record. She looked for the record and 

when she could not find the record she notified . Ms. 

also verified the record was not available. Ms. was notified of the 

record keeping noncompliance. 

5308 M6137 BXL2719122 

104N-1 

12/04/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C While performing Zero Tolerance Task, I observed a noncomplaince with the 

following regulatory requirments of regulations 9CFR 381.65 (e) and 9CFR 417.2 

(c)(4).At approximately 1317 hours, removed a 10 bird 

sample from Line #1 in Plant #1, I found one out of the ten birds with visible fecal 

contamination outside of the bird between the neck and the wing area. The fecal 

material was dark green in color, pasty in texture and measured approximately 1/4" 

wide by 3/4" long. This exceed the limit of Zero Tolerance for the process to be in 

control. I informed and of the 

noncomplaince. The protocol for fecal failure was implemented. Quality Control did 

a recheck at approximately 1346 hours and it passed.This is a violation of the 

critical limits of CCP-2B of the Plant's HACCP Plan for 

Slaughter. 

(b) (6)
(B)(6)

(B)(6)

(B)(6)

(B)(6)

(B)(4)

(B)(4)

(B)(4) (B)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3119122 

104N-1 

12/04/2013 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1325 hours, while monitoring the mid-shift rinse procedure at the 

rehang area #1, I observed the following; 

as prescribed in the 

SSOP Plan. The drip pan that is attached to the cabinet at the rehang 

area #1 and is identified as a food contact surface, was not rinsed and 

sanitized. The SSOP Plan states in part under Second Processing Rinse 

Procedure " 

".  This is a noncompliance with the following regulatory 

requirements of regulations 9CFR 416.13 (b) and 9CFR 416.13 (c).

 and were notified about the 

noncompliance. 

5308 M6137 BXL4304123 

504N-1 

12/04/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 12/03/2013 at approximately 2200 hours while monitoring Pre-Operational 

Sanitation Procedures in Plant 1, I observed the following. There was heavy beaded 

condensation over a large area on the concrete ceiling between stations 4 and 8. 

The ceiling was mopped off by approximately 2220 hours. At approximately 2202 

hours there was a pink colored slimy UFM (Unidentified Foreign 

Material)  inside two air hoses used to agitate the chiller 

water for Chiller #2. The UFM filled several feet of each hose. The 

hoses were disconnected and flushed restoring sanitary conditions. 

was informed of the noncompliance. At approximately 2320 hours in 

Packaging Area 1, there were numerous black specks of UFM that smeared 

like grease/oil on the white wheels that hold the product during cutting on Leg 

Processors 4-6.  There was pasty fat on the white nylon product portion of 

the ejector arm that moves the product from the shackle to the 

Leg Processor for Leg Processors 4 & 5. The area was recleaned 

restoring sanitary conditions by approximately 2325 hours. In Packaging 

Area #2, the Room, the white product cones on lines 1- are severely 

deteriorated with scuffs, scratches and deep cuts. The plastic 

pieces becoming part of the product is creating a Physical Hazard 

condition.  The rough surfaces are also making it impossible to 

clean the cones efficiently.  was informed of the 

noncompliance. My findings indicated a noncompliance with 9 CFR 416.1, 9 

CFR 416.2(b)(1), 9 CFR 416.4(a) and 9 CFR 416.13(c).     

(b) (6)
(B)(6) (B)(6) (B)(7)(C) (B)(7)(C)

(B)(6) (B)(4)

(b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5568 M20923 XUM581412 

3104N-1 

12/04/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C At approximately 0715 hours, while performing a routine PHIS task Pre-op review 

and observation inspection task (after establishment performed their 

pre-operational inspection and prior to start of production), I observed the 

following noncompliance: Line 2, Cook side of the establishment: I found pieces of 

chicken stuck on scale bracket from the previous day of production. I took a 

regulatory control action and applied USDA retain/rejected tag# B24829879. I 

informed sanitation and and 

of the non-compliance. The finding described in the non-compliance was on the 

food contact surface, it is reasonable to conclude that when production began it 

would be under insanitary conditions. Immediate corrective action was performed 

by establishment on all affected areas upon notification of my finding. After 

sanitary conditions had been restored, I relinquished the regulatory control action 

at 0755 hours. Plant SSOP Section1, page1, states: 

9CFR 416.13 (c) states: "All establishment 

shall monitor daily the implementation of the procedures in the sanitation SOP's". 

9CFR 416.4 (a) states: "All food contact surfaces, including food-contact surfaces of 

utensils and equipment, must be cleaned and sanitized as frequently as necessary 

to prevent the creation of insanitary conditions and adulteration of product". This 

document serves as written notification that failure to meet these regulatory 

requirement(s) could result in additional regulatory or administrative action. 

6036 P6164A OIJ0908123 

505N-1 

12/04/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C On December 4, 2013 at 1333 I, CSI performed a routine 

scheduled Poultry Zero Tolerance task.  I observed visible fecal material on 

one of the ten randomly selected carcasses. PHV verified my 

finding.  The 3/4” by 1/8” strip of fecal material was found on the left 

wingtip area consisting of dark green creamy material. I verbally notified 

of the failure and that a NR would be issued.  The 

plant implemented their fecal failure program.  The verbal response given as 

to the cause was the bottom nozzle of the New York wash cabinet was not 

working.  The nozzle was replaced.  A retest by QC found no further 

incidence of visible fecal present.  The verbal preventative measure given was 

that the New York bird wash cabinet nozzles will be checked every half hour until 

December 13, 2013. Records show that there have been no fecal noncompliances 

since August 29, 2013 which was caused by the PNT rollers.  Therefore, this 

NR is not linked to any other NR.  The Establishment Awareness Meeting 

notes show the last time fecal noncompliances were discussed was on September 5, 

2013. 

(b) (6)
(B)(6) (B)(6) (B)(6)

(B)(6)

(B)(6) (B)(7)(C) (B)(6) (B)(4) (B)(4) (B)(4) (B)(4)

(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD2200121 

803N-1 

12/03/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 12/02/2013, I observed the following: (1) Belting needed trimmed up on 

Grader Belts A and B., (2) Poultry Residue on Contherm Seals, (3) Hand 

Wash sign in Boning by MDP is separating and appears to have mold 

growth, (4) Rusty Interior Motors and Pumps on all injectors, ( I 

was told months ago they were to be sand blasted and reconditioned).,(5) Observed 

a piece of loose plastic in Filter Part in Cooler Nine. (6) Six Stainless Steel Tanks from 

Sister Plant were found with product residue in them. (7) Yellow Checkweigh line 

has loose parts that need tightening. (8) Cracks in end chute off of the Breast 

Sorter. These were shown to Mr. 

and or Mr. . Ms. was 

advised of these issues. This is linked to NR 0125-2013, Dated 10/3/2013 and its 

linkages. 

5308 M6137 BXL0217121 

403N-1 

12/03/2013 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1030 hours while performing Zero Tolerance Fecal Task, I 

observed three out the ten birds from each line in Plant #1, with black UFM 

(Unidentified Foreing Material) on the hock of the bird. I went to 

performed a Post-Chill Finished Product Standards at the exit of the 

chiller and found more birds with UFM on them. For the 

past two weeks at the weekly meeting USDA informed Management about 

the issue. USDA documented on MOI # BXL0111113927G and BXL4619114320G 

that CSI's and Line Inspectors saw black UFM on the hock of the birds. At 

approximately 0500 hours CSI informed 

about the same issue. This is a noncompliance with the following 

regulatory requirements of regulations 9CFR 416.4 (a) and 9CFR 416.4 

(d). was informed about the noncompliance.  

5308 M6137 BXL5308122 

903N-1 

12/03/2013 03J02 Slaughter HACCP C On 12/02/2013 during the 0100 hour while performing a direct observation 

of the establishments' proffered IOBW Monitoring procedure from the Verification 

Plan, I observed the following. The Quality Control monitor performed a check 

verifying the sprayers, shower heads and pumps and the psi, timing, 

alignment, and improper shackling on the IOBWs' on Lines and 

. I did not observe her monitoring the IOBW on the reprocessing 

Line I later checked the computer records for the IOBW on Line and checks were 

performed at 1040, 1131, 1246, 0331,and 0425 hours. There was no record 

of a check being done at the 0100 hour, (lunch is during the 0200 hour). The Notice 

of Deferral Verification Plan #4 states in part 

. I informed of 

the noncompliance.My findings indicate a noncompliance with regulatory 

requirements of regulation 9CFR 417.5(a)(1).  

(b) (6)
(B)(6) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5310 M6137B FFA5203122 

903N-1 

12/03/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On December 02, 2013 at approximately 0130 hours, after the establishment had 

finished their pre-operational sanitation inspection and prior to the start of 

operation, I observed noncompliance with SSOP Regulatory Requirement(s) 

416.13(c) and SPS 416.4(a). Raw Side Blending Room:  I 

observed several specks of black unidentifiable foreign material on the inside 

surface of the Large Frank Hopper(product contact) and aslo several specks 

of black unidentifiable foreign material on one of the white shovels (product 

contact).  U.S. Reject Tag NO. B38934391 was applied to the Hopper and 

Shovel.  and was 

informed and showed the noncompliance.  Immediate corrective action was 

implemented  by management:  The Hopper and Shovel was 

re-washed and sanitized.  After sanitary conditions was restored U.S. Reject 

Tag NO. B38934391 was removed.This does not comply with Regulatory 

Requirement(s) 416.13(c); which states in part:  "Each official establishment 

shall monitor daily the implementation of the procedures in the Sanitation SOP's, 

and 416.4(a); which states in part:  "All food-contact surfaces, must be 

cleaned and sanitized prior to the start of production".  This NR is linked to 

NR# FFA1704092319N/1 dated 09/19/13 for a similar noncompliance on Pre-op 

Product Contact Surface.  Management written response in Part: 

" Employee was instructed to inspect the equipment and re-clean when 

necessary", " Maintenance was asked not to handle the equipment until it 

has been released during USDA inspection and to re-sanitize food contact surfaces 

when necessary".This document serves as written notification that continue failure 

to comply with regulatory requirement(s) of 9 CFR Part 416 could result in 

additional regulatory or administrative actions as described in 9 CFR Part 500.4. 

(b) (6)
(B)(6) (B)(6)

(B)(6)

(B)(7)(C) (B)(6) (B)(6)

(B)(4)

(b)(4) (b)(4) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5568 M20923 XUM171212 

5603N-1 

12/03/2013 01D01 SPS Verification C At approximately 0945 hours, while performing a schedule routine SPS inspection 

task, on the cook side of the establishment, I observed the following 

noncompliance: Raw side of the production, I observed beaded and dripping 

condensation above air unit in front of wing cooler. I informed and showed to

 and of my finding. 

Immediate corrective action was performed by establishment upon notification of 

my finding. Plant SSOP Part 2 Operational Sanitation, Section 2, and Subsection B: 

Equipment and Facilities, Step 4 which states 

. 9CFR 416.1 states: 

"Each official establishment must be operated and maintained in a manner 

sufficient to prevent the creation of insanitary conditions and to ensure that 

product is not adulterated". 9CFR 416.2(d) states: "Ventilation adequate to control 

odors vapors and condensation to the extent necessary to prevent adulteration of 

the product and the creation of insanitary condition must be provided". This 

document serves as written notification that failure to meet these regulatory 

requirement(s) could result in additional regulatory or administrative action. 

6036 P6164A OIJ1103121 

903N-1 

12/03/2013 01D01 SPS Verification C At approximately 1843 on 11-30-13, while I, CSI , was performing the 

scheduled Raw Non Intact HACCP PHIS Task in the IF area, 

, asked to speak with me. At approximately 1844, she 

showed me a leak from the elbow of a pipe containing . It was located above 

and west of the box sealer in the IF area. I visually verified the leak did not directly 

contaminate product and was not in a high traffic area for moving or staging 

product. At approximately 1845, I verbally informed that I was 

issuing a noncompliance record. The pipe leak was the creation of a 

condition which may lead to adulteration of product. At approximately 1856, with 

the assistance of establishment employees, a red condemn barrel wrapped with 

yellow caution tape was placed below the leak. At approximately 1857, I applied US 

Rejected/US Retained Tag # B37852253 to the red barrel. At approximately 2335, I 

was informed by , the leaking pipe had been wrapped 

with plastic by maintenance. At approximately 2336, I visually verified the 

pipe had been wrapped and I removed the US Rejected/US Retained 

Tag # B37852253 I had applied to the red barrel in the IF area.  This NR is not 

linked to any other recent NR for the same root cause.   

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH180312 

3304N-1 

12/03/2013 03C02 Raw Intact HACCP C On the night of production that began on December 3, 2013 while in the HACCP 

office performing the records review portion of the raw intact HACCP task, the 

following was observed in the hazard analysis for rotis product.  At the 

recirculation step of the rotis hazard analysis a biological hazard (Salmonella) was 

identified but was considered not reasonably likely to occur.  The basis for 

this decision is outgrowth of the organism is controlled by keeping the below 

nbsp; The temperature control program and results of the SIP 

sampling are cited in the HACCP plan at the recirculation step as supporting 

documentation for this decision.  Mr. , was 

asked how the cited supporting documentation could justify that reusing that 

had previously been applied to raw poultry, the excess collected and subsequently 

reused and reapplied to additional raw poultry would not introduce a 

microbiological hazard into the process.  Mr. indicated he had no 

explanation.  Reuse of the was not addressed elsewhere in the HACCP 

or SSOP plans or in any prerequisite program and there were no antimicrobial steps 

in the recirculation process.  The establishment was reusing at 

the time. Mr. was informed the requirements of 9 CFR 417.2(a) and 

417.5(a)(1) and 417.5(a)(2) were not met and the noncompliance would be 

documented on a noncompliance record.   For a similar noncompliance refer 

to NR NHH1404070929N/1 dated July 28, 2013.  

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6) (B)(4)

(B)(4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH220412 

2803N-1 

12/03/2013 01C02 Operational SSOP 

Review and 

Observation 

C On the production shift that began on 09/18/2013, at approximately 2130, I was in 

the Evisceration Room Department at Establishment 33900  P to perform a 

finished product standards procedure on Evisceration line#2.  As I walked 

through the room on my way to the pre-chill station, I saw an oily rust colored 

liquid on the floor under the viscera shackle line on the #2 viscera line.  This 

oily water was dripping from the greasy rail onto the edible viscera below.  

    Regulatory Control Action was taken by rejecting the line with 

USDA Reject Tag #B38075842.    Mr. was shown the 

non-compliance.  The shackles were washed down with food grade chemicals 

and to remove the substance from the shackles by Sanitation, as a 

corrective action.  I then released the line to production.   The 

Preventive Measure given by Mr. was that ) 

would   inspect the shackle line before production begins, for the rest 

of the week (12/03-12/06) .   Mr. was informed a Noncompliance 

Record would be issued documenting the noncompliance.   The 

requirements of Regulations 416.1 and 416.13(c) were not being met. 

           & 

nbsp;          & 

nbsp;          & 

nbsp;          & 

nbsp;          & 

nbsp;        

           

             

The Establishments SSOP plan objective is 

        

(b) (6)
(B)(6) (B)(7)(C) (B)(6) (B)(6) (B)(6) (b)(4) (b)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1608122 

502N-1 

12/02/2013 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 2215 hours Food Inspector on line 2 

station 7 at startup observed black UFM (Unidentified Foreign Material) on 

the viscera. I collected several more sets of viscera and contacted Department 

. There were numerous specks and flakes to 

approximately 1/4" on the fat on the gizzard and on other tissues ( hearts, 

livers, intestines) that extended below the length of a normal hanging 

visceral.   From the location of the UFM on the viscera  it 

was obvious that the viscera  was being dragged across some insanitary 

surface. The line was already stopped as it was out of sequence. A small 

number of viscera at stations 7 & 8 involved were 

condemned. A mechanic was called to address the issue. The 

line was repaired and after lunch I observed the same black UFM on the 

viscera at stations 7 & 8.  The inspectors on stations 7 & 8 

were told to condemn viscera hanging lower then a normal set of viscera 

until the end of the shift. was informed of the 

ongoing condemnation and the noncompliance.   My findings 

indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.2(b)(1), 9 CFR 416.4(d), 9 

CFR 416.4(d) and 9 CFR 416.14. 

5308 M6137 BXL1808124 

902N-1 

12/02/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 0542 hours while performing a Zero Tolerance 

check on  line 2 in Plant 1, I observed the following. After taking a 

standard 10 bird sample, I observed  one bird with visible fecal 

contamination. The fecal material was inside the carcass adjacent to 

the  opening cut on the left side.  The fecal material was olive green in 

color, pastry in texture and  measured  approximately 1/4" by 1/8" in 

size. This exceeded the Zero Tolerance for the process to be in control. 

  was shown the fecal material and the protocol for fecal 

failure was implemented. A recheck passed at approximately 0517 hours. My 

findings indicated a noncompliance with 9 CFR 381.65(e), 9 CFR 417.2(c)(4), and the 

CCP-2B of the Plant's HACCP Plan for Slaughter. 

5568 M20923 XUM112112 

5102N-1 

12/02/2013 01B01 Pre-Op SSOP 

Record Review 

C On 12/2/2013, at approximately 1857 hours, while performing a routine scheduled 

SSOP Pre-Op Record Review in the QC Lab, I observed the following noncompliance: 

while reviewing the SSOP Weekly Implementation and Monitoring Log dated 

11/25/2013 the QC Representative with the initials identified an unacceptable 

finding at 06:40 hours during Pre-Op on Part 1 Pre-Operational Sanitation, Section 

1 Raw Area, Unit 79 (front of GCO) and didn't document the corrective actions 

performed to the area, a noncompliance per 9 CFR 416.16(a). I showed and 

informed Mr. of the forthcoming noncompliance. The 

requirement of 9 CFR 416.16(a) was not met. 

(b) (6)
(B)(6)

(B)(6) (B)(6) (B)(7)(C) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

6036 P6164A OIJ0721125 

102N-1 

12/02/2013 01C02 Operational SSOP 

Review and 

Observation 

O At approximately 2348 on 11-29-13, I, CSI was observing sanitary conditions 

in the packaging area. I observed nineteen unwrapped trays of product # 90883 

Jumbo Thighs stacked one on top of each other in two piles. The trays were located 

on either side of the thigh line belt immediately east of the thigh line wrapper. I 

observed the bottoms of the trays were in direct contact with product in the trays 

below them. It is reasonable to assume, considering the conditions I observed, 

there was direct product contamination. At approximately 2349, I showed 

, the conditions and verbally informed her 

I would be issuing a noncompliance record. At approximately 2350, I observed

 and , 

remove the product from the nineteen trays and place it in a brown tub. At that 

time, proposed a corrective action. To ensure the appropriate 

disposition of the product, the contaminated product would be salvaged according 

to the establishment’s written Reprocessing Floor Salvage Program. I agreed. At 

approximately 2351, I took a regulatory control action and applied US Rejected/US 

Retained Tag # B37852254 to the brown tub containing the contaminated product. 

I observed the tub of retained product as it was moved to the packaging floor 

salvage station.  At approximately 0030, after observing the process several 

times, I observed the establishment employee had finished individually washing 

and inspecting the contaminated product and putting it into another tub. This tub 

had a QC retained tag applied to it as per the establishment written salvage 

procedure. At approximately 0031, I removed the US Rejected/US Retained 

Tag # B37852254 from the tub and released the product. Later on the morning of 

11-30-13, I verified the proposed preventative measure of retraining the 

establishment employee on the proper handling of trays had been completed. It 

was documented on the establishment’s Employee Retraining and Monitoring Form 

as completed on 11-29-13. This NR is not linked to any other recent NR for the 

same root cause.  

(b) (6)
(B)(6)

(B)(6)

(B)(4)

(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH130612 

1002N-1 

12/02/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C At 0359 hours on the night of production which began on 12/01/2013, while 

performing required PHIS Poultry Zero-Tolerance task at the designated Line #1 

Pre-chill station at est. 33900 P, after randomly selecting 10 slaughtered and 

eviscerated and chilled chicken carcasses for the subgroup test and having begun 

the test at 0358 hours, Inspection found fecal material on the 5th bird in the set. 

The fecal material was a dark green color and of a pasty consistency which would 

easily smear to the touch. It consisted of three pieces 1/4” in diameter and 1/8” in 

thickness, located on the inside of the breast area. 

was shown the carcass and he concurred that the 

material in question was indeed feces. Upon investigation, it was found that the 

cause of the fecal find was ”. Plant 

Management’s Measure to prevent recurrence was “Employee counseled; first step 

of Company Disciplinary Policy.” The requirements of 9CFR381.65(e) and 

417.2(c)(4) were not met and Mr. was advised that the incident would be 

documented on a Noncompliance Record. Refer to NR #NHH2304110330N/1 dated 

11/30/2013 for a similar Noncompliance.Plant Management’s measure to prevent 

recurrence was: 

.” To date all preventive measures may not have been 

implemented as described or were ineffective in preventing recurrence. 

(b) (6)
(B)(6) (B)(7)(C) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH250412 

3402N-1 

12/02/2013 06D02 Other Inspection 

Requirements 

C On the night shift that began on 10/01/2013, at approximately 2215 hours I asked 

the Evisceration supervisor, Mr. , to perform a test in the picking 

room of   establishment 33900  P.  This Establishment 

uses a batching system of inspection, if the carcass is condemned or hung back for 

re-inspection the paw condemn button is pressed and a batch of paws are 

condemned.  This insures that all paws from condemned carcasses are also 

condemned.      The result of the test was that the 

establishment could not collect any of the paws that are used to show that all 

condemned paws would be captured and condemned. I talked to Dr. the 

IIC on night shift and explained what I had observed and informed him that I was 

going to reject the paw system.  Regulatory Control Action was taken by 

applying USDA Reject Tag #B38075841 to the system.    At 

approximately 2230 another test was performed on the line#1 system and the 

results allowed the Establishment to begin collecting paws from that line at 2300 

Hours, after the system had been rinsed with water.    At 

approximately 2305 another test was performed on line #2 paw system and the 

results displayed that the condemned paws could be captured and 

condemned.  At this time I was on the line inspecting carcasses due to a 

staffing shortage.  The Establishment began collecting paws from that 

system also.    The requirements of Regulation 381.76(b) were not 

being met.   Refer to NR NHH4600104801N / 1 dated 10/01/2013 for 

similar noncompliance.            

(b) (6)
(B)(7)(C) (B)(6)

(B)(6)

(B)(6) (B)(6)(B)(4)

(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1326 

1 

M33901 HAY521912 

3301N-1 

12/01/2013 01C02 Operational SSOP 

Review and 

Observation 

C On the calendar date of December 1, 2013 (Sunday) at approximately 1820h while 

performing the Operational SSOP Review and Observation task, I observed the 

following noncompliance during shift 2: I, CSI , observed a production 

employee pick up an empty cardboard roll from the floor and lay it on top of the 

freezer plate for line in the "IF" department.  The plate freezer film was 

being replaced.  The old cardboard roller had fallen on the floor.  A 

production employee picked it up from the floor and laid it on the 

surface of the product freezer plate.   No product was on the plate 

freezer, but the surface of the product freezer plate was contaminated by the 

cardboard roll from the floor. I immediately rejected the line with U. S. Tag 

#B34 913535 and informed the ) and Mr. 

Shift 2) that there was SSOP noncompliance.  

In addition, Mr. was shown the empty cardboard roll and he was shown the 

area of the plate freezer that had been contaminated.     In 

order to restore sanitary conditions, maintenance turned the freezer plate 

off.  Mr. had the freezer plate rinsed and sanitized.  As a 

preventive measure, he stated that the employee involved would be 

retrained.  After corrective actions were completed at approx. 1845h, the 

regulatory control action (U. S. Tag B34 913535) was removed. (No product was 

contaminated.)   The establishment’s Standard Operating Procedures for 

Sanitation (Part 2; Section 1) states: 

.   Equipment was not maintained in a sanitary 

manner and ineffective SSOP monitoring failed to prevent equipment used to 

transport raw product to the freezer from contamination.  In addition, the 

regulatory requirements for 416.13(c), 416.1, and 416.4(d) were not met. 

  

(b) (6)
(B)(6)

(B)(6) (B)(6) (B)(6) (B)(6)

(B)(4) (B)(4)

(b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH230411 

0330N-1 

11/30/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C At 0339 hours on the night of production which began on 11/29/2013, while 

performing required PHIS Poultry Zero-Tolerance task at the designated Line #1 

Pre-chill station at est. 33900 P, after randomly selecting 10 slaughtered and 

eviscerated and chilled chicken carcasses for the subgroup test and having begun 

the test at 0339 hours, Inspection found fecal material on the 1st bird in the set. 

The fecal material was a dark green color and of a pasty consistency which would 

easily smear to the touch. It consisted of one piece 1/8” in diameter and thickness, 

located on the outside of the bird on the upper right drumstick. 

was shown the carcass and he concurred 

that the material in question was indeed feces. Upon investigation, it was found 

that the cause of the fecal find was “ 

. Plant 

Management’s Measure to prevent recurrence was 

.” The requirements of 9CFR381.65(e) and 

417.2(c)(4) were not met and Mr. was advised that the incident would be 

documented on a Noncompliance Record. Refer to NR #NHH5502112830N/1 dated 

11/30/2013 for a similar Noncompliance.To date all preventive measures may not 

have been implemented as described or were ineffective in preventing recurrence. 

1325 

7 

P33900 NHH331311 

3930N-1 

11/30/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 1136 hours I performed a 10 bird Zero 

Tolerance task at the designated check station on line. the first 

sample bird contained feces in the lower kidney crypt area just below the tail of the 

bird. It was a smear of about 1/4 of an inch, past, and bright green in color. On the 

third and fifth sample bird there visible feces bedded in the same location as the 

first sample and were close to an inch or more in diameter of the same consistency. 

After finding three incidents in the 10 bird sample and having knowledge of the 

amount fecal contamination we were having due to the bird size, I took official 

control action by stopping the line. I notified and showed the three 

birds. Maintenance began an investigation to determine the cause. Afterwards

 notified me that the high pressure rinse nozzle on the line had been 

readjusted. I then released line.Shortly afterwards I began doing a check at the final 

trim station to determine if the adjusted showerhead had taken care of the 

problem. About the seventh bird that I looked at had a glob of feces an inch or so in 

diameter inside the crypts under the tail. I allowed the bird to 

continue through the final rinse before the chiller entrance and when I removed it 

the fecal matter was still present. I showed this to  and the line 

was stopped immediately. Further investigation was done and it was found that the 

IOBW had a busted hose. The line remained down until the hose was removed and 

replaced. QA was notified of the fecal failure. 

(b) (6)
(B)(6) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH550211 

2830N-1 

11/30/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C On November 29, 2013, at approximately 2148 hours while performing a Poultry 

Zero Tolerance task at the evisceration line 2 pre-chill station, I found feces inside of 

the tenth bird of a ten bird set.  The feces was inside the cavity of the 

bird, just cranial to the tail.  It was approximately one inch long by 1/16 inch 

wide and was brown in color.  was 

shown the carcass, and I informed him of the noncompliance.  Upon 

further investigation, Mr. said that the cause of the fecal find was 

that the inside-outside bird wash was not properly adjusted to accomodate 

small birds.  The establishment's measure to prevent recurrence was to 

retrain employees how to properly adjust the equipment.  The 

establishment did not meet the regulatory requirements of 9 CFR 381.65(e) and 9 

CFR 417.2(c)(4).Refer to NR #NHH4923113310N written on November 13, 2013, for 

a similar noncompliance.  

           & 

nbsp;    

(b) (6)
(B)(6)

(B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(7)(C) (B)(7)(C) (B)(7)(C) (b)(4) (b)(4)

(b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD1623110 

427N-1 

11/27/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C On 11/27/2013 at approximately 1554Hrs while performing my PHIS Zero 

Tolerance feces check, I observed visible fecal materials on the first bird sampled 

out of the ten whole body light hen turkey sampling test. One of  the fecal 

material was lodged inside the turkeys pelvic cavity and the second was on the 

inside flap (same right side). U.S. Retain Tag NO: B39554892 was applied to the 

affected carcass. The fecal materials were approximately 1/4" x 1/4" (pelvic cavity) 

and 1/8" x 1/8" (inside flap) in size; greenish, with white material in it which 

is an (indicative of uric acid) in color, as per Dr. SPHV, semi-solid in 

nature with the distinct odor consistent with fecal material. The line two ten bird 

random sample was collected after the final wash and before entrance into the 

chiller by the establishment's helper. I showed the fecal material to 

; and Dr.

 also was shown the fecal materials. Dr. concurred that it was fecal 

materials. Ms. immediately implemented the establishment's corrective 

actions. She had the turkey reconditioning by trimming and 

water ppm spraying and reinspection. At approximately 1600Hrs the turkey 

was released back to production after verifying the plant's appropriate corrective 

actions and reinspection. Ms. . conducted her rechecks after the final wash 

and they passed. This observed incident of visible-fecal material is a noncompliance 

to 9 CFR 381.65(e). Also is in violation to 9 CFR 417.2(c)(4) monitoring at the critical 

control point to ensure compliance to the established CCP 4B ( 

) after the final wash and before entering the chiller. At approximately 1919Hrs 

the plant's implemented corrective actions at the post chill were completed and 

passed by Ms. Ms. verified the checks. was notified of the 

noncompliance. This noncompliance is being linked to noncompliance (#134) 

JDD5821101818N/1 dated 10/17/2013 and (#112) JDD1623092204N/1 dated 

9/4/2013 for the same cause respectively. 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(4) (B)(4) (B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2504113 

727N-1 

11/27/2013 03J02 Slaughter HACCP C On 11/27/2013 at approximately 0145 hours in Packaging while monitoring 

sprayer functions required by the Establishments' Verification Plan 

that resulted from  a Notice Of Intended Enforcement (NOIE) dated 

October 7, 2013, I observed the following. On Line there was an uncut 

gizzard with approximately 2" of intestine attached and two more pieces of 

intestines piled on top of a half breast. There was fecal material leaking from the 

intestines onto the half breast. I contacted The half breast and 

intestines were scooped up and placed onto a yellow product tray. The immediate 

area of the belt was checked for more intestines but none were found. The half 

breast had not been packaged as it was a 'B' grade that would be sent to the end of 

the line for deboning. The fecal material on the half breast was light brown, 

creamy in texture and measured approximately 1" by 1/8" in size. As the product 

was coming from Plant #1 was called and 

shown the noncompliance. was called to perform immediate 

corrective actions. My findings indicated a noncompliance with 9 CFR 381.65(a), 9 

CFR 381.65(e) and 9 CFR 417.2(c)(4).     

5308 M6137 BXL3802113 

427N-1 

11/27/2013 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 0500 hours while walking past Line #2 in Plant 1 I 

observed the following noncompliance.  The heater duct that is directly 

above Station #8, Line #2 and the reprocessing line was covered in 

heavy beaded condensation that was dripping close to the line.  I 

immediately informed of my concerns, at which time he 

began cleaning the heater duct with a sponge mop.  The 

condensation dripped heavily from the mop spraying condensation on Station #8, 

Line #2 and Line which had birds on it at the time.  I immediately stopped 

the line and finished cleaning the heater duct, at which 

time the lines and Station were rinsed off.  The birds on the reprocessing 

line  at Station #8 were condemned, restoring sanitary conditions by 

approximately 0535 hours.  My findings indicate a noncompliance with the 

regulatory requirements of regulations 9CFR 416.4(b), 9CFR 416.1, 9CFR 

416.4(d) and 9CFR 416.2(d). 

(b) (6)
(B)(6) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4)

(b)(4)

(b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4700112 

527N-1 

11/27/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 11/26/2013 at approximately 0724 hours while monitoring Facilities in Plant #1 

rehang area, I observed the following. There was  

 spraying onto a light fixture from  the Cabinet used to 

treat carcasses going into Packaging for lines & The fluid was dripping 

from approximately a 1 1/2 foot section of the light fixture  into a 

tank of WOG's(with out giblets) being collected for the Rotisserie 

Room. The Rotisserie WOG's have already received there final microbial 

intervention. The light fixture is treated as a non-product contact surface. The 

fluids would rinse untold contaminants from the light fixture on to the 

finished product creating an insanitary condition. was called and 

after seeing the problem called for a mechanic. The partial tank of WOG's 

was reconditioned with water and returned to production by 

0745 hours.  My findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 

416.4(d), and 9 CFR 416.2(b)(1). 

5308 M6137 BXL5000115 

627N-1 

11/27/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 11/26/2013 at approximately 2145 hours while monitoring the Establishments' 

Pre-Operational Sanitation standards in Plant #2, I observed the following. 

There was a coating of a  light brown pasty UFM (Unidentified Foreign 

Material) on the black fingers associated with the fourth Picker on line . 

The UFM was in the grooves and on the smooth surfaces of most of the fingers 

associated with the unit.   was applied to the unit 

followed by a potable water rinse which removed very little of the 

UFM. The UFM was on the last three pickers on line and  was 

discussed at the morning meeting on 11/27/2013.  At approximately 2204 

hours there was three paint chips to approximately 1/2" by 

1/8" medium gray in color on the incline belt that moves product from the 

Reprocessing Line to the Chillers.  The belt was rinsed with potable water 

restoring sanitary conditions. The top of the wall opening that the 

incline conveyor belt passes through is severely deteriorated with rust 

and peeling paint that is the same color as that found on the belt. My findings 

indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.4(a), 9 CFR 416.2(b)(1), 9 

CFR 416.13(c) and 9 CFR 416.14. 

(b) (6)
(B)(6)

(B)(6) (B)(6) (B)(4) (b)(4) (b)(4) (b)(4) (b)(4) (b)(4) (b)(4) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2618110 

626N-1 

11/26/2013 03C02 Raw Intact HACCP C On 11/26/2013 at approximately 1100 hours while performing a HACCP Raw-Intact 

Record Review Task, I found the following; the HACCP Monitoring Log -CCP 3B-

), Plant #2 Rehang, dated on 

11/22/2013, PM shift had a concentration failure on one of the five sanitizer 

concentration checks. The first check at 1327 had a concentration of ppm of 

sanitizer ). The second check (Drop #7 top C) had ppm of sanitizer . At 

the comments Quality Control or designee had " fail re-check, 1347 

released". The following three checks were in compliance.  I asked 

about the failure. The concentration and the 

location for the recheck were missing. She informed me that the corrective action 

was completed, Quality Control or designee did not document the recheck 

concentration of the sanitizer ( and the location for the failure 

on the corrective action Log. My findings indicate a noncompliance with the 

following regulatory requirements of regulation 9CFR 417.5 (a)(3).I notified

 of the 

noncompliance.    

5308 M6137 BXL3018110 

926N-1 

11/26/2013 03J02 Slaughter HACCP C  On 11/26/2013 at approximately 1100 hours while performing a HACCP 

Slaughter Record Review Task, I found the following; the HACCP Monitoring Log 

-CCP 2B- (Plant 2) PM Shift dated on 11/22/2013 at 

approximately 1019 hours, Line , had a Zero Tolerance Failure by Quality Control. 

Production started performing corrective actions as the HACCP Plan for Slaughter 

Plant #2 stated. Corrective actions were performed and finished at approximately 

1224 hours. The Pre-Shipment Records Review CCP 2B ( ) 

mid-Shift, was signed at 1201 hours. The signed documented certifies that the 

product is ready to be shipped. The Pre-Shipment Records Review, mid-Shift 

was signed before the corrective actions for the failure were completed.My findings 

indicate a noncompliance with the following regulatory requirements of regulations 

9CFR 417.5 (c).I notified of the 

noncompliance. 

(b) (6)
(B)(7)(C) (B)(7)(C) (B)(6) (B)(6) (B)(6) (B)(4) (B)(4) (b)(4) (b)(4) (b)(4) (b)(4) (b)(4) (b)(4) (b)(4) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN211811 

0726N-1 

11/26/2013 03J02 Slaughter HACCP O In regards to the establishment’s corrective actions to the Notice of Intended 

Enforcement (NOIE), issued on 10/07/13; the following noncompliance has been 

noted. The verification plan included several antimicrobial treatments to mitigate 

bacterial pathogens. According to the Notice of Deferral Verification plan dated 

10/13/13 (including the most recent revision dated 11/6/13), the establishment 

made a commitment to implement a pre-chill cabinet by 10/20/13 and 

monitor the concentration. In addition, per the verification plan, the 

establishment is to monitor the levels of the “Chiller Fresh Make Up” as 

well as the “Chiller Red Water” with acceptable levels of 0ppm FAC and ppm 

FAC, respectively. From 11/18/13 to 11/20/13, the establishment discontinued 

the use and monitoring of concentration for the pre-chill cabinets. 

Also, from 11/18/13 to the present, the establishment discontinued the use and 

monitoring of acidified in the chiller. These actions contradict the terms 

outlined in the Notice of Deferral Verification Plan, dated 10/13/13 (including the 

most recent revision dated November 6, 2013). Consequently, there is 

noncompliance with 9 CFR 417.5(a)1.  The noncompliance referenced above 

was discussed with , on November 22, 2013 by the FLS, Dr.

 and EIAO . 

5309 P6137A NJN391211 

5827N-1 

11/26/2013 01C02 Operational SSOP 

Review and 

Observation 

C While I was performing an operational sanitation task in the fillet department, at 

approximately 1245 hours, I observed a mist of water raised from the area between 

# & When I went there to check the area, I found a plant employee 

washing down the floor using high presser water. I immediately stopped him 

because he over sprayed the portable incline conveyor as well as the products on 

the conveyor. I informed Mr. , of the noncompliance 

and explained to him that the incline conveyor is too close to the floor which 

exposes the conveyor as well as the product to the splashes of contaminated water 

from the floor. Also, I suggested that using the squeegee is better during 

operations, to clean the debris. Mr stopped the production line, washed and 

sanitized the conveyor, and sent the affected product to be reprocessed. The plant 

failed to comply with the regulations 9 CFR 416.1, 9 CFR 416.4(d), and protect the 

product from cross contamination. 

(b) (6)
(B)(6)

(B)(6)

(B)(4)

(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3113110 

025N-1 

11/25/2013 03J02 Slaughter HACCP O On 11/19/2013 while reviewing the company's computer records for 

IOBW (CP-4), I observed the following. On Line #1 the frequency of one hour 

on one check was over by 28 minutes. On Line #2 the frequency of one hour on one 

check was over by 38 minutes and on reprocessing Line the 

frequency of one hour on one check was over by 30 minutes. This is a 

noncompliance of the establishment not following the proffered IOBW Monitoring 

procedure. The Notice of Deferral Verification Plan #4. states in part " 

. I informed Quality Control

 of the noncompliance.My findings indicate a 

noncompliance with regulatory requirements of regulation 9CFR 417.5(a)(1). 

1325 

7 

P33900 NHH232311 

1625N-1 

11/25/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On the night of production which began on 11/25/2013, Inspection performed 

scheduled PHIS procedure Pre-op SSOP Review and Observation in the Evisceration 

Department of 33900 P. This was after Sanitation had finished cleaning the 

equipment and QA had finished their Pre-operational inspection of the equipment 

and released the area for USDA inspection. There are no additional Sanitation or 

Pre-operational steps prior to the start of production. The following noncompliance 

was observed: At 2035 hours while checking Line #2 Paw Unloader (Unit #1/Zone 

#3), Inspection found the Picker Fingers (Product contact surface) in an unsanitary 

condition with a greasy black residue which would easily rub off onto the hand. 

Inspection took Regulatory Control Action by applying US Reject Tag #B38075678 

to the Unit until it could be recleaned and reinspected, and was released at 2124 

Hours. The Requirements of 9CFR 416.13(c) were not being met and 

was shown the noncompliance and advised that a Noncompliance 

Record would be issued. The item of Equipment was randomly selected for 

Inspection as required. For a similar noncompliance refer to NR 

#NHH4423105223N/1 dated 10/23/2013. To date, all Preventive Measures may 

not have been implemented as described or were ineffective in preventing 

recurrence. 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(4) (B)(4)

(B)(4)

(b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1609113 

423N-1 

11/23/2013 04A06 Poultry Finished 

Product Standards 

O On 11/23/2013 at approximately 0511 hours while performing a Post-Chill 

Finished Product Standards check in Plant #1 from Chiller#1, I observed the 

following. After taking a standard random 10 bird sample, I accumulated 12 

nonconformance points. 5 of the 10 birds had black UFM(Unidentified Foreign 

Material) on the back side of the left hock. I contacted 

and informed him of the noncompliance. A QC recheck failed with 9 

nonconformance points at 0539 hours. At this point the process is judged to be out 

of control.  Post-Chill rechecks at 0546 hours and 0600 hours brought the 

process back into control. Post-Chill rechecks were performed every 30 minutes 

until the end of the shift. An employee was stationed near the  

to wipe off the UFM until the end of the shift.  stated that 

it was determined that the UFM was  caused by dirt on 

the shackles being  transferred to the carcasses at the auto-rehanger 

and that a work order to acid wash the shackles over the weekend had been 

submitted.  My findings indicated a noncompliance with 9 CFR 

381.76(b)(3)(iv) (d)(3). and 90 CFR 381.65(a).  

5309 P6137A NJN150111 

2923N-1 

11/23/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C At approximately 2235 hours, after the QC Technician had performed Pre 

operational Sanitation and released the area for production, I went on to perform 

the Pre-operation Sanitation task in area five, new products room, section A 

(Rotesserie Line). While doing so, I observed a precipitation of salt residue inside the 

pipe of the tank from the previous production shift. The residue measured 

approximately a 3⁄4 of an inch in thickness, whitish in color, and extended along the 

length of the pipe. The tank was rejected with US tag NO. B43303529. At 

2255 hours, and after the restoration of sanitary conditions, I re-inspected and 

released the tank. I informed Mr. , of the non 

compliance. The establishment failed to adequately monitor the implementation 

of sanitation SOP which in turn created insanitary conditions. This finding 

represents a non-compliance with 9CFR 416.13(c), 9CFR 416.4(a) and 9 CFR 416.1. 

Plant's written SSOP, part (1) Preoperational Sanitation section 4 further 

Processing, dated 10/15/2013 revised, which states: " 

". Continued failure to 

comply with regulatory requirement(s) could result in additional regulatory or 

administrative action as described in 9 CFR 500.4.   

(b) (6)
(B)(6)

(B)(6)

(B)(6) (B)(7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5310 M6137B FFA4421113 

522N-1 

11/22/2013 01D01 SPS Verification C On November 22, 2013, at approximatley 0215 hours  prior to the start of 

operation in the Blending Room I observed the following noncompliance.  On 

the underneath side of the metal bar that runs across the large blender dumper I 

observed a sharp piece of metal and  pieces of glue like material, 

this metal bar comes in contact with product, but at the time of my 

observation operation had not started.  U.S. Reject Tag NO. B34377420 was 

applied to the dumper.  Ms. and Ms. 

was informed and showed the noncompliance. Ms. was also 

informed.  At approximately 0300 hours the metal bar was repaired and 

re-inspected by CSI and released after sanitary conditions restored.This 

does not comply with Regulatory Requirement(s) 416.1; which states in part: "Each 

official establishment must be operated and manintained in a manner to ensure 

product is not adulterated", 416.3(a); which states in part:  "Equipment and 

utensils must be maintained in sanitary conditions so as not to adulterate 

product".This document serves as written notification that failure to comply with 

the regulatory requirement(s) of 9 CFR 416 could result in additional regulatory 

action as described in 9 CFR 500.4. 

(b) (6)
(B)(7)(C)

(B)(6)

(B)(6)

(B)(6) (B)(4) (B)(4) (B)(4) (b)(6) (b)(7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0905114 

121N-1 

11/21/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C At approximately 2139 hours while monitoring the Establishments 

Pre-Operational Sanitation Standards in Plant #2, CSI 

ey observed the following noncompliance. While inspecting the Line 

Stunner I observed a large amount of  sand, ingesta and feathers from 

the previous days production floating in the water at the bottom of the 

stunner.  I immediately informed of the noncompliance. The 

stunner was cleaned, restoring sanitary conditions and released at approximately 

2213 hours.  At approximately 2151 hours while inspecting Picker #3 on Line 

  there was a brown residue buildup on the metal plates associated with 

the picker fingers, the residue easily  scraped off  with a 

fingernail,.  There were also numerous feathers all over the picker and 

a thick, slimy yellow film on the back side of the rubber curtain at the top of the 

picker.  I immediately informed of 

the noncompliance. The picker was cleaned restoring sanitary conditions by 

approximately 2215 hours.  My findings indicated a noncompliance with 9 

CFR 416.1, 9 CFR 416.4(a) & (b) and  9 CFR 416.13(c).At approximately 

2154 hours in Plant #1 observed the following. There were 

several specks and smears to approximately 1/2" of black UFM(Unidentified 

Foreign Material) on the product contact surfaces of rehang belt and on the white 

rollers that support the rehang belt for line #1. There was black UFM that 

smeared like grease on the white nylon material covering the guide bar above the 

rehang belt.  The nylon material was replaced.  There was 

 a piece of caulking coated with black UFM that appeared to be mold hanging 

loose from the drip pan located adjacent to the rehang belt. Sanitary 

conditions were restored by approximately 2217 hours. The Cropper for Line 1, at 

approximately 2213 hours the shaft  that extends into the carcass 

during production had varying amounts of black UFM. The unit was cleaned 

and released by approximately 2219 hours. At approximately 2220 hours there was 

flakes of black UFM measuring to approximately 3/8" by 1/4" on 2 chiller 

paddles near the line carcass drop unit for product entering Chiller #1. The 

UFM was removed. At approximately 2222 hours there were several specks 

of black UFM on the paddle at the outflow side of chiller #2. There was a wear 

mark approximately 6" in length  on the end of a paddle at the 

exit end of chiller #2 with loose metal flakes. A small loose piece measuring 

approximately 2mm by 1mm was removed. 

was present so I showed him the deteriorated  condition of the 

paddle. There was several pieces of tissue to approximately 2" on the 

exit conveyor belt also from chiller #2. Sanitary conditions were restored by 

approximately 2225 hours. was informed of the 

noncompliance.In Rotisserie at approximately 2325 hours, the needles for the 

(b) (6)
(B)(6) (B)(6) (B)(6)(b)(4) (b)(4) (b)(4) (b)(4) (b)(4) (b)(4) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

injection machine were installed in the injection machine and not out ready for 

inspection. The needles were removed, inspected  and 

reinstalled.  At approximately 2327 hours there was a large amount of 

brown UFM leaking from a gear assembly for the dumper unit. The brown UFM 

wipes off easily with any contact.  A mechanic was informed. The area 

was recleaned. The brown UFM will continue to collect on the outside support 

bracket until repairs are made.   At approximately 2328 hours there 

were several flakes of black UFM on the first two white product belts on the right 

side of the Rotisserie cone line. There was a piece of tissue measuring 

approximately 2" by 1/4" inside the white nylon injection belt at the 

out flow side of the injection machine. Sanitary conditions were restored by 

approximately 2330 hours. was informed of the 

noncompliance.In Packaging Area #1 at approximately 0000 hours there was 

brown UFM leaking from a gear assembly at the end of the overhead wing 

conveyor belt. The  gear assembly associated with the belt located at 

the end of the belt near the elevator. The conveyor belt transports the wings 

from the Deboning room to the Packaging Area. The  brown 

UFM was dripping from the unit onto a second flexible product conveyor belt 

directly below it. Plastic was attached to the assembly until repairs 

can be made. The area was recleaned and released by approximately 0025 hours.

 was informed of the noncompliance. In Packaging Area 

#2, the Room, there was a red paint chip measuring approximately 

1/8" on a salvaged parts table near line #1. The fire fighting system piping 

mounted on the ceiling is painted the same  bright red color.  If 

on a chicken the bright red paint would be mistaken for a piece of blood. There 

were two white paint chips on a product belt along line #2. Paint issues in the 

Room were addressed at the morning meeting with establishment on 11/20/2013 

and documented on MOI BXL4619114320G. Towards the end of 

Pre-Operational Sanitation the drains in the Room overflowed due to a 

plugged drain the the Paw Room.  The water backs up in the Deboning 

Room, Plant #1 Cooler, and the Staging Cooler. Supervisors were called. Production 

was shut down on the loading dock and traffic through the plant 1 cooler 

was stopped.  The drains were cleared. 

had the floors rinsed and treated with . The 

 Room , Cooler #1, and the Staging Cooler were released by 

approximately 0230 hours. The Paw Room was rinsed and treated with by 

approximately 0330 restoring sanitary conditions. My findings indicated a 

noncompliance with 9 CFR 416.1, 9 CFR 416.2(b)(1), 9 CFR 416.2(e)(4), 9 CFR 

416.3(a), 9 CFR 416.3(b) and 9 CFR 416.13(c).   

(b) (6)
(B)(6)

(B)(6)

(B)(6) (B)(4)

(B)(4)

(b)(4)

(b)(4) (b)(4)

(b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4820110 

321N-1 

11/21/2013 03J02 Slaughter HACCP C While reviewing the company computer records, I found the following;

 (CP-19) was not performed on night shift in plant #1 

on 11/20/2013 and only two checks were performed on 11/21/2013 in Plant #1 

night shift also. I asked for a print out of 

Salvage Parts Treatment results for these two days. She informed me later that the 

Salvage Parts Treatment Procedure was not performed on the 11/20/2013 in Plant 

#1, and on 11/21/2013 Quality Control performed only two 

checks. HACCP Plan -Slaughter Plant 1- under step #37 states in part : 

Justification for 

decision. 

. 

Supplements 2, 7, 17, 18, 56. HACCP Supplement #56, Salvage Parts Treatment: 

CP-19 under procedure #4 states in part " 

". This is a noncompliance with the 

following regulatory requirements of regulation 9CFR 417.5(a)(2). 

5309 P6137A NJN451411 

1322N-1 

11/21/2013 04A06 Poultry Finished 

Product Standards 

C At approximately 0915 hours, while performing the finished product standards 

check on the reprocessing line, I found seven carcasses that were contaminated 

with ingesta on the crop area, two of them having bruises. The size of the 

contaminated areas varied from 1⁄2 inch to 1 inch. Also, I found one bird with 

excessive amounts of feathers on its back and the wings. I immediately 

stopped the reprocessing line and showed Mr. 

, and Mr. , my findings and informed 

them of the forthcoming noncompliance. The plant failed to keep the reprocessing 

line in compliance with the federal regulations.9CFR 381.89 states:"Any part of a 

carcass which is badly bruised shall be condemned and, if the whole carcass is 

affected as a result of the bruise, the whole carcass shall be condemned. Parts of a 

carcass which show only slight reddening from a bruise may be passed for food."9 

CFR 381.91(b)(1) states: " Any carcass of poultry accidentally contaminated during 

slaughter with digestive tract contents shall not be condemned if promptly 

reprocessed under the supervision of an inspector and thereafter found not to be 

adulterated. Contaminated surfaces that are cut shall be removed only by 

trimming. Contaminated inner surfaces that are not cut may be cleaned by 

trimming alone, or at an approved reprocessing station away from the main 

processing line, by any method that will remove the contamination, such as 

vacuuming, washing, and trimming, singly or in combination. All visible specks of 

contamination must be removed, and if the inner surfaces are reprocessed other 

than solely by trimming, all surfaces of the carcass shall be treated with 

water containing ppm available " 

(b) (6)
(B)(6)

(B)(6) (B)(6)

(B)(6)

(b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH420511 

2521N-1 

11/21/2013 04B04 General Labeling C On the night shift of production that began on 11/20/2013, I was in room #1 

Further Processing department at Est.33900  P to perform post chill 

requirements on product exiting the line #1 chill system.   When I 

started to collect carcasses for the line #2 chill system check the chillers were 

stopped and no carcasses were exiting the system.  I asked the 

, how long the system would be down.  Mr.

 explained the system was turned off for up to thirty minutes to separate 

the small Halah birds from the large Halah birds.  I asked for the moisture 

protocol procedures that would determine the amount of moisture that the 

carcasses would retain from this stoppage.  Ms. could not 

produce the document so Inspection could not determine if the establishment had 

met the requirements of 9CFR Ch.III Part 441.10. 

1325 

7 

P33900 NHH460311 

0921N-1 

11/21/2013 03J02 Slaughter HACCP C At approximately 0300 hours on 11/21/13 while completing a HACCP Slaughter 

task from 11/18/13 inspection noted the following noncompliance.  The 

records for CCP-1 on 11/18/2013 indicated the interval between CCP 1 monitoring 

checks exceeded the frequency of “ ” 

specified in the HACCP plan.  For line 1, CCP 1 was monitored at 0334 hours 

and again at 0439 hours for a total interval of 65 minutes.  Production on 

line 1 was ongoing during this entire interval.  The requirements of 9 CFR 

417.2(c)(4) and 417.5(a)(3) were not met.  

was notified of the noncompliance and informed it would be documented on 

a NR.  For a similar noncompliance refer to NR NHH4602110812N/1. 

(b) (6)
(B)(7)(C) (B)(7)(C) (B)(6) (B)(4) (B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4103115 

220N-1 

11/20/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C At approximately 2140 hours while monitoring the establishments Pre-Operational 

Sanitation Standards in Plant #2, CSI  observed the 

following noncompliance.  There was whole chicken foot floating in a brown 

cloudy puddle of water in the bottom of the stunner.  Sanitation 

immediately removed the chicken paw and the stunner was cleaned 

restoring sanitary conditions by approximately 2145 hours. At approximately 

2145 hours there was a heavy layer of brown UFM(Unidentified Foreign 

Material) on the fingers for Picker #5 on Line . The UFM easily scraped off 

with a finger nail.  The unit was cleaned and released by approximately 

0115 hours.  My findings indicate a noncompliance with the 

regulatory requirements of 9CFR 416.4(a), 9CFR 416.1, 9CFR 416.13(c) and 9CFR 

416.4(d). On 11/19/2013 CSI while monitoring the 

Establishments' Pre-Operational Sanitation standards in Plant #1 made the 

following observations. At approximately 2152 hours there was greasy product 

residue and feathers on the guide bars associated with  the Line #1 Hock 

Nicker. There was also dried product residue with black UFM(Unidentified Foreign 

Material) that appeared to be mold on support bracket near the top of the 

chain housing. The unit was cleaned and released by approximately 2159 hours. At 

approximately 2212 hours there was heavy beaded condensation and over 

spray on the ceiling and equipment support brackets throughout the 

Line room. The ceiling was dried off with a sponge mop. The sponges had fat and 

tissue imbedded and were deteriorating with pieces of sponge 

loose.  The sponges used caused  the condensates to 

drip on the equipment throughout most of the room creating an insanitary 

condition. The equipment was given a through rinse and the space was released at 

approximately 2229 hours. There was several specks of black UFM that 

smeared like grease on the inside of Chiller #1 on the out flow side. There was also 

heavy beaded condensation on the ceiling over the out flow side 

of chillers 1 & 2.  Sanitary conditions were restored 

by approximately 2250 hours. was informed of the 

noncompliance. In Packaging Area #1 at approximately 2345 hours there was black 

UFM along most of the tray belt associated with line  The belt was 

recleaned and sanitary conditions were restored by approximately 0004 hours. My 

findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.4(a) & (b), 9 

CFR 416.2(d), and 9 CFR 416.13(c). 

(b) (6)
(B)(6)

(B)(6)

(B)(6) (B)(6) (B)(6) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD2515114 

121N-1 

11/19/2013 01D01 SPS Verification C On 11/19/13 around 11:15 Hrs while I was going around the plant I 

observed  close to the osteo and salvage room one spray container lying with 

some chemical inside. There was no MSDS or ingredient label on 

it  . and 

 were notified of the non compliance . This is a violation of 9CFR 416.4(c). 

5112 M18909 JDD3504114 

321N-1 

11/19/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 11/19/2013 at approximatley 1000Hrs while performing pre-operational 

sanitation of the plant's Evisceration; Raw Fabrication Grinding and Bagging 

Department's after the plant Q.C. and before start up of production. I oberved the 

following noncompliance. was notified of the 

noncompliance and shown all incidents. I observed all of the plant's implemented 

corrective actions to the affected food contact surfaces. Mr. and Mr.

 verified the non food contact surfaces. 1.) Evisceration - Auto Kill blade 

had blood (food contact). b.) Chiller A end slide to chiller B- had many pieces of 

meat, skin and fat (food contact surface). c.) Trussing - had four (UFM) 

black grease drips on the food contact table. Also -The trussing belt-

 had a broken belt section which was not trimmed. The maintenance was 

called and replaced the broken section. d.) Final Wash- had UFM black grease drips 

on the middle section (non food contact). e.) The white conveyor into chiller A- had 

four pieces of meat one feather and two areas of meat residues (food contact). f.) 

White incline exiting the Gizzard defatter- had UFM black grease drips (food 

contact). g.) Steel glove- one had meat (food contact). 2.) Raw Fabrication  

Grinding- The # 1 grinder dumper-  had meat residues on the hand bar (food 

contact). b.) injector- had meat residues (food contact). 3.) Bagging 

Department- The blue line belt was unraveling at the edge and was dragging onto 

the floor when the conveyor was moving (food contact). The maintenance was 

notified to trim. The observed incidents of food contact surfaces found with meat, 

meat residues, skin, fat, feathers, UFM and untrimmed belt's from previous days 

operations is in violation to 9 CFR 416.4(d); 416.13(c) and 416.4(a). The non food 

contact surfaces not cleaned is in violation to 9 CFR 416.4(b). This noncompliance is 

being linked to noncompliance (#161) JDD4803115918N/1 dated 11/16/2013; 

(#153) JDD2203112512N/1 dated 11/11/2013 and (#147) JDD411114204N/1 

dated 11/4/2013 for the same cause respectively. 

(b) (6)
(B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5129 M210 LQN020311 

4419N-1 

11/19/2013 01C02 Operational SSOP 

Review and 

Observation 

C On November 18, 2013 at approximatley 1900 hours, while performing my 

Operational Sanitation Inspection in the Oven Room, Slice Pack Staging Room, and 

Coolers I observed the following noncompliance.Oven Room: (a) I observed 5 pieces 

of product on the floor  (b) I observed no sanitizer in the hand dip station, 

and (c) I observed no inedible barrel in the oven room.  I informed and 

showed Mr. the noncompliance, Immediate 

Corrective Action:  Product was put into inedible barrel and hand dip station 

was filled with sanitzer.Slice Pack Staging Room:  I observed 13 to 15 pieces 

of product (product code 6054) on the floor.  Cook Pack Cooler:  I 

observed two pieces of product on the floor. Slice Pack Cooler:  I observed 

three pieces of product on the floor.  Management Immediate Corrective 

Action:  Product was condemn and floor cleaned and sanitized.  At 

1930 hours sanitary conditions was restored.This does not comply with Regulation 

416.1; which states in part:  "Each official establishment must be operated 

and maintained in a manner sufficient to prevent the creation of insanitary 

conditions and to ensure product is not adulterated", and 416.13(c); which states in 

part:  "Plant monitors implementation of SSOP procedures".This 

noncompliance report serves as written notification that failure to comply with 

regulatory requirement(s) of 9 CFR 416 could result in additional regulatory or 

administrative actions. 

(b) (6)
(B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1307113 

919N-1 

11/19/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 11/19/2013 at approximately 0200 hours while conducting a Finished Product 

Standards check in Plant #1, I observed the following. There was condensation 

dripping from the ventilation ducting on to the QC Finished 

Product Standards(FPS) table on the line #1 side of the plant.  The 

ducting extends from the QC FPS table over eviscerating  lines 1 

& 2 and ends at an exhaust vent on the line 2 side of the plant 

near the Cropping Machine. There was heavy beaded condensation along the entire 

length of the ducting.  A second separate ventilation line 

extending from the entrance door to the employee break 

area  to the exhaust duct between stations 4 & 8. 

The ducting passes over line 2 and also had beaded condensation along its entire 

length. I contacted and showed him the noncompliance. 

The condensation was wiped up but immediately came back. Paper towels were 

placed on the light fixture to catch the dripping condensates. A mechanic was 

called to adjust the ventilation. I checked back later and the condensation 

was again being wiped off by an establishment employee. Ventilation ducting is 

treated as a non-product contact surface which is seldom cleaned. The 

contaminants added by the dripping condensates is causing an insanitary 

condition.  My findings indicated a noncompliance with 9 CFR 416.1 

and 9 CFR 416.2(d).  

(b) (6)
(B)(6) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4)

(b)(4)

(b)(4) (b)(4) (b)(4) (b)(4)

(b)(4)

(b)(4) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2107112 

419N-1 

11/19/2013 03J02 Slaughter HACCP C On 11/16/2013 at approximately 0525 hours while performing a direct 

observation task as part of the Verification Plan resulting from a Notice of 

Intended Enforcement(NOIE) dated October 7, 2013 , I observed the 

following.  I was observing the Establishments' monitor 

perform a scheduled check when we observed that the  

 spray on overhead line going into Packaging was 

not working. Line was running and untreated carcasses were entering Packaging. 

 The monitor called a Packaging Supervisor to stop the line and she 

called a mechanic to make repairs. With the line stopped arrived 

and QC hold tags were applied to a pallet of front halves 

at the Plant #2 Halvers,  to a rack of legs and a rack of thighs 

at a location near Packaging lines &  . The product 

collected before the line stopped were tagged in my presence.  I left 

assuming that corrective action was in progress. On 11/18/2013 at 

approximately 2030 hours I conducted a HACCP Slaughter records review of 

records filed from 11/16/2013.   The CCP-7B  for 

Plant #2 for 11/16/2013 showed the failure of the spray on overhead line 

at 0525 hours. The last good check  was at 0435 hours. A Corrective 

Action  Log for the HACCP Slaughter failure documented that 'Product 

was Involved' and that a pallet of front halves and two racks of  legs and 

of thighs were held for treatment with . When I left the area on 

11/16/2013 there were approximately 600 carcasses hanging from the 

unit past the Halving machine all the way to the Leg Processers with most of 

the shackles full. This product is cut, separated and directed to Packaging 

lines & A like amount of product is arriving onto Packaging belts 8 & 

9. The treated product arriving from plant #1 was contaminated by the untreated 

product arriving from plant #2.  The Establishment on line was also 

packing leg and thighs from Packaging Lines  & from 

the untreated product. There was a bin of thighs being collected adjacent to 

line . A full bin normally weighs approximately 2000 pounds. The 

Establishments Corrective action Log for the HACCP Slaughter failure does not 

address any of this product.   A review of the establishment' 

HACCP Plan - Slaughter Plant #2 Step 27 ' lists (B) Pathogens: i.e. Salmonella 

and Is the Hazard Significant? YES. Under 'Justification for Decision' it states

 CCP-7B -Corrective action' lists Supplement #10 as a 

supporting document for their decision. Supplement 10  under #3. Corrective 

Action Procedure (Concentration failure/ application) states under (f.) "If the 

line was not stopped at the time of the failure, product from the last passing check 

will be identified and placed on hold using the Corrective Action 

(b) (6)
(B)(6) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4)

(B)(4)

(b)(4) (b)(4) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

Checklist."  The establishment has no records of the affected 

product being used to pack the legs and thighs on lines &  into 

'Picnic Packs' on line the bin of thighs being collected near Packaging line nor 

the 600 carcasses on the overhead line from the  inoperable

 spray cabinet to the Leg processors. This is a failure of the 

Establishments' Corrective Action procedure as outlined in Supplement #10 to 

prevent contaminated carcasses from entering commerce.  My findings 

indicated a noncompliance with 9 CFR 417.3(c). 

5308 M6137 BXL4520111 

119N-1 

11/19/2013 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1335 hours, while performing direct observation on 

the Second Processing Rinse (mid-shift) at the Rotisserie 

Room, I observed the following; sanitation employees 

were washing the area and applying the sanitizer ( ). I 

observed when Quality Control  did the ( 

sanitizer concentration check, at approximately 1344 hours. The SSOP Plan 

states in part under procedure that " 

. The 

sanitation employees were almost finished with the application of the 

sanitizer when Quality Control measured the concentration.My findings indicate a 

noncompliance with the following regulatory requirements of regulations 9CFR 

416.13(b) and 9CFR 416.13 (c).I informed 

of the noncompliance.  

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6)

(B)(4)

(b)(4) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD1911114 

318N-1 

11/18/2013 03J02 Slaughter HACCP C On 11/18/2013 at approximately 0616Hrs, I observed the collection barrels of 

Turkey Fries at line one and line two. The plant's attachted tag #645935 

& 36 showed both barrels collection time was 0415Hrs. I was at the 

Line 2 barrel filling out my U.S. Retain Tag 

NO:B39554891 to apply to the barrel with temperature 98.6F.

 came up to me and was notified of the noncompliance 

and shown the temperature 98.6F. I also notified him that line one barrel of 

fries would be retained. The line one and line two Turkey fries had 

no ice or CO2. The establishment's CCP 2B requirement for fries had 

exceeded the time and temperature of 40F within 2 hours of harvesting. A plant 

employee took the line one barrel of fries and put them into the chilling tank. Mr.

 chose to plant condemn all of the  fries. The line two barrel of fries 

approximately 40 pounds was immediately taken out side and 

condemned/denatured. The line one turkey fries (44 pounds) were 

plant condemned when they came out of the chilling tank at approximately 

0650Hrs. This observed incident of Turkey fries found exceeding the two 

hour time limit and 40F temperature from harvesting is a violation to 9 CFR 

381.66(c)(4) and the plant's monitoring of the turkey fries 9 CFR 

417.5(a)(3).  was also notified of the noncompliance. 

5308 M6137 BXL1314110 

618N-1 

11/18/2013 03C02 Raw Intact HACCP C On 11/16/2013 while observing Quality Control personnel perform the CCP3B 

procedure in the Packaging Department at shift change,I observed the following 

noncompliance. Q.C. was measuring the sanitizer concentration on 5 contact 

surfaces in Packaging 1 Area. She was waiting for an employee to sanitize the halver 

machine that is located by the aged breast cooler and the deboning table. 

After the sanitizer was applied to the halver, Q.C. measured the sanitizer 

concentration on the halver chute and the concentration was zero on the test strip. 

She did not document the result on the CCP3B . Q.C. then 

checked the sanitizer coming out of the hose and it was also zero, she 

informed Supervision. Another Q.C. personnel came over and informed her 

that production would not be using the halver and then informed her which lines 

were going to be running. Both Q.C. personnel left the halver area, and sanitizer was 

not reapplied. The HACCP Plan states in part, 

, 

Further planned actions must be taken to ensure compliance with 9CFR 417.3. I 

informed of the noncompliance.My 

findings indicate a noncompliance with regulatory requirements of regulations 9CFR 

417.2(c)(4), 9CFR 417.2(c)(5), 9CFR 417.2(c)(6), 9CFR 417.4(a)(2)(ii), 9CFR 

417.5(a)(3), and 9CFR 417.5(b). 

(b) (6)
(B)(6)

(B)(6)(B)(6) (B)(6)(b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2020115 

818N-1 

11/18/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C While monitoring the Establishments' Pre-operational Sanitation Procedures in 

Plant #1, I observed a noncompliance with the following regulatory requirements of 

regulations 9CFR 416.1, 9CFR 416.4(a) and 9CFR 416.13 (c).At approximately 0709 

hours in the Area #4, Unit #16 Final Trim Station Line #1 and Line #2 and 

Cabinets, I found the drip pan for Line #2  that is going directly to the recycle 

water tank with chunks of dried and semi-dried fat from the previous day 

production. The drip pan from Line #1 that is attached to the cabinet had 

several spots of black material that appeared to be grease and also residue on the 

entire drip pan of the same material. I immediately attached a U.S. 

Retained/Rejected Tag #B31 406311 to the area and informed 

and about the noncompliance. They had an 

employee to scrub and rinse the area. Sanitary Conditions were restored at 

approximately 0717 hours, I then removed my tag. 

5769 M6492 DIO0702110 

018N-1 

11/18/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C At approximately 2300 hrs., I started my Pre-Operational Review and Observation 

task upon learning from that the area to be Pre-Oped is 

ready(Raw side). I noticed at kettle number 8 that there is a food residue( 

approximately 1”x3/4” in size) from previous production which is located at the 

connecting junction between pump and pipe that feeds the Burrito fillings down to 

the line. This surface is a Food Contact Surface. I notified Ms. and 

Sanitation personnel immediately cleaned and sanitized the affected surface and 

my reinspection reavealed no trace of food residue. Had this contaminant not been 

found, it will potentially adulterate product that will be produced. This is in 

violation of Title 9CFR416.4(a) Sanitary Operations and 9CFR416.13(c) 

Implementation of SOP’s   9CFR416.4(a)  All food-contact surfaces, 

including food-contact surfaces of utensils and equipment, must be cleaned and 

sanitized as frequently as necessary to prevent the creation of insanitary conditions 

and the adulteration of product.   9CFR416.13(c)   Each official 

establishment shall monitor daily the implementation of the procedures in the 

Sanitation SOP’s. 

(b) (6)
(B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH370411 

2419N-1 

11/18/2013 01C01 Operational SSOP 

Record Review 

C On the night of production that began on November 18, 2013, while performing 

SSOP records review, I found the following noncompliance.  There were three 

SSOP deviations documented by the establishment where the preventive measure 

for each deviation was an employee received instructions from a supervisor.  

There was no documentation that these instructions were given.  Therefore 

the preventive measure could not be verified.  For another deviation the 

preventive measure was an area check would be performed; however, the check 

was not documented.  The preventive measure for another deviation was 

training would be provided by the warehouse. There was no documentation for this 

training. This training could not be verified.  Mr. was notified 

the noncompliance would be documented on an NR. The requirements of 9 CFR 

416.16(a) were not met.  For a similar noncompliance refer to NR 

NHH1201100414N/1 dated October 13, 2013.  The preventive measure for 

this noncompliance was ‘Supervisor responsible for assuring Preliminary Response 

Forms will be answered by the end of the shift and retrained as such.”  These 

measures may have been ineffective or implemented incorrectly. 

(b) (6)
(B)(7)(C) (B)(7)(C) (B)(7)(C) (B)(7)(C)

(B)(6)

(B)(7)(C) (B)(7)(C) (B)(7)(C) (B)(7)(C) (B)(6) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD3502114 

518N-1 

11/17/2013 04C05 Poultry Good 

Commercial 

Practices 

C On 11/17/2013 at approximately 0715Hrs while giving a break to the line 

food inspector, I, , CSI observed the following non-compliance.  

While providing a break, I hung back 2 cadavers for Dr. SPHV to 

verify. Once the inspector returned from break, I immediately went outside 

to check Good Commercial Practices at the live hang/kill line area. Dr. 

examined the cadavers and determined that birds were cadavers; one of the 

cadavers had a kill cut but did not bleed fully, and the other did not have a kill cut. 

Upon confirmation of the cadavers, Dr. notified 

, about the two cadavers so immediate corrective action could be done; 

this is the plant's standard practive. When birds are determined to be 

cadavers, the establishment implements immediate corrective actions.During this 

time, both evisceration lines one and two were running at the maximum allowable 

speed of per line with two line inspectors for birds 16 lbs 

or over. Outside at the live hang/kill line area, I observed that the establishment 

was running mixed heavy hens and heavy toms. At the entrance to the inside scald 

area, an establishment employee was using a knife to manually cut the necks of the 

birds that were not properly stunned and birds that were missed by the automatic 

kill blade. While he was trying to cut the turkeys, I observed the birds 

violently thrashing about, indicating improper stunning.  A second plant 

employee stationed at the automatic kill blade was also using his knife to 

make manual cuts due to violent thrashing. These turkeys were missing the single 

line auto kill blade/knife because they were not sufficiently stunned.  I also 

observed the employee at the automatic kill blade has to wipe blood from 

his face before attempting to make another cut. This employee at the auto kill did 

not stop the line. Due to the inadequate stunning, the thrashing birds, and 

the difficulty the plant employee was having in making the kill cut, I was concerned 

that the process was out of control and I proceeded to ask another employee 

on the kill floor to notify a Supervisor. The employee was unable to raise a 

supervisor, so I hurried to the USDA Office to notify Dr. that the outside 

kill needed to be stopped. Upon arrival at the USDA office, I discovered that Dr.

 had to go the the evisceration floor due to more cadvers. At this time, I 

also went to the scalding area at approximately 0725Hrs. I observed two heavy tom 

turkeys with their heads up (in an arched manner) looking at me as birds were 

going into pre-scalder. Dr. examined 11 cadavers between the 

two inspection lines; five of the cadavers did not have the kill cuts and 

six cadavers had kill cuts but did not bleed sufficiently. In total, the 

establishment had a total of 13 cadavers at the inspectors' station within an 

approximately 15-minute time frame. The last cadaver was noted at 0730 hours by 

line inspector . The neck and head of all of the the 11 birds were 

collected and subsequently shown to Mr. , in the USDA 

(b) (6)
(B)(6) (B)(6) (B)(7)(C) (B)(7)(C) (B)(6) (B)(6) (B)(6) (B)(6) (b)(4) (b)(4) (b)(4) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

office; the establishment did not dispute Dr. findings that in this cluster 

of 11 cadavers, 5 were without a kill cut and 6 were with a kill cut but the birds 

were insufficiently bled, which made them also cadavers. 

notified me at approximately 0740Hrs that the issue was addressed. I notified Mr.

 that a noncompliance will be issued. Dr. concurred that the plant 

was not following good commercial practice, as evidenced by birds dying other 

than by slaughter and not being bled out properly, which is in 

violation to 9 CFR 381.65(b) which states in part; "Poultry must 

be slaughtered in accordance with good commercial practice in a manner 

that will result in thorough bleeding of the carcasses and ensure that 

breathing has stopped prior to scalding."  

5112 M18909 JDD0802115 

218N-1 

11/16/2013 04A03 MSS; MSP; PDBFT; 

PDPFT; PDCB; 

PDCP; AMRS 

C On 11/16/2013 at approximately 2150Hrs while performing my PHIS MSP task, I 

observed the (MSP) Mechanically Separated Poultry floor analyzer perform the 

bone content analysis.  The bone content analyzer showed the bone content 

was   This test was for Bin # 25 with time 

2147Hrs.  I saw the personnel take the MSP bin to the new shipping 

dock with the Boning Room Scale attached Tag #T001812522 and time 

2157Hrs. I went to the plant's Quality Control lab to verify if a recheck sample was 

performed.   was in the lab and she had not been 

notified of a needed retest for Bin #25 with Bone. was 

notified of the noncompliance. Mr. went with me to the shipping dock and 

we collected a retest sample, per plant requirement. Ms.  performed a 

retest on the sample in the Quality Control lab Analyzer.  The bone content 

was The retest passed and the MSP Bin # 25 was released back to 

shipping at approximately 2200Hrs after verifying the establishment's implemented 

corrective actions. This observed incident of the plant not following their corrective 

action when the first test exceeded the bone content required is in 

violation to 9 CFR 381.173 and Directive 7160.1. This is also a violation to 

establishment's in place bone requirement and corrective action procedure for 

the MSP. 

(b) (6)
(B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD4803115 

918N-1 

11/16/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 11/16/2013 at approximately 1110Hrs while performing pre-operational 

sanitation of the plant's Evisceration; Boning Room, Bagging and Raw Fabrication 

grinding Department's after the plant Q.C. and before start up of production. I 

observed the following noncompliance. was notified of 

the noncompliance and shown all incidents. I observed all of the plant's 

implemented corrective actions to the affected food contact and non food contact 

surfaces. 1.) Evisceration - Scalder (middle) had many long feathers (food contact) 

surface. a.) Hock Cutters (hand held holder) had meat and meat residues on the 

entire inside (food contact) surface. b.) The blue incline converyor 

to chiller A had meat, skin and fat on the bottom side (non direct food 

contact) surface. c.) Gizzard splitter had two long feathers (food contact) surface. d.) 

Chiller A end metal slide converyor had many pieces of meat, fat, skin and 

meat residues (food contact) surface. 2.) Boning Room - Fillet conveyor had two 

pieces of meat (food contact) surface. a.) The fillet conveyor had two broken 

untrimmed belt pieces. The maintenance was called and replaced the two broken 

belt sections. b.) The stainless steel work table had two pieces of meat (food 

contact) surface. 3.) Raw Fabrication- had meat residues inside the #1 grinder 

(food contact) surface. a.) The #1 grinder screen had meat residues (food 

contact) surface. 4.) Bagging Department - had belt threads wrapped around the 

yellow conveyor roller under side (non food contact) surface. a.) The Top 

slide conveyor which enters the Roser had meat; rust, blue and black netting, 

metal clips and a piece of a turkey bag) (non direct food contact) surface 

when turkey bags are closed. The observed incidents of food contact surfaces found 

with meat, meat residues, skin, fat and feathers from previous days operations is a 

violation to 9 CFR 416.4(d); 416.13(c), and 416.4(a). The non food 

contact surfaces not cleaned is in violation to 9 CFR 416.4(b). This 

noncompliance is being linked to noncompliance (#157) JDD2203112512N/1 dated 

11/11/2013; (147) JDD0411114204N/1 dated 11/4/2013 and (#145) 

JDD4511100430N/1 dated 10/30/2013 for the same cause respectively. 

(b) (6)
(B)(6) (B)(6)

(B)(6)

(B)(6) (B)(4) (B)(4)

(B)(4)

(b)(4) (b)(4) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2512115 

516N-1 

11/16/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 11/16/2013 while observing the Second Processing Rinse Procedure and CCP3B 

Procedure at shift change in the Packaging Department, I observed the following 

noncompliance. Q.C. personnel were measuring the sanitizer concentration on 5 

contact surfaces in Packaging 1 area. The sanitizer was measuring zero from 

the hose and was informed.  Two 

employees started applying t from the back pack sprayer to the fillet line. The

 concentration was within the acceptable range. Q.C. personnel was 

checking the contact surface on the saddlepack line and as I was standing there I 

noticed that on Line there were some wings already on the belt. I asked Q.C. if 

Line had been checked and she informed the employee with the back pack 

sprayer of to spray the belt. The wings were not removed from the belt before 

the sanitizer was applied. The Notice of Deferral Verification Plan #17 states 

in part that "Edible product will be removed from product contact 

surfaces. The establishment's SSOP Plan states in part, " 

The wings were condemned and I 

informed of the noncompliance. My findings indicate a 

noncompliance with regulatory requirements of regulations 9CFR 416.13(c), 9CFR 

416.13(b), and 9CFR 416.12(a). 

5308 M6137 BXL3203111 

916N-1 

11/16/2013 01D01 SPS Verification C On 11/15/13 at approximately 0103 hours while performing SPS Verification checks 

in the Rotisserie Room I observed the following noncompliance. I observed heavy 

beaded condensation on the ceiling above the injector machine and metal detector 

and pvc pipe next to the injection machine. I immediately took regulatory control 

by applying U.S. Reject tag # B31408102 to the area and informing  

of my findings, Mr. Short immediately stopped 

production and informed of my findings. All 

condensation was wiped off to restore sanitary conditions. Regulatory control was 

relinquished at approximately 0112 hours and production was then 

resumed. 

(b) (6)
(B)(7)(C)

(B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4)

(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1326 

1 

M33901 HAY431711 

3616N-1 

11/16/2013 01C02 Operational SSOP 

Review and 

Observation 

C On the calendar date of November 16, 2013 (Saturday) at approximately 1522h 

while performing the Operational SSOP Review and Observation task, I observed the 

following noncompliance during change of shift from shift I to shift 2: I, CSI 

, observed multiple droplets of condensation located on the underside of 2 

drip pans and several pipes that were directly above Line in the “IF” processing 

area.  One of the drip pans was angled downward and water was dripping off 

the pan from the lowest corner of the pan every 3-5 seconds and landing on 

the plate freezer film used to transport raw poultry product to the 

freezer.  This is a product contact area.  At the time of the observation 

(1522h), no product was on the line due to the shift change.  I immediately 

informed the lead person to call the shift I supervisor for the area.   

Mr. I) arrived at approx. 1530h and was 

shown the dripping condensation that was landing on the product plate freezer 

film.  In addition, he was shown the other drip pan and pipes directly above 

line that had multiple beads of condensation on them.  I informed Mr.

 that there was SSOP non-compliance and the line was rejected with U. S. 

Tag #B29 699994.  In order to restore sanitary conditions, Mr. 

had maintenance level the drip pan above line nbsp; In addition, all drip pans 

and pipes were wiped down.  He had the plate freezer film removed and new 

film placed on the line.   There was a fan not operating by line which 

was unplugged.  Mr. plugged it in and the fan began 

operating.  As a preventive measure, Mr. stated he would retrain 

the employees for line concerning condensation.  In addition, he asked the 

SSOP monitor for Shift II to do an extra SSOP monitoring check for line for 

11/16/13.  The regulatory control action (U. S. Tag B29 699994) was 

removed at approx. 1552h after the preventive measures were stated, sanitary 

conditions restored, and the product freezer film removed.   The 

establishment’s Standard Operating Procedures for Sanitation (Part 2; Section 1) 

states: 

.   Lack of adequate ventilation and 

ineffective SSOP monitoring failed to prevent product contact equipment from 

contamination with condensation.  In addition, regulatory requirement for 

416.13(c), 416.2(d) and 416.1 were not met. For a similar SSOP noncompliance 

record with the same cause (inadequate ventilation to control condensation), which 

resulted in product contamination, refer to HAY1122111802/1 dated 11/2/13. In 

addition on 11/5/13 and 11/6/13, there were 2 SPS NRs documented due to the 

same cause (inadequate ventilation; see NRs HAY1516111505N/1 and 

HAY5107110607N/1).   

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6) (b)(4) (b)(4)

(b)(4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD1706115 

717N-1 

11/14/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 11/14/2013 at approximately 1008Hrs, I observed seven whole body packaged 

turkey's on the floor at the netting area. The bagged turkeys were at two 

employees feet and one was under a tank.  At approximately 1012Hrs, I 

observed one employee pick up one of the whole body turkeys from the floor. He 

put it on to the food contact bag line. He then handed it to another employee which 

was on the other side of the line. The second employee put the 

turkey through the netting and then put it on to the line. The bagged 

turkey which was picked up from the floor was not rinsed. The two employees did 

not wash/sanitize their hands/gloves or the conveyor/table prior to or after putting 

the bagged turkey onto the line. and were 

immediately notified of the noncompliance. I showed Mr.  the 

affected turkey which was traveling on the conveyor belt. Mr. immediately 

removed the turkey form the belt. He had the affected bagged turkey 

reconditioned by water spraying at the product wash 

cabinet. He had the affected food contact conveyor sanitized. He 

had all employees in the area sanitize their gloved hands. Sanitary conditions 

were restored. This observed incident of a packaged 

food product picked up from the non food contact floor and put back with 

clean packaged food products on a clean conveyor is in violation 

to 9 CFR 416.4(a); 416.5(a), 416.4(d). This is also a violation to 

the establishment's Operational Sanitation 11 - A # 7.) Establishment's methods for 

production; 

." was not met. 

(b) (6)
(B)(6)

(B)(6) (B)(4)

(B)(4)

(b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3117115 

314N-1 

11/14/2013 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 0910 hours, I was monitoring the second processing, rinse 

procedure (shift change) and I observed the following; Production employees were 

rinsing and applying the sanitizer ) as prescribed in the SSOP Plan on some of 

the product surfaces areas in Main Packaging. At approximately 0920 hours 

they finished. I observed that the blue conveyor belt that transfer product from the 

dumper to the saddle pack line was not rinsed and sanitized, 

the reconditioning station between Line #2 and Line , two carts that were 

stationed there, one for dirty product and one for clean product were also 

not rinsed and sanitized. I tagged the area with U.S. Retained/ 

Rejected Tag # B31 406312I and contacted Department 

 and and informed them about the noncompliance. The SSOP 

Plan states in part under Second Processing Rinse Procedure that 

. 

Supervisors' contacted sanitation employees from dayshift and night shift, and they 

rinsed and sanitized the area. I released the area at approximately 0930 hours. My 

findings indicated a noncompliance with the following regulatory requirements of 

regulations 9CFR 416.13 (b) and 9CFR 416.13 (c). 

(b) (6)
(B)(6)

(B)(7)(C) (B)(7)(C) (B)(7)(C) (B)(7)(C) (B)(7)(C) (B)(7)(C) (B)(6)

(B)(6) (B)(6)

(B)(7)(C) (B)(7)(C) (B)(4) (B)(4) (b)(4) (b)(4) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4206110 

714N-1 

11/14/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 11/13/13 at approximately 2320 hours while performing pre-operational 

sanitation verification in plant 1 rehang area, after the establishments 

pre-operational checks and before the start of operation CSI and CSI

 found the following non-compliances to 9CFR 416.4(b) and 9CFR 416.4(a). 

Fat and protein build up was found on the filtering/tumbler unit and 

piping. The support beams and the conveyor belts utilized in the rehang area of 

plant 1 was observed to be in unsanitary due to fat and protein build up. 

was notified of our findings. Effected area's were cleaned 

before start up to restore sanitary conditionsAt approximately 2332 hours while 

performing pre-operational verification after the establishments pre-operation 

checks and start of operation in plant 2 rehang area CSI and CSI 

found fat on line loop belt and line conveyor belt, Fat and fat build up was 

found on # 9 drop conveyor machine chutes. The plastic curtain that hung 

over the exit of the chute was torn and cracked and unsanitary with small pieces of 

fat on all surfaces. The bed and conveyor belt beneath the chute was observed to be 

unsanitary due to small pieces of fat and protein buildup the the surface. Sanitation

 was notified of our findings Effected areas were cleaned 

before start up restore sanitary conditionsAt approximately 2350 hours while 

performing pre-operation verification after the establishments pre-operation checks 

and before the start of operation in the   room CSI 

and CSI found fat and protein buildup on deboning 3 and 4 units and 

supporting frames, Fat was also found on the contact surfaces of the product 

transfer belts of the units unsanitary due to small pieces of fat . We also found fat 

and protein residue on the walls of the room. 

was notified of our findings. Effected areas were cleaned before start up to 

restore sanitary conditions. 

5308 M6137 BXL4523113 

414N-1 

11/14/2013 01D01 SPS Verification C On 11/13/13 at approximately 0020 hours while performing the review and 

observation component of sanitation performance standard task code CSI 

and CSI observed the following noncompliance to 9CFR 

416.2(b)(1).In plant one we observed the curtain next to the inside outside 

bird washer that sanitation uses for over spray protection to be poorly maintained. 

There were large tears and worn spots in the fabric. 

was informed of our observation and noncompliance. 

(b) (6)
(B)(7)(C) (B)(6) (B)(6) (B)(6) (B)(7)(C) (B)(7)(C) (B)(7)(C) (B)(7)(C) (B)(7)(C) (B)(7)(C) (B)(6)

(B)(6)(B)(6)

(B)(4)

(B)(6)

(B)(7)(C) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2117112 

613N-1 

11/13/2013 06D02 Other Inspection 

Requirements 

C At approximately 1028 hours, while performing reprocessing  

procedures on Line (Reprocessing Line) in Plant #2, I observed a 

noncompliance with the following regulatory requirements of regulation 9CFR 

381.76 (b).After I took my 10 bird sample for the reprocessing check, I 

observed that there was not enough light intensity. This area is being 

used to inspect CCP-1B ) as a critical control point and the 

reprocessing defects. SCSI measured the light intensity and it was 

50 foot-candles. We asked to call an 

electrician. verified the light intensity and it was 

below 200 foot-candles. Electricians installed a temporary light, the light intensity 

was over 200 foot-candles. We informed of the 

noncompliance. 

5308 M6137 BXL4706115 

513N-1 

11/13/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 11/12/13 at approximately 2142 Hours while performing pre-operational 

sanitation verification after the establishments pre-operational checks and before 

the start of production, CSI and CSI  observed the 

following noncompliance. In area 1, unit 25 live hanging table we observed fat and 

feathers from the previous days production on the hanging table and wall, U.S. 

Reject tag # B41800076 was applied the the table and informed 

of my findings In area 2 feathers and fat was observed in 

picker # 2, line 1 and picker # 3 line 2, In area 4 we observed at inspection 

station # 7 fat from the previous days production. Fat residue was found floating in 

chiller # 2 by Dr. fat residue was removed before start of operation.At 

approximately 2250 hours while performing pre-operational sanitation verification 

after the establishments pre-operational checks and before the start of operation 

CSI and CSI the following noncompliance in the Rotisserie Room. 

Fat was found under the Packer product conveyor belt. 

was notified of our findings. Belt was cleaned  to restore sanitary 

conditions.At approximately 2300 hours while preforming pre-operational 

sanitation verification after the establishments pre-operational checks and 

the start of operation  in the Paw room CSI and CSI found 

a while plastic shovel in disrepair with pieces of plastic flaking off. Sanitation

 was notified of our findings. Shovel was removed and 

destroyed.At approximately 2325 hours while performing pre-operational 

sanitation verification after the establishments pre-operational checks and before 

the start of operation, the following noncompliance was observed in Packing 

department. At the front and back Leg Processers, Fat from the previous days 

production was observed on the leg processers. 

was notified of our findings. Leg processors and area was cleaned before start 

of operation. 

(b) (6)
(B)(6) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5014112 

913N-1 

11/13/2013 06D02 Other Inspection 

Requirements 

C On 11/04/2013,  at approximately 0915 hours, I was ready to perform a 

Post-Chill Finished Product Standard Task. To start the process, I wanted to wash 

the FPS table adjacent to Chiller #2 in Plant #1 and no water was available from the 

hose. I informed and he informed me that he will called 

maintenance to fix it. I came back at approximately 1500 hours to perform a 

Post-Chill Task again at Chiller #2 and still no water was available. I informed

 of the noncompliance, he then called maintenance. At 

approximately 1540 hours maintenance fixed the pipe and water was 

available.This  is a noncompliance with the following regulatory 

requirements of regulation 9CFR 381.76 (b). 

(b) (6)
(B)(7)(C) (B)(7)(C) (B)(6) (B)(6) (B)(6) (B)(6) (B)(7)(C) (B)(7)(C) (B)(6) (B)(6) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5206112 

213N-1 

11/13/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 11/12/13 at approximately 0007 hours while performing SSOP  review 

and observation  verification in plant 1 cooler  CSI 

and CSI  observed the following non-compliance to 9CFR 416.4(d) and 

9CFR 416.2(d). We observed heavy beaded condensation on the 

ceiling and pipes of plant 1 cooler, upon further inspection of the cooler I observed 

directly underneath a section of heavy beaded condensation a 

full tank of whole body chickens that had it's blue plastic tank 

covering partly exposing the product inside.The tank had a fully exposed chicken 

laying on top of the tank cover. We immediately took regulatory control 

action by applying U.S. Retain tag # B31407422 to the tank of chickens and 

informing of my findings. Mr. took corrective action 

by removing all the tanks underneath the condensation and replacing the tank 

covers and condemning the chicken that was exposed and wiping all the 

condensation to restore sanitary conditions. Regulatory control was relinquished at 

approximately 0120 hours and U.S. Retain tag # B31407422 was removed.At 

approximately 0020 hours while checking plant 1 staging cooler for 

condensation we observed heavy beaded condensation under the cooling 

unit of the staging cooler, Dripping condensation was observed falling onto a pallet 

with card board boxes of whole body chickens that were bagged and 

not exposed to the condensation. I immediately took regulatory control by applying 

U.S. Retain tag # B 31406172 to the pallet and informing Plant 

manager  of my findings. Mr. took corrective 

action by having the pallet removed from the area and having the condensation 

wiped off and replacing the boxes with new ones. Regulatory control was 

relinquished at approximately 0122 hours and U.S. Retain tag # B31406172 was 

removed.At approximately 0500 hours SCSI and CSI  

observed beaded and dripping condensation from the lights above the 

room . Beaded condensation was observed above exposed product on the table and 

conveyers and cones. and was 

notified of the noncompliance. Production stopped and all condensation was 

removed from the lights , tables, conveyors and effected cones was washed. area 

was released at approximately 0523 hours. 

(b) (6)
(B)(6)(B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5568 M20923 XUM592011 

0413N-1 

11/13/2013 01D01 SPS Verification C On 11/13/2013, at approximately 1838 hours, while performing a directed 

Sanitation Performance Standards (SPS) inspection task in response to a deficiency 

on the Cook Area Line Mezzanine, I observed the following noncompliance: a fire 

sprinkler attached to the overhead ceiling missing a cover plate causing a 

condition of exposed insulation directly over processing wing product 

creating insanitary conditions, a noncompliance per 9 CFR 416.1 and 

416.2(b)(2).This condition was in the post lethality processing area and 

could lead to the spread of pathogens of a food safety concern and cross 

contaminate exposed product. I took regulatory control by stopping the Line 

production and rejected the area with US Tag 785927. I showed and informed Mr. 

 of the forthcoming 

noncompliance. After corrective actions were performed by production and 

sanitary conditions were restored, I relinquished the US Tag at 1850 hours. The 

requirements of 9 CFR 416.1 and 416.2(b)(2) were not met.   

1325 

7 

P33900 NHH151511 

1213N-1 

11/13/2013 01D01 SPS Verification C 179At 0814 hours while performing an operational sanitation observation 

and review task I came across combos of inedible product (livers) in the inedible 

section of the back cooler that did not have denaturant applied. Management was 

notified and shown the combos. All of the combos had denaturant applied to the 

liners but there was no visible denaturant on the product in at least 3 of the 

combos. Edible and inedible containers of product were stored together. CFR 

381.95 states that denaturing shall be accomplished by liberally applying it to all of 

the carcasses and parts. CFR 416.2b states that inedible and edible must be 

separated by time or space. These requirements were not met; therefore, 

regulatory control action was taken and the product was retained and the cooler 

was rejected. The area was released after all requirements were met. 

(b) (6)
(B)(7)(C)

(B)(6)

(B)(6)

(B)(4)

(B)(4) (B)(4)

(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH252211 

3213N-1 

11/13/2013 01C02 Operational SSOP 

Review and 

Observation 

O On the calendar date of November 13, 2013 at approximately 0814 hours while in 

route to the pre-chill station to perform zero tolerance verification, the following 

noncompliance was observed: The establishment's SSOP states tha

 I, CSI , observed that a plastic tote at the 

reprocessing station exhibited black foreign particles. The tote was positioned for 

use directly behind the reprocessing line. At this time, I randomly selected and 

inspected 4 totes from the nearby pallet. My inspection revealed black stains that 

smeared with touch, brown residue, and fat particles on the inner surface of 3 of 

the totes. The totes were rejected with U.S. REJECTED tag # B40172786. 

, was shown the noncompliance, and she confirmed the 

findings. Ms. was informed that a noncompliance record would be issued. 

This noncompliance record should be discussed during the next weekly meeting. A 

similar noncompliance record was documented on November 11, 2011; please 

reference NR # NHH5106115212N-1. The establishment's response to 

NR # NHH5106115212N-1 is pending. 

1325 

7 

P33900 NHH291311 

3913N-1 

11/13/2013 01C02 Operational SSOP 

Review and 

Observation 

C #177On 11/12/13 while performing SPS tasks I observed that containers of product 

(inedible livers) staged in the designated "Inedible " section of the cooler were not 

properly labeled as such.The establishment's SSOP states that 

" These requirements along 

with the requirements of CFR 381.95 were not met. Management was notified and 

as a corrective action denaturant was placed on the product and inedible stickers 

were placed on all combos. 

1325 

7 

P33900 NHH471411 

2713N-1 

11/13/2013 01C02 Operational SSOP 

Review and 

Observation 

C 178At 0814 while touring the giblet room I observed 3 grossly contaminated 

containers being prepared to place inedible livers in . The combos had 

not been washed prior to bringing them in the plant. They contained a black build 

up on the inside and outside. These contents were also seen in the deep embedded 

grooves on the lips of each container. Slots had been cut on either side of one of the 

containers.There was mildew and traces of old meat scraps inside all of the combos. 

The establishment's SSOP states that " 

" Management was notified and shown the condition of the 

combos. The combos were retained. During the same tour I inspected the 

Inedible section of the cooler where I found containers of product which had 

not been labeled as such. The establishment SSOP also states that 

" ." These 

requirements and the requirements of 415.11 were not met therefore official 

control action was taken. corrective actions were completed and as a preventive 

measure, a written procedure for handling inedible product and containers was 

written by Management. 

(b) (6)
(B)(6) (B)(7)(C) (B)(6) (B)(6) (B)(6) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD3606113 

812N-1 

11/12/2013 04A06 Poultry Finished 

Product Standards 

C On 11/12/2013 at approximately 0202H, I observed a plant employee salvage a 

bird for airsacculitis.  Plant employee did not wash bird prior to 

making the initial incision in the salvage procedure.  Plant airsacculitis 

salvage procedures states that bird should be washed first before cuts are made for 

the salvaging of parts.  This failure to wash the bird before the initial incision 

is a violation to 9 CFR 381.65(a): Processing, other handling or storing of poultry 

product must be strictly in accord with clean and sanitary practices and must be 

conducted in a manner that will result in sanitary processing, proper inspection, 

and the production of poultry and poultry products that are not 

adulterated.  When birds are hanged in the USDA inspection hang 

back rail, fecal contaminated birds and birds for salvage are intermixed.  

Sometimes, the birds for salvage are also contaminated with feces and so it is very 

important that birds are washed thoroughly before birds are cut for salvage.  

Washing of the birds prior to the initial cut was not observed in this 

noncomplinace.  Mr. was informed about this noncompliance 

and tag number B39554830 was applied to tag the birds.  Plant did an 

immediate corrective action by having another employee wash the bird and had 

parts salvaged. 

1325 

7 

P33900 NHH281611 

0412N-1 

11/12/2013 01D01 SPS Verification C On the calendar date of November 12, 2013 at approximately 1451 hours while 

verifying Finished Product Standards at the post chill station, the following 

noncompliance was observed: Item D under Personal Conduct on page 5 of the 

establishment's GMP's states that "Spitting in the plant is prohibited." I, CSI 

, observed maintenance personnel spit into a drain (between the hang line 

and chiller areas) as he walk through room 1 of the further processing department 

towards the paw harvest area. and , were 

notified of my observation. Mr. questioned the employee involved at 

which time the employee stated that he "may have" spit into the drain. Mr. 

was informed that a noncompliance record would be issued. This 

noncompliance record will be discussed during the next weekly meeting. 

1325 

7 

P33900 NHH291011 

4712N-1 

11/12/2013 01D01 SPS Verification C (173)On 11/12/13 at 1010 hours while performing an operational sanitation 

observation and review task I came across three combos of inedible product 

(livers) in the inedible section of the back cooler that did not have denaturant 

applied. Management was notified and shown the combos. These combos were 

commingled with  with combos of livers that that were not labeled as 

inedible containers. CFR 381.95 states that inedible product shall be in rooms or 

compartments separate from those used for the preparation of edible products and 

that denaturing shall be accomplished by liberally applying it to all of the carcasses 

and parts. These requirements were not met; therefore, the product was retained 

and the area was rejected. 

(b) (6)
(B)(6)

(B)(6)

(B)(6) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH460211 

0812N-1 

11/12/2013 03J02 Slaughter HACCP C On the night of production which began on 11/11/2013, Inspection checked the 

HACCP Records for the Production Shift beginning on 11/10/2013 for the Slaughter 

HACCP CCP’s (Zero-tolerance for Whole Birds and Cut-up Parts and Pre-Shipment 

Review). In the Amendment Section of the Establishment’s Slaughter HACCP Plan an 

entry was made on 10/31/2013 concerning two Fecal Finds at the Post-chill Station 

on 09/13/2013 and 10/03/2013 respectively. It stated that a Reassessment of the 

Plan would be done by 11/08/2013. The QA Department was unable to produce 

Documentation of the Reassessment of the HACCP Plan. The Requirement’s of 9CFR 

417.4(a)(3)(ii) were not met and was informed 

that a Non-compliance Record would be issued.Refer to NR #NHH1222094216N/1 

(#136) dated 09/16/2013 for a similar Non-compliance. 

5112 M18909 JDD2203112 

512N-1 

11/11/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 11/11/2013 at approximately 1150Hrs while performing pre-operational 

sanitation of the plant's Evisceration; Boning Room, Raw Fabrication 

Grinding and the Bagging Department's after the plant Q.C. and before start 

up of production, I observed the following noncompliance. 

and/or were notified of the 

noncompliance and shown all incidents. I observed all implemented corrective 

actions to food contact and non food contact surfaces. Evisceration- Outside kill 

area many feathers on the non food contact floor. b.) White conveyor which 

carries the turkey's  into chiller A had too many to count pieces of meat, fat 

and skin (food contact). (c) Small gizzard table had three pieces of meat (food 

contact). d) Gib chiller had three meat pieces and meat residues (food 

contact). 2.) Boning Room - Drum had meat and meat residues (food 

contact) on a white piece which is attached. b.) Thigh - had meat and 

meat residues on a white piece which is attached; also meat and meat residues on 

the top left wheel (food contact). c.) The white thigh conveyor table had two 

pieces of meat (food contact). Raw Fabrication grinding room had meat and meat 

residues inside # 1 grinder (food contact). b.)The #1 grinder screen had meat 

residues (food contact). Bagging Roser Exit - lower belt had blue netting 

wrapped and jammed on the bottom side of the end roller (non food). b.) 

Second  & third roser conveyor belt also had blue netting jammed in 

the rollers and one torn turkey bag (non food). The observed incidents of food 

contact surfaces found with meat, meat residues, fat & skin from previous 

days operations is in violation to 9 CFR 416.4(d); 416.13(c) and 416.4(a). The non 

food contact surfaces not cleaned is in violation to 9 CFR 416.4(b). This 

noncompliance is being linked to noncompliance (#147) JDD0411114204N/1 dated 

11/4/2013; (#145) JDD4511100430N/1 dated 10/30/2013 & (#143) 

JDD3811102726N/1 dated 10/26/2013 for the same cause respectively. 

(b) (6)
(B)(6) (B)(6) (B)(7)(C) (B)(6) (B)(6)

(B)(4)

(b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD4808112 

212N-1 

11/11/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 11/11/2013 at approximately 0125Hrs, I observed a plant employee bring a 

Osteo Bird to the blue incline chiller belt. The employee put the Osteo bird on the 

incline in front of me and walked away. The incline was carrying birds into the 

chiller at this time. I removed the bird from the conveyor because I could see debris 

on the carcass. The carcass breast skin was pushed back, I observed 3 black specks; 

one brown speck and one brownish piece, approximately 3/8" x 2mm in 

size of floor debris on the turkey. The debris were attatched to the 

fascia. The HACCP personnel who was assisting me with my task at the pre 

chill USDA table call the employee back and ask him where he had collected 

the Osteo carcass. The employee showed us where the bird had fallen from the 

overhead conveyor belt onto the floor near the ladder.  The 

personnel  gave the carcass to an personnel working at the product 

wash cabinet for reconditioned. Then he put the carcass on the chiller 

converyor. Dr. and were notified of the 

noncompliance and shown the floor debris on the carcass. Mr. 

 immediately implemented the plant's appropriate corrective action. 

He had the affected carcass reconditioning by trimming 

and  water spraying. The carcass was reinspected and 

released back to production flow at approximately 0135Hrs after verifying the 

plant's corrective actions. This observed incident of food product adulteration by 

UFM (floor debries) not removed is in violation to the establishment's Operational 

Sanitation 11 Objective which states: 

." Sub - #7.) Dropped edible 

product will be picked up in a timely manner. Whole body or part - Rinsed and 

trimmed as needed." The needed trimming was not done. This is also in violation to 

the relevent regulations cited above. 

5112 M18909 JDD5219114 

611N-1 

11/11/2013 01D01 SPS Verification O At 0459 H PST, 11/11/2013 at the Carcass Dumper in the Boning Area, I observed 

several overhead Ceiling Panel missing and or loose. Ms. . and 

Mr. were shown the noncompliance and advised 

of Documentation of the same. Q.C. paerwork did not reflect this noncompliance 

prior to my notification of the same. This is a violation of the above 9 CFR's. This 

was written before (SAME ROOT CAUSE) on PRE-OP  Noncompliance report 

0107-2013, Dated 08/26/2013, JDD1010082526N/1 and Five other associated JDD 

Numbers and is linked. The repairs has proven inadequate or ineffective. 

(b) (6)
(B)(6) (B)(6) (B)(6)

(B)(4)

(B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4)

(B)(4)

(B)(4)

(b)(4)

(b)(4) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD5604112 

312N-1 

11/11/2013 03C02 Raw Intact HACCP C On 11/11/2013 at approximately 2222Hrs, I performed a physical verification check 

of the Raw Not Ground Turkey Breast and Drum meat which was 

weighed/scanned/loaded for shipping to the establishment's Plant #2. Using a 

company calibrated thermometer, I took the temperature of three Turkey Breast 1 

Bl SL W/O Flt Hen and one Turkey Drum SO container which was loaded in trailer 

#3901 at the new Shipping Dock. The temperatures were 

& U.S. Retain Tag NO's:B43241034; 

were applied to the loaded affected Breast & Drum meat for temperatures 

above at shipping. ; and 

were notified of the noncompliance and verified my temperature findings at 

shipping. The appeared not to be evenly dispersed over the turkey meat. The 

establishment chose to add more and put the affected (2046, 

2097, 2132) pounds of Breast and (2327) pounds of turkey drum meat 

products into the P-157 blast. At approximately 0230Hrs on 11/12/13 all of the 

Turkey Breast and Drum meat were released back to shipping after verifying that all 

of the food products was and below. This observed incident of turkey products 

being shipped above is in violation to 9 CFR 381.66 (b) and 417.2(c)(4) 

monitoring at the critical limit. The establishment's supporting documentation for 

Salmonella Initiative Program (SIP) states; 

The establishment's HACCP Plan at shipping states; 

. Product will be maintained at or below 

Since the supporting documentation for your SIP waiver states that the 

establishment will and the SIP is 

used as justification in your HACCP plan, a violation of 417.5(a)(2) also exists. 

(b) (6)
(B)(7)(C) (B)(6) (B)(6) (B)(7)(C) (B)(6) (B)(6)

(B)(4)

(B)(4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH040711 

2312N-1 

11/11/2013 01D01 SPS Verification C On the calendar date of November 11, 2013 at approximately 1626 hours while 

performing the Operational SSOP Review and Observation task, the following 

facility noncompliance was observed: The Operational Sanitation section of the 

establishment's SSOP's states that 

. I, CSI , 

observed multiple droplets of condensation on the overhead white piping (parallel 

to the hang line) in room 1 of the further processing department. The condensate 

covered approximately 25 ft. of the piping. At the time of the findings, whole birds 

were being processed in the area. Also, the area of the ceiling in which the piping 

begins exhibited heavy moisture as well. , was shown the 

noncompliance, and he confirmed the findings. Mr. was informed that a 

noncompliance record would be issued. This noncompliance record will be 

discussed during the next weekly meeting.A similar noncompliance record was 

documented on October 30, 2013; please reference NR # NHH4602102430N-1. The 

establishment's response to NR # NHH4602102430N-1 of, "The condensation was 

removed." - failed to prevent recurrence. 

1325 

7 

P33900 NHH510611 

5212N-1 

11/11/2013 01C02 Operational SSOP 

Review and 

Observation 

C On the calendar date of November 11, 2013 at approximately 1642 hours while 

performing the Operational SSOP Review and Observation task, the following 

noncompliances were observed: The establishment's SSOP states that 

I, CSI , observed blood specs, fat particles, and 

greasy residue on the inside of 9 plastic tubs near the front half drop conveyor. The 

tubs were pulled from a pallet labeled "Clean". I randomly selected and inspected 6 

additional tubs from the pallet and 4 of the tubs exhibited an orange residue which 

was greasy to the touch. The outside of 2 of the tubs exhibited the same residue. 

The tubs were rejected with U.S. REJECTED tag # B40172782. , 

was shown the noncompliance and he agreed to the findings. Mr. was 

informed that a noncompliance record would be issued. A similar noncompliance 

record was documented on October 29, 2013; please reference 

NR # NHH3405104029N-1. The establishment's response to 

NR # NHH3405104029N-1 of, "The affected tools were rinsed and sanitized." - failed 

to prevent recurrence. 

(b) (6)
(B)(6) (B)(6) (b)(4) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH492311 

3310N-1 

11/10/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C At 2133 hours on the night of production which began on 11/10/2013, while 

performing required PHIS Poultry Zero-Tolerance task at the designated Line #2 

Pre-chill station at est. 33900 P, after randomly selecting 10 slaughtered and 

eviscerated and chilled chicken carcasses for the subgroup test and having begun 

the test at 2133 hours, Inspection found fecal material on the 1st bird in the set. 

The fecal material was a dark green color and of a pasty consistency which would 

easily smear to the touch. It consisted of one piece 1/4” in diameter and measuring 

approximately 1/16” in width, located inside the carcass in the Kidney Crypt area.

 was shown the carcass and 

he concurred that the material in question was indeed feces. Upon investigation, it 

was found that the cause of the fecal find was “High Pressure tripped out causing 

to be clogged up resulting in fecal failure”. Plant Management’s Measure to 

prevent recurrence was “Turned 2nd High Pressure Pump on and replaced clogged 

Spray Nozzle on The requirements of 9CFR381.65(e) and 417.2(c)(4) were 

not met and Mr. was advised that the incident would be documented on a 

Noncompliance Record. Refer to NR #NHH0412112308N/1 dated 

11/08/2013 for a similar Noncompliance. Plant Management’s measure to prevent 

recurrence was: “The height was raised on the Machine and will be monitored 

for the duration of the day.” To date all preventive measures may not have been 

implemented as described or were ineffective in preventing recurrence. 

(b) (6)
(B)(6)

(B)(6)

(B)(6) (B)(7)(C) (B)(7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN511311 

4209N-1 

11/09/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 0932 hours, while performing PHIS Zero-tolerance task, in the 

evisceration department on the reprocessing off-line, prior to the birds entering the 

chiller, I observed one carcass in the ten (10) carcasses random sample 

contaminated with visible fecal material approximately one square centimeter in 

diameter, brown in color, pasty in consistency, located on the carcass right side flab 

area. I took regulatory control action by stopping the reprocessing line and applied 

US retain tag # B43303842 on the affected carcass. The findings were shown to Mr. 

, and Mr.

 Mr. asked for confirmation from the 

SPHV, Dr. . At approximately 0945 hours, Dr. checked the 

questioned material and confirmed my finding as fecal contamination. The 

reprocessing line and the affected carcasses were released to the establishment 

allowing QC representative, to perform a re-check and the plant procedures 

for fecal failure. The findings of fecal material on a carcass passed the final 

wash cabinet en route to the chilling system represents a zero tolerance failure as 

outlined in the establishment’s HACCP and in accordance with the regulations 9 CFR 

381.65(e) which states: "poultry carcasses contaminated with visible fecal material 

shall be prevented from entering the chilling tank." 9 CFR 417.2(c) (4) states: "List 

the procedures, and the frequency with which those procedures will be performed, 

that will be used to monitor each of the critical control points to ensure compliance 

with the critical limits."A PHIS slaughter HACCP task was performrd to verify that all 

corrective and preventative measures were completed.The plant took action to 

control CCP1B and turned up the chiller overflow to 1/4 of gallon per bird, 

marked the chiller to identify the end of the affected lot, and post chill checks were 

performed until the mark came out of the chiller. The plant determined that 

the cause of deviation was employee error, a disciplinary action was taken on 

employee for job performance as a preventative measure.Similar NRs were 

documented on 09/30/2013 #NJN2416091630N, and on 

10/21/2013 # NJN1314102921N.      & 

nbsp;          & 

nbsp;    

(b) (6)
(B)(6) (B)(6)

(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5310 M6137B FFA3419110 

109N-1 

11/09/2013 01C02 Operational SSOP 

Review and 

Observation 

C On November 9, 2013 at approximately 1635 hours while performing my 

Operational Sanitation Inspection in the "Raw Side Blending Room" I observed 

noncompliance with SSOP regulatory requirement 416.13(c) and SPS 416.1, 

416.4(d).Raw Side Blending Room:  I observed one damaged bin of 

Chicken MDP staged in the blending room ready to be used.  The bin 

was damaged at the bottom leg area and the plastic liner was torn exposing the 

Chicken MDP.  U.S. Retain Tag NO B38934390 was applied to this bin of 

MDP.  and Ms. ., 

was informed and showed the noncompliance.  Immediate corrective action 

was implemented by management.  At 1755 hours the bin of Chicken MDP 

was condemn and denatured in my presence. With the establishment back into 

compliance, U.S. Retain Tag NO B38934390 was removed.This does not comply 

with the establishment written SSOP Program which states in part:  

Objective; 

".  This is also a violation of Regulatory 

Requirement(s) which states in part: 416.1; "Operate in a manner to prevent 

insanitary conditions", 416.4(d); which states in part: "Product must be protected 

during processing, handling, and storage", and 416.3(c) which states in part: "Plant 

monitors implementation of SSOP Procedures".This noncompliance report serves as 

written notification that failure to comply with regulatory requirement(s) of 9 CFR 

416 could result in additional regulatory or administrative actions. 

(b) (6)
(B)(6)

(B)(6) (B)(7)(C) (B)(4) (B)(4) (B)(4) (B)(4) (b)(4)

(b)(4)

(b)(4) (b)(4) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

6036 P6164A OIJ1401114 

109N-1 

11/09/2013 06D02 Other Inspection 

Requirements 

C At approximately 2010 on 11-08-13, I, CSI performed the presentation test 

component of the regularly scheduled Other Inspection Requirements PHIS Task. 

The requirements state that

 At inspection 

stand two, I observed three viscera attached to carcass (scored per incident) and 

one viscera not uniform (scored per incident) for a total of total scored errors. 

At approximately 2012, I verbally informed 

, of the failed test results. I verbally informed him that a 

noncompliance record would be issued and I was taking the regulatory control 

action of reducing the line speed to as per requirements. At 

approximately 2026, I completed the establishment-requested presentation retest 

to verify process control at the line speed of All four online inspection 

stands met conformance levels. The line speed was increased to . At 

approximately 2056, I completed the presentation retest to verify process control 

at the line speed of . All four online inspection stands met conformance 

levels. This NR is linked to NR #OIJ0301103311N issued on swing shift 10-10-13. 

Including this NR, there have been six linked Other Inspection Requirements NRs 

issued in the last 90 days for the same root cause. Other Inspection Requirements 

NRs were most recently discussed and documented during a weekly Establishment 

Awareness Meeting on 10-17-13.    

(b) (6)
(B)(6) (B)(6)

(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5129 M210 LQN032211 

1408N-1 

11/08/2013 01C02 Operational SSOP 

Review and 

Observation 

C On November 8, 2013 while performing my operational sanitation inspection in the 

Raw Side Warehouse I observed the following noncompliance.  At 

approximately 1745 hours I observed a plant employee taking his bags of spices to 

the production area.  On his cart was two bags of brown 

sugar.  The bags of brown sugar had round holes along the side of the 

bags and the brown sugar was exposed.  U.S. Retain Tag B38934387 was 

applied to the damaged bags of brown sugar.  I informed and showed

 and the 

noncompliance.Upon further investigation three more bags of brown sugar was 

found damaged with holes in the bags.  Immediate Corrective Action was 

implemented by management all five bags of brown sugar was condemn by 

management in my presence. This does not comply with Regulatory 

Requirement 416.1 which states in part: "Each official establishment must be 

operated and maintained in a manner sufficient to prevent the creation of 

insanitary conditions and to ensure that product is not adulterated", and 416.4(d) 

which states in part: "Product must be protected from adulteration during 

processing, handling, storage, loading, and unloading".   Upon review 

of the establishment's written SSOP Program on page #3 Part II Operational 

Sanitation:  

".This NR serves as written 

notification that failure to comply with the regulatory requirement(s) of 9 CFR 416 

could result in additional regulatory or administrative actions". 

(b) (6)
(B)(6)

(B)(6)

(B)(6) (B)(6) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5129 M210 LQN311511 

5508N-1 

11/08/2013 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1305 while performing Operational Sanitation Review and 

Observation on the Raw side,  I obseved a small white edible roll around 

barrel in the Raw Oven area by the salt mixing tank. The white barrel 

had a yellow liquid like substance roughly 3 1/2 inches deep in it that was slippery 

to the touch. No noticable odor was smelled. I also observed multiple (8) black like 

spects (1/16in.) in size on the inside surface of the barrel. There was 

no identification on the white barrel indicating what the yellow substance is.This is 

a noncompliance of Regulation 416.4(c) and a failure of the Plant Operational 

 Sanitation Plan.U.S. Retained Tag NO.B39554790 was applied to the small 

white barrel with the yellow liquid. and

 were notified and observed the white barrel with the yellow liquid in it.This 

document serves as written notification that your failure to comply with regulatory 

requirement(s) could result in additional regulatory or administrative action. 

5129 M210 LQN480311 

5908N-1 

11/08/2013 01D01 SPS Verification C On November 7, 2013 while walking through Raw Side Cooler #4 I 

observed noncompliance with SPS regulatory requirement(s) 416.1 and 

416,4(d).  At approximately 2340 hours I observed dripping condensation on 

the overhead roll up door entering raw side cooler #4.  U.S. Reject Tag NO. 

B38937094 was applied to Cooler #4 door.  I informed and showed

 and the 

noncompliance.  This is a product traffic area but at the time of my 

observation no product was being taken into Cooler #4.Immediate Corrective action 

was implemented by management:  Cooler #4 Door was completely wiped 

down in my presence. At approximately 2350 hours sanitary conditions was 

restored and U.S. Reject Tag NO. B38937094 was removed.  This does not 

comply with Regulatory Requirement 416.1 which states in part:  "Each 

official establishment must be operate in a manner to prevent insanitary conditions 

and to ensure product is not adulterated", and Regulatory Requirement 416.4(d) 

which states in part: "Product must be protected from adulteration during 

processing, handling, and storage".  This document serves as written 

notification that failure to comply with regulatory requirement(s) of 9 CFR 416 

could result in additional regulatory action as described in 9 CFR 500.4. 

(b) (6)
(B)(6)

(b)(4)

(b)(4) (b)(4) (b)(4) (b)(4) (b)(4) (b)(4) (b)(4)

(b)(4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2305111 

408N-1 

11/08/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 11/08/2013 at approximately 0130 hours in Packaging while monitoring

 Belt Sprays function installed by the establishment as part of the 

corrective action resulting from the (NOIE) Notice of Intended Enforcement dated 

October 7, 2013, I observed the following. A 

unit  for saddle packed product was recently 

installed.  Using a ladder, I observed  that the 

required spray rinse at the end of the line was not operating. I moved to the 

opposite side of the unit and found the valve to the water hose that supplies 

rinse water to the unit was in the closed position. I contacted and 

asked why the required rinse was not on. He opened the valve but the 

spray heads only emitted an occasional drop of water. Mechanics were called 

and the spray heads were removed and cleaned restoring the rinse. 1 1/2 

racks approximately 6 1/2 brown product tubs of wings 

were unwrapped so that the required rinse could be applied. Sanitary 

conditions were restored by approximately 0235 hours. A review of the 

establishment computer records revealed that the concentration of 

at 0102 hours was documented to be at a concentration of ppm. A 

second computer entry "N/A" was made  under 'Potable Water Rinse'. I 

reviewed  the establishments' HACCP Plant -Raw Intact-Packaging  

Step 16 Saddlepack Dip.  Under Potential Hazards Introduced, 

Controlled or Reduced at the step it lists (C) and Is the 

hazard Significant? NO. Under 'Justification for Decision' it states 

. A review of FSIS Directive 7120.1  Rev 

 16  dated  8/13/2013 under 'Antimicrobial lists 

 used 'To treat the surface of raw poultry carcasses 

or parts (skin-on or skinless) and then 'Dip tank application' to treat 

poultry carcasses/parts 'not to exceed 10 seconds'... and then "When 

application is not followed by immersion in a chiller, the treatment will be followed 

by a potable water rinse." Product treated with and not rinsed is 

considered to be contaminated. My findings indicated a 

noncompliance with 9 CFR 416.1 and  9 CFR 

416.4(d).       

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6) (B)(6)

(B)(6)

(B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN150511 

5908N-1 

11/08/2013 04A06 Poultry Finished 

Product Standards 

C At 0300 hours while I was performing Finished Product Standards (FPS) check on 

the reprocessing line of the evisceration department; I observed one split tail 

carcass, out of a ten carcass sample, which had one side with kidney tissues still 

inside the pelvic cavity. Carcasses are marked with split tails to identify that 

vacuuming is required to remove and condemn all affected tissues including the 

kidneys. I performed a recheck at 0307 hours and observed two out of the ten split 

tail carcasses with, again, one side of the kidney tissue not removed from the inside 

of the pelvic cavity. I immediately informed ; 

and representative of my findings and forthcoming 

noncompliance report. Immediately, Mr. and Mr. started the 

establishments’ corrective actions as prescribed in the establishment’s vacuum 

procedure.The requirements of 9 CFR 381.84, 9 CFR 381.76 table 1 #7 and Plant 

Standered Criteria for air sac were not met.  This document serves as 

notification that your failure to comply with regulatory requirement(s) could result 

in additional regulatory or administrative action.     

1325 

7 

P33900 NHH041211 

2308N-1 

11/08/2013 03J02 Slaughter HACCP C On November 08,2013 while performing a routine pre-chill task at appoximately 

0829 hours on evisceration line #2, I observed fecal material on the right 

wing tip of the seventh bird of a ten bird sample.  It was greenish gray in 

color, appoximately an 1/8 inch in diameter and located in the hollow of the inside 

wing tip.  The findings indicated a deviation from the critical limit, no visible 

feces at CCP 1, as prescribed in the establishment's HACCP plan.  

There were no adequate interventions between this step and the 

chilling tanks when I performed this check.  Therefore it is resonable to 

assume that the feces would have entered the chilling tanks in violation of 

Regulation 9 CFR 381.65(e).  Mr. informed me that the cause of the 

noncompliance was equipment failure.  The height was raised on the vent 

machine and will be monitored for the duration of the day.Mr. 

, and , were shown the 

noncompliance and they confirmed the findings.A similar noncompliance record 

was documented on 10/17/13, please reference NR # NHH1812105817N/1. 

(b) (6)
(B)(6) (b)(4)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0504114 

307N-1 

11/07/2013 01B01 Pre-Op SSOP 

Record Review 

C On 11/05/2013 at approximately 2130 hours while performing a records 

verification procedure required by the establishments' (NOIE) issued on October 7, 

2013, I observed the following. The establishments' Pre-Operational Sanitation - Bio 

Trace Sampling Log-Evisceration/Packaging for 11/02/2013 registered a 

failure in Area 3 Room Line 1 on 10/28/2013 with a reading of 

584 Relative Light Units(RLU's). The 'Corrective Action' section on the form has not 

been updated with the new requirements outlined under the Establishments' 

"Notice of Deferral Verification Plan of October 13,2013. Which states under the 

Sanitation Standard Operating Procedures (SSOP) and Sanitation Performance 

Standards (SPS) section, Item 16, in part " 

;" I contacted who 

performs the Bio Trace Testing on the AM shift and asked her who does the 

rechecks for the PM shift. She said she did but was not aware of the failure. A 

review of the Bio-Trace Log for the week of 11/4 revealed that no checks were done 

on the failed item as part of the randomly selected items and that no 

required rechecks had been performed. I informed her that a noncompliance 

would be issued and she stated that correcting action for the 

noncompliance would address starting that night by adding the 

recheck to the randomly selected items.  My findings indicated a 

noncompliance with 9 CFR 416.12(a), 9 CFR 416.(a),(b) & (c), and 9 CFR 

416.16(a).  

5308 M6137 BXL1004115 

607N-1 

11/07/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 11/6/2013 at approximately 0010 hours while monitoring the Establishments' 

Pre-Operational Sanitation Standards in Packaging Area #1, I observed the 

following. There were several specks to approximately 1/16"  of black 

UFM (Unidentified Foreign Material) that smeared like grease on the top and and 

product contact side of the white nylon wheel for Leg Processors 7 & 8. The 

white wheels hold the product during cutting then drops the cut portion onto a 

collection belt that takes it to the packaging point. There was a piece of 

semi-dried tissue to approximately 3" on the under side of Leg Processor #7 and 

another piece of similar size on Leg Processor #9 near the chain. There 

was approximately 5 pieces of fat each several square inches in 

size on the drum associated with the collection belt under Leg Processors 

7-9.  The Leg processors were cleaned and sanitized then 

 released at approximately  0025 hours. My findings indicated a 

noncompliance with 9 CFR 416.1, 9 CFR 416.4(a) & (b) and 9 CFR 

416.13(c).   

(b) (6)
(B)(6)

(B)(6)

(B)(6) (B)(6) (B)(6) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1804112 

007N-1 

11/07/2013 01D01 SPS Verification C On 11/06/2013 at approximately 2215 hours while monitoring the Establishments' 

Pre-Operation Sanitation Standards in Plant #1, I observed the following. There was 

a piece of stainless steel approximately 3" long by 

1mm thick peeling off a guide bar associated with the 

for Line #1. The affected guide bar is on the out flow side of the unit. The guide bar 

is directly above the carcasses that is being opened at this point in the 

process. Flaking metal is creating an insanitary condition. This is a 

reoccurring issue caused by metal to metal contact between the guide bars and the 

carcass shackles. I contacted who called a mechanic. A piece of 

emery cloth was used to smooth the affected area. A review of the 

Establishments' HACCP Plan -Slaughter Plant #1 under (P) Physical Hazards 

states 'None Identified'. My findings indicated a noncompliance with 9 CFR 416.1 

and 9 CFR 416.2(b)(1).  

5309 P6137A NJN291211 

3007N-1 

11/07/2013 01D01 SPS Verification C Tuesday, November 5, 2013, at approximately 1940 hours, while in the fillet 

department I observed, in area six (section “C”), that the (singulators, cabinet, 

transfer and twin scale belt # 5) drip pan hose was missing.  Due to this there 

was a continuous dripping of water onto the north side cross feeder 

belt # 2. The plant failed to comply with the regulations 9 CFR 

416.4(d) and 9 CFR 416.1.9 CFR 416.1 states: "Each official establishment 

must be operated and maintained in a manner sufficient to prevent the creation of 

insanitary conditions and to ensure that product is not 

adulterated."  9 CFR 416.4(d) states: “Product must be protected from 

adulteration during processing, handling, storage, loading, and unloading at and 

during transportation from official establishments.” I immediately tagged the 

drip pan with USDA tag # B43303939 and informed Mr. 

, of the noncompliance. Mr. stopped the north side cross 

feeder belt, until they fixed the drip pan hose, and sanitized feeder belt #2. I 

brought Mr. and maintenance attention to the north side & south side 

cross feeder belts running over each other with no drip pans underneath the upper 

and middle belts, causing the dripping of water and an accumulation of small pieces 

of muscle and fat on the lower belts and surrounding structures. On Friday 

November 8th I checked the area, after they had completed the installation of the 

drip pans, and the area was found acceptable. Mr. informed me that the 

maintenance well change the drainage hoses of the five singulators, cabinet drip 

pans for effective drainage. On Monday, November 11th I checked the singulators 

cabinet drip pan hoses and they were found acceptable. 

(b) (6)
(B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH001511 

3007N-1 

11/07/2013 01C02 Operational SSOP 

Review and 

Observation 

C At 0839 hours I observed insanitary conditions and cross contamination of cut-up 

product in the reprocessing area of the evisceration department. The first four 

stands in the reprocessing area were being used to salvage cut-up product. Cut-up 

table #4 contained 5-6 carcasses piled together. Cut up table #3 had 6-8 frames 

piled at one end, removed parts stacked in the middle and 6-7 birds piled at the 

other end and scattered over the grate which was partly submerged in water due to 

the catch basin under the grill being stopped up. Water from the basin had also 

spilled over on the table area leaving all the product on the table in standing 

water.Cut-up table #2 had carcasses stacked on each end of the table area. The 

operations at those tables were stopped and was notified and shown 

the conditions of the salvage stations. US Reject/Retain tag #B38075589 was 

assigned. The establishment’s approved reprocessing procedure for cut-up salvage 

states that birds will be removed from the reprocessing line at the station(s) labeled 

Cut-up and handled individually until reconditioned. This is done because the 

carcass has already been designated as contaminated. First, there weren’t any signs 

on any of the reprocessing stations. Second, salvage product prior to conditioning 

and reconditioned product were comingled at all of the stations. (Example: piling 

removed parts on the table allowing them to accumulate and be oversprayed and 

recontaminated by other carcasses before placing them in the designated totes.) At 

1003 hours same conditions were observed at the IP savage station. There were 8 

unprocessed carcasses piled on the grate and the table .There is a statement in your 

Air Sac and IP salvage procedure that allows more than one bird on the salvage 

table as long as they are not being piled on top of each other. However, these 

requirements also were not met also. 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1229 V941 000341211 11/07/2013 01D04 SPS Verification (V) C At around 1800 H PST, Dr. , SPHV and I went to V941 to review the 

92 5307N-1 facilities and the following was observed. 1: In Mr. area was observed a 

crushed vector trap, spider cobwebs, too numerous to count on ceilings, large 

uncovered roll of plastic on floor. Also noted ceiling light electrical socket 

exposed, not with bulb or cover. 2: Mr. area, the bathroom 

exhaust fan has a thick coating of  grey black UFM on it. One wall urinal had 

paper towels in it. The papers on file, as done by Me. did not 

reflect the condition of the facility. Mr. was notified and he viewed the 

issues. I notified Ms at 00157  P/2 of the the 

noncompliances. Mr. and Mr. notified by e-mail. This is 

linked to NR 05-2013, Dated 07/18/2013, 0004122074318N/1 

§416.1   General rules. Each official establishment must be 

operated and maintained in a manner sufficient to prevent the creation of 

insanitary conditions and to ensure that product is not adulterated. 

§416.2   Establishment grounds and facilities. (a) Grounds and 

pest control. The grounds about an establishment must be maintained to prevent 

conditions that could lead to insanitary conditions, adulteration of product, or 

interfere with inspection by FSIS program employees. Establishments must have in 

place a pest management program to prevent the harborage and breeding of pests 

on the grounds and within establishment facilities. Pest control substances used 

must be safe and effective under the conditions of use and not be applied or stored 

in a manner that will result in the adulteration of product or the creation of 

insanitary conditions. (b) Construction. (1) Establishment buildings, including their 

structures, rooms, and compartments must be of sound construction, be kept in 

good repair, and be of sufficient size to allow for processing, handling, and storage 

of product in a manner that does not result in product adulteration or the creation 

of insanitary conditions. (2) Walls, floors, and ceilings within establishments must 

be built of durable materials impervious to moisture and be cleaned and sanitized 

as necessary to prevent adulteration of product or the creation of insanitary 

conditions. (h) Dressing rooms, lavatories, and toilets. (1) Dressing rooms, toilet 

rooms, and urinals must be sufficient in number, ample in size, conveniently 

located, and maintained in a sanitary condition and in good repair at all times to 

ensure cleanliness of all persons handling any product. They must be separate from 

the rooms and compartments in which products are processed, stored, or handled. 

(2) Lavatories with running hot and cold water, soap, and towels, must be placed in 

or near toilet and urinal rooms and at such other places in the establishment as 

necessary to ensure cleanliness of all persons handling any product.   

§416.4   Sanitatary Operations (b) Non-food-contact surfaces 

of facilities, equipment, and utensils used in the operation of the establishment 

(b) (6)
(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

must be cleaned and sanitized as frequently as necessary to prevent the creation of 

insanitary conditions and the adulteration of product. 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6)

(B)(4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD1623115 

706N-1 

11/06/2013 01C01 Operational SSOP 

Record Review 

O On the 7th during the PM hours, I notified Ms. that the Blue 

Incline Belt Bottom Door was open and allowing carcasses to go on the floor. 

She informed the Maintenance Leadperson. It still did not get fixed. Ms. 

mentioned that Maintenance was aware of this issue on the 6th. There was not any 

interventions in place to keep carcasses from getting on floor. I observed several 

carcasses get on the floor and were reconditioned. This is a violation of the 

Establishment's written SSOP Program which states in part: " 

bsp; This substance of this quote was not met. This is also a 

violation of the following 9 CFR's: §416.4   Sanitary operations. 

(d) Product must be protected from adulteration during processing, handling, 

storage, loading, and unloading at and during transportation from official 

establishments. §416.13   Implementation of SOP's. (b) Each 

official establishment shall conduct all other procedures in the Sanitation SOP's at 

the frequencies specified. (c) Each official establishment shall monitor daily the 

implementation of the procedures in the Sanitation SOP's.This is linked to the 

following Noncompliance 151-2013, Dated 11/02/2013. 

5129 M210 LQN562111 

2706N-1 

11/06/2013 01D01 SPS Verification C On November 6, 2013 at 1555 hours when I walked up to wash my 

 hands at the hand wash sink in the raws side Catering Department I 

observed noncompliance with SPS Regulatory Requirement(s) 416.1; and 

416.4(b).Raw Side Hand Wash Sink:  I observed that the hand wash sink in 

the Catering Department was plugged up with meat and water. Inside the hand 

wash sink was two sausage trays that is used for the D Shape  

products.  U.S. Reject Tag NO. B38937091 was applied to the hand wash 

sinks and sausage trays.  and QC Rep Mr.

 was informed and showed the noncompliance.  At 1615 hours 

after sanitary condition was restored (hand wash sink and sausage trays washed 

and sanitized) U.S. Reject Tag NO. B38937091 was removed.This does not comply 

with Regulatory Requirement(s) 416.1 which states in part: "Each official 

establishment must operate in a manner to prevent insanitary conditions and to 

ensure product is not adulterated", and 416.4(b); which states in part: 

"Non-Food-Contact surfaces of facilities, equipment and utensils used in the 

operation of the establishment must be cleaned and sanitized as frequently as 

necessary to prevent the creation of insanitary conditions and the adulteration of 

product".This document serves as written notification that failure to comply with 

the regulatory requirement(s) of 9 CFR 416 could result in additional regulatory 

action as described in 9 CFR 500.4. 

(b) (6)
(B)(6)

(B)(6) (B)(7)(C) (B)(6) (B)(6) (B)(6) (b)(4) (b)(4) (b)(4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0820110 

406N-1 

11/06/2013 01C01 Operational SSOP 

Record Review 

C On 11/05/2013 at approximately 1500 hours, I went to review the Establishments' 

Pre-Operational and Operational Sanitation Records (Daily Monitoring Logs) for 

the previous days. The SSOP Monitoring Log for Loading Dock for Day shift 

dated on 11/02/2013 was missing. I asked 

about the SSOP Daily Implementation and Monitoring Log for 

the Loading Dock. She informed me later that the SSOP Log in Loading 

Dock was performed but she can not find the Log. This is a noncompliance with the 

following regulatory requirements with regulation 9CFR 416.16 (a). 

5308 M6137 BXL5117111 

006N-1 

11/06/2013 03J02 Slaughter HACCP C While performing Finished Product Standards Task, I observed a noncompliance 

with the following regulatory requirements of regulations 9CFR 381.65 (e) and 9CFR 

417.2(c)(4).At approximately 1233 hours, I randomly removed a 10 bird sample 

from Line #1 in Plant #1, I found one out of the ten birds with visible fecal 

contamination inside the bird at the right side, under the leaf fat area. The fecal 

material was a smear measuring approximately 5/16" diameter in size, green and 

white in color and pasty in texture. This exceed the limit of for the 

process to be in control. I informed of the noncompliance. 

The protocol for fecal failure was implemented. Quality Control did a recheck 

at approximately 1245 hours and it passed.This is a violation of the critical limits of 

CCP-2B of the Plant's HACCP Plan for Slaughter. 

1326 

1 

M33901 HAY470711 

5907N-1 

11/06/2013 01C02 Operational SSOP 

Review and 

Observation 

C On the calendar date of November 6, 2012 at approximately 0739 hours while 

performing the Operational SSOP Review and Observation task, the following 

noncompliance was observed: I, CSI , observed beaded condensation and 

what appeared to be sud-like foam steadily dripping from underneath the grinder 

(near the X-Ray machine) into a combo of ground chicken. The combo was retained 

with U.S. RETAINED tag # B40172783. , was shown the 

noncompliance and he confirmed the findings. Mr. stated that the sud-like 

foam was actually sanitizer used by the sanitation crew, and since the sanitizing 

solution was diluted, that no product adulteration existed. I requested to review 

information on the sanitizer and was presented with the MSDS for 

Sanitizer, which is the common name for the 

sanitizer. The information stated that "Before use as a sanitizer, food products 

& packaging material must be removed from the room or carefully protected." 

The MSDS also states "Allow sanitized surfaces to adequately drain before contact 

with food and then air." Mr. was informed that a noncompliance record 

would be issued. This non compliance record will be discussed during the next 

weekly meeting. 

(b) (6)
(B)(7)(C) (B)(6) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1326 

1 

M33901 HAY510711 

0607N-1 

11/06/2013 01D01 SPS Verification C On the calendar date of November 6, 2013 at approximately 0705 hours while 

performing the Operational SSOP Review and Observation task, I, CSI , 

observed the following facility noncompliances: 1) Droplets of condensation on the 

ledge above the air curtain between the shipping cooler and the IF department. 2) 

Beaded condensation on a pipe directly above a stainless lug containing chicken 

breast on line 2 -zone 3. Condensation was also observed on a pipe above the 

conveyor leading into the breading area where chicken patties were being 

processed. 3) Multiple beads of condensation on the underside of the cooling unit 

above the hopper to the Ex-Ray machine. At the time of the findings, boneless 

skinless chicken breast were inside the hopper. Please be advised that employees in 

these areas were shown the condensation, and corrective actions were initiated. No 

product adulteration was observed. Also, at approximately 0836 hour while walking 

through the shipping cooler, I observed condensation dripping from the underside 

of a catch pan. At the time of the findings, water splatter was observed on one bag 

of batter, which was staged on a pallet below the drip pan. No contamination 

occurred, as the bag was sealed. , was shown the 

noncompliance and corrective actions were initiated. Mr. was informed that 

a noncompliance record would be issued. This noncompliance record will be 

discussed during the next weekly meeting. A similar noncompliance record was 

documented on November 5, 2013; please reference NR # HAY1516111505N/1. 

The establishment's response to NR # HAY1516111505N/1 is pending. 

(b) (6)
(B)(6) (B)(6)(B)(6) (B)(6) (B)(6)

(B)(6)

(B)(6) (B)(6)

(B)(4)

(B)(4)

(b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD4323113 

105N-1 

11/05/2013 01C02 Operational SSOP 

Review and 

Observation 

O  On 11/05/2013, I observed a Blue Tub, Designated by the Establishement's 

Color Coding System for edible use. It had a Ink Pen in it. Ink Pen not a 

product contact surface. This was on the Offal Wrapping Machine. I notified Ms. 

. and Ms. . Additionally 

this morning, 11/07/2013, I observed Gray Tote/Tub with scissors in it and the 

Establishment's color code (Gray) for inedible. Ms. and Ms. notified as 

was Ms. and Mr.

 by the phone. This is linked to 0148-2013. Dated 11/04/2013, 

JDD123111704N/1. This is a violation of the Establishment's written SSOP program 

stating in part: 

" was not met. This ia also a violation of the 

following 9 CFR's: §416.4   Sanitary operations. (a) All 

food-contact surfaces, including food-contact surfaces of utensils and equipment, 

must be cleaned and sanitized as frequently as necessary to prevent the creation of 

insanitary conditions and the adulteration of product. 

§416.13   Implementation of SSOP Procedures (c) Each official 

establishment shall monitor daily the implementation of the procedures in the 

Sanitation SOP's. §416.14   Maintenance of Sanitation SOP's. 

Each official establishment shall routinely evaluate the effectiveness of the 

Sanitation SOP's and the procedures therein in preventing direct contamination or 

adulteration of product(s) and shall revise both as necessary to keep them effective 

and current with respect to changes in facilities, equipment, utensils, operations, or 

personnel. 

5309 P6137A NJN510611 

2005N-1 

11/05/2013 01C02 Operational SSOP 

Review and 

Observation 

C At 0705 hrs. I was observing an employee in the packaging department between 

the chiller exit and #4, knife salvaging one legged carcasses by hand.  

The employee was using a movable wheeled stainless steel salvage table.  On 

this table there where several carcasses piled on top that where in the process of 

being salvaged.  I observed that the employee had a steel, used 

for sharpening his knife, that had rust formation down the entire length of the 

steel.  This steel was on top of the table, coming into contact with the 

carcasses that where piled on the table. I contacted and 

.  I informed them of the non compliance to the 

regulations cited above.  The steel was removed from production.  The 

product involved was sent to the reprocessing process.The establishment's 

Sanitation Standard Operating Procedures, Part 2, Section 2 states 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6) (B)(7)(C) (B)(6) (B)(6)(B)(6)

(B)(4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN542011 

2805N-1 

11/05/2013 01D01 SPS Verification C At approximately 1042 hours, I was in the MDP room when I observed a plant 

employee lifting a wooden pallet from the wet dirty floor, laying its bottom on his 

smock while moving it. Being that the bottom of the pallet was dirty and wet from 

the floor, it soiled the employees smock. After moving the pallet, the employee 

proceeded to work with his soild smock. I immediately stopped him and called the 

, and informed him of the noncompliance. 

Mr , without dely, asked the employee to change his sock. I, also noticed 

that all the employes working in the DMP room were all not wearing sleeve 

coverings, which is a requirement in this circumstance because they were handling 

exposed product. I explained this to Ms. , and 

asked her if they can wear aprons to be easy to wash and sanitize and provid them 

with sleeve covers. Ms brought aprons and sleeve covers to all the DMP room 

employes to wear. The plant failed to comply with the regulations 9 CFR 416.1, 

416.5(a) & (b), and their SSOP modification which states that: 

” 

1326 

1 

M33901 HAY061611 

2905N-1 

11/05/2013 01C02 Operational SSOP 

Review and 

Observation 

C  On the calendar date of November 5, 2013 at approximately 0933 hours 

while performing the Operational SSOP Review and Observation task, the following 

noncompliance was observed:I, CSI , observed an employee near the mega 

jet line handling cardboard boxes and frozen meat blocks of Ground Chicken Breasts 

simultaneously. A close examination of the box lids revealed foreign particles, which 

were gritty to the touch, and wood pieces from damaged pallets. At the time of the 

findings, 4 meat blocks were in a combo ready for processing. I observed as the 

employee remove lids from 2 additional boxes and then proceeded to remove the 

frozen meat blocks with the same gloves that came in contact with the insanitary 

lids without washing or sanitizing his hands. I took regulatory control as delineated 

in 9 CFR 416.6 and asked the employee to cease operations. The product was 

retained with U.S. RETAINED tag # B38464348. , and 

, were shown the noncompliance and they confirmed the 

findings. Mr. was notified that a noncompliance record would be issued. 

Please be advised that approximately 300 lbs of frozen Ground Chicken Breast Meat 

was denatured and condemned. This noncompliance record will be discussed during 

the next weekly meeting.A similar noncompliance record was documented on 

11/2/2013; please reference NR # HAY1122111802N/1. The establishment's 

response to NR # HAY1122111802N/1 is pending. 

(b) (6)
(B)(6)

(B)(6) (B)(7)(C)

(B)(6)

(B)(6) (B)(4)

(B)(4)

(B)(4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1326 

1 

M33901 HAY151611 

1505N-1 

11/05/2013 01D01 SPS Verification C On the calendar date of November 5, 2013 at approximately 0659 hours while 

performing the Operational SSOP Review and Observation task, the following 

facility noncompliance was observed: I, CSI , observe multiple droplets of 

condensation on the underside of the refrigeration cooling unit directly above 

line in the IF department. At the time of the findings, wing portions were being 

processed on the line, but no product contamination was observed. 

was shown the noncompliance and he confirmed the findings. Mr.

 was informed that a noncompliance record would be issued. This 

noncompliance record will be discussed during the next weekly meeting. A similar 

noncompliance record was documented on September 9, 2013; please reference 

NR # HAY0614093509N/1. The establishment's response to 

NR # HAY0614093509N/1 failed to prevent recurrence. 

5112 M18909 JDD0123111 

704N-1 

11/04/2013 01C02 Operational SSOP 

Review and 

Observation 

C At 1940 in the MDP Area I observed the following: An employee used a Red Inedible 

Shovel that was in inedible product and then with out washing hands or changing 

gloves used the Stainless Steel Probe (Edible use equipment) in MDP. Ms.

 and Mr. were advised of the situation 

and noncompliance. This is a violation of the Establishment's written SSOP program 

11-A) #2: 

" B: 

" was not met. This is also a violation 

of the following 9 CFR's: §416.4   Sanitary operations. (a) All 

food-contact surfaces, including food-contact surfaces of utensils and equipment, 

must be cleaned and sanitized as frequently as necessary to prevent the creation of 

insanitary conditions and the adulteration of product. (d) Product must be 

protected from adulteration during processing, handling, storage, loading, and 

unloading at and during transportation from official establishments. 

§416.13   Implementation of SOP's. (c) Each official 

establishment shall monitor daily the implementation of the procedures in the 

Sanitation SOP's. §416.14   Maintenance of Sanitation SOP's. 

Each official establishment shall routinely evaluate the effectiveness of the 

Sanitation SOP's and the procedures therein in preventing direct contamination or 

adulteration of product(s) and shall revise both as necessary to keep them effective 

and current with respect to changes in facilities, equipment, utensils, operations, or 

personnel. This is linked to JDD1301100125N/1, Dated 10/24/2003, NR 139-2013. 

(b) (6)
(B)(6) (B)(6) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD0411114 

204N-1 

11/04/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 11/4/2013 at approximately 1030Hrs while performing pre-operational 

sanitation of the plant's Evisceration; MSP, Boning, Cooler 9, Raw Fabrication 

grinding, Tray Pack, Box Out and Bagging Departments, after the plant Q.C. and 

before start up of production, I observed the following noncompliance.

 and/or were notified 

of the noncompliance and shown all incidents. I observed all corrective action to 

food contact and non food contact surfaces. Evisceration - NE Scalder (food contact) 

had many feathers in the scald water. b.) Straddle picker & tail puller (food 

contact) both had meat, meat residues and feathers. c.) neck conveyor - had one 

blood and two meat pieces (food contact). d.) Retrussing table - had two 

feathers on the top side (food contact) and had one meat piece and feathers 

on the underside (non food contact). e.) Gizzard splitter -  had two meat 

pieces, meat residues and four feathers (food contact). f.) Three steel gloves - had 

meat. g.) Chiller A - 1st. section - had many pieces of meat and fat on the 

screens and meat residues on one paddle (food contact). h.) Chiller B - exit 1st 

section had four meat pieces and one Esophagus (food contact). 2.) Raw Fabrication 

grinder - needle injector - had one 2" x 1/4" blue hard plastic tie up which 

was laying on the food contact injector. 3.) MSP - Beehive screen had two meat 

pieces and meat residues (food contact). b.) Contherm # 2 had meat residues (food 

contact). 4.) Boning - White cutting board - had three pieces of meat. b.) Blade 

Saw - had meat residues (food contact). 5.) Bagging - Product wash cabinet (inside) 

had one piece of meat. b.) One piece (8" x 1/8") of belt trimmings on the underside 

(non food contact). The observed incidents of food contact surfaces found 

with meat, meat residues, feathers, plastic tie up from previous days 

operations is in violation to 9 CFR 416.4(d); 416.13(c) and 416.4(a). The non food 

contact surfaces not cleaned is in violation to 9 CFR 416.4(b). This noncompliance is 

being linked to noncompliance (#145) JDD4511100430N/1 dated 10/30/2013; 

(#143) JDD3811102726N/1 dated 10/26/2013 and (#136) JDD1711103122N/1 

dated 10/22/2013 for the same cause respectively. 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6)

(B)(6)

(B)(6)(B)(6)

(B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4)

(B)(4)

(B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4)(B)(4)

(B)(4)

(B)(4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD5910114 

705N-1 

11/04/2013 03J02 Slaughter HACCP C On 11/04/2013 at approximately 0920 & 0930Hrs and again at approximately 

2225Hrs, I found the plant failed to meet the established Boning Department 

Chilling CCP 5B requirement of or less within 8Hrs from slaughter. Using a 

company calibrated thermometer, I performed a physical verification check of the 

Whole Body Heavy Tom Turkeys (Lot# 7988) which were at the Chiller B exit. My 

findings were &  & . U.S. 

Retain Tag NO's:B31 390407& 08 were attatched to two combo bin, 

approximately 4000 pounds, with temperatures above . The attatched plant's 

tags showed the combo bins exiting the chiller at 0320Hrs & 

0321Hrs.  was notified of the noncompliance and 

verified my findings. Mr. chose to add more ice to the affected turkeys.

 was called and she also applied her retain tags. At 

approximately 1130Hrs the affected product was rechecked and the 

temperature was and below. 2.) At approximately 2225 to 2331Hrs on 

11/4/2013, I found Turkey Brst 1 B/L S/L W/O Flt Tom and Turkey Trim A.K. white 

with temperatures exceeding the time and temperature requirement of 

within 8Hrs from slaughter. The affected food products was on 

the New Shipping Dock for shipping. U.S. Retain Tag NO's:B39554693; 

&   where applied to turkey product with 

temperatures exceeding . The plant's attatched tags showed the turkey breast 

and white trim leaving the Boning Room at 0810; 0941, 1035, 1043, 0956, 

0824 & 1042Hrs. Using a company calibrated thermometer. My temperature 

findings were & . and 

were notified of the noncompliance and verified my temperature 

findings. Mr. had the affected product put into the P-157 blast. 

. also added her retain tags. On 11/5/2013 at approximately 1120Hrs (3 

released) and 2320Hrs (4 released). The (11535 total pounds) of turkey breast and 

one bin of white trim was released back to production after verifying all of the 

affected product was at or below . The establishment chose to run the 

University of Wisconsin PMP calculation and it showed no Salmonella outgrowth 

using the 1100pm dated 11/4/2013 to 1100am on 11/5/2013. The establishment 

has Salmonella Initiative Program (SIP), a waiver to 9 CFR 381.66(b). This waiver 

allowes the establishment chill whole birds/parts to in 8Hrs from slaughter. 

This observed incident of product temperatures above exceeding the 8Hrs from 

slaughter is in violation to the plant's HACCP Plan at the Boning Department 

monitoring of CCP 5B which states in part; 

. 

The plant's CCP 5B established company 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6) (B)(7)(C)

(B)(7)(C)

(B)(7)(C) (B)(4) (B)(4)

(B)(4)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

critical limit which states; 

, was not sufficient in preventing temperatures above 45F. This 

noncompliance is being linked to noncompliance (#108)JDD2323083626N/1 dated 

08/26/2013 for the same cause respectively. 

5129 M210 LQN300011 

2504N-1 

11/04/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On November 3, 2013 at approximately 2150 hours while performing my 

Pre-Operational Sanitation inspection in the HPP Department I observed 

noncompliance with SPS regulatory requirements 416.4(b). HPP 

Packaged/Box Out Area:  After the packaged product received it's lethality 

step and exit the HPP Department into the Packaged Box Out Area I observed 

 both Chutes where bags of product come in contact with prior to being 

boxed out had a build up of black unidentifiable foreign material on the top 

surface of the chutes, which may create insanitary conditions. I immediately 

informed and showed Ms. the noncompliance.  

Immediate Corrective Action was implemented to restore sanitary conditions in my 

presence.  The HPP Department is address in the establishment written 

SSOP.  1. Pre-Operational Sanitation Objective:  

This does not comply with Regulatory Requirements 

416.4(b); which states in part: "Non-food-contact surfaces must be cleaned and 

sanitized as frequently as necessary to prevent the creation of insanitary 

conditions".  This NR is linked to NR#LQN1600102214N/1 dated 10/14/13, 

for a similar NR on Pre-op Inspection in the HPP Department.  Management 

response to NR#LQN1600102214N/1; "Immediately after USDA rejected the boards 

they were removed and disposed of in the presence of USDA. 

5308 M6137 BXL2219112 

804N-1 

11/04/2013 01D01 SPS Verification C At approximately 1625 hours, Line Food Inspector observed a 

live juvenile cockroach when she was applying sanitizer to her gloves from the 

sanitizer dispenser box that is located between Line and Line attached to the 

wall in front of the ice machine. She caught the cockroach and contacted CSI 

and CSI and showed them her findings. We contacted

 and showed him our findings. contacted 

. The area was washed.This is a 

noncompliance with the following regulatory requirements of regulations 9CFR 

416.1 and 9CFR 416.2 (a). 

(b) (6)
(B)(6) (B)(6) (B)(6)

(B)(6)

(B)(4) (B)(4) (B)(4) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2709113 

904N-1 

11/04/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 11/04/2013 at approximately 0652 hours while monitoring the establishments 

Pre-Operational Sanitation procedures in Plant #2, I observed the following. In Area 

#2, Unit # 9, 1/2 of Picker #1 Line , there were numerous feathers, too many to 

count, from the last production day which was 11/02/2013, inside the 

picker. I informed of the noncompliance. I continued with 

the Pre-Operational Sanitation procedure and I observed also in Area #2, Unit # 22, 

1/2 of Picker #4 Line also had numerous feathers inside the picker. I again 

informed . Sanitation rewashed both pickers, restoring 

sanitary conditions. I reinspected and released the pickers at approximately 

0704 hours.My findings indicate a noncompliance with regulatory requirements of 

regulations 9CFR 416.1, 9CFR 416.14, 9CFR 416.4(a), and 9CFR 416.13(c). 

5309 P6137A NJN441411 

4904N-1 

11/04/2013 04A06 Poultry Finished 

Product Standards 

C At approximately 0911 hours, while performing the finished product standards 

check on the reprocessing line, I found six carcasses with trim defects. Four of them 

had cellulitis lesions on the breast and flab areas ranging from three to one square 

inches, one carcass had a large mutilated area about two square inches on the 

breast, and another had part of the cloacae and intestine still attached 

(approximately one inch long). Also, I found a carcass that was contaminated with 

ingesta on the crop area. I immediately stopped the reprocessing line and showed 

Mr. , and Mr.

 my findings and informed them of the forthcoming noncompliance. The 

plant failed to keep the reprocessing line in compliance with the federal 

regulations.9 CFR 381.86 states: " Any organ or other part of a carcass which 

is affected by an inflammatory process shall be condemned and, if there is evidence 

of general systemic disturbance, the whole carcass shall be condemned."9 CFR 

381.91(b)(1) states: " Any carcass of poultry accidentally contaminated during 

slaughter with digestive tract contents shall not be condemned if promptly 

reprocessed under the supervision of an inspector and thereafter found not to be 

adulterated. Contaminated surfaces that are cut shall be removed only by 

trimming. Contaminated inner surfaces that are not cut may be cleaned by 

trimming alone, or at an approved reprocessing station away from the main 

processing line, by any method that will remove the contamination, such as 

vacuuming, washing, and trimming, singly or in combination. All visible specks of 

contamination must be removed, and if the inner surfaces are reprocessed other 

than solely by trimming, all surfaces of the carcass shall be treated with 

water containing ppm available " 

(b) (6)
(B)(6)

(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH280211 

3904N-1 

11/04/2013 01C01 Operational SSOP 

Record Review 

C At  approximately 0100 hours on 11/4/13 Inspection observed the following 

noncompliance.  While a performing scheduled SSOP Records Review task for 

the night of production that began on 10/31/13, a SSOP deficency was noted for 

11/1/13 at 0257 hours. The deficency involved 90 lbs of WOGS on the floor. The 

establishment determined the chiller exit belt diverter gate was at fault. The 

establishment gave a preventive measure of “

 There was no notation/documentation in the 

SSOP Record that this preventive measure was performed. This is a noncompliance 

of section 9CFR 416.15(b) and 9CFR 416.16(a). was notified 

of this noncompliance. Refer to NR#NHH1201100414N for a similar noncompliance. 

  

(b) (6)
(B)(6) (B)(7)(C) (B)(6) (B)(4) (B)(4) (B)(4)

(B)(4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1326 

1 

M33901 HAY112211 

1802N-1 

11/02/2013 01C02 Operational SSOP 

Review and 

Observation 

C On the calendar date of November 2, 2013 (Saturday) at approximately 2055h 

while performing the Operational SSOP Review and Observation task, I observed the 

following noncompliance: I, CSI , observed 5-10 droplets of condensation 

located on the underside of a drip pan  directly above Line product.  

Raw, unfrozen wing poultry product was being processed on line when I observed 

the condensation droplets.  I immediately informed the lead person for the 

line (Mr. ) to stop the line.  He had the line stopped and 

proceeded to find some plastic to cover the product, but before he could return 

with the plastic I observed it drip onto product located on the stopped line.  I 

immediately informed management (Ms. ) that product 

on the line had been contaminated with the dripping condensate from the drip 

pan.  She condemned about 5 lbs of wing product and removed several feet 

of the plate freezer film the product was on to restore sanitary conditions.  

As a preventive measure, she informed me that someone had turned the fan off 

that was used for adequate ventilation above line   She immediately turned 

it on and informed me she would retrain her employees to keep the fan on.  

After this preventive measure was stated,  sanitary conditions restored and 

the product involved condemned, I allowed production to resume.  As a 

regulatory action, I had the line stopped, but a U. S. tag was unnecessary since I 

remained until all corrective actions were taken that met 416.15.  Production 

resumed at approx. 2100h. The establishment’s Standard Operating Procedures for 

Sanitation (Part 2; Section 1) states: 

.   Lack of adequate ventilation and ineffective SSOP 

monitoring failed to prevent product and product contact equipment from 

contamination with condensation.  In addition, regulatory requirement for 

416.13(c), 416.2(d) and 416.1 were not met. For a similar noncompliance record 

with the same cause (inadequate ventilation to control condensation) please refer 

to HAY0614093509N/1 dated 9/9/13. 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD4201114 

502N-1 

11/01/2013 03J02 Slaughter HACCP C On 11/01/2013 at approximately 0819Hrs, I observed that the establishment failed 

to remove the WIP (work in process) tag prior to putting the reprocessed whole 

body turkeys into production flow. I saw two plant employees taking whole body 

turkeys out of a barrel and putting them into a tank containing whole body 

turkeys. The barrel was tagged with a WIP (work in process) red tag. The tank of 

whole body turkeys had been released by the HACCP Monitor. One employee 

was putting the whole body turkeys from the tank onto the blue incline 

which was taking the birds into the chiller. U.S. Retain Tag NO:B39554900 

was applied to the tank containing the WIP birds from the barrel. Ms. was 

near by and was notified of the noncompliance. She called 

to come to the chiller incline. Mr. was notified of the noncompliance and 

showed the WIP tagged empty barrel. I notified Mr. that the employees had 

put the bird from the barrel into the tank. He questioned the employees. He took 

immediate corrective actions. He had all of the birds in the tank reconditioned bird 

by bird with ppm water spraying. The whole body reprocessed 

birds were released back to production flow at approximately 0848Hrs after 

verifying the plant's appropriate corrective actions and reinspection. This observed 

incident of personnel not following the establishment's Reprocessing Whole body 

Turkey's WIP procedure is in violation to the Reprocessing Whole body 

turkeys HACCP Plan monitoring for CCP 1B. The in place CCP 1B 

is to comply with 9 CFR 381.65(e) zero tolerance for feces and the 

plant's in place monitoring 9 CFR 417.2(c)(4). This noncompliance is being 

linked to noncompliance (#118) JDD2321092618N/1 dated 9/18/2013 for the same 

cause respectively. 

(b) (6)
(B)(6)

(B)(6) (B)(6)

(B)(6) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN511911 

0401N-1 

11/01/2013 04A06 Poultry Finished 

Product Standards 

C At 1545 hours, I was performing a zero tolerance verification task on the 

tubs of salvaged parts in the evisceration department.  I randomly selected 5 

pieces of salvaged parts from each tub.  I found one piece of drum stick 

contaminated with unidentified black foreign material in a tub identified from 

A-line.  The size of the foreign material was approximately 1⁄2 centimeter 

by 1⁄4 of centimeter, I tagged the tub with the USDA retain tag # B43303858, and 

showed my finding to , and 

. The product was released after the 

corrective actions where proffered, which involved reworking the tub of 

product.  I also informed  

, of the non compliance with 9 CFR 381.65(a) which states: 

“Operations and procedures involving the processing, other handling, or storing of 

any poultry product must be strictly in accord with clean and sanitary practices and 

must be conducted in a manner that will result in sanitary processing, proper 

inspection, and the production of poultry and poultry products that are not 

adulterated.” 

5310 M6137B FFA0713113 

901N-1 

11/01/2013 01D01 SPS Verification C On November 1, 2013 while making a routine patrol of the establishment's raw 

production department; (kitchen) I observed noncompliance with SPS regulatory 

requirement(s) 416.2(d), 416.1, 416.4(d) and 416.2(b)(1). At 10:44 hours I observed 

beaded dripping condensation on the bottom side of the gray beams and iron rails 

between oven #1 & #2 loading areas in front of stuffer #6; no product affected. 

As well there was a brass valve leaking water onto the walls and the white pvc pipes 

behind the small blender. were notified and 

shown the condensation and was notified and shown the 

leaking valve. This NR represents SPS noncompliance of the regulations cited above; 

as well as written notification that failure to comply with regulatory requirement(s) 

may result in additional regulatory or administrative actions as described in 9 CFR 

500.4. 

(b) (6)
(B)(6)

(B)(6) (B)(6) (B)(6)

(B)(4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD4511100 

430N-1 

10/30/2013 01B01 Pre-Op SSOP 

Record Review 

C On 10/30/2013 at approximately 0050Hrs while performing pre-operational 

sanitation of the plant's Chiller B; MSP, Boning Room and Raw Fabrication Grinding 

Departments, after the plant Q.C. and before start up of production, I observed the 

following noncompliance. were notified of the 

noncompliance and shown all incidents. I observed all corrective actions to food 

contact surfaces. 1.) Evisceration - Chiller B- The 6th. bays section had 4 

pieces of meat and one meat residue. 2.) MSP and Boning Room - The # 4 

cylinder had meat on the inside. B.) The grey thigh trim belt on the top side 

had meat residues. 3.) Raw Fabrication Grinding Room - The (injector) had 

meat and meat residues. This observed incidents of food contact surface found with 

meat and meat sesidues from previous days operations is in violation to 9 

CFR 416.4(a); 416,4(d) and 416.13(c). This noncompliance is being linked to 

noncompliance (#143) JDD3811102726N/1 dated 10/26/2013; (#136) 

JDD1711103122N/1 dated 10/22/2013, and (#135) JDD1507102418N/1 dated 

10/18/2013 for the same cause respectively.  

5129 M210 LQN160910 

0730N-1 

10/30/2013 01D01 SPS Verification C At approximately 0615 while performing hands on Pre-Operational Sanitation, on 

October 30th, 2013, after company Pre-Operational Sanitation and before the start 

of production in Zone E, I observed a non compliance with the 

Blenders.I requested that both of the chain drive cabinets (5' wide X 6' 

tall) for the Blenders be opened up for inspection. 

Maintenance has the tool to open the cabinets. Once the cabinets for the 

Blenders were opened, I observed the inside of the cabinets, the gears and chains 

were covered in a red like substance that was slick and smeared at the touch. 

I observed meat tissue pieces, to numerous to count, ranging in size from 

1/4 inch to 2 inches from the previous days production on the inside of the cabinet 

doors and thru out the intire cabinet. The inside of the gear drive cabinet is a non 

product contact surface, but could create crosscontamination from liquid draining 

out the bottom of the cabinet onto the floor.This is a noncompliance of Regulation 

416.1 and 416.4(b) and a failure of the company SSOP Plan Pg. 2. I.

 observed the noncompliance. 

 was notified and observed noncompliance.

 for nights was notified and observed the cabinets. Inspection was 

informed that sanitation does not have access to the cabinets for daily cleaning.This 

document serves as written notification that your failure to comply with regulatory 

requirement(s) could result in additional regulatory or administrative action. 

(b) (6)
(B)(6) (B)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5102104 

030N-1 

10/30/2013 04A06 Poultry Finished 

Product Standards 

C On 10/30/2013 at approximately 0006 hours while performing a Pre-Chill Finished 

Product Standards check on line in Plant #2, I observed the following. After 

taking a standard random 10 bird sample, I accumulated 45 nonconformance 

points. 7 of the 10 birds had crops. This exceeded the subgroup absolute limit of 

points. I contacted and informed him of the failure. A QC recheck 

failed at 0016 hours with 37 nonconformance points. 5 of the 10 birds had 

crops. At this point the process is judged to be out of control. Pre-Chill 

rechecks at 0046 and 0117 hours brought the process back into control. Post-Chill 

checks at 0028 hours and for every 30 minutes until 0200 hours passed.  My 

findings indicated a noncompliance with 9 CFR 381.76(b)(3)(iv)(d)(4). 

(b) (6)
(B)(7)(C) (B)(6) (B)(6) (B)(7)(C) (B)(7)(C)

(B)(6)

(B)(6) (B)(6) (B)(7)(C) (B)(4) (B)(4) (B)(4) (B)(4)

(B)(4)

(b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN230210 

0430N-1 

10/30/2013 01C02 Operational SSOP 

Review and 

Observation 

C On Sunday October 27th, at the beginning of the night shift, CSI 

observed the following on the first process area: At approximately 2315 hours 

while walking through the slaughter area, she observed birds falling from the auto 

re- hang equipment on to the floor.  During approximately  5 to 8 

minutes the birds were consistently falling on the floor making two piles of 

approximately 200 birds each. Some of the birds were directly falling inside of the 

drain blocking the flow of water in the drain, which started to rise almost reaching 

the surface of the floor. , started picking up the bird from the 

drain and by doing so, her boot came into direct contact with the pile of birds on 

the floor. As she removed the carcasses from the drain, she was holding and 

swinging them on top of the pile of birds on the floor. These carcasses were heavily 

dripping causing cross contamination on the rest of the birds.  The water 

from the drain is loaded with contaminants including feces, which may increase 

bacteria growth on contaminated carcasses. She condemned the birds from the 

drain but proceeded to grab the hose with the intention to rinse the rest of cross 

contaminated birds.  CSI immediately approached her and explained 

to her that those birds had been cross contaminated with water from the drain. 

  then proceeded to condemn the rest of the birds on the 

pile. Approximately a full inedible barrel was filled with condemned carcasses. There 

was a second employee that came to the area and grabbed the hose and started to 

wash the birds on the other pile. He was spraying each carcass and placing them on 

the re- hang conveyor. At approximately 2330 hours, CSI requested 

to perform a check on the hose being utilized to rinse the 

birds from the floor. There was no being supplied through this hose. 

 She then, notified and proceeded to place a Rejected 

/Retained hold tag N0 B43303847 on the hose.  This hose was not connected 

to the main piping system and therefore removed by maintenance. 

Another hose was connected directly from the piping system and 

brought above the auto re hang equipment and down onto the area were birds fall 

on the floor and are to be rinsed.  The level on this new hose was 48 

PPM. CSI released the US hold tag, after sanitary conditions were restored. 

This is a failure to implement the establishment’s  SSOP program as written. 

As stated on the  SSOP Part 2- Operational Sanitation, Section 1 for 

Evisceration, under Description of Sanitation Procedures states: 

was notified of the non compliance the 

morning of 10/28/2013 at approximately 0530 hours. This represents non 

compliance with regulatory requirements of regulations 9 CFR 416.4(d) and 

416.13(c) 

(b) (6)
 

 

 

 

 

(B)(6)

(B)(6) (B)(6) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH050310 

5231N-1 

10/30/2013 01D01 SPS Verification C On the night of production that began on October 30, 2013, while in Room 1 

Further Processing at approximately 005 hours I observed water leaking from the 

roof onto the production floor in the corner of the room near the entrance to the IF 

department creating an insanitary condition.  The establishment was 

producing product in the area at the time and was salvaging product from the 

floor.  Employees were observed walking through the area of the roof 

leak.  The area was rejected with US tag B38075689.  Mr 

, was notified of the issue and informed it would be 

documented on a noncompliance record.  Mr. contacted 

maintenance and plastic was hung to collect the water.  The regulatory 

control action was then released. The requirements of 9 CFR 416.2(b)(1) were not 

met. 

1325 

7 

P33900 NHH230110 

2530N-1 

10/30/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On the production shift that began on 10/29/2013, I performed pre-operational 

sanitation review and observation at Est. 33900  P.   This 

Pre-Op was performed in the first processing (evisceration) department of the 

Establishment, on equipment that was randomly drawn from the evisceration 

schematics for pre-op inspection.  This was after sanitation had completed 

cleaning the equipment and the establishment had completed pre-operational 

sanitation inspection of the equipment and released the area for USDA 

inspection.  There are no additional sanitation or inspection steps prior to 

the start of production.  This procedure was completed before product 

reached the areas inspected.    The following non-compliance 

was observed on the line 1 gut saw (unit #37) fat and a brown protein residue was 

in the under side of the blade cover of the unit (product contact portion of the 

unit).  This residue ranged in size from 1/8 inch to 1/2 inch in size and 

numbered more than 10 pieces on the gut saw.   The line 1 Auto rehang 

(unit number 1) had 3 chicken feet lodged on the wheel on the top of the 

unit.   The feet were removed and both units were re-cleaned by 

Sanitation and re-sanitized.  I then re-inspected and released the units to 

Production.   The requirements of Regulations 416.4(a) and 416.13(c) were 

not being met.       The noncompliance was shown to 

Mr. and Mr. and they were informed that it would be 

documented on a NR.    For similar noncompliance refer to 

NR # NHH4423105223N / 1, dated 00/23/2013. 

(b) (6)
(B)(6)

(B)(4)

(B)(4)

(b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH460210 

2430N-1 

10/30/2013 01D01 SPS Verification C On the night shift that began on 10/29/2013, at approximately 2310, I was in the 

further processing department at Establishment 33900  P.  I was in 

Room 1, further processing when I observed heavily beaded condensation on the 

yellow hose and the electrical conduit pipes in the overhead.  This 

condensation was actively dripping on the floor.  This area has a product 

drop-slide and the establishment has a floor salvage procedure in the area so I was 

about to reject the area.  A QA Tech in the area told me she would have the 

condensation dried and the floor re-washed, which she did in a timely manner so no 

Regulatory Control Action was taken.  When this was done I continued 

monitoring the area.   The establishment's SSOP plan objective states: 

 " 

."    The SSOP plan also states 

on page 10, paragraph 4,

  Regulation 416.2 (d) states “Ventilation. Ventilation 

adequate to control odors, vapors, and condensation to the extent necessary to 

prevent adulteration of product and the creation of insanitary conditions must be 

provided.   The requirements of 9 CFR 416.2(d) was not met.   

Refer to NR #NHH4604103809N / 1, dated 10/09/2013 for similar non-compliance 

of dripping condensation.     To date all measures to prevent 

recurrence by management may not have been implemented properly or were 

ineffective. 

5308 M6137 BXL3608105 

329N-1 

10/29/2013 03J02 Slaughter HACCP C On 10/29/2013 at approximately 0046 hours while monitoring Post-Chill Finished 

Product Standards in Plant #1 from product exiting Chiller #2, I observed the 

following. After taking a standard 10 bird sample, I observed one bird with visible 

fecal contamination. There was a cloacae with approximately 2" of 

intestine attached inside at the tail.  The  fecal material was inside the 

carcass on tissue under the left side fat flap. The fecal material was light 

brown in color, pasty in texture and measured approximately 1/4" by 1/4". This 

exceeded the limit of for the process to be in control. I had the 

hanging of product going into Packaging stopped. There were no QC personnel 

available so I performed a recheck that passed at approximately 0049 hours.

 was informed. The procedure for a Post-Chill   fecal 

failure was implemented. My findings indicated a noncompliance with 9 CFR 

381.65(e), 9 CFR 417.2(c)(4) and the CCP-2B Zero Fecal Contamination of the Plant's 

HACCP Plan for Slaughter. 

(b) (6)
(B)(6) (B)(6) (B)(6)

(B)(6)

(B)(6) (B)(6)

(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH340510 

4029N-1 

10/29/2013 01C02 Operational SSOP 

Review and 

Observation 

C On the night of production that began on October 28, 2013 at approximately 2340 

hours in Room 1 Further Processing I observed two stainless steel scoops and two 

stainless steel shovels on the roller belt used to transport boxed product to the 

cooler.  This belt is not considered a product contact surface and the scoops 

and shovels were thereby contaminated.  When asked what the utensils 

were used for, Mr. , stated the scoops and shovels 

were used to place ice onto product.  The utensils were rejected with US tag 

B38075687.  Mr. was notified the noncompliance would be 

documented on a noncompliance record.  Mr. restored sanitary 

condition to the utensils and as a verbal preventive measure, stated the responsible 

employee would be retrained to properly handle the scoops and shovels.  

The regulatory control action was then released.  At approximately 2345 

hours at the end of the grade A wog line, boxes with plastic liners were stacked on 

each other such that the outer surface of the box contacted the inner surface of the 

liner, a product contact surface, thereby contaminating the liners.  Six boxes 

and liners were rejected with US tag B38075683.  Mr. 

, was notified of the noncompliance and informed it would be 

documented on a noncompliance record.  Inspection observed as Mr. 

discarded the packaging material.  As a preventive measure, Mr.

 stated the responsible employees would be retrained.  The 

regulatory control action was then released. The establishment’s SSOP plan states 

” The requirements of 9 CFR 416.13(c) were 

not met. For a similar noncompliance refer to NR NHH5113102621N/1 dated 

October 21, 2013.  The preventive measure for this noncompliance was 

employees would wash their hands prior to handling product.  These 

measures may have been implemented incorrectly or may have been ineffective at 

preventing recurrence. 

(b) (6)
 

 

 

 

(B)(6) (B)(6) (B)(6)

(B)(4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH030310 

2928N-1 

10/28/2013 01C02 Operational SSOP 

Review and 

Observation 

C On the production shift that began on 10/27/2013, at approximately 2315 Hours I 

was in Room #2 at Establishment 33900  P.  I was in the marination 

line area to perform operational sanitation inspection on product contact surfaces 

of the fryer marination line.  Two production personnel were mixing 

marination for the start of operations.  These 2 workers were opening and 

mixing marination without removing the outer wrapper of the bag.  These 

outer wrappers are considered insanitary and the Establishment’s procedure is to 

remove the outer wrapper before emptying the contents into the mixer.  

Regulatory Control Action was taken by applying USDA Reject Tag numbered 

B38075840 to the Start/Stop switch of the marination machine. The 

non-compliance was shown to Ms. and she had the marination 

emptied from the miser and the marination pipes and the mixer and pipes 

recleaned and sanitized.  Ms. was informed that a non-compliance 

record would be issued. The requirements of Regulations 416.4(d) and 416.13(c) 

were not being met.    The preventive measure given by Ms. 

was that the employee that was opening the bags would be written up for improper 

job performance.</P> <P><SPAN><SPAN><SPAN></SPAN></SPAN></SPAN></P> 

<P><SPAN><SPAN><SPAN>Refer to NR #NHH2900073301N/ 1, dated 08/20/2013 

for similar non-compliance of an adulterant on product contact surfaces (insides of 

hoses). </SPAN></SPAN></SPAN></P> 

<P><SPAN><SPAN><SPAN></SPAN></SPAN></SPAN></P> 

<P><SPAN><SPAN><SPAN><SPAN>      & 

nbsp;      

           & 

nbsp;          & 

nbsp;          & 

nbsp;          & 

nbsp;  </SPAN></SPAN></SPAN></SPAN></P> 

<P><SPAN><SPAN><SPAN><SPAN>The Establishment’s SSOP plan objective is 

</SPAN></SPAN></SPAN></SPAN></P> 

<P><SPAN><SPAN><SPAN><SPAN> </SPAN></SPAN></SPAN></SPAN></P> 

<P><SPAN><SPAN>  </SPAN></SPAN></P> 

<P><SPAN><SPAN> </SPAN></SPAN></P> <P><SPAN></SPAN></P> 

<P><SPAN></SPAN></P> <P><SPAN></SPAN></P> <P> </P> 

(b) (6)
(B)(6) (B)(6) (B)(6)

(B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD2815101 

226N-1 

10/26/2013 01C02 Operational SSOP 

Review and 

Observation 

O On 10/26/13 at approximately 1251 Hours while performing Operational SSOP 

Review and Observation task in cooler # 1. I observed the following 

non-compliance . I observed a stainless tank containing approximately 1652 

pounds of edible necks with a tank liner that was torn along the top 

sides of the liner. Brown and black grease was observed along side the non food 

contact surface of the liner near the tears in the liner. No grease came into contact 

with product. I immediately took regulatory control by applying U.S. Retain 

tag # B39554887 to the tank and informing of my 

findings. Mr. took immediate corrective action in my presence by 

removing effected part of the liner and replacing the tank with a new cover. 

Sanitary conditions were restored and regulatory control was relinquished. 

5112 M18909 JDD3811102 

726N-1 

10/26/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 10/26/2013 at approximately 1220Hrs while performing pre-operational 

sanitation of the plant's Evisceration,  Raw Fabrication, MSP and Bag 

Line Departments, after the plant Q.C. and before start up of production, I observed 

the following noncompliance. and

 were notified of the noncompliance and shown all incidents. I 

observed all corrective actions to food contact surfaces and non food contact 

surfaces.  1.) Evisceration - Trussing table (food contact) had UFM (rail 

type) dripping from the overhead line. One was flake black pieces and One was 

black liquid dripping. b.) Gizzard Splitter and Gizzard Defatter (food contact) - both 

had meat pieces; gizzard peel and feathers. c.) Chiller Transfer A to B - 3 pieces of 

meat. 2.) Bag Line- Yellow line had one meat and one trachea on bottom side of 

conveyor (non food contact). The Red line had two pieces of meat on bottom 

side of conveyor (non food contact). The Blue line conveyor (food contact) had UFM 

flakes (brown & black) which fell from the ceiling when the employee was 

removing condensation. 3.) Raw Fabrication - Poss Machine (food contact) had 

meat on 2 of the parts and one piece of meat on the metal detector (inside). 

4.) MSP - Beehive screen (food contact) had 2 pieces of meat. One part had meat 

residues; One long pipe had 2 pieces of meat. The observed incidents of food 

contact surface found with meat, meat residues, feathers and black & brown 

UFM from previous days operations is in violation to 9 CFR 416.4(d); 416.13(c) and 

416.4(a). The non food contact surfaces not cleaned is in violation to 9 CFR 

416.4(b). This noncompliance is being linked to noncompliance (#136) 

JDD1711103122N/1 dated 10/22/2013 and (#135) JDD1507102418N/1 dated 

10/18/2013 for the same cause respectively. 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6) (B)(4) (B)(4) (B)(4)

(B)(4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4507103 

926N-1 

10/26/2013 03J02 Slaughter HACCP C On 10/25/2013 at approximately 2200 hours while reviewing a previously 

requested copy of the establishments' computer records, I observed the 

following. It appeared that since 10/16/2013 when red water readings in 

chiller #3 at 2316 hours that the establishment has been adding

 to Chiller #3 while 'Organic' product was being processed.  After 

startup for slaughter kill date 10/26/13 at 

approximately 0100 hours I checked the computer records and found 

entries at 12:14 PM that 'Makeup water" was 34ppm and at 2301 

hours that the red water was 3.9ppm. A review of the establishments' HACCP Plant 

for Slaughter for Plant #2-Organic" Step 24 'Carcass Chilling' under 

Potential Hazards Introduced, Controlled, or Reduced at this point (c):Chemical has 

" NONE Identified".  I contacted and 

asked him about the being used in Chiller #3. I read him the 

section from the HACCP Plan for Slaughter -Organics which does not include a 

reference for the use of as a processing aid and informed him of the 

noncompliance for an inadequate hazard analysis. My findings indicated a 

noncompliance with 9 CFR 417.2(a)(1), 9 CFR 417.2(c)(1), 9 CFR 

417.2(c)(2)(i), 417.2(c)(3), 9 CFR 417.4(a)(3)(i), 9 CFR 417.5(a)(1) and 9 CFR 

417.5(a)(2). 

5308 M6137 BXL4716100 

426N-1 

10/26/2013 01C01 Operational SSOP 

Record Review 

C On 10/25/2013 while performing an Operational Sanitation Records Review Task, I 

observed that there was no SSOP Log for the Loading Dock on 10/20/2013, A.M. 

shift. I asked about the missing 

SSOP Log and she informed me that she would investigate the matter as it was the 

A.M. shift Log. The next day, 10/26/2013, informed me that no 

SSOP Log for the "Dock" on 10/20/2013 had been documented. The SSOP Plan 

states in part, that QA Inspector or designee "

 I informed

 of the noncompliance.My findings indicate a noncompliance with 

the following regulatory requirements of regulations 9CFR 416.13(b), 9CFR 

416.16(a), and 9CFR 416.13(c). 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD2403101 

426N-1 

10/25/2013 01D01 SPS Verification O On 10/25/2013 at approximately 0517Hrs, I observed heavily beaded condensation 

on the bottom side of the approximately 2" wide grey beam (non food contact) 

which runs parallel to the white (food contact) large cooler units drip pan at the 

boning room rehang table. The beam is directly over the turkey processing line and 

processing table. The line was full of whole body turkeys at this time of my 

observation. I immediately notified Ms. and showed her the 

beaded condensation/water. I ask for a supervisor.  

came and implemented appropriate corrective action. He had the hanging line 

stopped. He covered the line with plastic.  He was also shown heavily beaded 

condensation/water which was on a grey beam over the line and also on the 

ceiling at the overhead turn wheel. He had the condensation removed by 

wiping. He restarted the line at approximately 0521Hrs. I did not observe any direct 

food products adulteration at this time. This observed incident of heavily beaded 

condensation over food products and processing line during production was 

creating insanitary conditions and a potential food products adulteration. This is in 

violation to the relevant regulation cited above. This noncompliance is being linked 

to noncompliance (#111) JDD4522091103N/1 dated 9/3/2013 and (#92) 

JDD2523074126N/1 dated 7/26/2013 for the same cause respectively. Mr. 

. were notified of the noncompliance. 

5112 M18909 JDD2511100 

026N-1 

10/25/2013 06D02 Other Inspection 

Requirements 

C On 10/25/2013 at approximately 0830Hrs, I found the establishment failed to meet 

the regulatory requirements to 9 CFR 381.68(b). When I looked at the plant's 

(presentation/line speed) checks for line One and line two. I found the speed was 42 

birds per minute at 709Hrs on line two and 42 birds per minute on line One 

at 705Hrs. The Evisceration at this time (655 to 739Hrs) was running 

Consumer Tom Turkeys with scheduled weight 25 pounds each bird.  

The line speed was exceeded on line one and line two. This is in violation to the 

Maximum inspection rates for (NTIS) New Turkey Inspection System regulation 

chart which states in part..maximum line speed for birds weighting 16 pounds are 

more for two inspector on one line is 41 birds per minute. . was 

immediately notified and Ms. notified that a 

noncompliance will be issued. This noncompliance is being linked to noncompliance 

JDD2521095525N/1 for the same cause respectively. 

(b) (6)
(B)(6) (B)(6) (B)(6)

(B)(6) (B)(6)

(B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4)

(B)(4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD3420102 

525N-1 

10/25/2013 01D01 SPS Verification C On 10/25/13 at approximately 1810 Hours while performing SPS Verification check 

in cooler # 4. I observed beaded condensation on the overhead beams and pipes 

above covered tanks of product. No product was contaminated by the 

condensation. I immediately took regulatory control by applying U.S. Reject 

tag # B39554888 to the area and informing of my 

findings. Mr. took immediate corrective action in my  presence by 

removing the tanks of product from the area and removing the condensation from 

the beams and pipes to restore sanitary conditions. U.S. Reject tag # B39554888 

was removed and regulatory control was relinquished at approximately 1835 

Hours. 

5308 M6137 BXL0521105 

625N-1 

10/25/2013 03B02 Raw Non-Intact 

HACCP 

C At approximately 1520 hours while performing a HACCP Raw-Non Intact 

Records Review task, I found a noncompliance with the following regulatory 

requirements of regulation 9CFR 417.2 (c)(4).The HACCP Monitoring Log -CCP3BSanitizer Concentration Verification Raw-Non Intact, dated on 10/23/2013 for AM 

shift, had Monitoring, Direct Observation and Records Review with the same 

initials. I asked if it was the same Quality 

Control or designee person that signed the HACCP Raw-Non Intact Log. She 

informed me later that the Direct Observation was performed by the same person 

that performed the monitoring of activities and Records Review. I explained 

that Quality Control or designee can not perform  Direct Observation 

on their own monitoring activities. I informed  

 about the noncompliance. 

5308 M6137 BXL1121102 

425N-1 

10/25/2013 03J02 Slaughter HACCP C At approximately 1500 hours while performing a HACCP Slaughter Records review 

task, I found a noncompliance with the following regulatory requirements of 

regulation 9CFR 417.2 (c)(4).The HACCP monitoring Log -CCP2B- Final Bird Washer, 

Plant #2 (Line  and ) AM shift had the following Zero Tolerance checks 

times: Line , 0333 hours and 0440 hours. Line , 0340 hours and  0447 

hours. The gap between the two checks on Line was one hour and seven minutes 

and on Line was one hour and seven minutes also.The HACCP Plan states in part 

under monitor procedures that " 

).I informed 

of the noncompliance. 

(b) (6)
(B)(6) (B)(6)

(B)(6)

(B)(6)

(B)(4) (b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5023105 

525N-1 

10/25/2013 01B01 Pre-Op SSOP 

Record Review 

C On 10/24/2013 at approximately 2200 hours while performing a records 

verification procedure required by the establishments' (NOIE) issued on October 7, 

2013, I observed the following. The establishments' Pre-Operational Sanitation - Bio 

Trace Sampling Log - Evisceration/Packaging for the week of  

10/19/2013 registered a failure of ss (stainless steel) tanks in Area #5 on 10/18 

with a reading of 1514 measured in Relative Light Units(RLU's). The unit was 

recleaned and a retest registered 43. The  'Corrective Action' section 

on the form has not been updated with the new requirements outlined under the 

Establishments' 'Notice of Deferral Verification Plan of October 13, 2013. Which 

states under the Sanitation Standard Operating Procedures (SSOP) and Sanitation 

Performance Standards (SPS) section, item 16, in part 

bsp; 

." The required 5 rechecks are 

not documented because was not aware of the new 

requirements.  I discussed the noncompliance with and 

made her aware of the new requirements.  My findings indicated a 

noncompliance with 9 CFR 416.12(a), 9 CFR 416.(a),(b) & (c), and 9 CFR 

416.16(a).    

5309 P6137A NJN020510 

4125N-1 

10/25/2013 04C05 Poultry Good 

Commercial 

Practices 

C At 0230 AM on October 25, 2013 during the night shift at Est. P 6137A, I observed 

the following non compliance:A carcass, which clearly showed signs of having died 

by means other than slaugther, was found coming down evisceration line B.  

The carcass was congested on one side, with large areas of ichemia on the 

breast.  The viscera was very congested, and the liver was very dark, 

congested, and friable.  I showed the carcass to 

and .Regulations not met include 9 CFR 

381.65(b) which states that poultry must be slaughtered in a manner which 

will result in thorough bleeding of the carcass, 9 CFR 381.71 which states that 

carcasses showing on antemortem any disease or condition that would cause 

condemnation on post-mortem inspection shall be condemned, 9 CFR 

381.83-Carcasses showing evidence of septicemia or toxemia, or evidence of an 

abnormal physiological condition shall be condemned.  This would include 

dying chickens as well as those dead on arrival. 

(b) (6)
(B)(6) (B)(6)

(B)(6) (B)(6)

(B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

4630 M7322 AOA321110 

3924N-1 

10/24/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 10/24/13 while performing Sanitation Standard Pre-operational Inspection. The 

following deficiencies were observed after the establishment’s Q. C. Technician had 

informed me that the establishment’s inspection was complete. 1. At 

approximately 0418 hours I observed a roll of blue plastic liners that were wet with 

an unidentified type of liquid, laying directly on top of a wooden pallet that had 

approximately 9 bags of uncovered evaporated salt stored on it. The blue liners 

have been observed in used to cover combos that contain edible product. The 

manner that the blue combo liners (product contact surfaces) were stored could 

have cause insanitary condition to the product. was notified. 

No reject tag was applied as I observed immediate corrective actions. The area was 

release at approximately 0425. 2. At approximately 0501 hours, before FSIS had 

completed the inspection of the peel room area to determine the sanitary 

conditions, I observed an employee attempting to enter the peel room area with a 

pallet that contained a roll of blue combo liners (product contact surface) and dry 

ingredients. The outer layer of the liner had a misty looking liquid covering the 

surface and the liners were observed lying directly on top of the bags of dry 

ingredients with undetermined sanitary conditions. The employee’s actions to enter 

the area with product before pre-op inspection was completed and the condition of 

the blue combo liners (product contact surfaces), did not meet the requirements 

outlined in, FSIS-PHIS Directive 5000.1 “Verifying an Establishment’s Food Safety 

System”, Chapter 2 part III “Sanitation Standard Operating Procedures (Sanitation 

SOPs). was notified. 3. At approximately 0520 hours I 

observed 2 batter pumps that had some thick whitest liquid looking material 

coming out of the bell areas while maintenance was attempting to prepare them for 

my inspection, while inspecting the pumps I observed some highly visible creamy 

whitish looking material build up inside the metal portion of the pump and around 

the inside rubber seal area. The whitish material appeared to be product batter left 

from the previous day’s production. Official control action was taken. 

was notified. U.S. retain tag #B22393369 was applied. Q.C. 

informed me that the area had been cleaned and was ready for re-inspection. While 

I was re-inspecting the pumps, I observed some whitish dry crusty looking 

substance around the entire edge of the inside seal of one of the pumps. 

was notified. The area was released at approximately 0558 when 

corrective measures were verified by FSIS. 4. At approximately 0534 hours while 

inspecting the frank product wash sinks located at the end of each fryer in the 

frying room, I observed some sticky, gluey material at the top right hand corner on 

3 sinks (at fryers #s 2, 3 & 7). The material was covering an area approximately 

6X4 square inches. The material appeared to be the clue or tape left as a result of 

removing the equipment label signs (Frank Wash Sink). The was 

notified. No reject tags were applied as I observed immediate corrective action by 

(b) (6)
(B)(7)(C)(B)(6)

(B)(6)

(B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (b)(4) (b)(4) (b)(4) (b)(4) (b)(4)

(b)(4)

(b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

the establishment. The area was released at approx. 0608 hours. -The deficiencies 

describe on this noncompliance record did not met all the requirement of 9CFR 

416.13(c), 416.1, 416.4(a) & 416.4(d).-This document serves as written 

notification that your failure to comply with regulatory requirement(s) could result 

in additional regulatory or administrative action(s). 

5112 M18909 JDD0402105 

225N-1 

10/24/2013 03C02 Raw Intact HACCP C On 10/23/2013 at approximately 0900Hrs, Dr. and I reviewed the 

10/18/2013 (Chicken Monitoring Log) during our records review. We 

found that the plant failed to document what was done to the product as part of 

the plant's corrective action when the level was 2300ppm which 

is above the recommended level of use. The plant's Quality Control Raw Fabrication

 Log for Chicken showed that on 10/18/2013 

at 1606Hrs, the Boneless Chicken Breast with Rib Meat concentrations were 

2300ppm. As part of the plant's corrective action for the maintenance was 

informed. The record did not show what happened to the product. The plant's 

HACCP Plan identified chemical contamination as "not likely to occur" because 

of an established Monitoring program (Attachment # 7) (FTP1

 Monitoring T1.1/090 Revision # 2 page 2 of 2 date 12/16/11). 

The procedure states, 

" The 2300ppm is above the recommended use by the supplier. 

The Plant Chicken Monitoring Record did not document the 

corrective action done to the product when the level was at 2300ppm.  

This failure to document the corrective action done to the Chicken Breast food 

products is a recordkeeping violation to 9 CFR 417.3(c) which states, "All corrective 

actions taken in accordance with this section shall be documented in records that 

are subject to verification in accordance with 417.4(a)(2)(iii) and the recordkeeping 

requirements of 417.5(a)(3) of this part" and 5000.1. and 

were notified of the noncompliance. 

(b) (6)
(B)(7)(C) (B)(6) (B)(6) (B)(4)

(B)(4)

(B)(4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD1301100 

125N-1 

10/24/2013 01C02 Operational SSOP 

Review and 

Observation 

O On 10/24/2013 at approximately 0841Hrs, Dr. observed a plant Boning 

Room personnel using a inedible red labeled stainless steel hook/rod (hand 

tool) to scoop together 16 pieces of drumsticks that fell on the floor 

underneath the drumstick conveyor belt prior to the feeding of drumstick to be 

deboned in the drumstick .  The floor is a non food 

contact surface and the plant employee tried to scoop the product towards her by 

using a red labeled hook which is used for inedible product only according to Plant 

Good Commercial Practice.  By scooping the products towards her, she 

further contaminated the product by allowing drumsticks to brush against the 

floor, a nonfood contact surface.  She placed the drumsticks in a white 

edible barrel for reconditioning.  U.S. Retain Tag NO:B39554834 was applied 

to the edible barrel containing the affected 16 drumsticks. 

was immediately notified of the noncompliance and showed the drumsticks in the 

edible barrel and inedible hook used on the product. Mr. 

chose to plant condemn the affected drumsticks. This observed incident of an 

employee using a inedible hand tool to scoop up dropped edible 

product which she put into an edible barrel for reconditioning is a 

violation to the relevant regulation cited above. This is also in violation to the 

establishment's in place Operational Sanitation 11-A.) # 2.) " 

" B.) " 

was not met. Also the establishment's in place GMP (good 

manufacturing practices) "Production tools: Stainless rod/hook with red 

tape - inedible use or inedible product." was not implemented. 

(b) (6)
(B)(6) (B)(6) (B)(6)

(B)(6) (B)(4)

(b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0405101 

824N-1 

10/24/2013 01D01 SPS Verification C On 10/23/2013 at approximately 2225 hours while monitoring Pre-Operational 

Sanitation  in Plant #1, I observed the following. There were metal splinters 

on a guide bar associated with the bird drop assembly at the point 

where  carcasses enter chiller #2. The splinters measured 

approximately 4mm to 10mm in size. The guide bar is worn  with the 

edges raised and  flattened. The splinters were flaking off from the flattened 

edges.  The loose splinters were removed. will have 

maintenance remove the flattened edges after production. At this point in the 

process carcasses are being removed from the evisceration line and dropped into 

the chiller. With the affected guide bar directly above the carcasses the metal 

splinters will end up in the carcasses or in the 

chiller.     At approximately 0025 hours in Packaging Area 

#2  there was a small flake measuring less than 1/4"that appeared to 

be red paint on an overhead product belt  near the entrance to 

the room. The fire fighting piping throughout the room has deteriorated 

with rust and loose peeling flaking red paint throughout. I 

informed of the noncompliance. A work order will be 

submitted. My findings indicated a noncompliance with 9 CFR 416.1 and 9 CFR 

416.2(b)(2). 

5308 M6137 BXL0813105 

024N-1 

10/24/2013 03J02 Slaughter HACCP C On 10/23/2013 at approximately 1008 hours while conducting a Post-Chill Finished 

Products Standards procedure on product exiting Chiller #4 in Plant #2, I observed 

the following. After collecting a standard 10 bird sample, I observed one carcass 

with a shiny piece of metal  approximately 3mm in size attached to the 

connective tissue by the neck area. I informed and 

of the noncompliance. According to PDD, FSIS considers metal of any size 

on a carcass to be an unacceptable contaminant that should be addressed by the 

establishments' Hazard Analysis. The Establishments' HACCP Plan - Slaughter Plant 

#2 under (P) Physical Hazards states 

. The product was on a chiller 

exit conveyor belt just prior to hanging for final microbial intervention and 

packaging. The issue of metal contamination has been discussed at previous 

morning meetings with the establishment.One tank of whole birds was retained by 

Quality Control. The birds were reworked and released by Quality Control.My 

findings indicate a noncompliance with regulatory requirements of regulations 9CFR 

416.4(d), 9CFR 417.3(b)(1), 9CFR 417.3(b)(2), 9CFR 417.3(b)(3), and 9CFR 

417.3(b)(4). 

(b) (6)
(B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH210310 

4123N-1 

10/23/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On the night of production which began on10/22/2013, Inspection 

performed  PHIS procedure  SSOP Review and Observation in the 

2nd Processing Department of 33900 P. This was after Sanitation had 

finished cleaning the equipment and QA had finished their Pre-operational 

inspection of the equipment and released the area to production There are no 

additional Sanitation or Pre-operational steps prior to the start of production. The 

following noncompliance was observed: At 2318 hours while waiting for the birds 

to exit the chiller for a Post chill testing of line 1, I noticed grease residue on the 

shackles .I proceeded on to the hang line where I found the shackles (Product 

contact surface) in an unsanitary condition with grease residue ,and debri particles 

.Inspection took Regulatory Control Action by applying US Reject Tag #B38075587 

to the hangline until it was recleaned and reinspected, and was released at 2338 

Hours. was shown the noncompliance. To date, all 

Preventive Measures may not have been implemented as described or were 

ineffective in preventing recurrence. 

(b) (6)
(B)(6) (B)(6)

(B)(6)

(B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH442310 

5223N-1 

10/23/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On the night of production which began on 10/23/2013, Inspection performed 

scheduled PHIS procedure Pre-op SSOP Review and Observation in the Evisceration 

Department of 33900 P. This was after Sanitation had finished cleaning the 

equipment and QA had finished their Pre-operational inspection of the equipment 

and released the area for USDA inspection. There are no additional Sanitation or 

Pre-operational steps prior to the start of production. The following noncompliance 

was observed: At 2037 hours while checking Line #1 Paw Unloader (Unit #1/Zone 

#2), Inspection found the Picker Fingers (Product contact surface) in an unsanitary 

condition with a greasy black residue which would easily rub off onto the hand. 

Inspection took Regulatory Control Action by applying US Reject Tag #B29699073 

to the Unit until it could be recleaned and reinspected, and was released at 2104 

Hours. The Requirements of 9CFR 416.13(c) were not being met and 

was shown the noncompliance and advised that a Noncompliance 

Record would be issued. This item of Equipment was randomly selected for 

Inspection as required. For a similar noncompliance refer to NR 

#NHH4900083727N/1 dated 08/26/2013. To date, all Preventive Measures may 

not have been implemented as described or were ineffective in preventing 

recurrence. 

4630 M7322 AOA580710 

3722N-1 

10/22/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 10/22/13, while performing Pre-Operational Sanitation Standard Operational 

Procedures Inspection, after the Establishment’s Quality Control Technician 

informed me that her inspection was complete and the areas were ready for 

processing, the following deficiencies were observed: 1. At 0539 hours I observed 

what appeared to be bread crumbs (to numerous to count) on the product contact 

surface of the retail line incline conveyor belt that is located immediately after the 

retail line wide pack out belt. Official control action was taken. 

was notified. US reject tag #B23922689 was applied. I released the area at 

approximately 0556 hours when correct measures were verified. 2. At 0552 hours I 

observe the freezer product decline belt and stainless steel slide pan at the retail 

processing line area had what appeared to be very visible dry and wet bread crumbs 

to numerous to count (over 20) on the open left area of slide pan and randomly 

scattered throughout the product conveyor belt. There were what appeared to be 

loose bread crumbs, product grease and scum build up on bottom product 

conveyor guide rails and turn wheels. Official control action was taken. 

and was notified. US retain tag #B8541730 was 

applied. The area was released at approximately 0615 hours when corrective 

measures were verified. -The listed deficiencies did not meet the 

requirements of 9 CFR 416.13(c) & 9 CFR 416.4(a).-This document serves as 

written notification that your failure to comply with regulatory requirement(s) 

could result in additional regulatory or administrative action(s). 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6) (B)(6)

(B)(6)

(B)(4) (B)(4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD0711105 

822N-1 

10/22/2013 03J02 Slaughter HACCP C On 10/22/2013 at approximately 1325Hrs, I observed the collection 

barrels of Turkey Fries at both lines. The plant's attachted tags 

showed the time of collection was 1100Hrs (2300). U.S. Retain Tag 

NO's:B39554883 & 84 were applied to the barrels of fries with temperatures 

95.7F & 92.6F. The establishment's CCP 2B requirement for 

fries had exceeded the time and temperature of 40F within 2 hours of 

harvesting. The turkey fries did not have any ice or CO2. When I presented 

this to management, informed me that they did not start collection 

until 1130Hrs. This observed incident is a record keeping violation to 9 CFR 

417.5(a)(3) since the plants recorded time on the barrels and what Mr. 

said that the collection started time is not the same. Mr. chose to 

plant condemn the 92 pounds of turkey fries. Mr. was notified of the 

noncompliance. 

5112 M18909 JDD1711103 

122N-1 

10/22/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 10/22/2013 at approximately 1020Hrs while performing pre-operational 

sanitation of the plant's Evisceration, Boning Room, Raw Fabrication and Cooler 9 

Departments, after the Q.C. and before start up of production, I observed the 

following noncompliance. and 

were notified of the noncompliance and shown all incidents. I observed 

all corrective actions to food contact surfaces and non food contact surfaces except 

the solution screen. No retain tags were applied.1.) Evisceration-SK5 Kill machine 

had dried blood on knife and feathers on (non food contact)-overhead shackles. b.) 

Quill Puller-had meat and feathers. c.) NE Main Scalder had feathers in the scald 

water and on the (non food contact) shackles (too many to count on both). d.) 

Picker # 4 had fat residues and feathers. e.) Hock Cutter had meat residues, 

fat and feathers. f.) Osteo room had meat, blood on the racks and feathers 

on the (non food contact) floor. g.) Chiller A (1st part) screens full of meat and 

fat.  2.) Boning Room-Thigh Deboner ) had meat and fat. b.) Drum 

Deboner had meat, fat and black UFM.  3.)  Raw Fabrication 

Grinding- (injector) had meat. b.) Injection solution tank-The small screen 

had meat and was torn. The torn screen was taken to maintance for repair. 4.) 

Cooler 9 (Raw Fabrication further processing)- The patty machine (form plate) had 

meat. The observed incidents of food contact surface found with meat, blood, fat, 

meat residues, black UFM and feathers from previous days operations is in 

violation to 9 CFR 416.4(d); 416.13(c) and 416.4(a). The small screen is in violation 

to 9 CFR 416.3(a). The non food contact surfaces not cleaned is in violation to 9 CFR 

416.4(b). This noncompliance JDD1711103122N/1 is being linked to noncompliance 

(#135) JDD1507102418N/1 dated 10/18/2013 for the same cause respectively. 

(b) (6)
(B)(6)

(B)(6)

(B)(6) (B)(6) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3118101 

022N-1 

10/22/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C While performing a Zero Tolerance Fecal Task, I observed noncompliance with the 

following regulatory requirements of regulations 9CFR 381.65 (e) and 9CFR 417.2 

(c)(4).At approximately 1447 hours, I randomly removed a 10 bird sample from Line 

#2 in Plant #1, I found one out the ten birds with visible fecal contamination outside 

of the bird on the skin of the neck. The fecal material 

was approximately 1/4"  diameter in size, green in color and 

pasty in texture. This exceed the limit of for the process to be in 

control. I informed and 

 of the noncompliance. The protocol for fecal failure was implemented. 

Quality Control performed a recheck at approximately 1510 hours and it 

passed.This is a violation of the critical limits of CCP-2B of 

the Plant's HACCP Plan for Slaughter. 

5308 M6137 BXL3614103 

721N-1 

10/21/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 10/21/2013 at approximately 0909 hours, I observed birds coming out of Chiller 

#3 in Plant #2. I noticed that there were no production or Quality 

Control Supervisors monitoring the birds as they exited the chiller.The 

establishments SSOP Correcting Action Logs under 'What actions were taken or are 

being taken to prevent recurrence...' has consistently stated "Product will continue 

to be monitored by Supervision prior to being put into production". I started 

inspecting the birds coming out of Chiller #3 and I observed several birds with 

black/brown UFM on them. The employees that hang the birds coming out 

of Chiller #3, started arriving at the re-hang belt and I informed them not to hang 

the birds as I went to inform a Supervisor. I saw  

come over to the re-hang area and I showed him one of the birds with black UFM 

on it. He started tanking the birds and I tagged the tank with U.S. Rejected/U.S. 

Retained tag # B31408109. Quality Control applied their Red Hold tag on the tank 

and I removed my tag. I informed of the 

noncompliance.Quality Control retained ten tanks of whole birds, four pallets of 

front breast halves and 26 lbs. of drums, thighs, and leg quarters. The whole birds 

were reconditioned, the breasts were reworked, and the drums, thighs, and 

leg quarters were condemned. My findings indicate a noncompliance with 

regulatory requirements of regulations 9CFR 416.14, 9CFR 416.12(a), 9CFR 

416.15(b) and 9CFR 416.4(d). 

(b) (6)
(B)(6)

(B)(6) (B)(6)

(b)(4)

(b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN131410 

2921N-1 

10/21/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 1140 hours, while performing PHIS Zero-tolerance task, in the 

Evisceration Department on the reprocessing off-line, prior to the birds entering the 

chiller, I observed one carcass in the ten (10) carcasses random sample 

contaminated with visible fecal material approximately one inch by half inch in 

diameter, brown in color, paste-like consistency, and located on the top of the hock 

joint, also there was another two pieces of fecal material on the leg approximately 

half inch by half inch in diameter, greenish in color pasty in consistency. I took 

regulatory control action by stopping the reprocessing line and applied US retain 

tag # B43303652 on the affected carcass. The findings were shown to 

, and . At approximately 1110 

hours, the reprocessing line and the affected carcasses were released to the 

establishment allowing QC representative to perform the plant corrective actions. 

Mr. was informed of the forthcoming NR. The findings of fecal material on a 

carcass passed the final wash cabinet en route to the chilling system represents a 

zero tolerance failure as outlined in the establishment’s HACCP and in accordance 

with the regulations 9 CFR 381.65(e) which states: "poultry carcasses contaminated 

with visible fecal material shall be prevented from entering the chilling tank". 9 CFR 

417.2(c) (4) states: "List the procedures, and the frequency with which those 

procedures will be performed, that will be used to monitor each of the critical 

control points to ensure compliance with the critical limits".  The 

establishment's written HACCP Plan dated 4/18/2013 states

 A similar NR was documented on 

09/30/2013 # NJN2416091630N/1, no plant response.  PHIS slaughter 

HACCP task performed to verify that all corrective and preventive measures were 

completed. The plant determined that the cause of the deviation was a sprayer 

found in wrong position not spraying the top part of the hock. The chiller overflow 

was turned up to 1⁄4 gallon of water per bird, and the chiller was marked to identify 

the end of the effected lot. Post chill checks were performed until 

the murk came out at 1317 hours. All post chill checks were found acceptable. 

(b) (6)
(B)(6)

(B)(6) (B)(7) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN300710 

5421N-1 

10/21/2013 01D01 SPS Verification C At approximately 0249, while I was passing through the evisceration department 

employee break room, I observed the following non compliances: the 

floor had stagnant water, used paper towels and debris everywhere. I 

proceeded to live hang rest room I observed the floor filled with used paper towels 

and filthy tissues. Also the rest room had no running hot water. Mr 

, was informed and he took corrective 

actions to restore sanitary condition and also notified of the forthcoming 

non-compliance record.The Requirements of 9 CFR 416.1, 9 CFR 416.2(b) (2), 9 CFR 

416.2(h) (1) and 9 CFR 416.2(h) (2) were not met. This document serves as written 

notification that your failure to comply with regulatory requirement(s) could result 

in additional regulatory or administrative action(s) as described in 9 CFR 500.4. 

5309 P6137A NJN560110 

2321N-1 

10/21/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C At approximately 2252 hours, and after sanitation and QC performed 

preoperational sanitation and released the New Products Room for operations. I 

performed PHIS task, preoperational sanitation, in the area 5, Section C: IQF # 2 I 

observed the following noncompliance: In unit # 16 ( product incline conveyor), I 

observed numerous pieces of fat and muscle from previous shift of production 

ranges from 1/8 inch to 1⁄2 inch in diameter. The product incline conveyor is direct 

product contact surface.  I immediately applied U.S. Rejected tag NO. 

B43303520 notified and showed Mr. , of my 

findings and the forthcoming NR. The unit was re-washed, sanitized, re-inspected 

found acceptable and released at 2300 hours.   At approximately 2356 

hours. CSI was performing pre-operation inspection in the food 

service area, when he observed a piece of fat, approximately four inches by one inch 

inside of a blue drip pan hose that is located adjacent to unit # 21 (multicut # 1) 

according to the pre-op schematics.  Mr. was present during this 

inspection.  The hose was rewashed and found acceptable.  The area 

was released at 0003 hrs.   The requirements of 9 CFR 416.1, 9 CFR 416.4(a) 

and 9 CFR 416.4(b) were not met.   This document serves as written 

notification that your failure to comply with regulatory requirement(s) could result 

in additional regulatory or administrative action as described in 9 CFR 500.4. 

      

(b) (6)
(B)(6) (B)(6) (b)(4) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH511310 

2621N-1 

10/21/2013 01C02 Operational SSOP 

Review and 

Observation 

C #160At approximately 1001 as I entered room one second processing I observed 

cross contamination of product at the first tray pack line. There were at least four 

employees were handling trays of product that had already gone through the 

wrapping and sealing machine and restyling the trayed product simultaneously and 

placing them back on the conveyor. Inside the there is a stained cloth 

textured belt that does not appear to be properly cleaned or sanitized daily. The 

wire conveyor inside the also accumulates a rust like buildup during 

operations. The blue belt at the end of the line also has a brownish buildup inside 

the links. These surfaces cannot be considered as product contact surfaces; 

therefore, once the bottom of the trays and wrappers contact these surfaces they 

should be handled in a manner that prevents cross contamination of the product. 

These requirements were not met. Us tag #B36322947 was applied to the 

operation and the affected product. and were 

shown the condition of the belts. As a preventive measure, Management stated 

that when reworking trayed, the employee handling and opening the trays will not 

handle product prior to washing/sanitizing their hands. The affected product (~35 

trays) was taken to the product wash station.  The area was released after 

sanitary conditions were restored. 

(b) (6)
(B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (b)(4) (b)(4) (b)(4) (b)(4) (b)(4)

(b)(4)

(b)(4) (b)(4) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0309103 

919N-1 

10/19/2013 03J02 Slaughter HACCP C On 10/18/2013 at approximately 2250 hours while monitoring the 

Establishments' computer records for CP-5 pH and 

Monitoring, I observed the following. An 

 establishment employee at 0219 hours on 10/15/2013 

recorded that the 'Red Water' in Chiller #4 was at 8.3 ppm (parts per 

million). At 0651 hours also on 10/15/2013 the recorded value of the 'Red 

Water  was ppm in Chiller #3. At 23:01 hours on 

10/16/2013 for Chiller #3 the recorded value was ppm. On 10/17/2013 

at 0.09 hours the Red Water in Chiller #3 was records as being at ppm. 

At 0229 hours on 10/17/2013 the red water was ppm in Chiller 

#4. At 0608 hours on 10/17/2013 the red water   in chiller #3 was 

recorded as being ppm. At 2252 hours on  10/17/2013 the red water

 was recorded as being at 16.3 ppm for chiller #3. At 2346 

hours on 10/17/2013 the red water from chiller #3 was recoded as being at 11.8 

ppm. A review of the establishments' HACCP Plan - Slaughter 

plant 2, Step 24 Carcass Chiller under Hazards lists (C) Chemical then 

Is the hazard significant. NO.  Under 'Justification for Decision' it states 

ree concentration 

for the recirculated water and the chiller water is monitored as part of a plant 

program. Supplement 7 CP-5 pH,and monitoring under 

' Monitoring' states that for carcass chiller red water and 

that is the operating limit. Under 

'Corrective Action' it states "Notify maintenance/production. Perform a recheck 

once notified by maintenance that adjustments has been made."  Item 7 on 

the Establishments Action Plan resulting from an NOIE dated October 13,2013 is for

 and nbsp;lists 'Carcass Chiller Red Water and states "The 

operating limits are < ppm free and ph . Even after being 

informed of the noncompliance as of 10/24/2013 the establishment continues to 

fail on a nightly basis.  My findings indicated a noncompliance with 9 CFR 

417.5(a)(1).  

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(4) (b)(4) (b)(4)

(b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD1507102 

418N-1 

10/18/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 10/18/13 at approximately 0423 hours while performing Pre-Operational 

sanitation after the establishments Pre-Operations checks and before the start of 

production in the Raw Fab # 9 cooler room I observed the following 

non-compliances. In the Raw Fab # 9 cooler room.  I observed fat and 

muscle residue on the walls of entrance to the room from the previous days 

production, this is a non-compliance to 416.2(b)(2). Fat and muscle tissue and 

residue was observed on the exterior non product contact surfaces and interior 

product contact surfaces of the and machines from the previous 

days production, This is a non-compliance to 416.13(a) , 416.4(a) and 416.4(b). I 

immediately took regulatory control by applying U.S. Reject tag # B31390666 to the 

machines and room and informing and

 of my findings. Mr. and Mr. 

took immediate corrective action in my presence cleaning and sanitizing the room 

and machines to restore sanitary conditions. 

5308 M6137 BXL0315104 

718N-1 

10/18/2013 03J02 Slaughter HACCP C On 10/18/2013 at approximately 0907 hours while performing Finished Product 

Standards task, I reviewed the HACCP Monitoring Log - CCP 2B-

(Plant #2) on PM shift, Line and I found that one check was 

missing. I asked  about the missing 

check because I saw the Quality Control performing a check.  She 

informed me later that the Zero Tolerance check was performed at 0847 hours by 

Quality Control but not annotated in the HACCP Log at the time 

performed. This is a noncompliance with the following regulatory 

requirements of regulation 9CFR 417.5 (b).  

5308 M6137 BXL1205103 

018N-1 

10/18/2013 01C01 Operational SSOP 

Record Review 

C On 10/16/2013 at approximately 2310 hours while verifying corrective action by 

the Establishment in response to the Notice of Intended Enforcement action dated 

October 7, 2013, I observed the following. The Establishments Action Plan Item 

16  refers to an  ATP Bio-trace procedure that was to be addressed in 

the Establishments' SSOP beginning October 14, 2013.  The record review 

revealed no entry in the Establishments SSOP that addresses the ATP-Bio-trace 

procedure. My findings indicated a noncompliance with 9 CFR 416.12(a). 

(b) (6)
(B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN451610 

2218N-1 

10/18/2013 01D01 SPS Verification C While in the packaging area, at approximately 10 28 hours, I noticed an employee 

heading towards the door of the cooler, which is located beside the spice room. He 

was wearing a freezer suit and stacker gloves and dragging a red trash receptacle. 

The trash receptacle was empty but, heavily soiled with filth. I immediately stopped 

him from entering the cooler with the soiled trash receptacle.  Without a 

response, he head towards the hose in the packaging area, picked up the hose, and 

started to wash it down.  Again, I stopped him and informed him that he is 

not to wash nor enter into the production area at all with any filthy 

contaminants.  He then left the trash receptacle and headed to enter the 

cooler.  I, once more, stopped him and told him that again his gloves were 

now contaminated from the trash can and he cannot enter nor touch anything in 

the production area, so he took them off and throw them down into the filthy trash 

can that he had left in front of me. I tagged the trash receptacle with the 

USDA reject tag # B43303655 and, since there were no supervisors at the time, I 

had one of the lead persons call a supervisor over. Mr. 

came to me in the packaging area and I inform him of the events and the 

forthcoming noncompliance. The plant failed to comply with the regulations sited. 

9 CFR 416.2(h)(3) states: “Refuse receptacles must be constructed and maintained 

in a manner that protects against the creation of insanitary conditions and the 

adulteration of product.” 9 CFR 416.4(b) states: “Non-food-contact surfaces of 

facilities, equipment, and utensils used in the operation of the establishment must 

be cleaned and sanitized as frequently as necessary to prevent the creation of 

insanitary conditions and the adulteration of product.” 9 CFR 416.5 states:”All 

persons working in contact with product, food-contact surfaces, and 

product-packaging materials must adhere to hygienic practices while on duty to 

prevent adulteration of product and the creation of insanitary conditions.” 

(b) (6)
(B)(6)

(B)(6)

(B)(7)(C) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

6036 P6164A OIJ2416101 

418N-1 

10/18/2013 04A06 Poultry Finished 

Product Standards 

C On October 18, 2013 I, CSI performed a scheduled Finished 

Product Standard test at the Prechill area.  This test is applied to permit FSIS 

to estimate when the production process is in control for ready-to-cook 

poultry.  The test consists of two parts, trim and processing 

nonconformances.  The absolute limit allowed for processing 

nonconformances is points. My test at 1233 resulted in 47 points.   

At 1245 a retest was performed by using a tighten criteria 

of 25 points which failed with 31 points.  I verbally notified 

of the noncompliance and that I would be issuing a NR.  The 

plant implemented the required procedures for FPs failure.  The Prechill 

nonconformances I observed at 0706 were:  3 ingesta < 1/16” (3 pts), 

 5 partial oil glands (5 pts),  2 whole oil glands (4 pts), 2 partial lungs 

(2 pts), 4 whole lungs (8 pts),  1 cloaca (5 pts), 1 bursa (2 pts), 4 small 

feathers (4 pts), 8 large feathers (8 pts), and 3 long hocks (6 pts). On October 16, 

2013, NR # OIJ151610191N (#79) was issued for processing noncompliance.  

The written response given is that Maintenance made adjustments to bring the 

process under control.  This noncompliance is linked to NR # OIJ151610191N 

(#79) for the same root cause.  The Establishment Awareness Meeting notes 

show that FPS NRs were last discussed at the October 17, 2013 meeting. 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(7)(C) (B)(7)(C) (B)(6) (B)(6) (B)(6) (B)(6) (b)(4) (b)(4) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD5821101 

818N-1 

10/17/2013 03J02 Slaughter HACCP O On 10/17/2013 at approximately 1100Hrs during my (Finish Product 

Standard) random 10 necks per sample check, I observed one turkey neck 

with visible fecal material out of the ten. The fecal material was found on two sites 

close to the base of the neck. The thick and mucoid fecal materials were medium to 

dark olive green with a brownish tinge which is consistent with fecal material. 

 Both of the fecal materials were approximately 2" x 1/4" x 2mm thick. U.S. 

Retain Tag NO:B39554626 was applied to the tank which had the affected neck. I 

requested the sanitation personnel, who was at the turkey pickers, to notify

 to come to the neck removal and chilling area. Ms. was 

shown the fecal material on the neck. I notified , and Dr.

 SPHV of the noncompliance and showed them the fecal material 

which was still attached to the turkey neck. Dr. concurred that it was fecal 

material. Ms. said it appears to be bile. She kept the neck. Ms. had 

all of the necks in the tank (one by one) reconditioned with

 water spraying ppm/trimming and reinspected. The necks 

approximately 1800 pounds were released back to production flow at 

approximately 1555Hrs after verifying the plant's implemented corrective action 

and reinspection by Ms. . The establishment does not monitor the 

necks for fecal  at the neck collection/ ice chilling tanks. The 

plant's HACCP Plan does not identify feces as a hazard in the neck 

collection/chilling. I asked , and he said to 

use the CCP 3B ).  The necks collected from 

reprocessed birds are monitored for feces at the establishment's (CCP 3B) check 

and when found free of feces are added to the neck chilling tank. This observed 

incident of visible fecal material not removed is a noncompliance to the 

establishment's CCP 3B s) critical limit 

per 9 CFR 381.65(e) and 417.2(c)(4) monitoring at the critical control point prior to 

entering into the chilling tank. This noncompliance JDD5821101818N/1 is 

being linked to noncompliance (#112) JDD1623092204N/1 dated 9/4/2013 for the 

same cause respectively. 

(b) (6)
(B)(6)

(B)(6)

(B)(6) (B)(6) (b)(4) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1205100 

417N-1 

10/17/2013 04A06 Poultry Finished 

Product Standards 

C On 10/16/2013 at approximately 0334 hours while monitoring Post-Chill Finished 

Product Standards from product exiting the Chillers in Plant #2, I observed 

the following. The last of the carcasses were coming out of Chiller #3. The Post-Chill 

Finished Product Standards log for the shift had an establishment entry for product 

exiting Chiller #3 at 0032 hours. No further checks were made by the 

establishment for the shift for chiller #3. Periods between checks at the post-chill 

are not to exceed . I contacted and informed him of the 

noncompliance.  I checked with live hang and they finished hanging 'Organic 

'  at  0152 hours. My findings indicated a noncompliance with 9 CFR 

381.76(e)(1)(i).    

5308 M6137 BXL4620105 

417N-1 

10/17/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 10/17/2013 at approximately 1735 hours, while walking pass the Re-hang area 

in Plant #1, I observed the following noncompliance. There was a tank of whole 

birds, approximately 1/4 full next to the chick weight line #1 . Directly above the 

tank was a drip pan that was dripping water into the tank of birds. I tagged the tank 

with U.S. Rejected/U.S. Retained tag #B31408104 and I informed 

and he called who I informed of the noncompliance. 

The birds were washed at approximately 1800 hours, I removed the tag 

and the tank was washed, restoring sanitary conditions.  My 

findings indicate a noncompliance with regulatory requirements of regulations 9CFR 

416.1 and 9CFR 416.4(d). 

5310 M6137B FFA5601105 

717N-1 

10/17/2013 04B04 General Labeling C On October 16, 2013 at approximately 2200 hours, while performing Operational 

Sanitation in Cooler #2,  I observed  five white edible 

barrels full of franks with no identification or labels. I immediately tagged the 

product with U.S. Retain Tag NO. B34377191, B31408670, B31408539, B31408537, 

B31408662.Ms. and Ms. was informed and 

showed the noncompliance.  Immediate Corrective Action was implemented 

by Management:  All five barrels of franks was condemn in my 

presence.  After product was condemn and denatured U.S. Retain Tags were 

removed.This does not comply with CFR 9 381.116 which states in part:  

"Wording on labels of immediate containers".  This noncompliance is linked 

to NR# FFA5218091320N/1 dated 09/20/13, for a similar noncompliance.  

As of today 10/16/13, Management has not given a written response to this 

NR.This NR serves as written notification of a labeling noncompliance .  

Continue failure to comply with regulatory requirement(s) could result in additional 

regulatory or administrative actions. 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(6)

(B)(4)

(b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH081310 

4417N-1 

10/17/2013 01C02 Operational SSOP 

Review and 

Observation 

C On Thursday, October 17, 2013 while leaving the Evisceration Department at 

approximately 1110 hours I observed the following noncompliance.  At the 

Reprocessing Area in evisceration there were totes and lids staged to be used for 

parts on a dollie.  There was two stacks that had ten each in them.  

The top two totes were found to be in an insanitary condition.  There was 

black specks inside the totes.  I removed the top two totes and checked three 

more totes they had black specks in them too.  One of the totes had some 

dried fat inside of it.  The totes (20) were rejected with US Reject Tag # B 29 

699853.  Mr. , was notified and 

informed the noncompliance would be documented on a noncompliance 

report.  Mr. had the totes taken back to the tub wash room to be 

rewashed.  As a preventive measure, Mr. , said "the employee that is 

responsible for getting the totes for reprocessing would check each tote before they 

bring it to the Reprocessing Area".The requirements of 9 CFR 416.13(c) were no 

met.The establishments SSOP plan states 

"There 

has not been a similar noncompliance written in the last thirty days. 

1325 

7 

P33900 NHH181210 

5817N-1 

10/17/2013 03J02 Slaughter HACCP C On Thursday, October 17, 2013, at approximately 1101 hours, while performing 

Poultry Finished Product Standards (Prechill) on Evisceration Line #1, I observed 

fecal contamination on the outside of the tenth carcass randomly selected for the 

ten bird sample.  The fecal material was located on the back of the carcass 

underneath the oil gland.  There was two pieces of fecal, both approximately 

1/8 inch in size and light brown in color.  It had a watery texture to the 

touch.  There were no plant employees between me and the chilling tanks 

when I performed this check.  Therefore, it is reasonable to assume that the 

feces would have entered the chilling tanks in violation of Regulation 9 CFR 

381.65(e).  Ms. , was notified of the 

deviation for the Critical Control Point CCP-1, at CCP-1, and she was 

shown the carcass.  She immediately implemented the 

establishment's corrective action for visible feces at CCP-1.At 1115 hours, 

Mr. , notified me that the cause of the 

noncompliance was equipment malfunction.  Mr. stated, "that the 

Bird Brush was turning in the wrong direction".  Maintenance corrected the 

direction of the motor.  The preventive measure that was given was that 

production will perform two checks on the Bird Brush two times for the rest of the 

shift.A similar noncompliance was documented on NR NHH4602090526N/1 dated 

09/26/2013.  The further planned action may not have been implemented or 

was ineffective in preventing the reoccurrence of this similar noncompliance. 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(7)(C) (B)(7)(C) (B)(7)(C) (B)(6) (B)(6) (b)(4) (b)(4) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD0123100 

616N-1 

10/16/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 10/16/2013 at approximately 1140Hrs, I observed UFM (unidentified foreign 

material) on the Chiller B exit food contact belt. The UFM was very black in color; 

thick/smear grease type when touched/rubbed. The thick UFM was smeared 

approximately 1" x 10" in size on the food contact belt. The UFM appeared to be a 

drip/chunk and then smeared. The food contact chiller belt was full of whole body 

heavy tom turkeys at this time. I saw . near the Bagging Area. I 

notified her of the UFM on the belt. She called . U.S. Retain 

Tag NO:B39554696 was applied to the affected food contact belt. I showed the 

UFM to Mr. and Ms. . Mr. stopped the belt and removed 

the UFM from the belt using sanitized towels. The belt was released for operations 

at approximately 1142Hrs after verifying the restored sanitary conditions. U.S. 

Retain Tag No's: B39554115 & B39554424 were applied to one and 3/4 

tanks of whole body turkeys which were on the affected conveyor belt. At 

approximately 1230Hrs the (2800 pounds) of heavy tom turkeys were released 

back to production flow after verifying the plant's implemented reconditioning by 

ppm water spraying/trimming and reinspection. One 

Turkey was found with UFM. Mr. was notified of the noncompliance. This 

observed incident of UFM on a food contact surface during food production 

operations is in violation to 9 CFR 416.4(a); 416.4(d) and monitoring of the plant's 

operational sanitation 9 CFR 416.13(c). This noncompliance JDD0123100616N/1 is 

being linked to noncompliance (#130) JDD2422102710N/1 dated 10/10/2013; 

(#119) JDD1922091518N/1 dated 9/17/2013 for the same cause respectively. 

5112 M18909 JDD3123104 

616N-1 

10/16/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 10/16/2013 at approximately 1304Hrs, I was notified by , line one 

inspector, that she had just observed a live fly land on 3 turkeys in front of 

her.  The live fly landed on one turkey's tail. The fly flew to another turkey 

and landed on the turkey's tail. The fly flew to another turkey and landed on 

its leg. Ms. stopped the line and had her trimmer removed the three 

affected turkeys from the line for reconditioning. Ms. was able to terminate 

the fly when it landed on the turkey's leg. The Evisceration line was full of whole 

body turkey's at this time. This observed incident of a live fly landing on food 

products during food products operation is in violation to 9 CFR 416.2(a); 416.4(d) 

and the establishment's monitoring of their operational sanitation 9 CFR 416.13(c). 

The establishment does have in place a outside pest management service. The three 

affected turkey's were reconditioned by water spraying ppm and 

reinspection off line. The turkey's were returned to production flow. This 

noncompliance JDD3123104616N/1 is being linked to noncompliance (#116) 

JDD4809095216N/1 dated 9/16/2013.  and

 were notified of the noncompliance. 

(b) (6)
(B)(6) (B)(7)(C) (B)(6)(b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1117104 

116N-1 

10/16/2013 01C01 Operational SSOP 

Record Review 

C On 10/16/2013 at approximately 1100 hours while performing Operational 

Sanitation Records Review Task, I found a noncompliance with the following 

regulatory requirements of regulation 9CFR 416.13 (b) and 9CFR 416.13 

(c).The SSOP Daily Implementation and Monitoring Log  dated on 

10/15/2013 AM shift for WP Rewrap Room, under Operational SSOP 

monitoring had only two checks, one at 0212 hours and the 

other at 0606 hours.Operational Sanitation procedures states in part under 

monitoring frequency of action (minimum four times per shift) by QA inspector or 

designee. Observations are recorded on the SSOP daily implementation and 

monitoring log for operations.I informed 

of the noncompliance. 

6036 P6164A OIJ1516101 

916N-1 

10/16/2013 04A06 Poultry Finished 

Product Standards 

C On October 16, 2013 I, CSI performed a scheduled Finished 

Product Standard test at the Prechill area.  This test is applied to permit FSIS 

to estimate when the production process is in control for ready-to-cook 

poultry.  The test consists of two parts, trim and processing 

nonconformances.  The absolute limit allowed for processing 

nonconformances is points. My test at 1330 resulted in 34 points.  Plant 

records showed a failure within the last 5 tests and a CuSum above the start 

number of 11. Specifically the test at 0936 resulted in a CuSum of .  The 

plant implemented the required procedures for FPS failure.  I verbally 

notified that I would be issuing a NR.  Plant records 

show no failures occurred at Post chilland the plant achieved two passing tests at 

Prechill at 1408. No further failures occurred for the remainder of the shift. The 

Prechill nonconformances I observed were:   6 partial oil glands (6 

pts),   5 partial lungs (5 pts),  4 whole lungs (8 pts),  

 1 cloaca (5 pts),  1partial crop (2 pts), 3 small feathers (3 pts), 

 3 large feathers (3 pts),  and 1 long hocks (2 pts). On this same day 

NR # OIJ2213103616N (#78) was issued for processing noncompliance. This 

noncompliance is linked to NR # OIJ2213103616N (#78) for the same root 

cause.  The Establishment Awareness Meeting notes show that FPS NRs were 

last discussed at the October 10, 2013 meeting. 

(b) (6)
(B)(6)

(B)(6)

(B)(7)(C)

(B)(6)

(B)(7)(C) (B)(6) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

6036 P6164A OIJ2213103 

616N-1 

10/16/2013 04A06 Poultry Finished 

Product Standards 

C On October 16, 2013 I, CSI performed a scheduled Finished 

Product Standard test at the Prechill area.  This test is applied to permit FSIS 

to estimate when the production process is in control for ready-to-cook 

poultry.  The test consists of two parts, trim and processing 

nonconformances.  The absolute limit allowed for processing 

nonconformances is points. My test at 0850 resulted in 45 points.   

At 0923 a retest was performed by using a tighten criteria 

of 25 points which failed with points.  I verbally notified

 of the noncompliance and that I would be issuing a NR.  The 

plant implemented the required procedures for FPs failure.  Plant records 

show 2 passing tests were achieved at 0943 and no failures occurred at Postchill. 

The Prechill nonconformances I observed at 0706 were:  3 ingesta < 1/16” 

(3 pts),  5 partial oil glands (5 pts),  5 partial lungs (5 pts), 5 whole 

lungs (10 pts), 2 bursa (4 pts), 2 partial crop (4 pts), 1 trachea < 1” (1 pt), 

  6 small feathers (6 pts), 5 large feathers (5 pts), and 1 long hocks (2 

pts). On October 9, 2013, NR # OIJ3522102109N (#74) was issued for processing 

noncompliance.  No response is available at this time. This noncompliance is 

linked to NR # OIJ3522102109N (#74) for the same root 

cause.   The Establishment Awareness Meeting notes show that 

FPS NRs were last discussed at the October 10, 2013 meeting. 

1325 

7 

P33900 NHH220610 

5017N-1 

10/16/2013 01D01 SPS Verification C On the calendar date of October 16, 2013 at approximately 2358 hours while 

performing the Operational SSOP Review and Observation task, the following 

facility noncompliances were observed: I, CSI , accompanied by 

, observed an excessive amount of water on the 

underside of several stainless drip pans, piping, and overhead structures above bird 

shackles in rooms 1, 2, and 3 in the further processing areas. Please be advised that 

product adulteration was observed and the findings were documented on a 

separate noncompliance record; please reference NR # NHH3605100717N/1. In 

addition, 6 live spiders and several spider webs were observed in various areas of 

the ceiling in the small bird box room. No packaging material or boxes were 

affected. Mr. was informed that a noncompliance record would be issued. 

This noncompliance record will be discussed during the next weekly meeting. A 

similar noncompliance record was documented on July 16, 2013; please reference 

NR # NHH1203071216N-1. The establishment's response to 

NR # NHH1203071216N-1 of, - "The spider webs were taken down and spiders were 

killed." - failed to prevent recurrence. 

(b) (6)
(B)(6)

(B)(7)(C) (B)(6) (B)(6)

(B)(4)

(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH360510 

0717N-1 

10/16/2013 01C02 Operational SSOP 

Review and 

Observation 

C On the calendar date of October 16, 2013 at approximately 2358 hours while 

performing the Operational SSOP Review and Observation task, the following 

noncompliances were observed in further processing: Part 2 of the SSOP's states 

tha 

I, CSI , accompanied by 

, observed water dripping from the box chute 

(in the Rotisserie area) into a combo of WOGs. Water was also observed dripping 

from the underside of a stainless drip pan into a combo of ice (that was being 

collected to apply to product) in room 1. Mr. immediately retained the WOGs 

and Ice, and the combos were removed from the processing area. Please be advised 

that corrective actions were performed in my presence. In addition, Part 2 of the 

SSOP's states that . At 

approximately 0104 hours (10/17/13) while observing operations in rooms 2 and 3, 

I observed blood specs and residue, fat particles, a black greasy substance, 

rust, and various debris on the inside and outside of several brown baskets used to 

hold bagged product. At the time of the findings, several baskets contained bagged 

product and visible stains were observed on the outside of the bags. The baskets 

were rejected with U.S. REJECTED tag #'s B40172390 and B40172389. Mr. 

was informed that a noncompliance record would be issued. This noncompliance 

record will be discussed during the next weekly meeting.A similar noncompliance 

record was documented on October 15, 2013; please reference 

NR # NHH5005105216N-1. The establishment's response to 

NR # NHH5005105216N-1 is pending. 

(b) (6)
(B)(6) (B)(6) (B)(6)

(B)(6)

(B)(6)(B)(6)

(B)(7)(C) (B)(6)

(B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN280510 

1815N-1 

10/15/2013 03J02 Slaughter HACCP C I noted the following non compliance during a verification check of the 

establishment's off-line reprocessing process.  At 0101 hours I randomly 

selected ten carcasses from the off line after the final wash cabinet.  Two of 

the ten carcasses had visible ingesta material, one at the inside of the tail 

area,the other carcass at the crop area.  I stopped the reprocessing line and 

showed these findings to .  The 

Line was restarted at which time production personnel instituted corrective actions 

of adding two additional employees to the reprocessing line, one to conduct knife 

trimming and one to wash the carcasses.  I performed a recheck at 0111 

hours.  During the ten random carcass verification I noted one carcass with 

visible ingesta material on the inside of the tail area.  I stopped the line 

showed this finding to .  Mr. initiated 

the written corrective actions procedures for an off line contamination 

failure.  These procedures included diverting carcasses off the line 

and then performing rechecks on the affected carcasses. 

 performed the rechecks and then marked the chiller with a red net 

to identify the affected lot and initiated post chill checks on the affected lot. 

 and 

where informed of the issuance of this non compliance 

report of the failure to meet the regulation cited above. 

1325 

7 

P33900 NHH500510 

5216N-1 

10/15/2013 01C02 Operational SSOP 

Review and 

Observation 

C On the calendar date of October 15, 2013 at approximately 2340 hours while 

observing operations in room 2 of the further processing area, the following 

noncompliance was observed: Part 2 of the Sanitation SOP's states that

 I, CSI , observed condensation dripping from the upper 

portion (toward the ceiling) of the stainless steel ice chute directly into a combo of 

ice. Employees in the area confirmed that the ice was going to be used in the 

packing of product, and the ice was immediately discarded. In addition, another 

part of the ceiling in close proximity to the ice chute exhibited a steady drip of 

water (which fell onto the floor), and corrective actions were immediately 

implemented. , was shown the 

noncompliance as well and informed that a noncompliance record would be issued. 

This noncompliance record will be discussed during the next weekly meeting.A 

similar noncompliance record was documented on July 25, 2013; please reference 

NR # NHH4717074025N-1. The establishment's response to 

NR # NHH4717074025N-1 failed to prevent recurrence. 

(b) (6)
(B)(6) (B)(6) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5129 M210 LQN160010 

2214N-1 

10/14/2013 01D01 SPS Verification C On 10/13/13 while performing pre-operational sanitation in the HPP department I 

observed noncompliance with SPS regulatory requirements 416.2(b)(1) & 

416.4(b). At approximately 21:50 hours I observed two white hard plastic cuttings 

boards placed on a metal rack on the floor at the beginning of the HPP package 

boxing area; these two cutting boards are used to catch packages after they exit the 

HPP machines and the packaged product has recieved it's lethality step; both 

cutting boards, (Non food contact surfaces) had cuts and crevices on the boards' 

surfaces; upon closer observation it was determined that the boards may create an 

insanitary condition due to black unidentifiable foreign material in cuts/crevices; 

that may harbor bacteria which could in turn affect the cleaning and sanitizing of 

the cutting boards. and were shown and 

notified of the establishment's noncompliance with 9 CFR sections: 416.2(b)(1) 

& 416.4(b). This document serves as written notification of an SPS 

noncompliance; and also as a notification that failure to meet regulatory 

requirements can lead to enforcement actions as described in 9 CFR 500.4. 

5308 M6137 BXL4516101 

214N-1 

10/14/2013 04A06 Poultry Finished 

Product Standards 

C On 10/11/2013 at approximately 1510 hours, a review of the Records for Post Chill 

Finished Product Standards , while writing down the check that I performed, 

I observed the following, the checks performed by Quality 

Control were:  the first check performed was at 0855 hours (chiller 1) and 

0858 hours (chiller 2). The second check was performed at 1004 hours (chiller 1) 

and 1005 hours (chiller 2). The third check was at 1306 hours (chiller 1) and 1308 

hours (chiller 2), the last check was at 1505 hours (chiller 1) and 1501 hours 

(chiller 2). The birds finished coming out from the chiller that day at 

approximately 1850 hours. The gap between the second check and the third 

check was approximately three hours. The gap from the last check to the end of the 

shift was approximately three hours and fifty minutes.I also found while 

reviewing the records, that on 10/09/2013 the checks were performed as 

follow: (chiller 1) 0902 hours and 1127 hours and (chiller 2) 0858 hours and 

1125 hours. The birds finished coming out from the chiller that day at 

approximately 1500 hours. The gap from the last check to the end of the shift was 

approximately three hours and thirty minutes.This is a noncompliance with 

the following regulatory requirements of regulation 9CFR 381.76 (e)(1)(i).I 

informed of the noncompliance.  

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(4) (B)(4)

(B)(4)

(B)(4) (b)(4)

(b)(4)

(b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN441110 

2114N-1 

10/14/2013 01D01 SPS Verification C   On 10/14/13 at approximately 825 hours I observed the following while 

performing the SPS task in the packaging room . Observing the reprocessing station 

I noticed the nut and surrounding area on the handle were oxidized 

the fittings used to connected the brass shut off valve showed signs of 

oxidization (rust) also .Taking a regulatory control action I immediately applied US 

REJECTED/RETAINED tag # B43 303643 and contacted who was 

near . placed the establishments QC hold tag on the reprocessing station 

and contacted . notified 

maintenance immediately . The maintenance worker disassembled the plumbing on 

the back portion of the reprocessing station a new shut off valve was 

installed teflon tape was used on the smaller fittings . The unit 

was reassembled and rinsed with water . Sanitary 

conditions were restored at approximately 1030 hours and the area was 

released . was informed of the non-compliance.  My 

findings indicate non-compliance with the following regulations 9CFR 416.1 Which 

states that each official establishment must be operated and maintained in a 

manner sufficient to prevent the creations of insanitary conditions and to ensure 

that product is not adulterated and 9CFR 416.4(d) which States that product must 

be protected from adulteration during processing, handling, storage, loading, and 

unloading at and during transportation from official establishments . 

5309 P6137A NJN090610 

3813N-1 

10/13/2013 03C02 Raw Intact HACCP C At approximately 0322 hours; I asked , to check the 

temperature of twelve brown tubs of product, in the fillet cooler room. His 

thermometer (# 464) registered . I 

took regulatory control action and applied a U.S. Retention tag NO43303527 to the 

pallet containing the twelve brown tubs filled with tender breast and salvaged 

thigh. Mr. , was notified 

of the noncompliance. The U.S. Retention tag was removed at 0335 hours and the 

product was released to production due to the plant’s validation study on time and 

temperatures. The plant failed to maintain the product temperature constantly at

 ; that the product being staged on the cooler exceeded

 represent a noncompliance with 9 CFR 381.66 (c) (3). The 

establishment is required to comply with the chilling temperature requirements in 

9 CFR 381.66(C) (3).   The establishment HACCP plan II, Raw Not Ground for 

the 2nd Processing Department, process step Refrigerated Storage: 

; .   

(b) (6)
(B)(6)

(B)(6)

(B)(6) (B)(4)

(b)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN500610 

4813N-1 

10/13/2013 04B04 General Labeling C At approximately 0322 hour, while monitoring the temperature on fillet cooler, I 

observed a staged product of salvaged thigh mixed with tender breast in twelve 

brown tubs. The pallet had empty yellow label stamped Wednesday, and on the 

back a different date, 10/12/13, and the name was hand written in. The label 

did not identify the kind of poultry nor did it even have a code. Mr. 

, and , were notified of the 

noncompliance. 

5568 M20923 XUM090010 

1513N-1 

10/13/2013 01D01 SPS Verification C On 10/12/2013 at approximately 2100 hours, while performing a routine 

Sanitation Performance Standards (SPS) inspection on the Raw Side Department on 

Line #2, the following noncompliance was noted: water and batter mixture flooding 

the drain which runs east to west adjacent to Line #2 creating insanitary conditions. 

At the time of my observation Line #2 was sorting breast meat. I took regulatory 

control by stopping the line and informing

 of the insanitary conditions and the forthcoming 

noncompliance. 3 combo bins of chicken breasts were removed from the area until 

the drain was cleared and sanitary conditions were restored and the line was 

released. During this task I also observed the floor drain next to Line #1 was flooded 

as well, no product was being processed in this area. The requirements of 9 CFR 

416.1, 416.2(e)(4), 416.2(b)(2), and the establishments SSOP plan were not met. 9 

CFR 416.1 states: “Each official establishment must be operated and maintained in 

a manner sufficient to prevent the creation of insanitary condition and to ensure 

that product is not adulterated”. 9 CFR 416.2(e)(4) states: “Plumbing system must 

be installed and maintained to provide adequate floor drainage in all areas where 

floors are subject to flooding type cleaning or where normal operations release or 

discharge water of other liquid waste to the floor”. 9 CFR 416.2(b)(2) states: “Walls 

floors, and ceilings within establishments must be built of durable materials 

impervious to moisture and be cleaned and sanitized as necessary to prevent 

adulteration of product or the creation of insanitary conditions”. The 

establishments SSOP plan, Part 2 Operation Sanitation, Section 1 Raw Area, 

Subsection D Equipment and Facilities, Step #3 states: 

”. 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6) (B)(6)

(B)(6)

(B)(4) (B)(4)(B)(4) (B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH120110 

0414N-1 

10/13/2013 01C01 Operational SSOP 

Record Review 

C On the night of production which began on 10/13/2013, Inspection reviewed the 

SSOP Records generated for the night of production beginning on 10/10/2013 

(Prod. Date 10/11/2013) and found them out of compliance. On that shift, 

Management had documented cardboard boxes in the SB (South Cooler) containing 

product with overspray on them and the Preventive Measure on the 

establishment’s deficiency form stated that “Employee would be retrained not to 

overspray on 10/11/2013.” No documentation was available for review by 

Inspection that this retraining was done, thus not meeting requirement’s of 9CFR 

416.16(a). was notified that a Noncompliance 

Record would be issued. Refer to NR #NHH2904083119N/1 (#125) dated 

08/19/2013 for a similar Noncompliance. 

1325 

7 

P33900 NHH510410 

5014N-1 

10/13/2013 03J02 Slaughter HACCP C On the night of production that began on October 13, 2103 while observing the 

start of operations in the evisceration department I noticed a new spray bar at the 

exit end of the PNT.  Mr. , informed me that the 

spray bar had been installed over the weekend to deliver acidified to the 

product.  He also informed me that the acidified was in use at 

multiple other locations in the evisceration department.  I proceeded to the 

HACCP office and asked Ms. , if the slaughter 

HACCP plan had been amended to show the use of acidified in the 

evisceration department.  Ms. informed me the HACCP plan had not 

been amended and that the acidified was not supposed to be in use until 

later in the week.  Plant management elected to discontinue use of the 

acidified until the HACCP plan could be modified.  The affected 

product, two combos of wogs, was retained with US tag B38075686.  Ms.

 modified the HACCP plan and provided the necessary supporting 

documentation and proposed the affected product be rinsed with potable 

water.  Inspection reviewed the HACCP plan changes and supporting 

documentation and concluded the establishment was in compliance and that the 

proposed corrective actions were reasonable.  The regulatory control action 

was released after the product had been rinsed.  Ms. 

, was informed the noncompliance would be documented on a 

noncompliance record.    The requirements of 9 CFR 417.5(a)(1) were 

not met. 

(b) (6)
(B)(6)

(B)(6) (B)(6)

(B)(6) (B)(4)

(B)(4)

(b)(6)

(b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1405100 

812N-1 

10/12/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 10/12/2013 at approximately 0035 hours while monitoring Operational 

Sanitation procedures at the rehang area of Plant #1 for product going into 

Packaging, I observed the following. There was product collecting on a rehang belt 

for birds going to the bag fryer line in Packaging. The carcasses at this point 

have already received their final microbial intervention. The carcasses at the end of 

the belt had varying amounts of a dark brown UFM(Unidentified Foreign Material) 

collecting on the carcass  where the skin  was in contact with the 

flexible belt. I contacted an employee who called  . 

Product was redirected to the cutup line. The line was stopped. A 

partial tank of carcasses were collected that were on the belt. The belt was sprayed 

with a sanitizer and rinsed with water.  A review of the 

Establishments' SSOP Section 11-Operational Sanitation under Corrective Action: 

states 

There is no cleaning process described in the Operational 

Sanitation SSOP to be used to restore sanitary conditions. The dirtiest  

carcasses were condemned by production. I observed the reconditioning of the 

affected carcasses which were rinsed with water per establishment 

policy. A recheck was acceptable and the product was released at 

approximately 0130 hours.  My findings indicated a noncompliance with 9 

CFR 416.1, 9 CFR 416.4(d) and 9 CFR 416.14. 

5308 M6137 BXL5211100 

612N-1 

10/12/2013 01C01 Operational SSOP 

Record Review 

C On 10/10/2013 while performing an Operational Sanitation Records Review Task, I 

made this observation on the SSOP Daily Implementation and Monitoring 

Log for Packaging on 10/08/2013. There was no check documented on the 

Glove/Utensil Check at Start-up (if applicable). I asked 

on 10/11/2013 about the missing check and she informed me that 

it was the night shifts SSOP Log and she would send 

r an e-mail asking him about it. On 10/12/2013 I spoke with 

and he informed me that the Glove/Utensil Check at Start-up had 

been done and written down. However, the check was done by one Quality Control 

person and when a different Quality Control person did an SSOP monitoring check 

in packaging, she used a different SSOP Log. and the Quality 

Control employees were unable to find the SSOP Log that contained the 

Glove/Utensil Check at Start-up on 10/08/2013.My findings indicate a 

noncompliance with the following regulatory requirements of regulations 9CFR 

416.13(b) and 9CFR 416.13(c). 

(b) (6)
(B)(6)

(B)(6) (B)(6)

(B)(6)

(B)(6) (B)(6) (B)(4) (B)(4)

(b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN421810 

3112N-1 

10/12/2013 01D01 SPS Verification C At approximately 0940 hours, in the packaging area, I noticed that the cooler door 

was covered with ice on its side and bottom. I immediately contacted Mr. 

, and showed him the ice that was built-up on the 

door. Mr. checked the door and informed me that he will order some parts 

to fix the door. Also I informed him that the cooler door open into Fillet 

Department does not close properly. Later on, while performing an operational 

sanitation task in the packaging area, I noticed that the cooler door beside the spice 

room was open. So, I waited almost three minutes for some one to close it but, 

nobody came to close it. I went inside the cooler and noticed that the plastic curtain 

had heavy condensation to the point that it was dripping water. I showed Mr. 

, the condensation and informed Mr. 

, of the forthcoming noncompliance. Mr. then assigned an 

employee to wipe the condensation and to keep the door close. 9 CFR 416.2(d) 

states: "Ventilation adequate to control odors, vapors, and condensation to the 

extent necessary to prevent adulteration of product and the creation of insanitary 

conditions must be provided."   9 CFR 416.2(b)(1) states:”their structures, 

rooms, and compartments must be of sound construction, be kept in good repair.” 

  9 CFR 416.1 states: “Each official establishment must be operated and 

maintained in a manner sufficient to prevent the creation of insanitary conditions 

and to ensure that product is not adulterated.” 

5308 M6137 BXL1918104 

811N-1 

10/11/2013 03J02 Slaughter HACCP C On 10/11/2013 while performing a Pre-Chill Finished Products Standards Task in 

Plant #2 on Line , I observed a noncompliance with the following regulatory 

requirements of regulations 9CFR 381.65(e) and 9CFR 417.2(c)(4).At approximately 

1533 hours, I randomly removed a 10 bird sample from Line . I found one out of 

the ten birds with visible fecal contamination below the right hock. The fecal 

material was approximately 7/16" in diameter in size, olive green in color and pasty 

in texture. I informed and the protocol for fecal failure was 

implemented. At approximately 1557 hours, Quality Control performed a recheck 

and passed.This is a violation of the critcal limits of CCP-2B, 

of the Plant's HACCP Plan for Slaughter. 

(b) (6)
(B)(6) (B)(6) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2207100 

611N-1 

10/11/2013 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 2000 hours while monitoring Operational Sanitation 

in the Plant #1 Cooler, I observed the following. A partial pallet of 

giblets with a white Dolly Tag marked Night Shift had a puddle of very dark 

brown blood on top of the lid. I opened the lid to see the condition of 

the giblets inside and found  3 uncut  gizzards full of 

ingesta and several feet of intestines full of fecal material mixed 

in with the livers near the top of the product. The partial pallet of 5 tubs was placed 

under USDA Retained. At approximately 0030 hours I contacted 

and showed him the uncut gizzards and intestine in the livers. The 5 tubs on the 

pallet were from a previous days production and were condemned by Production. 

At approximately 0335 hours I observed the giblets that had come out of the giblet 

chiller just before lunch. The brown product tubs collecting the edible giblets were 

filled with a froth making it difficult to examine the 

contents. Moving the froth aside there were uncut gizzards full of 

ingesta and several feet of intestine full of fecal material in the livers. 

There was also a neck that was collected in the product container with the hearts 

that was coated with a thick layer of brown UFM  (Unidentified Foreign 

Material).  The giblets had already received their final microbial intervention. 

Giblets are placed back into the whole fryer carcasses as part of an 

unwrapped giblet pack. I contacted and showed him the 

product. All three tubs of  product was condemned and placed into a 

gray inedible barrel.  In the future will turn off the giblet 

collection conveyor belt during wash downs to prevent unsorted product from 

entering the giblet chiller. The UFM coated neck was provided to 

the establishment to aid in determining the content and source 

of the UFM. Ingesta and fecal material from the uncut gizzards and intestines will 

leach into the edible product during storage and handling contaminating the 

giblets. My findings indicated a noncompliance with 9 CFR 416.1 and 9 CFR 

416.4(d).      

(b) (6)
(B)(6) (B)(6) (B)(6) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2907100 

711N-1 

10/11/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C At approximately 1945 hours while monitoring Pre-Operational Sanitation 

processes in the Rotisserie Room, I observed the following. Sanitation 

personnel were starting to clean the room after PM shift 

production was completed. At approximately 2035 hours I returned 

and the  Injection machine was being cleaned using the 

establishments' clean in place procedure. The machine is operated 

recirculating  a cleaning solution. I returned 

at approximately 2100 hours the machine was stopped. At 

approximately 2145 hours the injection machine internal and external surfaces 

were being cleaned. At approximately 2230 hours the top of the Injection Machine 

was open and a sanitation employee was removing the needles that had been 

cleaned with the machine during the clean in place procedure. The top of the 

machine was rinsed and a second set of needles that are soaked in a solution 

of vinegar and water over night were inserted into the machine. I checked the 

injector needles that were removed after being cleaned with the clean in place 

procedure and observed that most of the needles were covered 

with a froth of product from the previous days production. The needles were 

rinsed with potable water and the water/vinegar solution was added. At 

approximately 2300 hours was starting her SSOP 

Pre-Operational Sanitation check in Rotisserie. I asked her how she 

inspected the injector needles listed on the form. She said that only the external 

surfaces of the injector needles installed in the machine were checked. At 

approximately 2345 hours I selected the Injection Machine for my 

Pre-Operational Sanitation Verification procedure in the Rotisserie 

Room.   I spoke with about the frothy residue 

on the needles that were cleaned with the machine then asked for the Operators 

Manual with the manufactures recommended cleaning procedures. The manual was 

located in the Packaging Department Repair Office. The manual dedicated a chapter 

to the cleaning of the machine covering each piece i.e. piping, belts, screens 

etc.  A note in the manual stated that the recommended cleaning procedure 

was to be used to address production  for a shift. I told to 

fill the machine and run it so I could see if it was clean.  Upon running 

the machine numerous pieces of fat, tissue, and coagulated blood from very 

small to approximately 1/2" in size came out of the drain line from the upper 

collection tank under the injection needles.  The fluids drains into a lower 

tank that filters the fluid  and returns it to the injection 

needles.  The unit was drained, recleaned and released at 

approximately 0020 hours after a steady stream of water flowed from 

the injection needles and the water flowing into the collection tank was clear. 

(b) (6)
(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

My findings indicated a noncompliance with 9 CFR 416.1, 9 CFR  416.4(a), 9 

CFR 416.12(a), 9 CFR 416.13(c) and 9 CFR 416.14.    

(b) (6)
(B)(6)

(B)(6)

(B)(7)(C) (B)(6) (B)(4) (B)(4) (B)(4)

(B)(4)

(B)(4) (B)(4) (b)(4) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

6036 P6164A OIJ0301103 

311N-1 

10/11/2013 06D02 Other Inspection 

Requirements 

C At approximately 2107 on 10-10-13, I, CSI performed the missing viscera 

test component of the regularly scheduled Other Inspection Requirements task. The 

maximum allowed missing viscera at the line speed of is and I 

observed 18. , witnessed the test 

and I verbally informed her of the failed test results. At approximately 2207, I 

performed the retest for missing viscera and I observed 15. 

witnessed the retest. I immediately notified him 

of the failed test results, that I was taking the regulatory control action of slowing 

the line to as per requirements, and that a NR would be issued to 

document the noncompliance. At approximately 2218, I performed a missing 

viscera retest requested by to verify process control at the line 

speed of The maximum allowed missing viscera at the line speed of 

is and I observed 10. The line speed was increased to . At 

approximately 2244, I performed the missing viscera test to verify process control 

at the line speed of and I observed 12.    This NR is linked to 

NR # OIJ2522103210N issued on swing shift, 10-10-13. Including this NR, there 

have been six linked Other Inspection Requirements NRs issued in the last 90 days 

for the same root cause. Maintenance adjustments in response to previous Other 

Inspection Requirements NRs were not effective in preventing this NR. Other 

Inspection Requirements NRs were most recently discussed and documented during 

a weekly Establishment Awareness Meeting on 10-03-13.    

(b) (6)
(B)(6)

(B)(7)(C) (B)(7)(C) (B)(6)

(B)(6)

(b)(4) (b)(4) (b)(4) (b)(4) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

6036 P6164A OIJ2118103 

815N-1 

10/11/2013 03J02 Slaughter HACCP C At 2042 I, Dr. , began performing a routine Pre-Chill Finished Product 

Standards PHIS task. At 2053 I identified fecal material on the eighth bird located 

on the internal surface of the right ventral body cavity just medial to the ventral fat 

pad and approximatly 1.5 inchs (4cm) inside the bird. It was light brown, semi-solid, 

creamy consistency with no plant material contained therein and was 

approximately 1⁄4 inch (6mm) diameter. There were no establishment employees 

between the final wash cabinet and the carcass chiller therefore it is reasonable to 

believe the carcass would have entered the chill system.

 was immediately notified and observed the 

noncomplicance at 2054. Dr. , confirmed it was fecal matter at 2057. At 

2058 the establishment implemented its written fecal failure procedure including a 

five minute live hang skip beginning at 2058. The cause of the zero tolerance fecal 

failure was identified by and 

at 2140 during scheduled establishment break. It was determined that on the

 In/Out bird wash two nozzles were not working properly and on the 

In/Out bird wash two leaf fat lifters had two nozzles that were missing extenders to 

increase the opening of the birds. Preventative measures implemented included 

maintenance on the offending machines (all lifters on the were changed by 

maintenance at break) and increased monitoring of the and three 

times per shift during company breaks and lunch. To verify the process was back 

under control after prevenative measures were taken, the establishement 

completed a succesful zero tolerance at 2120. This was followed by tests done 

every thirty minutes for the next two hours totalling four tests without any 

documented visible fecal contamination. To verify all possibly affected carcasses 

entering the chiller system were not contaminated by visible fecal material the 

establishment began a series of zero tolerance tests of carcasses exiting the chiller. 

The tests began at 2130, consisting of 32 birds for each rake (approximately five 

minutes) of the chiller system, ending at 2245 with last of the affected group exiting 

the chiller. There was no documented visible fecal contamination Post Chill. All 

affected carcasses were sprayed with . This NR is linked to NR# 

OIJ3522085229N issued on swing shift 8/29/13. Including this NR there are three 

linked NRs issued in the last ninety days. Zero tolerance NRs were most recently 

discussed and documented during an Establishment meeting on 9/5/13. 

(b) (6)
(B)(6) (B)(6)

(B)(6)

(B)(6) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD2422102 

710N-1 

10/10/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 10/10/2013 at approximately 1005Hrs, I observed UFM (unidentified foreign 

material) on the Chiller B exit food contact belt. The UFM was very black in color; 

thick/smear grease type when touched/rubbed. The thick UFM was smeared 

approximately 8" x 3" in size on the belt. The food contact chiller belt was full of 

whole body heavy tom turkeys at this time. I saw  , Boning 

Room personnel, who was near the Boning Room Wings area. I waved to him for 

help and notified him of the UFM on the belt. Mr. called 

r. He removed the whole body turkey's from the affected belt. 

U.S. Retain Tag NO:B39554699 was applied to the affected chiller exit belt. Mr.

 was showed the UFM on the conveyor belt. He restored sanitary 

conditions by stopping the conveyor and removing all of the UFM from the belt 

with a sanitized cotton glove. The belt was sanitized and 

reinspected. The conveyor was released for operations at approximately 

1010Hrs. U.S. Retain Tag No's: B39554697 & 98 was applied to the one 

and 1/4 tanks of whole body turkeys which were on the affected conveyor belt. At 

approximately 1110Hrs the (2300 pounds) of heavy tom turkeys were 

released back to production flow after verifying the plant's implemented 

reconditioning by water spraying/trimming and 

reinspection. One Turkey was found with UFM. This observed incident of 

UFM on a food contact surface during food products processing operations is in 

violation to 9 CFR 416.4(a); 416.4(d) and monitoring of the plant's operational 

sanitation 416.13(c). This noncompliance JDD2422102710N/1 is being linked to 

noncompliance (#119) JDD1922091518N/1 dated 9/17/2013 and  (#86) 

JDD1419071502N/1 dated 7/2/2013 for the same cause respectively. 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(4) (B)(4) (B)(4) (b)(4) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD2422102 

710N-2 

10/10/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 10/10/2013 at approximately 1340Hrs, I observed injesta spilling out of 

a  whole body heavy hen turkey's crop. The turkey was on the chiller B exit 

converyor with other whole body turkeys. I pulled the turkey from the food contact 

converyor onto the food contact chiller B inspection table. The injesta was still 

spilling out of the  broken open crop. As the contamination was extensive, 

U.S. Retain Tag NO:B39554114 was applied to the turkey and table. The 

Evisceration Line was at lunch break, I went to the Supervisor's office and notified 

. Ms. immediately had the affected turkey carcass 

which did not have it's crop properly removed taken to the Evisceration 

reprocessing room. She had the injesta contamination on the food contact 

surfaces removed by water spraying ppm. She had the crop 

properly removed by trimming and washing with ppm 

spraying. The turkey was reinspected by Q.C.. The turkey was released back 

to production flow after verifying the plant's implemented appropriate 

corrective actions. This observed incident of  turkey food product and food 

contact surfaces adulteration is in violation to 9 CFR 416.4(a); 416.4(d) and 

monitoring of the plant's operatioal sanitation 9 CFR 416.13(c). Ms. 

and Ms, were notified of the noncompliance. 

5308 M6137 BXL2414103 

510N-1 

10/10/2013 04A06 Poultry Finished 

Product Standards 

C On 10/10/2013 while monitoring the Establishments' Reprocessing Procedures on 

Line  in Plant #2, I observed the following noncompliance. At 

approximately 1032 hours, with a line speed of  nbsp;and two 

House Inspectors, I randomly removed a 10 bird sample and found one split 

tail bird with airsacculitis exudates and one split tail bird with partial lung 

remaining in the bird. I took regulatory control action by stopping the line 

and I informed  . The line was started back 

up with a line speed of  and three House Inspectors and 

product was retained in a tank. I performed a recheck at approximately 1043 

and failed with one split tail bird containing airsacculitis exudates. I 

informed and the line remained running with all split tail 

and missing tail birds being retained. I performed a recheck at approximately 1054 

hours and passed, bringing the process back into control. I tagged the tank of 

retained birds with U.S. Retained/Rejected Tag #B31408095 pending rework of the 

product and I informed of the noncompliance. I 

performed a recheck of the held product at approximately 1345 hours and it 

passed. I removed my tag and released the product back to production at that time. 

My findings indicate a noncompliance with regulatory requirements 9CFR 381.76(b) 

and 9CFR 381.84. 

(b) (6)
(B)(6)

(B)(6) (B)(6) (B)(6)

(B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN491110 

1810N-1 

10/10/2013 01D01 SPS Verification C On Tuesday October 8th at approximately 12 O’clock, I observed that the drain of 

the offal area was clogged, and the area around the drain, approximately 20 feet by 

20 feet, was covered with bloody water. I immediately asked one of the plant 

maintenance to inform management about the drain in order to take care of the 

problem. The following day, at approximately 0910 hours, I went to check the area 

and found that the drain still clogged and covered with smelly stagnant water. At 

this time the plant supervisors were in a meeting so, I informed Ms. 

, of my observation and the forthcoming NR. Also, later in that day I 

informed MR. , of the noncompliance 

documentation. Mr. informed me that he will take care of the Problem. At 

approximately 1600 hours, the area was found acceptable. 9 CFR 

416.2(e)(1)(2)(3)(4) states:  “ Plumbing systems must be installed and 

maintained to: (1) Carry sufficient quantities of water to required locations 

throughout the establishment; (2) Properly convey sewage and liquid disposable 

waste from the establishment; (3) Prevent adulteration of product, water supplies, 

equipment, and utensils prevent the creation of insanitary conditions throughout 

the establishment; (4) Provide adequate floor drainage in all areas where floors are 

subject to flooding-type cleaning or where normal operations release or discharge 

water or other liquid waste on the floor.” 

5309 P6137A NJN581610 

1910N-1 

10/10/2013 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1430 hours, while performing an operational sanitation 

inspection in the new room, I observed the following noncompliance: There was a 

pallet of returned boxed rotisseries placed in the new room for rework (cut up). The 

boxes were damaged not clean and wet. A plant employee started to process the 

first box, she moved her gloved hands on the surfaces of the box to open it, and 

then she took a pair of scissors to open the plastic bag containing the rotisseries, 

after that, she proceeded to take the carcasses out of the bag without washing or 

sanitizing her gloves, creating an insanitary condition and cross contaminating the 

product. I showed Ms.  , my finding, also, Mr. 

(day), was informed of the noncompliance and the forthcoming 

NR. 9 CFR 416.5(a) states: “All persons working in contact with product, 

food-contact surfaces, and product-packaging materials must adhere to hygienic 

practices while on duty to prevent adulteration of product and the creation of 

insanitary conditions.” 9 CFR 416.4(d) states: “Product must be protected 

from adulteration during processing, handling, storage, loading, and unloading at 

and during transportation from official establishments.” 

(b) (6)
(B)(6)

(B)(6)

(B)(6) (B)(7)(C) (B)(6) (B)(6) (B)(6) (B)(4) (B)(4) (B)(4)

(B)(4)

(B)(4) (B)(4) (b)(4) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

6036 P6164A OIJ2522103 

210N-1 

10/10/2013 06D02 Other Inspection 

Requirements 

C At approximately 1648 on 10-10-13, I, CSI , performed the missing viscera 

test component of the regularly scheduled Other Inspection Requirements task. The 

maximum allowed missing viscera at the line speed of is and I 

observed 15. , witnessed the test 

and I verbally informed her of the failed test results. At approximately 1730, I 

performed the retest for missing viscera and I observed 15. 

witnessed the retest. I immediately notified him 

of the failed test results, that I was taking the regulatory control action of slowing 

the line to as per requirements, and that a NR would be issued to 

document the noncompliance. At approximately 1747, I performed a missing 

viscera retest requested by to verify process control at the line 

speed of The maximum allowed missing viscera at the line speed of

 is and I observed 11. The line speed was increased to At 

approximately 1829, I performed the missing viscera test to verify process control 

at the line speed of and I observed 10.    This NR is linked to 

NR # OIJ4713094919N issued on day shift, 09-19-13. Including this NR, there 

have been five linked Other Inspection Requirements NRs issued in the last 90 days 

for the same root cause. Maintenance adjustments in response to previous Other 

Inspection Requirements NRs were not effective in preventing this NR. Other 

Inspection Requirements NRs were most recently discussed and documented during 

a weekly Establishment Awareness Meeting on 10-03-13.    

5308 M6137 BXL0004102 

109N-1 

10/09/2013 01D01 SPS Verification C On 10/09/13 at approximately 0135 hours while performing SPS Verification task in 

plant 2 at the giblet chiller exit area I observed the following non-compliance to 

9CFR 416.4(a) and 9CFR416.1. I observed black specks of foreign material in 

2 brown tubs that were stationed to be used for storage of chicken giblets coming 

from plant 2 giblet chiller. Black specks foreign material was also observed on the 

last chicken sorter exit shoot nearest to the giblet chiller and in a stainless steel cart 

that was next to the brown tubs. All the specks that were found were on product 

contact surfaces. No product was involved. I immediately took regulatory control 

action by applying U.S.Reject tag # B31407337 to the tubs and area and informing

 and of my findings. Mr. took 

immediate corrective action by having the tubs removed and cleaning the area. 

(b) (6)
(B)(6)

(B)(6)

(B)(6) (B)(4)

(B)(4)

(b)(4)

(b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5004105 

509N-1 

10/09/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 10/08/2013 at approximately 2210 hours while monitoring Pre-Operational 

Sanitation cleaning procedures in the Rewrap Room, I observed the following. A 

sanitation worker was using an air hose to blow down the conveyor belt, Stainless 

Steel  table, product table and finally the floor until approximately 

2230 hours. He swept up the big pieces of paper then blew the rest of the 

dust and dirt out into the packaged products storage area.  He then sprayed 

some hand sanitizer on the tables and belt then wiped it off with brown 

paper towels. The employee left at approximately 2244 hours. I checked back 

several times and I observed no further cleaning in the Rewrap Room. A 

review of the establishments' Pre-Operational Sanitation 'Daily Procedures'  

states 

." under Wet 

Clean-Up (food contact surfaces) it states in part 

"  At approximately 2355 

hours when my Pre-Operational Sanitation Verification 

procedure started, I selected the Rewrap Room. There was black UFM 

(Unidentified Foreign Material) on the belt and belt stainless steel support bracket, 

on the stainless steel table,  on the stainless product table, and on 

 the majority of the floor. I discussed the cleaning procedures with 

 who said they only use soap on Saturdays when the area 

is cleaned at the same time that the stair well that goes down into packaging 

is cleaned. There is no floor drain in the Rewrap Room to 

facilitate a normal cleaning process. The Establishments' SSOP 

Implementation and Monitoring Log for the Rewrap Room lists the 

. These areas are 

treated as product contact surfaces  that should be addressed on a 

daily basis using the Establishments' Wet -Cleanup (food contact surfaces) 

 Pre-Operational SSOP procedure. The General sanitation log was completed 

at approximately 2248 hours by , and a QC according to 

the  SSOP implementation and Monitoring Log for the shift found the 

area to be acceptable at 2337 hours. The Rewrap Room routinely unwraps and 

rewraps consumer packaged products that were dumped on the floor in the 

Weigh & Price cooler and are highly contaminated. The 

Establishment uses a Bio-Trace test for organic material on product contact surfaces 

to check the effectiveness of the cleaning process. According to 

Bio-Trace testing is not used on product contact surfaces in the 

Rewrap Room.   My findings indicated a noncompliance 

(b) (6)
(B)(6) (B)(7)(C) (B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (b)(4)(b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

with  9 CFR 416.1, 9 CFR 416.4(a) & (b), 9 CFR 416.12(a), 9 CFR 

416.13(c), 9 CFR 416.14, and 9 CFR 416.2(e)(4).   

5310 M6137B FFA3316103 

409N-1 

10/09/2013 01C01 Operational SSOP 

Record Review 

C On October 9, 2013 at approximately 0430 hours, while performing my operational 

record review for 10/08/2013. I observed that the operational records (Sanitary 

Practice Log) record for the night shift Raw side was not available for review. 

I informed of the noncompliance.This does not comply with 

establishment Monitoring and Record keeping: which states; The Qa Manager/ 

designee has the responsibility for the daily monitoring of the Sanitation-SOP and 

recording the findings and corrective action that have to be taken. Results are 

recorded on Establishment P-6137B Sanitary Practice Log Form B.This also does not 

comply with 416.16(a); which states in part "Each official establishment shall 

maintain daily records sufficient to document the implementation and monitoring 

of the Sanitation SOP's and any corrective action taken". " Daily records required, 

responsible individual, initialed and dated.This document serves as written 

notification that failure to comply with regulatory requirement(s) of 9CFR Part 416 

could result in additional regulatory or administrative action. 

6036 P6164A OIJ3522102 

109N-1 

10/09/2013 04A06 Poultry Finished 

Product Standards 

C On October 9, 2013 at 1551 I, Dr. preformed a pre-chill Finished 

Product Standard (FPS) test in order to verify finished product standards were being 

met for ready  to cook poultry prior to entry into the chiller. The absolute 

limit allowed for processing nonconformance is points, I observed 47 points. 

Nonconformances observed were as follows: 7 oil gland remnants (7pts), 1 whole 

oil gland (2pts), 2 partial lungs (2pts), 4 whole lungs (8pts), 1 Bursa of Fabricius 

(2pts), 1 partial crop (2pts), 3 tracheas >1” (6pts), feathers or pin feathers (9pts), 

 feathers >1” (3pts), and 3 long shanks (6pts).  

was verbally notified of the USDA failure and preformed a retest at 1602. The 

tightened nonconformance standard for a retest is pts, observed 34. 

The nonconformance observed by were as follows: Extraneous material 

>1” (2pts), 5 partial oil glands (5pts), 2 partial lungs (2pts), 3 whole lungs (6pts), 

3 Bursa of Fabricius (6pts), 1 partial crop (2pts), 2 trachea >1” (4pts), feathers 

>1” (2pts) and 2 long shanks (4pts). Plant immediately implemented their FPS 

failure procedures. had a passing test at 1620 (25pts) and 1641 

(22pts) bringing the plant back into compliance. Auto out at post chill was 

1810. Post chill documentation showed no failing tests. I verbally informed

 of the failing prechill FPS tests and that a 

noncompliance report would be issued. This noncomplicance report is linked to 

OIJ0416100007N which was issued on 7 October 2013 for processing FPS 

noncompliance. It remains unanswered at this time. Linked FPS noncompliance was 

last discussed at the plant meeting on 3 October 2013. 

(b) (6)
(B)(7)(C) (B)(6) (B)(6)

(B)(4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH460410 

3809N-1 

10/09/2013 01D01 SPS Verification C On the calendar date of October 9, 2013 (for the shift beginning on 10/8/13) at 

approximately 0118 hours while performing the Operational SSOP Review and 

Observation task, the following facility noncompliance was observed in the Breast 

Cone line processing area:Part 2 of the Sanitation SOP's states that 

I, CSI , observed multiple beads of condensation on the 

ceilings above the tender and frame conveyors. At the time of the findings, tenders 

and frame were on the conveyors; however, no product adulteration was observed. 

Also, while in the area, I observed larger droplets of condensation on the 

ceiling near the light fixture (yellow cord attached). , 

was shown the noncompliance and he confirmed the findings. Mr. was 

informed that a noncompliance record would be issued. This noncompliance record 

will be discussed during the next weekly meeting. A similar noncompliance record 

was documented on September 18, 2013; please reference 

NR # NHH0703094920N/1. The establishment's response to 

NR # NHH0703094920N/1 of - "The condensation was removed."- failed to prevent 

recurrence. 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (b)(4) (B)(6) (b)(4) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD3621100 

708N-1 

10/08/2013 01D01 SPS Verification C On 10/8/2013 at approximately 1420Hrs, I observed the establishment's six 

restrooms. The Evisceration Live Hanging restroom had standing brownish water at 

the floor drain which appeared to be plugged. The toilet bottom was 

leaking onto the floor around the floor seam. 2.) In the women's Evisceration 

restroom seven toilets had water coming out through  

the pipes connected to the flush handles. The water was going 

onto the floor. 3.) The men's Evisceration restroom had 2 sinks dripping at the back 

wall pipes onto the floor. Two toilets had water coming out through the pipes 

connected to the flush handles which was going onto the floor. 4.) The women's 

Boning Room restroom had two toilets leaking through the pipes at the flush 

handles and one broken towel dispenser. 5.) The men's Boning Room restroom had 

a puddle of brownish/yellow fluids on the floor near a urinal and one towel 

dispensor was broken. was notified of the 

Evisceration restrooms and showed the leaking toilets and standing water at the 

floor drain.  was notified and showed 

the Boning Room's men's restroom.  Ms. and Mr. ensured 

inspection the observed issues will be addressed. Ms. 

and Mr. were notified of the noncompliance.  This observed incident 

of restroom not in good repair is in violation to (facilities) 9 CFR 416.2(h)(1) which 

states in part; "Dressing rooms, toilet rooms, and urinals must be maintained in a 

sanitary condition and in good repair at all times to ensure cleanliness of all persons 

handling any product."  The floors with standing water and fluids is in 

violation to 9 CFR 416.4(b) non-food contact surfaces, cleaned and sanitized. 

5112 M18909 JDD5122103 

208N-1 

10/08/2013 01D01 SPS Verification C On 10/8/2013 at approximately 1050Hrs while performing sanitary operations 

(food contact utensils). I saw several staged at the blender in the Raw 

Fabrication Room. The establishment was refilling them with ground turkey blends. 

I looked inside one and saw an approximalely 1" crack/split. The crack was 

open and sharp to the touch. U.S. Retain Tag NO:B39554113 was applied to the

 to prevent it's use. was notified of the 

noncompliance and showed the crack/split. This observed incident of a food contact 

container not maintained in good repair was creating insanitary conditions and a 

potential food products adulteration which is in violation to the relevant 

regulations cited above. The remains on hold for repairs. 

(b) (6)
(B)(6) (B)(6) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4)

(B)(4)

(B)(4)

(b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0423102 

508N-1 

10/08/2013 03C02 Raw Intact HACCP C On 10/07/2013 at approximately 1945 hours while monitoring Packaging at the 

end of the PM shift, I observed the following. Packaged product was backed 

up outside the Crust Tunnel. There were numerous racks of packaged 

product in the bulk product storage side of the Crust Tunnel some with a packaging 

time on the Dolly Tags from 11 AM. I went to the exit end of the crust tunnel which 

was full of crusted product as the elevators were not functioning. The elevators take 

the crusted product to the Weigh & Price Cooler for shipping. I 

checked the Establishments computer to see if there was anyone monitoring 

the product exiting the crust tunnel or the product being stored in the bulk 

storage side of the crust tunnel. The last entries were made for Crust Tunnel 

Temperatures at approximately 1940 hours. There were no entries for product 

monitoring in the Bulk Storage Area.  The crust tunnel is normally 

approximately and the bulk product storage side is normally 

approximately . At approximately 2130 hours .using 

a company calibrated thermometer,  the temperature 

of  one item labeled 'Fresh' in the bulk storage side of the crust 

tunnel was found to be satisfactory. The temperature of a 

packaged product exiting the Crust Tunnel was warmer then usual at 

approximately . A rack of bulk product exiting the Crust Tunnel 

was at approximately . With the elevators broken the crust 

tunnel had been turned off. I contacted in the QC 

Office and informed her that the last check in the Crust 

tunnel was at 1940 hours. I returned later to let her know that the last 

product exiting the Crust Tunnel was loaded onto the elevators at 

approximately 2207 hours and that no temperatures had been taken for over two 

and one half hours. There were  no Supervisors or QC 

personnel monitoring the process. I contacted 

on 10/08/2013 and was told there are no procvedures 

written for when the  Crust Tunnel or associated elevator 

fail. A review of the establishments' HACCP plan - Raw not 

ground - Packaging under Step #9, states in part: Crust Tunnel (B) Pathogens, i.e. 

Salmonella. Is the Hazard Significant? NO.  'Justification for Decision' 

Refrigerated temperatures will prevent the growth of pathogens, such as 

salmonella. Temperatures are monitored as part of the plant program. Supplement 

#35, CP-14 , states in part that: 

" No temperatures were taken 

from approximately 1940 hours to approximately 2207 hours as required by CP-14 

(b) (6)
 

(B)(6) (B)(6)

(B)(6) (b)(4) (B)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

which is used to support the Hazard Analysis. My findings indicated a 

noncompliance with 9 CFR 417.5(a)(2).      

5309 P6137A NJN002110 

4108N-1 

10/08/2013 04A06 Poultry Finished 

Product Standards 

C At approximately 0920 hours, while performing finished product standards check 

on the reprocessing line I noticed the following:  the plant employee assigned 

to check the bird starts to pull the bird out of the line and retain them either by 

hanging them behind him or retain them in a metal container, in spite of that I 

found three birds with cellulitis trim defect and that require a re-check. I 

immediately informed Mr. 

, of my findings and asked him to inform the QC

 to perform the re-check. The recheck pass at approximately 0930 

hours, with one trim defect. At approximately 0945 hours, I noticed that the 

reprocessing line was full so I elected to perform another check to make sure that 

the reprocessing line is incompliance and the product is wholesome. In the 10 birds 

ample I found three birds with contamination in various areas of the carcasses, and 

three birds with trim defect. I immediately took control action and stopped the line, 

and informed Mr. , of my findings 

and the forthcoming noncompliance. The plant failed to keep the reprocessing line 

in control and comply with the regulations sited.9 CFR 381.91(b)(1) states: " Any 

carcass of poultry accidentally contaminated during slaughter with digestive tract 

contents shall not be condemned if promptly reprocessed under the supervision of 

an inspector and thereafter found not to be adulterated adulterated. Contaminated 

surfaces that are cut shall be removed only by trimming. Contaminated inner 

surfaces that are not cut may be cleaned by trimming alone, or at an approved 

reprocessing station away from the main processing line, by any method that will 

remove the contamination, such as vacuuming, washing, and trimming, singly or in 

combination. All visible specks of contamination must be removed, and if the inner 

surfaces are reprocessed other than solely by trimming, all surfaces of the carcass 

shall be treated with water containing ppm available " 9 

CFR 381.86 states: "Any organ or other part of a carcass which is affected by an 

inflammatory process shall be condemned and, if there is evidence of general 

systemic disturbance, the whole carcass shall be condemned." 

(b) (6)
(B)(6)

(B)(6)

(B)(6) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD5106103 

107N-1 

10/07/2013 01D01 SPS Verification C On 10/06/2013 I observed the Giblet Chiller Tank. Chilled water circulates around 

numerous stainless steel pipes that contain the Giblets on the interior of the 

pipes. The Exterior of these pipes in the chilling tank are black in color, 

greasy, grimy with UFM. Mr. , Mr. 

, Mr. 

and Mr. were shown or were verbally notified. This is a violation of 

the following 9 CFR's: § 416.3   Equipment and utensils. 

(a) Equipment and utensils used for processing or otherwise handling edible 

product or ingredients must be of such material and construction to facilitate 

thorough cleaning and to ensure that their use will not cause the adulteration of 

product during processing, handling, or storage. Equipment and utensils must be 

maintained in sanitary condition so as not to adulterate product. (b) Equipment 

and utensils must not be constructed, located, or operated in a manner that 

prevents FSIS inspection program employees from inspecting the equipment or 

utensils to determine whether they are in sanitary condition. 

§ 416.4   Sanitary operations.   (b) 

Non-food-contact surfaces of facilities, equipment, and utensils used in the 

operation of the establishment must be cleaned and sanitized 

(b) (6)
(B)(6) (B)(6)

(B)(6)

(B)(4) (B)(4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0416102 

007N-1 

10/07/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 10/07/2013 at approximately 1225 hours while walking past the 

packaging re-hang area in Plant #2, I observed the following noncompliance. 

An employee was throwing whole breasts with wings attached into a 

brown tub that was designated for fillet pack out.The employee threw a 

breast but missed the tub and it landed on the floor. The 

employee picked up the breast and sprayed it with water from a red hose 

and then put it into the brown tub. The Establishments SSOP states in part 

that 

". 

. I tagged the tub with U.S. 

Retained tag #B31 408090 and asked the lead person to call . 

The lead person dumped the brown tub of breasts into a stainless 

steel mesh cart. The production employee responsible for reconditioning started 

washing the product and  putting them into another stainless 

steel cart. I applied the retain tag to the cart and I started inspecting the product. 

came over and I informed him of the noncompliance. While 

inspecting the product I found two breasts with some black specks, 

UFM (Unidentified Foreign Material) on them. I showed them to 

and he told the employee responsible for reconditioning to condemn the 

product in the cart. I followed the employee to the edible dump room where I 

removed the tag and the product was condemned.My findings indicate a 

noncompliance with regulatory requirements of regulations 9CFR 416.4(d), 9CFR 

416.13(c), and 9CFR 416.1. 

(b) (6)
(B)(6)

(B)(7)(C) (B)(7)(C) (B)(6) (b)(4) (b)(4) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1818103 

907N-1 

10/07/2013 01C02 Operational SSOP 

Review and 

Observation 

C While monitoring the Establishments' Operational Sanitation Procedures at the 

start of the shift at the Re-wrap Room, at approximately 0910 hours, I found 

the following there: at the area just outside of the Re-wrap Room, at the end of the 

line for re-wrap product,  there was two gray baskets stack on 

top of each other. The baskets were covered with blue plastic and were full 

of product. The product was uncovered, dry and had some blacks specks 

UFM (Unidentified Foreing Material) on them. Also on the first basket was a pair of 

green rubber gloves and a ball of already used wrap plastic. The product 

was from the previous day production (saturday 10/05/2013). I immediately 

tagged the gray baskets with U.S Rejected/Retained Tag # B31 

406280. Since no Supervisor was there, I informed 

of my findings.At approximately 1045 hours CSI 

removed the tag and observed when a company employee from the Re-wrap 

Room, took the product to the edible dump room and condemned it.This is a 

noncompliance with the following regulatory requirements of regulation 9CFR 

416.1 and 9CFR 416.4 (d).  

6036 P6164A OIJ0416100 

007N-1 

10/07/2013 04A06 Poultry Finished 

Product Standards 

C On October 7, 2013 I, CSI performed a scheduled Finished 

Product Standard test at the Prechill area.  This test is applied to permit FSIS 

to estimate when the production process is in control for ready-to-cook 

poultry.  The test consists of two parts, trim and processing 

nonconformances.  The absolute limit allowed for processing 

nonconformances is points. My test at 0900 resulted in 45 points.  Plant 

records showed a failure within the last tests and a CuSum above the start 

number of . Specifically the test at 0648 resulted in 44 points and a CuSum of 

19.  The plant implemented the required procedures for FPS failure.  I 

verbally notified that I would be issuing a NR. 

 Plant records show no failures occurred at Post chilland the plant achieved 

two passing tests a t Prechill at 0945. No further failures occurred for the remainder 

of the shift. The Prechill nonconformances I observed were:   1 

ingesta < 1/16” (1 pt),  3 partial oil glands (3 pts),   2 partial 

lungs (2 pts),  5 whole lungs (10 pts),   1 bursa (2 pts),  3 

small feathers (3 pts),  4 large feathers (4 pts),  and 9 long hocks (18 

pts). On September 25, 2013 NR # OIJ3321093125N (#72) was issued for 

processing noncompliance. This noncompliance is linked to NR # OIJ3321093125N 

(#72) for the same root cause.  The Establishment Awareness Meeting notes 

show that FPS NRs were last discussed at the September 26, 2013 meeting. 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(4) (B)(7)(C) (b)(4) (b)(4) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1605100 

305N-1 

10/05/2013 03J02 Slaughter HACCP C On 10/05/2013 at approximately 0108 hours while conducting a Pre-Chill Finished 

Products check on line , I observed the following. After taking a standard 10 bird 

random sample, I observed one carcass with visible fecal contamination. There was 

a small cut at the base of the tail at the junction with the 

saddle on the left side of the carcass. The fecal material was in that tissue 

tear. The fecal material was olive green in color, pasty in texture and 

measured approximately 1/8" by 1/4". This exceeded the Zero Tolerance for the 

process to be in control. I contacted and the protocol for fecal 

failure was implemented. A QC recheck passed at 0135 hours. My finding 

indicated a noncompliance with 9 CFR 381.65(e), 9 CFR 417.2(c)(4) and the CCP-2B

 of the Plant's HACCP Plan for 

Slaughter.    

5112 M18909 JDD2712102 

406N-1 

10/04/2013 01C02 Operational SSOP 

Review and 

Observation 

O On 10/04/2013 at approximately 1320Hrs, Dr. and I observed the plant 

personnel touching the outside (non food contact) and inside of the (food contact) 

casings in the Raw Fabrication Cooler 9 Department. The plastic casing were being 

filled with 95559 ground turkey products. The casings were blowing open inside the 

machine as they were being filled.  The meat was exposed through the 

openings approximately 8" to 4". The exposed meat open casings were dropping 

onto a food contact table. The open casings were landing on 

top of each other on the table. The meat coming out of the casings was touching 

the outside plastic casings.  The personnel was touching the turkey products 

as she struggle to remove the meat from the open rolls. She scooped the meat out 

with her gloved hands and put the affected 95559 turkey into a food contact 

next to the table. She did not change her gloves or sanitize her hands. She did not 

sanitize the affected rolls or table. U.S. Retain Tag NO:B39554112 was applied to 

the affected product in the . was notified 

of the noncompliance. Mr. immediately sanitized another table and 

separated the rolls. The affected exposed meat rolls were opened and 

put into the . The not open plastic casing were sanitized  and put on 

the clean table for rework because the did not meet the net weight. 

(b) (6)
(B)(6) (B)(6) (B)(4)

(B)(4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2105102 

704N-1 

10/04/2013 01D01 SPS Verification C On 10/04/2013 at approximately 0100 hours while performing a scheduled SPS 

Verification procedure in Plant #2, I observed the following. There were loose 

stainless steel splinters at three locations on a guide bar located behind the 

mirror at the middle inspection station on line .  The guide bar is 

approximately 2' in length. Two splinters were attached to the top of the bar and 

one was attached to the bottom. The splinters were approximately 4mm and 

(2) 12mm in length. The Guide Bar is approximately 1/4" thick with the wear 

process caused by the metal to metal contact between the Guide Bar and 

the stainless steel carcass shackles. Approximately 1/2 of the 

guide bar has worn away. With the guide bar directly above the 

carcasses  metal splinters flaking off are creating a Physical 

Hazard condition. Metal of any size on or in a carcass would be 

considered a contaminant by USDA. I contacted who called a 

mechanic.  The guide bar had raised flattened edges that were 

the source of the splinters.   Mechanics scraped off the raised edge 

removing pieces of varying size from 1mm to over 2" in length and up to 

approximately 2mm wide. A piece of emery cloth was used to remove any 

remaining loose pieces. The area was rinsed with potable water and released by 

approximately 0115 hours. The establishment has no metal detectors. 

  I gave a sample to . The 

metal to metal contact creating a Physical Hazard has been occurring for 

sometime. A review of the Establishments' Haccp Plan - Slaughter Plant 

2 which was last revised on July 9, 2013 states under 

nbsp; This issue has been discussed at several weekly 

meetings with the Plant Management. My findings indicated a 

noncompliance with 9 CFR 416.1 and 9 CFR 416.2(b)(1). 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(4) (B)(4)

(B)(4)

(B)(4)

(b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3818105 

904N-1 

10/04/2013 03J02 Slaughter HACCP C At approximately 1500 hours while performing a HACCP Slaughter Record Review 

Task, I found a noncompliance with the following regulatory requirements of 

regulation 9CFR 417.2 (c)(4).1.-The HACCP Monitoring Log -CCP 1B-

) for Line dated on 09/27/2013 AM shift had the 

following Zero Tolerance checks times: One check at 0518 hours and the 

following check at 0637 hours. The gap between these two checks was 

1 hour and 19 minutes.2.-The HACCP Monitoring Log -CCP1Bfor Line , dated on 10/02/2013 AM shift had the 

following Zero Tolerance checks times: One check at 0520 hours and 

the following check at 0636 hours.  The gap between these two 

checks was 1 hour and 16 minutes. The HACCP Plan states in part under 

monitor procedures that  " 

". * A 

unit may be a carcass or a part.  "Approximately is defined as 15 (-)(+) 

minutes". I notified  of the 

noncompliance. 

1325 

7 

P33900 NHH310410 

0104N-1 

10/04/2013 01C02 Operational SSOP 

Review and 

Observation 

C On the night of production that began on October 3, 2013 at approximately 2150 

hours while observing the start of operations in the evisceration department I 

observed an unlabelled plastic spray bottle hanging on a hook used to hang birds at 

the line 1 mirror station.  The outer surface of the bottle including the handle 

was greasy and dirty thereby contaminating the hook (product contact 

surface).  The bottle was approximately one fourth full of an unidentified 

liquid.  The hook and the bottle were rejected with US tag 

B38075936.  At the time, no product was on or near the hook.  Mr. 

, was notified of the noncompliance.  The 

establishment elected to discard the bottle and cleaned and sanitized the 

hook.  As a verbal preventive measure, Mr. stated maintenance 

employee would be retrained to properly label containers and not to hang them on 

product contact surfaces.  The regulatory control actions were then 

released.  The establishment’s SSOP plan states

 The requirements of 9 CFR 416.4(c) and 416.13(c) were not met. For a 

similar noncompliance refer to NR NHH5202082501N dated July 31, 2013.  

The preventive measure for this noncompliance was pipes would be removed from 

the production area prior to the start of production.  These measures may 

have been implemented incorrectly or may have been ineffective at preventing 

recurrence. 

(b) (6)
(B)(6) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5112 M18909 JDD1911101 

703N-1 

10/03/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C While performing PRE-OP this date 09/30/2013 at 0400 H PST above the 

south end of Chiller B is a fan with flaking rust over the Carcass Chiller B. The 

following noted in Boning: 1): Product residue in the Tendon Puller. 2): Shrouds on 

the Frame Work of the MDP Motor was not disassembled an much product 

residue was noted. 3): Pallet Jack had product residue on it. 4): Two incidences of 

product residue in the Spiral Belt. 5): Belt Cog on the Thigh Skinner had product 

residue in it. 6): Cooler Ten: Three SS Tanks from sister facility has product residue 

in it. 7): The Door to Room by the Rosier is rusty. 8): Motor, Piping  Etc. 

under the Injector in Bagging needs reconditioning as it is rusty with flaking paint. 

Items noted were corrected by Sanitation, Maintenance or are programmed to be 

fixed. Ms. was notified by e-mail. This is linked to NR 

122-2013, Dated 09/27/2013, JDD00080955127N/1 and Seven other 

JDD # numbers listed on NR 122-2013. This is a violation of the Establishment's 

written SSOP Procedures and the following 9 CFR's: 

§ 416.4   Sanitary operations. (a) All food-contact 

surfaces, including food-contact surfaces of utensils and equipment, must be 

cleaned and sanitized as frequently as necessary to prevent the creation of 

insanitary conditions and the adulteration of product. (b) Non-food-contact 

surfaces of facilities, equipment, and utensils used in the operation of the 

establishment must be cleaned and sanitized as frequently as necessary to prevent 

the creation of insanitary conditions and the adulteration of product. (d) Product 

must be protected from adulteration during processing, handling, storage, loading, 

and unloading at and during transportation from official establishments. 

§ 416.14   Maintenance of Sanitation SOP's. Each official 

establishment shall routinely evaluate the effectiveness of the Sanitation SOP's and 

the procedures therein in preventing direct contamination or adulteration of 

product(s) and shall revise both as necessary to keep them effective and current 

with respect to changes in facilities, equipment, utensils, operations, or personnel. 

(b) (6)
(B)(6) (B)(6) (B)(7)(C) (B)(6) (B)(6) (B)(6)

(B)(6)

(b)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5129 M210 LQN251210 

4903N-1 

10/03/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C At approximately 0540 while performing hands on Pre-Operational Sanitation after 

company Pre-Operational Sanitation and before the start of production I observed 

the following noncompliance's in Zone D, Catering-rapid pack #1.Observed 1 knife 

holder on the side of the production belt with meat particules from the previous 

days production inside the knife holder all around the inside at the bottom.Also 

observed build up of material from previous days production on 5 rubber strips 

(5"highX6"long) which make up the steam guard at the front of the 

shrink tunnel. There were 2 rubber strips with buildup from the previous days 

production  (1/2"wideX 5"long) at the exit of the shrink tunnel.The knife 

holder is a direct product contact surface, and the rubber strips on the shrink 

tunnel are product contact surface which could create cross contamination.This is a 

noncompliance of Regulations 416,4(a), 416.13(c) and a failure of the company 

SSOP Plan Pg 2, I. , and were notified and 

observed the noncompliance's. Immediate corrective action was implemented to 

restore sanitary conditions in my presence.This NR is being linked to NR 

LQN3314090018N/1 dated 09/18/2013.This document serves as written 

notification that your failure to comply with regulatory requirement(s) could result 

in additional regulatory or administrative action. 

1325 

7 

P33900 NHH270310 

4603N-1 

10/03/2013 03J02 Slaughter HACCP C On the night shift that began on 10/02/2013, from 2245 until 2305, while giving 

relief breaks to the line inspectors, Dr. and I observed a large 

amount of carcasses that displayed cloacaes and intestines attached to the 

carcasses.  At approximately 0100 I went to the exit end of the chiller system 

to verify that all of these cloacaes and intestines had been removed.  I 

inspected approximately 20 carcasses and found 4 with cloacaes and intestines still 

attached to them.  On the fourth carcass that still displayed an intestine, I 

observed feces on the inside of the carcass.  The fecal material was tanish 

brown in color and smeared easily to the touch.   The two spots of 

feces were each approximately 1/8 inch in size.   Two of the in the 

area (Mr. and Mr. ) were shown the feces at this time. 

  I had randomly selected the carcasses to sample from the designated Post 

chill collection point, located at the station designated by the Establishment.  

There are no other check points and/or employees stationed between where the 

carcass was selected from the line and the point where they enter the rehang 

area.  The carcass was also shown to Mr. .  Mr.

 was also notified.    The establishment failed to meet the 

requirements of 9 CFR 417.2 (c)(4) and 9 CFR 381.65 (e).   For similar 

noncompliance refer to NR #NHH4104053703N /1, dated 05/03/2013. 

(b) (6)
(B)(6) (B)(6)(B)(6) (B)(6) (B)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5129 M210 LQN251510 

2502N-1 

10/02/2013 01D01 SPS Verification C At approximately 13:10 while performing SPS verification I observed light from the 

outside coming in under the left corner (2inchX2inch) of the exit door 

between pest boxes 28&29 and over the doors top right 

hand corner (12 inches long) The door is in the raw oven staging area 

behind the weighing scale. This is a non compliance of Regulation 416.2(b)(3).Also 

observed peeling paint (3inchX 4inch), (2inchX 2inch) on the wall behind the 

salt mixing tank, and several places up the wall. I observed small pieces (1/4") 

of white peeling paint on the walls behind the guard rails (24 plus feet in lenght) on 

both sides of the hallway just inside the swinging doors from cooler #3, 

leading to the raw side oven area.This is a non compliance of Regulation 

416.2(b)(2).Also observed 2 holes- 1 (12"X 8") and 1 (3"X4") in the 

floor topping in Raw Cooler #2 in a high traffic area. This is a non compliance of 

Regulation 416.2(b)(1).These non compliances are a noncomplianc of Regulation 

416.1. and were notified and observed the 

noncompliances.This document serves as written notification that failure to comply 

with regulatory requirement(s) could result in additional regulatory or 

administrative actions. 

5308 M6137 BXL2713104 

402N-1 

10/02/2013 04A06 Poultry Finished 

Product Standards 

C On 10/02/2013 at 1050 hours, while monitoring the Establishments AQL Procedure 

in Plant #1, I randomly selected ten livers. Three out of the ten livers 

had whole spleens attached and one liver had a whole gall bladder attached. This 

exceeds the limit of incomplete trim-major defects for the process to be in 

control. I informed and of 

the noncompliance. Quality Control performed a recheck at 10:53 hours and 

failed with four incomplete trim-major defects and two incomplete 

trim-minor defects.Quality Control retained three tubs of livers. A recheck passed at 

1112 hours, bringing the process back into control. The three tubs of livers were 

reworked and released by Quality Control.This is a noncompliance with regulations 

9CFR381.65(a) and 9CFR381.1 "Giblets". 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6) (B)(6) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4)(b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1905105 

301N-1 

10/01/2013 06D02 Other Inspection 

Requirements 

C At approximately 0139 hours, I performed a presentation check in Plant 1 on Line 2 

at a line speed of ). Station #5 had 4- viscera not 

uniformed, and 2- opening cut for a total of 34 nonconformance points. Station #6 

had 3- viscera not uniformed, 2- viscera attached to carcass, and 1- opening cut for 

a total of 49 nonconformance points. Station #7 had 2- viscera not uniformed, 2-

viscera attached to carcass, 2- opening cut, and 1- parts inside for a total of 43 

nonconformance points. This exceeded the limit of nonconformance points or 2 

occurances for the process to be in control. I informed 

and of the noncompliance, the line speed was 

reduced to At approximately 0205 hours I performed a recheck with the 

line speed at Station #7 failed with 3- viscera not uniformed, and 1-

opening cut for a total of 25 nonconformance points. I informed 

line  of the noncompliance, the line speed was reduced 

to Rechecks at approximately 0231 hours, at a line speed of 

again at approximately 0349 hours at a line speed of and again at 

approximately 0439 hours at a line speed of All rechecks passed bringing 

the process back in control. 

5308 M6137 BXL2211104 

201N-1 

10/01/2013 03J02 Slaughter HACCP C At approximately 0914 hours while performing scheduled Pre-Chill Finish Product 

Standards task I observed the following noncompliance.  After taking a 

random 10 bird sample from Line in Plant #2, I observed one carcass with visible 

fecal contamination.  There were two spots of fecal material on the leaf fat 

on the right side of the carcass, both pieces measuring approximately 1/4" x 

1/8" in size.  The fecal material was brownish green in color and thick and 

pasty in texture.  I immediately informed and

 of the noncompliance.  The Protocol for fecal failure was 

implemented.  Quality Control performed a recheck at approximately 0946 

hours which passed, bringing the process back into control.  My findings 

indicate a noncompliance with 9CFR 381.65(e), 9CFR 417.2(c)(4) and the critical 

limits of CCP2B, of the Plants HACCP Plan for 

Slaughter. 

(b) (6)
(B)(6) (B)(6) (B)(6) (B)(6) (B)(4) (B)(4) (B)(4)

(B)(4)

(b)(4) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2708101 

801N-1 

10/01/2013 04A06 Poultry Finished 

Product Standards 

C On 10/01/2013 at approximately 0217 hours while monitoring Pre-Chill Finished 

Product Standards on line I observed the following. After taking a standard 10 

bird sample I accumulated 50 nonconformance points. 30 points were from whole 

lungs. At this point CUSUM exceeded  the Action Number allowed 

(22) so the process is judged to be out of control.  I contacted

 who slowed the line to birds per minute. Normal line speed is 

birds per minute.  Three extra personnel were placed at the end of the line 

to manually remove the lungs as there is no vacuuming facility available at 

that location.  A QC recheck passed at 0226 hours. As product from lines 

& B are mixed coming out of the chiller, Post-Chill checks passed at 

0321 hours and 0336 bringing the process back into control. The line was repaired 

and the line speed was returned to birds per minute at approximately 0420 

hours. My findings indicated a noncompliance with 9 CFR 381.76(b)(3)(iv)(e)(3). 

5568 M20923 XUM021210 

0401N-1 

10/01/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C At approximately 0725 hours, while performing a routine PHIS task Pre-op review 

and observation inspection task (after establishment performed their 

pre-operational inspection and prior to start of production), I observed the 

following noncompliance: Line 2, Cook side of the establishment: I found few pieces 

of food crumbs on blue add back conveyor belt and the also on the back stainless 

plate from the previous day of production. Upon continuing my inspection Line 

found few pieces of food particles on takeaway and transfer conveyor belt also from 

the previous day of production. I took a regulatory control action and applied USDA 

retain/rejected tag# B24829895. I informed 

and and of the non-compliance. The finding 

described in the non-compliance was on the food contact surface, it is reasonable to 

conclude that when production began it would be under insanitary conditions. 

Immediate corrective action was performed by establishment on all affected areas 

upon notification of my finding. After sanitary conditions had been restored, I 

relinquished the regulatory control action at 0800 hours. Plant SSOP Section1, 

page1, states: " 

". 9CFR 416.13 (c) states: "All establishment shall monitor daily the 

implementation of the procedures in the sanitation SOP's". 9CFR 416.4 (a) states: 

"All food contact surfaces, including food-contact surfaces of utensils and 

equipment, must be cleaned and sanitized as frequently as necessary to prevent the 

creation of insanitary conditions and adulteration of product". This document 

serves as written notification that failure to meet these regulatory requirement(s) 

could result in additional regulatory or administrative action. 

(b) (6)
(B)(6) (B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

1325 

7 

P33900 NHH460010 

4801N-1 

10/01/2013 06D02 Other Inspection 

Requirements 

C On the night shift that began on 09/30/2013, at approximately 2115 hours I asked 

the Evisceration supervisor, Mr. , to perform a test in the picking 

room of the establishment.  This Establishment uses a batching system of 

inspection, if the carcass is condemned or hung back for re-inspection the paw 

condemn button is pressed and a batch of paws are condemned.  This 

insures that all paws from condemned carcasses are also condemned.  

    The result of the test was that the establishment could not collect 

but three of the paws that are marked to show that all condemned paws would be 

captured and condemned on line #2.  Mr. diverted all paws from 

this system to the drain so no Regulatory Control Action was taken.   Line 

#1 segregated and condemned all 4 of the marked paws, so this line was allowed to 

collect paws from this system.   At approximately 2230 another test was 

performed on the line #2 system and the results were that all the paws were 

segregated and condemned.  This allowed the Establishment to begin 

collecting paws from that line also.    The requirements of Regulation 

381.76(b) were not being met.   Refer to NR NHH4620090922N / 1 dated 

09/22/2013 for similar noncompliance.      

(b) (6)
(B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (B)(4) (b)(4) (b)(4) (b)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4305093 

430N-1 

09/30/2013 01D01 SPS Verification C On 09/30/2013 at approximately 0100 hours while performing an 

 SPS Verification task in Plant 2, I observed the following. There was 

rust on the painted support brackets for the kickout assembly on the first 

inspection for Line . There was rust on the support brackets for the motor 

assembly for Line at the same location. There was rust and peeling paint on a 

section of a dead end electrical conduit over the IOBW (inside/outside bird washer) 

over line that extends over the presenters area through line and At the 

second inspection station of line the light support bracket that measures 

approximately 2" by 15' has peeling paint. Mounted on the ceiling over the Liver 

& Heart machine are two support brackets for the rail that each 

measure approximately 3" by 15' both are rusted. At the third inspection station 

for line over the gray wing salvage container there is a support bracket that 

measures approximately 2" by 20' that has peeling paint. Over the Liver & 

Heart machine on line is a bracket that measures approximately 2" by 6' that is 

rusted. Over the Gizzard Puller for line a bracket that measures approximately 

2" by 3' is rusty. At the backup gizzard pullers station a pipe holder that measures 

approximately 2" by 20' is rusted. Near the Liver & Heart machine for line 

ia a pipe hanger that measures approximately 2" by 2' that has rust and peeling 

paint. Over the backup gizzard pullers station there was a bracket measuring 

approximately 2" by 10' that is rusty. Over the Lunger for line a bracket that 

measures approximately 4" by 4' is rusty. A 4" dead end pipe near the ceiling 

at the same location is rusty. Two brackets over the bird washer for line 

are rusty. On line there are two support brackets over the bird washer 

that are rusted. A 4" air pipe over the Liver & Heart machine has peeling paint. 

At the third inspection station there was rust on the painted brackets for the 

kickout.  The painted surfaces of the kickouts for line & at all 

three inspection stations are rusty/peeling paint. Over the Gizzard Puller backup 

station for line there are three pipe hangers that are rusted. A support bracket 

measuring approximately 3" by 10' over the bird washer for line 

 is rusty. Rust and corrosion and peeling/flaking paint directly over 

exposed product passing down the Evisceration line is creating an insanitary 

condition.  My findings indicated a noncompliance with 9 CFR 416.1 and 9 

CFR 416.2(b)(1).          

(b) (6)
(B)(6) (B)(6)

(B)(6)

(B)(6) (B)(7)(C) (B)(7)(C) (B)(6) (B)(6) (B)(4) (B)(4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN241609 

1630N-1 

09/30/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C On 9/30/13 at approximately 1445 hours I observed the following while performing 

the Zero Tolerance procedure on line # 2 at the FPS station . After pulling a ten bird 

 random sample I noticed the back side of one bird with 

dark green spots were the oil gland had been removed .  The area was 

approximately 1 sq inch size . I immediately reported my findings  to

 who observed the bird and contacted 

Evis/Pkg. Dept.  while 

nbsp;performed a  recheck . requested further 

disposition  from Dr. . After confirmation by  Dr the 

establishment was informed of the noncompliance. My finding indicate 

noncompliance with regulation 9CFR 381.65(e) which states that carcasses 

contaminated with fecal material shall be prevented from entering the chiller tank 

the establishments, the criteria for  CCP 1B was also compromised .   

. 

5568 M20923 XUM542209 

5830N-1 

09/30/2013 01D01 SPS Verification C On 9/30/13, at approximately 2028 hours, while performing a routine scheduled 

Sanitation Performance Standard (SPS) inspection task on the Cook Area Line by 

the north portion of the Oven Room, I observed the following noncompliance: 

leaking water from piping to the belt wash pump creating insanitary conditions of 

flooded standing waste water on the flooring by the electrical room door a 

noncompliance per 9 CFR 416.1 and 416.2(e)(2). This type of environment can 

possibly grow and spread food borne pathogens such as Listeria Monocytogenes. I 

took regulatory control by rejecting the area with US Tag # 147503. I showed and 

informed Mr. of the forthcoming 

noncompliance. After corrective actions were performed by production and sanitary 

condition were restored, I relinquished the US Tag at 2048 hours. The requirements 

of 9 CFR 416.1 and 416.2(e)(2) were not met. A similar noncompliance 

XUM5919094917N/1 was documented on 09/17/2013. 

5568 M20923 XUM542209 

5830N-2 

09/30/2013 01D01 SPS Verification C On 9/30/13, at approximately 2036 hours, while continuing my Sanitation 

Performance Standards (SPS) inspection check, on the Cook Area Cooling Line 

Mezzanine, I observed the following noncompliance: two plumbing pipes that 

provide water for the upper mezzanine leaking water creating insanitary 

conditions, a noncompliance per 9 CRF 416.2(e)(3) and 416.1. This condition 

was leaking water to the mezzanine floor causing standing water. I showed and 

informed Mr. of the forthcoming 

noncompliance. The requirements of 9 CFR 416.2(e)(3) and 416.1 were not met. 

(b) (6)
(B)(6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5769 M6492 DIO4902091 

230N-1 

09/30/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C At approximately 2315 hours I started my Pre-operational Review and Observation 

task upon learning from the QC  that the area(Raw Processing) is ready for 

Inspection. I noticed at kettle number 7 that there are specks of debries of unkown 

origin which is black and hairlike of about 1/16”x1/8” to 1/16”x3/8” of an inch 

scattered at the center of the kettle which numbered to approximately 100 specks. I 

called the attention of and he immediately called the 

Sanitation worker to clean up the said debries. Had this contaminants not been 

found, it will potentially contaminate and adulterate the product that will be 

produced in that kettle. This is in violation of Title9CFR416.4(a) and 9CFR416.13(c) 

  9CFR416.4(a)All food-contact surfaces, including food-contact surfaces of 

utensils and equipment, must be cleaned and sanitized as frequently as necessary 

to prevent the creation of insanitary conditions and the adulteration of product. 

  9CFR416.13(c) Each official establishment shall monitor daily the 

implementation of the procedures in the Sanitation SOP’s. 

1325 

7 

P33900 NHH411109 

2330N-1 

09/30/2013 01D01 SPS Verification C At 0952 hours while performing a Sanitation Performance Standard task  I 

came across 11 combos of product that were 

labeled "Inedible" and placed in the inedible section of the back 

cooler that did not have denaturant applied. There were 8 combos of  livers 

and 3 which contained bones. Management was notified and shown the 

combos. CFR 381.95 states that denaturing shall be accomplished by liberally 

applying it to all of the carcasses and parts. These requirements were not met; 

therefore, US reject tag #B36322955 was applied to the cooler.The same 

noncompliance was reported in Noncompliance Records 

NHH4811092411/1  on 09/11/2013 and NHH4612063721/1 on 

06/21/2013. Efforts to prevent the recurrence of this noncompliance either have 

not been made or have not been effective. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (7)(C) (b) (7)(C) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN241609 

1630N-1 

09/30/2013 03J04 Poultry Zero 

Tolerance 

Verification 

O On 9/30/13 at approximately 1445 hours I observed the following while performing 

the Zero Tolerance procedure on line # 2 at the FPS station . After pulling a ten bird 

random sample I noticed the back side of one bird with dark green spots were the 

oil gland had been removed . The area was approximately 1 sq inch size . I 

immediately reported my findings to 

who observed the bird and contacted while

 performed a recheck . requested further 

disposition from Dr. . After confirmation by Dr the establishment was 

informed of the noncompliance. My finding indicate noncompliance with regulation 

9CFR 381.65(e) which states that carcasses contaminated with fecal material shall 

be prevented from entering the chiller tank the establishments, the criteria 

was also compromised . . 

5308 M6137 BXL5322094 

125N-1 

09/25/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 09/24/2013 at approximately 2225 hours while monitoring Pre-Operational 

Sanitation Procedures in Plant #1, I observed the following. There was Black/Brown 

UFM(Unidentified Foreign Material) on the metal brackets associated with the 

Check/Weight unit that the shackle wheels run on for lines 1& 2. The area was 

washed but upon reinspection the flakes of UFM washed from the unit had 

migrated to a puddle of water directly in front of the wash cabinet. The drip 

tray at this location drains back into the unit. The drip tray and unit 

are considered product contact surfaces. The UFM buildup is coming from the chain 

which is very rusty and will be acid washed along with the Check/Weight Unit on 

Saturday. There was a brown film residue along approximately a 20' section of the 

drip tray associated with Unit for lines The drip pans are near the 

ceiling and only partially accessible with a ladder for cleaning. A sanitizer was 

applied. The brown film is rust as it returns when the surface of the drip pan drys. 

The area was released at approximately 2250 hours. At approximately 2355 hours 

in Packaging Area #1 there were several areas of black UFM that appeared to be 

mold on the white nylon portion of the support brackets associated with the tray 

lines for product lines The areas affected by the UFM varied in size from 

approximately 1' to 6' in length. The center product collection belt for leg 

processors 7-9 that collects the legs was covered with black UFM that smeared like 

grease. The block of leg processors is not being used as Plant #2 is closed. The 

cracked surfaces and frayed edges of the belt were extensive so instead of cleaning 

the belt a work order was placed to replace the belt. Sanitary conditions were 

restored be approximately 0015 hours. My findings indicated a noncompliance with 

9 CFR 461.1, 9 CFR 416.4(a) & (b), 9 CFR 416.2(b)(1) and 9 CFR 416.13(c). 

(b) (6)
(b) (6) (b) (6)

(b) (4)

(b) (4) (b) (4)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1109091 

021N-1 

09/21/2013 01D01 SPS Verification O On 09/20/2013 at approximately 0520 hours while monitoring Operational 

Sanitation, I observed the following. Packaging workers were leaving the Plant #2 

restroom/break room area after lunch. There was a thick layer of black UFM 

(Unidentified Foreign Material) on the floor in the hallway outside the mens 

restroom and on the floor inside the Weigh & Price packaged products storage area 

that Packaging employees were using to return to the Packaging area. I went inside 

the restroom area that consists of three sections. A space to hang aprons and 

smocks, the hand washing area, and the toilet and urinal area. The entire floor was 

wet with potable water leaking from a cleaning unit mounted on the wall, from a 

water supply valve for one of the toilets, and from the supple valve for one of the 

hand wash sinks. There was a strong odor of urine. There is only one floor drain. The 

floors are not sloped toward the drain. There was black UFM covering virtually the 

entire floor area with the heaviest concentration in the front of each urinal, toilet 

and along both hand wash sinks. In the toilet stalls there were numerous pieces of 

tissue on the floor some that has been there for some time as the tissue was 

dissolving into the liquified black UFM. The establishment has no boot scrubbers so 

the UFM is being collected on employees boots to be deposited onto the Packaging 

floor. The majority of the UFM is coming from the Weigh & Price cooler floor as the 

'A' side is covered with brown liquified UFM. There are no Sanitation Supervisors 

available so I contacted and showed him the insanitary 

condition. Building maintenance was called to fix the leaks. The employee that 

'Cleans' the space during Operations was contacted. The employee does not know 

how to use the cleaning station equipment mounted on the wall, so she used a 

spray bottle of degreaser and a bottle of toilet bowel cleaner which did little to 

clean the floor. Until the leaks were fixed cleaning the floor was wasted effort. The 

exhaust fan does very little to help dry up the area. A review of the establishments' 

SSOP Pre-Operational Sanitation under daily cleaning states 

. I talked to who said restrooms are 

cleaned . The establishments' General Sanitation records do not 

include 'restrooms' so it is unlikely that a Supervisor observes that the spaces are 

satisfactory prior to operations. The Establishment's SSOP under Operational 

Sanitation does not reference how restrooms are maintained to prevent the 

creation of an insanitary condition during operations as required by 9 CFR 416.4(b). 

The Establishment' SSOP for product that comes 

in contact with an insanitary condition i.e. a Cooler Floor that the product will be 

. My findings indicated a noncompliance with 9 CFR 416.1, 9 

CFR 416.2(b)(1) and 9 CFR 416.2(b)(2). 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (4)

(b) (4)

(b) (4)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1206094 

021N-1 

09/21/2013 01C02 Operational SSOP 

Review and 

Observation 

O On 09/21/2013 at approximately 0035 hours while monitoring Operational 

Sanitation at startup in Packaging, I observed the following. There was numerous 

specks and streaks of black and brown UFM (Unidentified Foreign Material) that 

smeared like grease on the center product belt that collects the cut legs and leg 

quarters from leg processors #4-6. The largest area of UFM was over 1 foot long 

and approximately 1" wide. was nearby so I showed him the UFM. 

No product was yet on the belt. was called and he stopped 

the line. Sanitation workers were called and brought an 

unmarked bottle with a clear liquid, a green scouring pad and some paper towels.

 applied the fluid from the spray bottle. The belt was scrubbed and 

wiped for several minutes until the UFM no longer appeared. Flushing the belt 

would have washed contaminants onto the main product belt for line . The line 

was released at approximately 0045 hours. As the cleaning solution bottle was not 

labeled, I asked what was in the bottle. He said he was not sure. I 

sprayed the fluid onto my hand. It gave off no soap, chlorine or sanitizer odor but 

the fluid did have an oily texture. I asked if he knew what the fluid 

was, he said no. I took the bottle to the mechanics office in plant #1 and showed it 

to the lead mechanic who said it was mineral oil used to lubricate equipment at 

startup and that someone had likely grabbed the wrong bottle. I returned to 

Packaging and informed of the oil. A review of the 

Establishments' SSOP for Operational Sanitation states 

The Operational SSOP does not mention that mineral oil 

can be used to clean or sanitize any product contact surfaces. Under Corrective 

Action the SSOP states 

but it does not say how. A review of the Establishments' Hazard Analysis - Raw Not 

Ground -

My 

findings indicated a noncompliance with 9 CFR 461.1, 9 CFR 416.12(a), 9 CFR 

416.14 and 9 CFR 416.15(b). 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6) (b) (7)(C) (b) (4)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4704091 

421N-1 

09/21/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 09/20/2013 at approximately 0500 hours while performing the weekly AQL 

Finished Products Standards check on giblets exiting chiller #4, I observed the 

following. I placed the lid from a brown product tub under the exit end of the giblet 

chiller to capture a random sample of livers. One of the livers exiting the chiller had 

visible fecal material measuring approximately 3/8" by 1/8", olive green in color 

and pasty in texture. I called and showed him the fecal material. 

The brown tub of livers being collected from the giblet chiller was condemned and 

placed into a gray inedible container. The livers are finished product having received 

final microbial intervention with up to while being 

chilled. The livers are normally used as part of the giblet pack placed unwrapped 

back into whole frying chickens. A review of the establishments' HACCP 

Plan -

My findings indicated a noncompliance with 9 CFR 

416.1 and 9 CFR 416.4(d). 

5333 P7632 HYE120809 

2921N-1 

09/21/2013 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 0436 hours in the Evisceration department I, CSI , 

observed that the heart harvester for line #2 had overflowed to the point that a 

large pile of hearts where on the floor. Also the viscera condemn chutes for USDA 

inspection stations #3 and #4 were clogged overflowing with condemned parts and 

visceras. With the drain being clogged in two spots water flooded the area between 

lines #1 and #2 from station #2 to #4. I showed my findings to 

then notified them of the 

noncompliance for the failure to meet the regulatory requirements cited above.

 took a immediate corrective action by having one lead person 

unclog the drain and a mechanic unclog the heart harvester. The maintenance 

employee used the stainless steel lid of the harvester to unclog the harvester, the 

lid was covered with water, meat, and fat particles from the days production.

 stopped the pump to the harvester then instructed the employee 

to empty and sanitize the equipment. Sanitary conditions were restored at 0455 

hours. 

(b) (6)
(b) (6) (b) (6) (b) (7)(C) (b) (7)(C) (b) (6) (b) (4)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4808095 

320N-1 

09/20/2013 04A06 Poultry Finished 

Product Standards 

C On 09/20/2013 at approximately 2335 hours while conducting the weekly AQL 

Finished Product Standards check in Plant #2 from product exiting Giblet Chiller #3, 

I observed the following. There were numerous pieces of ingesta on all 10 necks 

taken as part of the sample. I counted 50 nonconformance points (minors) from 

ingesta and 2 majors. The limit for the process to be in control is 5 majors and 14 

total nonconformance points. This is finished product that is normally treated with 

up to during chilling. The establishment places the necks 

back into the whole carcasses as part of an unwrapped giblet pack in Packaging 

prior to the carcasses being bagged. I contacted who checked the 

product being collected in the neck collection tank. The entire tank of product was 

condemned and taken to the edible dump room for disposal. An employee was 

assigned temporarily to sort the necks from chiller #3. The AM shift does not 

normally have a person that sorts out the contaminated product full time but uses 

the employee that scales the tubs of giblets to sort product when time allows. A 

review of the Establishments' HACCP Plan -

My findings indicated a noncompliance with 9 CFR 

381.76(b) and 9 CFR 381.65(a). 

5333 P7632 HYE440809 

1620N-1 

09/20/2013 01D01 SPS Verification C While in the Evisceration department at approximately 0052 hours on September 

20, 2013 I, CSI , and CSI observed the following 

noncompliance. Between Evisceration line #1 and the South Chiller I observed black 

mold and fat residue on the South Chiller's splash guards (clear plastic curtains) and 

on the orange handle of the long hook utensil used to unclog the neck separator. 

On the chiller's splash guards I found holes in the plastic curtains for the purpose of 

tying them together and also cracks from wear and tear. In these holes and cracks 

black mold and fat residue had build up from the previous days productions. Upon 

further inspection I observed that the unused post chill evaluation station's 

overhead light also had black mold forming on it. I showed my findings to 

and notified them of the failure to meet the regulatory requirements cited above. 

, was also notified of the noncompliance. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (7)(C) (b) (7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3014095 

719N-1 

09/19/2013 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 0842 hours while I was walking from the end of Chiller #1 in Plant 

#1 to Chiller #2, to perform my Post Chill task, I observed the following 

noncompliance. While I was walking by the Sizing Lines Drop #1 I happened to look 

inside the large grey bin lined with blue plastic that was staged there for product 

and observed a carcass on top of the pile of birds in the bin that had numerous 

pieces of black UFM (unidentified foreign material) on the thigh of the left leg. The 

pieces of UFM measured anywhere from approximately 1/4" in length x 1/8" in 

width to small tiny specks. On further investigation I found one more bird near the 

top of the pile that had a small speck of black UFM located on the breast at the 

opening cut. I immediately took regulatory control action and tagged the bin with 

USDA Retain tag #B31 408085 and informed and

 of the noncompliance. immediately had a 

company employee remove the bin of carcasses from the end of the sizing belt and 

washed it, restoring sanitary conditions to the belt. The bin was taken to have the 

carcasses reworked. USDA was notified that the carcasses had been reworked and 

CSI went to check the carcasses and found them to be clean, restoring 

sanitary conditions. CSI then removed my tag at approximately 1000 hours. 

My findings indicate a noncompliance with the regulatory regulations of 9CFR 416.1 

and 9CFR 416.4(d). 

5308 M6137 BXL4508093 

119N-1 

09/19/2013 04A06 Poultry Finished 

Product Standards 

C On 09/19/2013 at approximately 0407 hours while monitoring Post-Chill Finished 

product standards from product exiting Chiller #3, I observed the following. After 

taking a standard 10 bird sample, I accumulated 14 nonconformance point from 

ingesta. This exceeded the Subgroup Absolute Limit of 10 points. I contacted 

. A Quality Control recheck failed at 0408 hours failed with 7 

nonconformance points which exceeded Tolerance the (5) points allowed for a 

recheck. At this point the process is judged to be out of control. Product was tanked 

until rechecks at 0410 and 0415 hours brought the process back into control. My 

findings indicated a noncompliance with 9 CFR 381.76(b)(3)(iv)(e)(3). 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (7)(C) (b) (7)(C) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4808091 

219N-1 

09/19/2013 06D02 Other Inspection 

Requirements 

C On 09/19/2013 at approximately 0451 hours while conducting a Presentation 

check on Line in Plant #2, I observed the following. The first Station had (4) 

viscera on the shackle, (3) not reflective and (3) parts inside for a total of 41 

nonconformance points. This exceeded the limits of 24 points or 2 occurrences for 

one error for the process to be in control. A total of over 40 nonconformance points 

requires an immediate reduction in line speed. I contacted 

and informed him of the process being out of control. The line was slowed to 81 

birds per minute.The second station had (1) viscera not uniform, (2) viscera on the 

shackle and (2) membranes for a total of 28 nonconformance points. The third 

station had (1) viscera not uniform, (2) viscera on the shackle, (5) membranes and 

(4) not reflected for a total of 42 nonconformance points. 

was informed and retraining was conducted. Quality Control rechecks 0503 at 81 

birds per minute and 0509 hours at birds per minute brought the process back 

into control. According to the establishments' log for the 

shift the birds being run at the time of the Presentation check 

had an average weight was pounds. My findings indicated a noncompliance with 

9 CFR 381.76(b). 

5308 M6137 BXL4914091 

719N-1 

09/19/2013 04A06 Poultry Finished 

Product Standards 

O While performing the Establishments' AQL procedure at the exit end of Gib Chiller 

#4 in Plant #2, I observed a noncompliance with the following regulatory 

requirements of 9CFR 381.65 (a) and 9CFR 381.76 (b). At approximately 0848 

hours, I took a sample of 10 necks coming out of the Gib Chiller #4, I found three 

necks out of the ten, full of ingesta and counts three minors points each one. I 

found another two necks with some pieces of ingesta and counts two minors points 

each one, I found one windpipe and one incomplete trim that counts one major 

point each one. The total was 13 minor points and 2 major points total of 15 

points. The limit for the process to be in control is 5 majors and 14 total 

nonconformances points. My findings indicate that the process is out of control. I 

immediately tagged the tank of necks with U.S. Retained/Rejected Tag # B31 

407917 and informed Quality Control Personnel and of the 

noncompliance. I released the product to Quality Control and she placed a red hold 

tag # 39833 to the tank. At approximately 0901 hours Quality Control did a recheck 

and passed. The retained product was send to the edible dump room to be 

condemned. 

5308 M6137 BXL2316094 

018N-1 

09/18/2013 01C02 Operational SSOP 

Review and 

Observation 

O At approximately 1250 hours, while performing post-mortem inspection on Line 

, Station in Plant #2 ,Line Food Inspector observed a live fly 

inside a bird. She put the viscera inside the bird to catch the fly. She contacted SCSI

 and CSI and showed them her findings. We contacted

 and showed her the bird with the fly inside. the bird was 

condemned. This is a noncompliance with the following regulatory requirements of 

regulations 9CFR 416.1, 9CFR 416.2 (a) and 9CFR 416.4 (d). 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4003093 

118N-1 

09/18/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 09/17/2013 at approximately 01:27 hours, while performing a Operational 

Sanitation task, I observed the following. At the exit end of chiller #2 in plant 1, a 

drain pan over the production belt had large beaded condensation dripping directly 

onto the product of whole body chickens. was informed of 

the non compliance. The drip pan was immediately wiped off product was 

reconditioned and sanitation conditions restored at 01:40 hours. My findings 

indicate a noncompliance in regulations 416.4(d), 416.1, and 416.2(d). 

5308 M6137 BXL1208095 

317N-1 

09/17/2013 04A06 Poultry Finished 

Product Standards 

O On 09/17/2013 at approximately 0200 hours while monitoring Facilities in Plant 

#2, I observed the following. Line was stopped and carcasses were collecting at 

the auto-rehang station. I started my stop watch and proceeded to the Paw 

Collection room to see if the automated paw rejection system was functioning. I 

observed the equipment for 10 minutes and not a single paw was being 

condemned. With the system operating properly and the line stopped some paws 

should have been rejected. I contacted and informed him of my 

observations. I reset my stopwatch, pressed the calibration/paw condemnation 

button at the backup body openers station and we proceeded to the paw collection 

room. We observed the function for another 6 minutes and again no paws were 

rejected. was called and I detailed my observations. A mechanic 

was called. The mechanic opened a cabinet mounted on the wall for Line . In the 

cabinet the air pressure gage read zero PSI. The mechanic removed the air supple 

hose, cleared it and reconnected it. The air pressure gage returned to a normal 

range and the paw rejection process started immediately. The paws that had 

collected from line were condemned and taken to the PC plant by 0235 hours. 

The paw automatic reject system is monitored by the establishment. 

According to the Establishments' computer records the checks passed at 

My findings indicated a noncompliance with 9 CFR 381.65(a) and 9 CFR 

381.78(a). 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3000091 

917N-1 

09/17/2013 01D01 SPS Verification O On 09/16/2013 at approximately 1940 hours while monitoring Operational 

Sanitation in the Plant #1 Cooler, I observed the following. The unit 

mounted near the ceiling (W-2) was defrosting. Condensates were dripping from 

the front drip tray associated with the unit onto a pallet of brown tubs and a 

portable conveyor belt located directly under the unit. I contacted

 and showed him the noncompliance. The tops of the brown 

tubs had numerous specks to approximately 1/8" in size of black UFM (Unidentified 

Foreign Material) . An employee was called to move the pallet of product to a dry 

location. Sanitation employees removed the conveyor belt, cleaned it, covered it 

and returned it to the cooler location. The brown tubs, a partial pallet of salvaged 

parts, were rinsed thoroughly with warm potable water and restacked. A mechanic 

arrived and said the problem with the unit was that the door was open 

allowing to much warm moist air into the cooler. Sanitary conditions were restored 

by approximately 2000 hours. My findings indicated a noncompliance with 9 CFR 

416.1 and 9 CFR 416.2(b)(1). 

5308 M6137 BXL5903091 

717N-1 

09/16/2013 01D01 SPS Verification C On 09/16/2013 at approximately 2326 Hrs. while monitoring the overhead 

structure in plant #1 for condensation I observed the following. Line #1 at 

inspection station #3 I noticed that one of two stainless steel drip pans which is 

hanging below several stainless steel pipes, was covered with beaded condensation 

that is directly over the slaughter line,and the salvage line which is carrying 

exposed edible chicken carcasses to and from inspection stations.I notified the 

, and the deficiency was corrected. Sanitary conditions were 

restored at approximately 2330 Hrs. was notified of this 

deficiency. My finding indicate noncompliance with regulations .416.1: Operate in a 

manner to prevent insanitary conditions 416.2(d): Ventilation 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0209092 

314N-1 

09/14/2013 04B04 General Labeling O On 09/13/2013 at approximately 2000 hours while monitoring Operational 

Sanitation in Packaging at the end of the PM shift, I observed the following. There 

was a partial rack consisting of 4 baskets of packaged product in the Crust Tunnel 

and numerous packages of product on the floor. The product included packages of 

Foster Farms and Organic product including whole body and various cutup items 

labeled 'Fresh'. Using a company calibrated thermometer I took the temperature of 

a couple of packages of with the coldest to approximately 19 degrees. I contacted

 and showed him the noncompliance. He said it was not an 

issue as he . I informed 

him that I had previously seen similar product in the Weigh & Price cooler. I 

informed that I would contact and if a 

procedure was not available as to how the Establishment handles this product a 

noncompliance would be issued for the product temperature being labeled as fresh 

while being below 25 degrees. The product was collected and placed in gray product 

baskets under USDA Retained. At approximately 2200 hours in the Weigh & Price 

Cooler there was a partial rack of four baskets near the elevators that was very 

frosty. My thermometer registered temperatures below 25 degrees, I placed the 

partial rack under USDA Retained. At approximately 2300 hours, I contacted 

, the product was to solid to accurately temp but using a company 

calibrated thermometer I show him the thermometer registered approximately 16 

degrees. Again the product consisted of whole body and miscellaneous packed 

items both Foster Farms and Organic labeled 'Fresh'. I checked and the other 

product was still in the Crust Tunnel. The Establishment does not affix a Kill Date or 

Packaged Date on its product but relies on a label that is placed on each rack before 

it enters the 'Crust Tunnel'. The product was not labeled in any manner nor was it 

marked as being frozen. I proceeded to the QC Office and talked to 

who said there was no written procedure and that the product did 

not have to be condemned for being to cold. As a temporary corrective action

 had a label fixed to the three partial racks of product, 

approximately 200 packages. The product was sent to the rewrap room in 

Weigh & Price for down grade and rewrapping into . There are varying 

amounts of frozen product in the crust tunnel daily. However, a review of PHIS 

'Establishment Reporting' of daily Poultry Lot Information from FSIS Form 6510.7 

revealed that the establishment only 'Certifies Fresh' product. My findings indicated 

a noncompliance with 9 CFR 381.129(b)(6)(i) and 9 CFR 381.145(b). 

5308 M6137 BXL0821090 

214N-1 

09/14/2013 01D01 SPS Verification O At approximately 1355 hours, I observed a live juvenile cockroach on the floor 

between the liver tumbler/ belt and the wall in Plant #1. I caught the cockroach and 

immediately showed it to the . She immediately called

 and informed him about my findings. This 

is a noncompliance with the following regulatory requirements of regulations 9CFR 

416.1, 9CFR 416.2(a). 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4820092 

114N-1 

09/14/2013 06D02 Other Inspection 

Requirements 

C While monitoring the Establishments' Reprocessing Procedures on Line in Plant 

#1, I observed a noncompliance with the following regulatory requirements of 

regulation 9CFR 381.91 (b). At approximately 0836 hours, I randomly removed a 10 

bird sample for my reprocessing test, I found one out of ten birds with numerous 

pieces of ingesta by the neck area. I performed a recheck at approximately 0840 

hours, in which two out of the ten birds sample contained ingesta, one had 

numerous pieces of ingesta by the tail area and the other had some pieces of 

ingesta by the neck and breast area. I immediately stopped the Line and informed

 of the noncompliance. They 

started the line and retained the product into a tank. At approximately 0857 hours, 

Quality Control performed a recheck and it passed. I released the retained product 

to Quality Control. The retained product was reworked and released by Quality 

Control. 

5333 P7632 HYE510809 

3614N-1 

09/14/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C While performing a Zero Tolerance verification task in the Evisceration department 

on Evisceration line #1 I, observed the following noncompliance. At approximately 

0555 hours I randomly selected ten chicken carcasses. The tenth carcass of the ten 

had a greenish brown fecal smear approximately 1 inch in length and 1/4 of an inch 

in width located on the left leaf fat. I took regulatory control of the product by 

applying U.S. retain tag B38495430 to the product. I then showed 

, my 

findings and informed them of the noncompliance. , 

performed the recheck as per the establishment's corrective actions passing two 

consecutive ten carcass checks and the carcass was released to . 

This failure represents a noncompliance with regulation 9 CFR 381.65(e), which 

states: "Poultry carcasses contaminated with visible fecal material shall be 

prevented from entering the chilling tank." The failure also represents a deviation 

with the establishment's written HACCP plan, regulatory requirements of 9 CFR 

417.2(c)(4), which states: "List the procedures, and frequency with which those 

procedures will be performed, that will be to monitor each of the critical control 

points to ensure compliance with the critical limits." 

(b) (6)
(b) (6)

(b) (6) (b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6)

(b) (4)

(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0505091 

313N-1 

09/13/2013 01C02 Operational SSOP 

Review and 

Observation 

O On 09/13/2013 at approximately 0025 hours while monitoring the Establishments' 

Post-Chill Finished Products Standards from product exiting Chiller #2 in Plant #1, I 

observed the following. After taking a standard 10 bird sample I accumulated 16 

nonconformance points. This exceeded the subgroup absolute limit of 10 points. 

ust arrived so I showed her the brown residue on the carcass in her 

hand and told her that my Post-Chill check had failed and that her check would be a 

recheck. arrived and was instructed by to tank the 

product exiting the chiller. I took a carcass to 

and showed him the brown/black residue on the bird. I proceeded to Chiller 

#2 and at approximately 0032 hours after taking a standard 10 bird sample I 

accumulated 25 nonconformance points. I told that the carcasses 

exiting Chiller #1 also had the brown/black residue. QC rechecks started at 

hours on Chiller #2 and at hours on Chiller #1 passed bringing the process 

back into control. 9 tanks were placed under QC hold pending reconditioning. The 

brown/black residue on the carcasses is an ongoing issue identified by the 

establishment as high Manganese in the city water. A review of the establishments' 

SSOP Correcting Action Logs under 'What actions were taken or are being taken to 

prevent recurrence...' has consistently stated "Product will continue to be 

monitored by Supervision prior to being put into production." or Maintenance and 

Refrigeration are working on a filtration system. There were no production or QC 

Supervisors at the chiller exit monitoring the carcasses exiting the chillers. The 

filtering system had worked properly Monday thru Wednesday but failed to 

prevent product contamination on Thursday indicating a need for more frequent 

maintenance. This issue was discussed with in 

Production. My findings indicated a noncompliance with 9 CFR 381.76(b), 9 CFR 

416.4(d), 9 CFR 416.12(a), 9 CFR 416.14 and 9 CFR 416.15(b). 

5308 M6137 BXL0907091 

613N-1 

09/13/2013 03J02 Slaughter HACCP C On 09/13/2013 at approximately 0354 hours while conducting a Post-Chill Finished 

Product Standards check from product exiting chiller #1 in Plant #1, I observed the 

following. After taking a standard 10 bird sample, I observed one carcass with 

visible fecal contamination. I had the lead person at the chiller exit tank product 

exiting the chiller and instructed the establishment personnel at the rehang station 

to stop hanging product entering packaging. I contacted and 

showed him the fecal material. The fecal material was located approximately 2" 

inside the carcass on the right side near the kidneys. The fecal material was olive 

green in color, pasty in texture and measured approximately 1/4" by 1/8". This 

exceeded the Zero Tolerance for the process to be in control. There were no QC 

personnel available so I performed a recheck that passed at 0400 hours. Three 

tanks of carcasses were placed on QC hold pending reinspection. My findings 

indicated a noncompliance with 9 CFR 381.65(e), 9 CFR 417.2(c)(4) and CCP-2B 

of the Plant's HAACP plan for Slaughter. 

(b) (6)
(b) (6) (b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4222090 

413N-1 

09/13/2013 04A06 Poultry Finished 

Product Standards 

O On 09/13/2013 at approximately 0030 hours while monitoring 

performing the Paw Verification procedure on Line 1 in Plant 1, I observed the 

following. The marked carcass was coming out of the Venting Machine when the 

line stopped. The carcass and paws are no longer associated at this point as the kill 

line continues on with the paws while the Eviscerating Line with carcasses is 

stopped. The verification procedures which requires the monitoring at the Paw 

Harvester for the tagged shackle is invalid as the paw shackle and the carcass is no 

longer synchronized. found the procedure started at 2329 hours as being 

acceptable as recorded in the establishments computer records. When the line 

stopped the process should have been started over with a new carcass being tagged 

prior to the auto re-hang. A review of the establishments procedure on file as 

written does not state what to do if the line stops and the paw and carcass are 

separated. The Paw Verification process is conducted twice per shift to verify that 

the system is condemning the paws associated with the condemned carcass. Failure 

to conduct the procedure properly would allow condemned paws and adulterated 

product to enter commerce creating a food safety hazard. I contacted 

and detailed my observations. 

discussed the issue with who had perform the 

procedure a second time. My findings indicated a noncompliance with CFR 

381.65(a) and 9 CFR 381.78(a). 

5308 M6137 BXL3408094 

512N-1 

09/12/2013 01C02 Operational SSOP 

Review and 

Observation 

O On 09/12/2013 at approximately 0040 hours while monitoring Operational 

Sanitation in Packaging at startup, I observed the following. There were a few 

specks to approximately 1/8" of black UFM (Unidentified Foreign Material) that 

looked and smeared like grease on the white product cones on Deboning line 

. Production had just started and the plant runs for . I 

contacted and showed him the contamination. They stopped 

hanging front halves(breasts & wings) on line and emptied off the product on 

the line. Production was moved to line #2. The flow of water in the spray cabinet 

that washers the modules was increased. The spray cabinet is on continuously 

during production as the water is used to lubricate the chain. Line was stopped 

and restarted as sanitation personnel removed the modules with the visible black 

UFM. As the line continued to run more and more modules were being 

contaminated with the UFM. After approximately 5 minutes of run time there was 

water with numerous specks of the UFM flowing down the inside and outside 

surfaces of the white product cones. was called and 

the line was cleaned and released for use by approximately 0250 hours. My findings 

indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.2(b)(1) and 9 CFR 416.4(a). 

(b) (6)
(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2722094 

911N-1 

09/11/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 09/11/2013 at approximately 0010 hours while monitoring the establishments' 

Pre-Operational Sanitation Procedures in Packaging Area #1, I observed the 

following. There were numerous pieces of fat and tissue on the top of the belt to 

approximately 1/2" at the base of the blue incline belt that transports breast fillets 

from the x-ray machine to a trim station. There were also numerous pieces of fat 

and tissue to approximately 3" on the white nylon support brackets for the belt at 

the same location. The tissue on the support brackets on the inside the belt gave off 

a extremely strong rancid odor. The area was recleaned and released by 

approximately 0025 hours. In Packaging Area #2, the Room, at approximately 

0030 hours on line #1 there was a thick layer of pink pasty tissue on both stainless 

cutting wheels associated with the machine that makes the first cuts on the wings. 

There was a piece of tissue inside a white product cone that measured 

approximately 4" by 1/4". A second cone had a semi-dried piece of blackened 

connective tissue measuring approximately 1" by 1". Approximately a 1 foot section 

adjacent to the spray nozzle of the pink hose at the loading end of the line had 

black UFM(Unidentified Foreign Material) that appeared to be mold. The hose is 

used during production to rinse down the line. The stainless cutting wheels on the 

machines that make the first cuts along the keel bone on lines 1 & 2 had rust 

developing. The rust was cleaned off temporarily with a green pad until the wheels 

can be replaced. Sanitary conditions were restored by approximately 0050 hours. 

My findings indicated a noncompliance with 9 CFR 416.4(a), 9 CFR 416.2(b)(1), and 

9 CFR 416.13(c). 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE261309 

2211N-1 

09/11/2013 01C02 Operational SSOP 

Review and 

Observation 

C While I was observing the process in the packaging department I observed a 

deficiency noncompliant with the 9 Code of Federal Regulations, Sections 416.1, 

416.4(a), 416.5(a) and 416.13(c). At approximately 1030 hours an employee was 

pushing a cart with 2 bags containing 15” by 8” Styrofoam trays; than I noticed that 

two trays fell on the floor and the employee pushing the cart picked them up and 

carried them along, once the cart was unloaded the employee placed the 

contaminated trays on top of a stack of clean trays that were on a table along with 

more stacks of trays. I took regulatory control action by stopping the employees 

from using the affected trays before being placed on the tray belts, Ossid#1(Area IV, 

Unit 2) and be packed with edible product. I informed F 

. implemented immediate corrective actions by 

disposing of the contaminated trays and washing and sanitizing the table assigned 

to place the trays which are product contact surface. Approximately one hour 

earlier I noticed a similar incident. At the Thigh Drop Chute, Traypack line# , Thigh 

meat belt (Area IV, Unit 16) I observed a employee opening the primary bag of 

styrofoam trays then opened the secondary bag and handled the trays and placed 

them on a rack that was wrapped with a blue plastic liner without washing nor 

sanitizing her hands. The primary bag is exposed to the elements (dirt, dust, etc.) in 

the storage area. I informed . 

condemned the affected trays as immediate corrective action and instructed the 

employee to sanitize her gloves. The establishment has the responsibility to ensure 

that employees are engaging in personal hygienic practices and product handling 

practices that prevent insanitary conditions and reduce the likelihood of 

contaminating product, food-contact surfaces, and product-packaging materials. 

Section 416.5(a) of the 9 Code of Federal Regulation requires that all persons 

working in contact with product, food-contact surfaces, and product-packaging 

materials must adhere to hygienic practices while on duty to prevent adulteration 

of product and the creation of insanitary conditions. was 

informed of the forthcoming documentation for the failure to comply with 

regulatory requirements cited above. 

(b) (6)
(b) (6) (b) (6) (b) (6)

(b) (4) (b) (4)

(b) (4) (b) (4)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0423095 

710N-1 

09/10/2013 03C02 Raw Intact HACCP O On 09/10/2013 at approximately 2000 hours while monitoring Operational 

Sanitation in Packaging at the end of the PM shift, I observed the following. The 

leftover product on the Salvage Parts Table was being placed in brown product 

tubs. Some of the product at the wing line side of the table was off colored as if it 

had been there for some time so I took the temperature of the legs and found 

temperatures over 70 degrees. There were no Quality Control or Supervisors 

present to assist the employee clearing off the line so I sorted out the legs over 60 

degrees and placed them onto a brown tub lid and contacted 

Using a company calibrated thermometer temperatures registered in the high 60's 

to approximately 76.8 degrees. The product, 28 legs(drums) were condemned by

 and placed into a gray inedible barrel. The room temperature at the 

location was approximately 79.3 degrees. A review of the Establishments' HACCP 

Plan-Raw Not Ground-Packaging step #8 

There are no supplemental supporting documents listed under 

'Justification for Decision'. However, CP-12 is 

used by the establishment to monitor temperatures in the processing areas on 

product being packaged. CP-12 temperatures are taken approximately 

A check of the establishments' computer showed that the last temperatures 

were taken at approximately hours. The procedure states under Corrective 

Action Procedure that The 

establishments' HACCP Plan-Raw Not Ground-Packaging Step #1 

This is a reoccurring loss of process control. The 

product was being collected into edible product containers, iced and saved for 

further processing creating an insanitary condition. My findings indicated a 

noncompliance with 9 CFR 381.66(b), 9 CFR 381.1(b)(iv), 9 CFR 381.145(b), 9 CFR 

417.2(c)(4), 417.2(a)(1), 9 CFR 417.5(a)(2) and the establishments' SIP Protocol. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4918094 

309N-1 

09/09/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C While monitoring the Establishments' Pre-operational Sanitation Procedures in 

Plant #1, I observed a noncompliance with the following regulatory requirements of 

regulations 9CFR 416.1, 9CFR 416.4 (a) and 9CFR 416.13 (c). At approximately 0652 

hours, while inspecting Area #3, Unit #10, I found the chute that catches and 

transfer the birds that falling down from the automatic re-hang machine to the 

transfer table for Line #1, with numerous pieces of black specks (UFM) Unidentified 

Foreing Material and dried feathers on it. I informed . He 

had a sanitation employee, rewashed the entire area. At approximately 0655 hours 

the area was released. At approximately 0706 hours in the Area #4, Unit # 16 Final 

Trim Station Line #1 and Line #2 and Cabinets, I found the recycle water tank 

with numerous pieces of dried and semi-dried fat from the previous day 

production. The trays that the trimmers used to hold the birds in Line #1 and Line 

#2, had numerous pieces of blacks specks (UFM) on it. The drip pans from both 

lines that are attached to the cabinets and are a food product contact surface 

had several spots of black material that appeared to be grease measuring 

approximately 1/4" diameter in size and also residue on the entire drip pan of the 

same material. I informed and he had an 

employee scrub and rinse the area. Sanitary conditions were restored at 

approximately 0716 hours. I informed of the 

noncompliance. 

(b) (6)
(b) (6)

(b) (6)

(b) (4) (b) (4) (b) (4)

(b) (4)

(b) (4)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4508093 

907N-1 

09/07/2013 03C02 Raw Intact HACCP C On 09/07/2013 at approximately 0305 hours while monitoring Operational 

Sanitation in Packaging, I observed the following. There were a row of legs(Drums) 

in the space between the conveyor product belt and the stainless support assemble 

on line Using a company calibrated thermometer I collected several of the legs 

and the temperatures of the product registered to approximately 64.2 degrees. I 

contacted and showed him where I found the legs and that all 9 legs 

registered at temperatures over 60 degrees. The last QC temperature check of line 

according to the establishments computer records was taken at hours at 47.3 

degrees. The room temperature at that location was approximately 65.2 degrees. A 

sample of temperatures of product moving down the line registered between 

approximately 45.6 to 52 degrees. A review of the Establishments' HACCP Plan-Raw 

Not Ground-Packaging Step #8 

There are no supplemental supporting documents provided under 

'Justification for Decision'. However, CP-12 Processing Temperature Verification is 

used by the establishment to monitor temperatures in the processing areas on 

product being packaged. The procedure states under Corrective Action Procedure 

that "Product >60 degrees will be condemned." CP-12 temperatures are taken 

approximately . The establishments' HACCP Plan -Raw Not 

Ground-Packaging Step #1' 

My 

findings indicated a noncompliance with 9 CFR 381.66(b) and 9 CFR 417.2(c)(4). 

5308 M6137 BXL1504094 

206N-1 

09/05/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 9/5/13 at approximately 0030 Hrs. while performing Pre-Operational Sanitation 

Verification Review and Observation Task, beginning with Pre-Op record review. 

Plant employee indicated the equipment and area was ready to begin processing, 

records indicated that all machines were ready for use. During sanitation 

verification I observed the following deficiencies. Room, line #1 Fillet Halving 

Machine, the first set of circular blades, approximately half of one blade was 

covered with fat residue (smeared) from previous shift’s production. The motor 

housing’s cooling fins had several small pieces of fat and meat tissue, 1/8” and 

smaller. The Tendon Cutting Machine had one side of one blade completely covered 

with fat residue. And The Backmeat Harvesting Machine, at the rear of the rotating 

portion of this machine used to strip meat and fat tissue from bone, had stringy 

tissue wrapped around and hanging from machine parts. These three machines are 

direct product contact contact surfaces. All affected areas were scrubbed and 

washed and reinspected, and released at approximately 0045 Hrs.. 

was aware of the noncompliance. My finding indicate noncompliance with 

Regulations 416.4(a): Food contact surface, cleaning & sanitizing as frequency 

416.4(b): Non-food contact surface, cleaning & sanitizing 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2207090 

805N-1 

09/05/2013 04A06 Poultry Finished 

Product Standards 

O On 09/05/2013 at approximately 0150 hours while monitoring the Establishments' 

Post-Chill Finished Product Standards from product exiting Chiller #4, I observed the 

following. After collecting a standard 10 bird sample, I accumulated 14 

nonconformance points from specks and smears of black/brown UFM(Unidentified 

Foreign Material). This exceeded the subgroup absolute limit of 10 points. I 

contacted . I showed the carcasses that I retained from the 

sample to in Packaging. The first birds exiting the chiller were 

being tanked by production. A recheck by Quality Control failed at 0205 hours with 

11 nonconformance points. The limit for a recheck is Tolerance (5) points. At this 

point the process is judged to be out of control. Production continued to tank 

product which was placed on QC hold pending rework. Quality Control rechecks 

passed at 0252 and 0259 hours bringing the process back into control. My findings 

indicated a noncompliance with 9 CFR 381.76(b)(3)(iv)(e)(3). 

5308 M6137 BXL1619092 

703N-1 

09/03/2013 03J04 Poultry Zero 

Tolerance 

O On 09/03/2013 at approximately 1242 hours, while performing the Zero Tolerance 

Task in Plant #1 on Line #1, I found visible fecal contamination on one of the ten 

Verification birds I randomly removed. The fecal was located inside the bird on the right side 

close to the tail. The fecal material measured approximately 1/8" in diameter, olive 

green in color and pasty in texture. This exceeds the limit of Zero Tolerance for the 

process to be in control. I informed of the 

noncompliance and the protocol for fecal failure was implemented. Quality Control 

performed the recheck at approximately 1306 hours and it passed. My findings 

indicate a noncompliance with 9CFR 381.65(e), 9CFR 417.2(c)(4), and the critical 

limit of CCP2B, of the Plant's HACCP Plan for Slaughter. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2308090 

703N-1 

09/03/2013 01C02 Operational SSOP 

Review and 

Observation 

O On 08/31/2013 at approximately 0024 hours while monitoring Post-Chill Finished 

Product Standards from product exiting chiller #2 in Plant #1, I observed the 

following. After taking a standard random 10 bird sample I accumulated 19 

nonconformance points. Eight of the ten carcasses had black/brown residue that 

has been previously identified by the Establishment as high Manganese in the city 

water. I contacted and showed him the carcasses. As carcasses 

were already entering Packaging I had called. 

A QC Post-Chill check on Chiller #2 at 0022 hours had passed with 4 

nonconformance points. A QC recheck of the USDA failure also passed at 0037 

hours. The first carcasses coming out of the chillers are tanked and are normally the 

dirtiest as they tend to sweep out the contaminants. I placed the first tank of 

carcasses from chiller #2 on hold. I proceeded to Chiller #1 and performed a 

Post-Chill Finished Products check on the first tank of carcasses from the chiller and 

accumulated 12 nonconformance points for the same black/brown residue. I placed 

that tank of carcasses on hold. A QC Post-Chill check on Chiller #1 passed at 0027 

hours with 2 nonconformance points . The residue was originally documented on 

NR# BXL0809113523N/1 written on 11/23/2012. The issue with the water has 

been occurring on a periodic basis since. A review of the establishments' SSOP 

Corrective Action logs under 'What actions were taken or are being taken to 

prevent recurrence...' has consistently stated "Quality Control and Production 

Supervisors will continue to monitor carcasses exiting the chillers." or 

"Maintenance and refrigeration are working on a filtration system." With dirty 

carcasses entering packaging and with no Supervisors monitoring product exiting 

the chillers this a failure of the establishments' SSOP Corrective Action procedure to 

prevent recurrence. My findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 

416.4(a), 9 CFR 416.12(a), 9 CFR 416.14 and 9 CFR 416.15(a). 

5308 M6137 BXL3403095 

103N-1 

09/03/2013 03J02 Slaughter HACCP O On 09/03/2013 at approximately 0008 hours while monitoring Pre-Chill Finished 

Product Standards on line in Plant #2, I observed the following. After taking a 

standard random 10 bird sample, I observed one bird with visible fecal material. I 

informed who implemented the protocol for fecal 

failure. The fecal contamination was a smear on the inside of the carcass on the left 

side under the fat flap adjacent to the kidneys. The fecal material measured 

approximately 1" by 1" , was olive green in color and pasty in texture. A QC recheck 

passed at 0028 hours. My findings indicated a noncompliance with 9 CFR 381.65(e), 

9 CFR 417.2(c)(4) and CCP-2B of the Plant's HACCP Plan 

for Slaughter. 

(b) (6)
(b) (6) (b) (6) (b) (4)

(b) (4)

(b) (6)(b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4304092 

803N-1 

09/03/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 9/2/13 at approximately 0048 hrs. while preforming Operational Sanitation 

Task, I observed the following. Packaging area: Located at the end of the bag line 

(Line ) there are two stainless steel tables used to process salvaged leg 

quarters, I observed a plant employee picking up a brown edible container from a 

handcart placing the bottom of brown containers on top of two open containers 

that were partially filled, with edible product, causing the product to cross 

contaminate with enviromental contamination from the bottom of the container. 

Stainless steel handcarts are used to move containers with edible product from one 

place to another. These carts are primarily a square shaped angle iron frame 

without a bottom or protection to prevent the wheels from slinging contaminated 

water from the floor to the bottoms of the containers. These carts are used in high 

traffic areas with no means of foot or floor sanitation to control floor 

contamination. I immediately notifed who was close 

by. She took control of the contaminated product, and had it re washed at that 

time. Sanitary conditions were restored at 0100 hrs.. was made 

aware of the deficiency . My findings indicate noncomplanice with regulations 

416.1, and 416.4(d) 416.1: Operate in a manner to prevent insanitary conditions 

416.4(d): Product processing, handling, storage, loading, unloading, and during 

transportation must be protected 

5309 P6137A NJN401509 

1703N-1 

09/03/2013 01D01 SPS Verification O At approximately 1055 hours, while verifying the plant compliance with the 

sanitation performance standard on the kill floor, I observed accumulations of black 

pasty material mixed with feathers on several areas of line (B) guide bar, on the 

lower surface. The most affected part of the bar was close to the oil gland removing 

machine. The formation of this black pasty matter is due to the friction between the 

metal shackles and guide bar, and the fat residue from the birds. This pasty black 

material increased and with the presence of water there is high probability that this 

accumulations of contaminant to fall on the carcasses cross contaminating them. I 

immediately showed Ms. , and Mr. 

, my finding and informed them of the forthcoming 

noncompliance documentation. The plant failed to comply with their procedure 

which states:

 9 CFR 416.1 states: "Each official establishment 

must be operated and maintained in a manner sufficient to prevent the creation of 

insanitary conditions and to ensure that product is not adulterated." 

(b) (6)
(b) (6)

(b) (6) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE151109 

4603N-1 

09/03/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 0752 hours I was performing the Review and Observation of a 

Zero Tolerance verification PHIS task. To perform this task I collected a sample of 

ten carcasses at Line 2 FPS Inspection Station located after the cabinet and 

before the carcasses enter the North chiller. I observed in the fifth carcass a 

material with a paste consistency brownish/green in color consistent with fecal 

material. The fecal Material was located inside the carcass cavity right below the tip 

of the keel bone with an approximate measurement of 1⁄2 inch long by 1/8 inch 

wide. I took regulatory control action by stopping the line and applying Retain 

Tag # B38495417 to the affected carcass. I showed my finding to 

began 

corrective actions as prescribe in the establishment’s HACCP plan. The affected 

carcass was reprocessed on the reprocessing line. The establishment failed to 

prevent fecal material from reaching the Line 2 FPS inspection station with the 

potential of entering the chiller. Section 381.65(e) from the 9 Code of Federal 

Regulations requires that the establishments shall prevent contaminated carcasses 

with visible fecal material from entering the chiller. The finding of fecal material did 

not meet the requirements of the establishment’s HACCP plan. was 

informed of the forthcoming documentation for failure to comply with the 

regulatory requirements cited above. Similar noncompliances were documented on 

8/25/13 and 8/27/13. Previous preventive measures failed to prevent recurrence of 

fecal material reaching the FPS station. 

(b) (6)
(b) (6) (b) (6)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5004080 

731N-1 

08/31/2013 01D01 SPS Verification C On 08/30/2013 at approximately 2205 hours while monitoring Pre-Operational 

Sanitation conditions in Plant #1, I observed the following. There were numerous 

pieces of stainless steel flaking off the guide bars associated with the venter/body 

opener on line #1. There were flakes loose on the guide bar that wraps around the 

unit and also on the guide bar that guides the carcasses out of the unit. The 

carcasses are being opened at this point in the slaughter process. The carcasses 

hang from shackles as they pass through the machine. The open carcasses when 

passing through the machine are just below the guide bars. Metal flakes of any size 

on or in a carcasses would be considered a contaminant by USDA. 

was called and I showed him the material defect. The wear on the guide bars is 

caused by metal to metal contact between the guide bars and the carcass shackles. 

Mechanics used pieces of emery cloth to removed the loose metal pieces. The 

venter/body opener on line #2 was in a similar condition with several metal flakes 

on the outflow guide bar associated with the unit. I collected several of the flakes 

and they measured up to approximately 3mm by 5mm in size. The units were 

rinsed with potable water restoring sanitary conditions by approximately 2220 

hours. The guide bars are made of stainless strips that are approximately 1 1/4 and 

3/4 inches in width and up to approximately 1/4" thick. The weight of the carcasses 

is putting pressure on the guide bars causing the metal to flatten out forming a 

shape brittle edge on both the top and bottom sides, it then cracks into varying 

sized pieces before flaking off. All the guide bars associated with both units have 

the sharpened edges. I showed the mechanic that maintains the unit the wear spots 

on the guide bars with the worst spot worn almost completely in half with a large 

crack that extended almost its entire length . He said he had just replaced the bars 

the previous month. The establishment has no metal detectors. A review of the 

establishments HACCP Plan- Slaughter Plant #1 under 

' My findings indicated a noncompliance with 9 CFR 416.1 and 9 

CFR 416.2(b)(1). 

5308 M6137 BXL2204085 

430N-1 

08/30/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 08/30/13 at approximately 0147 Hrs. while proforming Operational Sanitation 

task, I observed the following. At the exit of chiller #2 the conveyor end used to 

divert product from the rehang area to tanks, I noted a full tank of exposed edible 

product (Whole body chicken) that was placed under a section of overhead drip pan 

covered with beaded condensation that was dripping on to the product. Chiller #1 

at the front portion of the rehang table, closest to the chiller exit, I noted 

approximately 5-6 feet of overhead drip pan covered with beaded condensation 

creating the potental to contamnate exposed product on the conveyor. Drip pans 

are not a considered a direct product contact surface. 

was made aware of the deficiencies. Both areas were immediately wiped down, and 

the tanked product was rewashed, sanitary condittions were restored. My findings 

indicate a noncomplaince with regulations 416.4(d), 416.1, 416.2(d) 

(b) (6)
(b) (6) (b) (6)

(b) (6) (b) (6) (b) (6)

(b) (6)

(b) (6) (b) (6)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3120081 

629N-1 

08/29/2013 01C01 Operational SSOP 

Record Review 

O On 08/27/2013 at approximately 1900 hours while performing Operational 

Sanitation Records Review Task, I noticed that the SSOP Log for 08/24/2013 "Dock" 

Loading Dock Area was missing. The next day I asked

 about the missing log. She informed me later that the SSOP 

Procedure was performed but not documented. The SSOP plan states in part that 

QA inspector or designee 

This is a noncompliance with 

the following regulatory requirements of regulations 9CFR 416.13(b) and 9CFR 

416.13(c). 

5308 M6137 BXL5120084 

629N-1 

08/29/2013 01C02 Operational SSOP 

Review and 

Observation 

O At approximately 1525 hours, while performing Raw Non-intact HACCP task in 

Rotisserie Room, I found the following, I was taking temperatures on the birds that 

were in the tanks staged there for dumping into the belt for the cones lines, when I 

observed in one tank a bird that had several small pieces of blue plastic on it. When 

I looked in another nearby tank, I found a couple birds with numerous black specks, 

UFM (Unidentified Foreign Material) on them. In a third tank more birds with UFM 

on them. The tanks were covered with blue plastic. I informed 

and she tagged the tanks. I inspected another two tanks that were 

coming from the Cooler in Plant#1 and found more birds with UFM on them. 

Quality Control tagged five tanks total. I informed and

 of the issue. I went to the Plant #1 Cooler to inspected 

the tanks with product covered with a blue plastic and found more birds with UFM. 

I Tagged four tanks total with U.S. Retained/ Rejected Tag # B31 407940, B31 

408051, B31 408052 and B31 408053 and one more was tagged with the QC red 

hold tag. was informed of the noncompliance. At 

approximately 1635 hours, I released the product to 

I removed my tags and Quality Control placed a red hold tags on the tanks.

 informed me that was 

going to inspected every the product that the company employee was 

reworking. This is a noncompliance with the following regulatory requirements of 

regulations 9CFR 416.1 and 9CFR 416.4 (d). 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (4)

(b) (4)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5708084 

229N-1 

08/29/2013 04B04 General Labeling C On 08/28/2013 at approximately 2220 hours while monitoring Facilities in Plant #2 

Aged Breast Cooler, I observed the following. There were 4 brown tubs of product 

that were not labeled. The product was changing color, and the bloody fluids 

present were slimy and smelled old. As Packaging production personnel were not 

available, I placed the product under U.S. Retained. At approximately 0100 hours I 

contacted and showed him the noncompliance. Three tubs 

totalling approximately 200 pounds of front halves (breast & wings) and 2 packages 

of saddle packaged half breasts were condemned and placed into a gray 

inedible container before dumping in the edible dump room. The establishment 

does not apply a 'Pack Date' to its product when packaged. Product needs to be 

identified in some manner (not full label) such that inspection program personnel 

can reinspect at any time or as often as they deem necessary to assure the products 

are not adulterated or misbranded. My findings indicated a noncompliance with 9 

CFR 9 CFR 381.145(b) and 9 CFR 381.180(a). 

5308 M6137 BXL5908081 

529N-1 

08/29/2013 01C02 Operational SSOP 

Review and 

Observation 

O On 08/29/2013 at approximately 0015 hours while monitoring Packaging 

Department Operational Sanitation at startup in Plant #1, I observed the following. 

Three bins were staged at the Check Weight lines with plastic liners installed ready 

for use. The birds were just about to start to come out of the chillers. I lifted one of 

the plastic liners from a bin and observed a large area of brown UFM (Unidentiofied 

Foreign Material) in the bottom and several black specks on the sides. I checked the 

other bins and found more black and brown UFM including several flakes measured 

approximately 1/2" by 3/4" by 1/8". Although the bins have a plastic liner the UFM 

will be added to the product during dumping. I contacted the lead person nearby 

and asked him to contact a Production Supervisor. The employee who does bin 

staging asked if there was a problem. I showed him the bins and he removed the 

plastic liner, rinsed the bin with cold potable water and replaced the liner. I asked 

him where the bins that were staged for used had been brought from. He showed 

me the truck on the loading dock that still had 9 bins that were stacked inside each 

other. The establishments' marking system uses a blue plastic cover which 

identifies that the bin is clean and ready for use. None of the bins on the truck were 

covered. I returned to the Check Weight lines and showed the 

bins. contact a Sanitation Supervisor for assistance. A review of 

the SSOP Part 1 under

 A review of SSOP Section 2-

My findings indicated a 

noncompliance with 9 CFR 416.1, 9 CFR 416.4(a), 9 CFR 416.11 and 9 CFR 

416.12(a). 

(b) (6)
(b) (6)

(b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE271608 

0229N-1 

08/29/2013 01D01 SPS Verification C At approximately 1346 hours the following noncompliance was observed in the 

packaging department; By the Brine tank of the injection line 1, and north of Dark 

Meat Conveyor, a combo bin with a blue liner was being used to hold thigh 

segments. Three holes were observed in the liner approximately 1 inch square to 3 

inch square. U.S. Rejected tag # B38495413 was placed on the bin and

 was informed. The product was below the holes, so no 

product was adulterated by coming in contact with the exposed noncontact surface 

of the bin. removed the product 

from the bin and had the liner removed and discarded. Product was released at 

1350. Quality Control SSOP records for 08/09/2013 show a similar occurrence that 

happened at 1217 hours with a bin of whole birds used for the rotisserie line. My 

findings indicate a noncompliance with regulations 9CFR 416.1 each official 

establishment must be operated and maintained in a manner sufficient to prevent 

the creation of insanitary conditions and to ensure that product is not adulterated. 

9CFR 416.3(a) Equipment and utensils used for processing or otherwise handling 

edible product or ingredients must be of such material and construction to facilitate 

thorough cleaning and to ensure that their use will not cause the adulteration of 

product during processing, handling, or storage. Equipment and utensils must be 

maintained in sanitary condition so as not to adulterate product. 9CFR 416.4(d) 

Product must be protected from adulteration during processing, handling, storage, 

loading, and unloading at and during transportation from official establishments. 

(b) (6)
(b) (6)

(b) (6)

(b) (6)

(b) (6) (b) (6)

(b) (6) (b) (6)

(b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2514080 

128N-1 

08/28/2013 01C02 Operational SSOP 

Review and 

Observation 

O At approximately 1057 hours while conducting scheduled Operational SSOP Review 

and Observation task in the Packaging area I observed the following noncompliance. 

While I was walking by Line I observed heavy beaded condensation on the large 

drip pan that is between Line and the hand wash sinks, I showed the 

condensation to and and expressed my 

concerns to them as there were two full racks of product directly under it. He 

immediately got a sanitation employee to start wiping down the drip pan. On 

further investigation I walked between Lines and to look at the drip pans that 

run the length of the lines as I noticed condensation on them also. When I got to 

the end of the lines I saw that the drip pan that crosses over the top of Line had 

heavy beaded condensation on it that was right over the top of product. 

instructed the sanitation employee to wipe down the drip pan and as he 

did so numerous drops of condensation fell onto the product on the line. I 

immediately took regulatory control action and applied USDA retain tag #B31 

407791 to the line. immediately stopped the line and removed 

the product placing it in a brown tub while he washed the line, restoring sanitary 

conditions to the line at approximately 1105 hours at which time I removed my tag. 

At that time I accompanied to the scale and edible dump room 

where he condemned approximately 72 pounds of leg quarters at approximately 

1112 hours restoring sanitary conditions. My findings indicate a noncompliance 

with the regulatory requirements of 9CFR 416.1, 9CFR 416.2(d), 9CFR 416.4(b) and 

9CFR 416.4(d). 

5308 M6137 BXL5110083 

928N-1 

08/28/2013 01D01 SPS Verification C On 08/28/2013 at approximately 0834 hours, after performing a Finished Products 

Standards task on the giblets in Plant #2, I observed the following. The drip pan that 

runs under Line #2 in the re-hang area was dripping condensation at the point 

where the drip pan slopes down, next to the USDA graders table. There were clean 

brown tubs staged for the gibs right next to the drip pan that was dripping 

condensation, and the uncovered finished tanks of necks are brought through 

under that drip pan. I informed 

that I was issuing a noncompliance for the insanitary condition. 

had the clean brown tubs moved into the cooler and had the condensation 

wiped off. At approximately 1030 hours as I was about to perform a Finished 

Products Standards task on Line I again observed condensation 

dripping from the same drip pan. I informed and 

that I would add this information to the noncompliance that I had 

observed at approximately 0834 hours and that the corrective action from earlier 

was insufficient. The condensation was wiped off restoring sanitary conditions. My 

findings indicate a noncompliance with regulatory requirements of regulations 9 

CFR 416.1 and 416.2(d). 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (6)

(b) (4) (b) (4)

(b) (4)

(b) (4)

(b) (4)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1919080 

127N-1 

08/27/2013 03C02 Raw Intact HACCP C On 08/24/2013 at approximately 1500 hours, I went to review the company results 

in the computer for that day. I noticed that the last check performed for 

temperatures in the crust tunnel was for AM Shift at hours. Day shift has no 

records for temperatures performed by Quality Control. The End of the Shift for 

that day was at approximately hours. On Monday 08/26/2013, I asked

 about the records and she informed me 

that no temperatures were performed that day in the Crust Tunnel. The HACCP Plan 

-Raw not ground- Packaging under Step #9, states in part: 

ram. Supplement 

6,21,35. HACCP Supplement # 35, CP-14 

, states in part that: 

No 

temperatures were taken for the Dayshift which is used to 

support the Hazard Analysis. This is a noncompliance with the following regulatory 

requirements of regulation 9CFR 417.5(a)(2). I informed 

5308 M6137 BXL3203082 

027N-1 

08/27/2013 06D02 Other Inspection 

Requirements 

C At approximately 0049 hours, I performed a presentation check in plant 2 on line

 at a line speed of BPM (birds per minute). Station #2 had 2- viscera on 

shackles, 2- membranes, 2- not reflected, and 1- contamination inside bird for a 

total of 30 conformation points. This exceeded the limit of 25-39 conformation 

points for the process to be in control. I informed

 Quality Control performed a recheck at approximately 0102 hours and 

station #3 failed with 2- viscera not uniformed, 1- not reflected, 1- parts inside, and 

1- contamination inside bird for a total of 25 conformation points. This exceeded 

the limit of 25-39 conformation points for the process to be in control. 

was again informed of the failure and the line speed 

was reduced to 81 BPM. At approximately hours a QC recheck passed with a 

line speed of 81 BPM and again at approximately hours with a line speed of

 BPM, bringing the process back in control. 

(b) (6)
(b) (6)

(b) (6) (b) (6)

(b) (6) (b) (7)(C)

(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4207084 

227N-1 

08/27/2013 03J02 Slaughter HACCP O On 08/27/2013 at approximately 0023 hours while conducting a Post-Chill Finished 

Products Standards procedure on product exiting Chiller #2 in Plant #1, I observed 

the following. After collecting a standard 10 bird sample, I observed one carcass 

with a shiny metal flake approximately 2mm by 5mm in size attached to the 

connective tissue on a piece of untrimmed neck tissue approximately 1/2" long. I 

informed 

of the noncompliance. According to PDD FSIS considers metal flakes of any size on a 

carcass to be an unacceptable contaminant that should be addressed by the 

establishments' Hazard Analysis. The Establishments' HACCP Plant -

states

 The product was on a chiller 

exit conveyor belt just prior to hanging for final microbial intervention and 

packaging. The issue of metal contamination has been discussed at previous 

morning meetings with the establishment. My findings indicated a noncompliance 

with 9 CFR 416.4(d), 9 CFR 417.3(b)(1), 9 CFR 417.3(b)(2), 9 CFR 417.3(b)(3) and 9 

CFR 417.3(b)(4). 

5333 P7632 HYE501208 

4727N-1 

08/27/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 0839 hours I was performing the Review and Observation 

component of a Finish Product Standards Task at Line 1 FPS (inspection station) 

prior to the carcasses entering the South chiller. While I was performing my 

verification task, I observed on the seventh carcass from the ten carcass sample a 

smear dark green in color with a paste like material consistent with fecal material 

(FSIS Directive 6420.2 Attachment 1). The fecal material was located on the tail 

bone/ oil gland area. The approximate measurement was 10 mm long and 3 mm 

wide. I took regulatory control action by stopping the line and retaining the affected 

carcass with U.S. Retain tag# B38495416. The production was resumed after I 

showed my finding to 

initiated corrective actions as stated in the establishment’s HACCP plan. Mr.

 respectfully requested a second opinion from the IIC. At approximately 

0915 hours SPHV, Dr. confirmed that the material smeared on the 

tail bone was fecal material. The affected carcass was reprocessed. The 

establishment failed to prevent fecal material from reaching the Line 1 FPS 

inspection station with the potential of entering the chiller. Section 381.65(e) from 

the 9 Code of Federal Regulations requires that the establishments shall prevent 

contaminated carcasses with visible fecal material from entering the chiller. The 

finding of fecal material did not meet the requirements of the establishment’s 

HACCP plan. Mr. was informed of the forthcoming documentation for 

failure to comply with the regulatory requirements cited above. 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (4) (b) (4) (b) (4)

(b) (4)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4)

(b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1921080 

226N-1 

08/26/2013 03J02 Slaughter HACCP C On 08/22/2013 at approximately 1830 hours while performing a HACCP Slaughter 

Record Review Task, I found the following: The Pre-shipment Record Review for the 

End of the shift for CCP-2B ), Zero Tolerance for Line #2 in Plant 

#1 dated on 08/21/2013 PM Shift was signed at hours. The Pre-shipment 

Record Review for the End of the Shift for CCP-1B Zero Tolerance 

for the Reprocessing Line in Plant #1 dated on 08/21/2013 was signed at 

hours. The Pre-shipment Records Review for the End of the Shift for CCP-1B 

dated on 08/21/2013 PM Shift was signed at hours. I observed that at 

1738 hours the birds were finished at the first inspector station (station #5), from 

there to after the cabinet at the Zero Tolerance collection Area CCP-2B, it is 

approximately . Generally at the end of the Shift the Line Supervisor 

has Inspector helpers hang back birds on the hang back rack. The Supervisor collects 

the birds on a portable rack and transfers them to Line before the neck cracker. 

The time from the neck cracker to after the house inspection employee at the Zero 

Tolerance collection Area CCP-1B, it is approximately . The End of the 

Shift for that day of 08/21/2013 was at approximately hours for Line #2 and

 hours for Reprocessing Line and Salvage parts. The signed document 

certifies that the product is ready to be shipped. The Pre-shipment Record Review 

was signed before the End of the Shift. My findings indicate a noncompliance with 

the following regulatory requirements of regulations 9CFR 417.5 (c). I informed

 about the noncompliance. 

5333 P7632 HYE100308 

2726N-1 

08/25/2013 03J04 Poultry Zero 

Tolerance 

Verification 

O While performing a Zero Tolerance verification task in the Evisceration department 

on Evisceration line #2 I, observed the following noncompliance. At approximately 

0001 hours I randomly selected ten chicken carcasses. The fourth carcass of the ten 

had a greenish brown fecal smear approximately 1 inch in length and 1/4 of an inch 

in width located inside the cavity on the breast plate. I took regulatory control of 

the product by applying U.S. retain tag B43249968 to the product. I then showed

 my findings and informed them of the noncompliance. 

performed the recheck as per the establishment's 

corrective actions passing two consecutive ten carcass checks and the carcass was 

released to at 0005 hours. This failure represents a noncompliance 

with regulation 9 CFR 381.65(e), which states: "Poultry carcasses contaminated 

with visible fecal material shall be prevented from entering the chilling tank." The 

failure also represents a deviation with the establishment's written HACCP plan, 

regulatory requirements of 9 CFR 417.2(c)(4), which states: "List the procedures, 

and frequency with which those procedures will be performed, that will be to 

monitor each of the critical control points to ensure compliance with the critical 

limits." 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (6) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE100308 

2726N-2 

08/25/2013 03J04 Poultry Zero 

Tolerance 

Verification 

O While performing a Zero Tolerance verification task in the Evisceration department 

on Evisceration line #2 I observed the following noncompliance. At approximately 

0001 hours I randomly selected ten chicken carcasses. The fourth carcass of the ten 

had a greenish brown fecal smear approximately 1 1inch in length and 1/4 of an 

inch in width located inside the cavity on the breast plate. I took regulatory control 

of the product by applying U.S. retained tag B43249968 to the product. I then 

showed 

n, my findings and informed them of the noncompliance. 

, performed the recheck as per the 

establishments corrective actions passing two consecutive ten carcass checks and 

the carcass were released to at 0005 hours. This failure represents 

a noncompliance with regulation 9 CFR 381.65(e), which states: "Poultry carcasses 

contaminated with visible fecal material shall be prevented from entering the 

chilling tank." The failure also represents a deviation with the establishment's 

written HACCP plan, regulatory requirements of 9 CFR 417.2(c)(4), which states: 

"List the procedures, and frequency with which those procedures will be performed, 

that will be monitor each of the critical control points to ensure compliance with 

the critical limits. 

5309 P6137A NJN331608 

3524N-1 

08/24/2013 01D01 SPS Verification O On saturday 8/24/13 at approximately 1432 hours, I observed the following in the 

offal area while performing the SPS task . The over head auger had guts dangling, a 

hole bird hanging on the angle iron support bracket, a large pile of guts on the floor, 

flies circling the area with a foul odor in the room .Similar finding were observed on 

Saturday July 27th and also on Saturday August 3rd . The establishment was 

notified at the weekly on Tuesday August 6th . My findings are violation of 

regulations 9 CFR 416.1 which states " each official establishments must be 

maintained in a manner sufficient to prevent the creation of insanitary conditions 

and ensure that product is not adulterated " . 

5308 M6137 BXL1009082 

223N-1 

08/23/2013 03J02 Slaughter HACCP C On 08/23/2013 while performing Pre-Chill Finished Products Standards Task, I 

obvserved a noncompliance with the following regulatory requirements of 

regulations 9CFR 381.65(a) and 9CFR 417.2(c)(4). At approximately 0638 hours, I 

randomly removed a 10 bird sample from Line #2 in Plant #1. I found one out of the 

ten birds with visible fecal contamination inside the bird under the leaf fat on the 

right side close to the tail. The fecal material was approximately 5/16" in diameter 

in size, olive green in color and pasty in texture. I informed of 

the noncompliance and the protocol for fecal failure was implemented. At 

approximately 0700 hours, Quality Control performed a recheck and passed. The 

cause of the deviation was the first bird turner. This is a violation of the critical 

limits of CCP-2B, of the Plant's HACCP Plan for Slaughter. 

(b) (6)
(b) (6)(b) (6)

(b) (4) (b) (4) (b) (4)

(b) (4)

(b) (4)(b) (4)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5700084 

122N-1 

08/22/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 08/21/2013 at approximately 2214 hours while monitoring the establishments 

Pre-Operational Sanitation procedures in Plant #2, I observed the following. In Area 

2 Unit 30, Line drip pan that runs from the Picking Room to Area 3, had a piece 

of fat approximately 1" in diameter on the side of the drip pan. The inside of the 

drip pan was covered with numerous feathers and bits of fat. I informed 

of the noncompliance and he rewashed the drip pan. My findings 

indicate a noncompliance with regulatory requirements of regulations 9CFR 416.1, 

9CFR 416.13(c), and 9CFR 416.4(b). 

5308 M6137 BXL5020081 

420N-1 

08/20/2013 03C02 Raw Intact HACCP C At approximately 1742 hours, using a company calibrated thermometer # 32 from 

Quality Control Day Shift, I was taking the temperatures on product in Main 

Packaging Area. On Line Bag fryer line, I took the temperature on the gizzards 

and the temperatures ranged from 60.1 degrees to 65.1 degrees. 

was close and I showed him my findings and informed him about the 

noncompliance. He immediately stopped the line and sent a company employee to 

take the product to be condemned. The product was approximately a 1/4 of a gray 

inedible barrel. A review of the Establishments temperatures records on Line 

under giblets temperature at 1710 hours revealed that the temperature was 46.3 

degrees by Quality Control. The HACCP Plan -Raw Not Ground- Packaging Step #8 

states in part, 

HACCP Supplements #33, 

CP-12 , states in part that 

. The Establishments' HACCP 

Plan -Raw Not Ground- Packaging Step #1 

This is a noncompliance with the following regulatory requirements of 

regulations 9CFR 381.66 (b) and 9CFR 417.2 (c)(4). 

(b) (6)
(b) (6)

(b) (6) (b) (7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE340808 

0420N-1 

08/20/2013 01C02 Operational SSOP 

Review and 

Observation 

C At 0454 hours in Area III (chiller rehang) on August 20, 2013, while performing an 

operational sanitation inspection procedure I observed the reprocessing station had 

two additional brown tubs that where full of product (whole body carcass) tagged 

by Q.C. rep to be reconditioned. These two tubs where being used because the 

reprocessing cart had approximately twenty-five carcasses piled on top of it leaving 

no room for any other product. Carcasses were observed on overhead drip pans, 

under employee work stations and product conveyors. I, CSI , informed 

, of the product on the floor and drip pans. 

The product was removed from the drip pans, floor and work stations to be 

reprocessed as per establishment procedure. At 0619 hours in the chiller rehang 

area the reprocessing station cart had approximately thirty carcasses piled on top 

of each other. The two additional brown tubs were piled up to the point of 

overflowing. At the chiller rehang table product was overflowing off the table onto 

the employee's boots and piling up on the platform. On the employee platform 

there were two piles of product that was impeding establishment employee work 

space totaled approximately twenty carcasses. One establishment employee was 

removing product as product continued to repeatedly falling from the table to the 

platform and floor, I then informed 

of the non compliance for the failure to meet the 

regulatory requirements cited above. The product was removed from the floor and 

employee platform and was reprocessed as per establishment procedure. 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6)

(b) (7)(C)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE340808 

0420N-2 

08/20/2013 01C02 Operational SSOP 

Review and 

Observation 

C Due to a noncompliance generated during nightshift by CSI, for product 

falling on the floor at the Rehang area, North chiller exit, I decided to walk through 

the rehang area to verify that the establishment implemented immediate corrective 

actions to prevent recurrence of product falling on the floor creating pile ups or 

carcasses falling constantly on the floor through the rehang area. At 0708 hours I 

observed approximately 15 carcasses dispersed on the stand located at the north 

side of the rehang belts where some of the carcasses were leaning on the 

employees’ shoes. A pile of approximately 15 carcasses on the floor around the 

carcass catcher located under the incline conveyor was also observed. I showed the 

insufficiency to 

. While the carcasses that were on the floor were being picked up 

more carcasses were observed falling on the stand because the rehang belts were 

overflowing; resulting in more carcasses to be reconditioned to the point where the 

employee reconditioning the carcasses could not keep up. At approximately 0719 

hours the affected carcasses were reconditioned and sanitary conditions were 

restored. The 9 Code of Federal Regulations sections 416.15 (a) and 416.15 (b) 

require that the establishment implement corrective actions when Sanitation SOP’s 

failed to prevent product contamination and implement corrective actions to 

prevent recurrence of product contamination. Mr. was informed of the 

forthcoming documentation for the failure to comply with regulatory requirements 

cite above. 

5308 M6137 BXL1008085 

816N-1 

08/16/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 08/16/2013 while performing a Post Chill Finished Products Standards Task, I 

found a noncompliance with the following regulatory requirements of regulations 

9CFR 416.4 (d) and 9CFR 416.12 (a). At approximately 0350 hours while performing 

the FPS check, I observed a pile of birds on the floor between Chiller #1 and Chiller 

#2 in Plant #1, approximately 20 to 25 birds. I finished my FPS check and went to do 

another task. I was around the Area and the birds had not been picked up. At 

approximately 0430 hours I went to see the birds closer and they were getting dry. I 

contacted Quality Control and she called the Supervisor for that Area. 

came and I showed him my findings. The SSOP Plan states in part

 At approximately 0440 hours, 

picked up the birds, put them on a cart and took them to the condemned 

room. I informed him about the noncompliance. 

(b) (6)
(b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1814081 

115N-1 

08/15/2013 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 0901 hours while performing scheduled Operational SSOP Review 

and Observation task I observed the following noncompliance. While walking 

through the packaging area I observed heavy beaded condensation on the drip pan 

located at the Breast Halver machine that is directly across from the Bag Fryer line. 

The drip pan was directly above a tank full of ice that was being used on the 

product being put in brown tubs. As no Supervisor was immediately available I 

showed the employees working there my cooncerns about the condensation. An 

employee started to wipe down the condensation with a squeeze sponge mop and 

as he was cleaning the drip pan numerous drops of water fell all over the ice in the 

tank. I immediately took regulatory control action by telling them not to use the 

tank of ice and attached USDA Retain tag #B31407792 to the tank. As I was 

attaching my tag arrived. I 

accompanied to the edible dump room where he emptied and 

washed the tank, restoring sanitary conditions at approximately 0918 hours, at 

which time I removed my tag. My findings indicate a noncompliance with 9CFR 

416.4(d), 9CFR 416.2(d), 9CFR 416.4(b) and 9CFR 416.1. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2907084 

415N-1 

08/15/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 08/14/2013 while monitoring the Establishments' Pre-operational Sanitation 

Procedures in Plant #1 and Main Packaging, I observed a noncompliance with the 

following regulatory requirements of regulations 9CFR 416.1, 9CFR 416.4 (a) and 

9CFR 416.13 (c). At approximately 2220 hours, while inspecting Area # 3, Unit #20 

and Unit #21 ( Inspector Stations #5 and #6), I found on the viscera shackles, 

semi-dried brown and red residue from the previous day production. I went to 

Inspectors stations #7 and #8 and found the viscera shackles with the same brown 

and red residue. I tagged the Line with U.S. Rejected/Retained Tag # B31 407939 

and informed of the 

noncompliance. had sanitation employees scrubbed and 

rewashed the viscera shackles from Inspector Station #5 to Inspector Station #8. I 

continued performing Pre-operational Sanitation Procedures on Area #4 and Area 

#5 and then I came back to reinspected the Area, at approximately 2240 hours 

sanitary conditions were restored, I then released the area. At approximately 2348 

hours, I went to performed Pre-operational Sanitation Procedures in Main 

Packaging, I was waiting in the Rehang Area in Plant #1 to start my inspection when 

I observed a company employee bringing a stainsteel tank into Rehang Area from 

the Cooler in Plant #1 to catch the ice. I decided to inspect the tanks that were 

covered with blue plastic and found one with numerous pieces of fat from the 

previous day production. I went inside the Cooler and found eleven tanks that were 

not covered with blue plastic and had numerous pieces of fat and meat from the 

previous day production . I contacted and 

informed him about the noncompliance. The SSOP states in part "

 instructed sanitation 

employees to as per company 

procedure. At approximately 0010 hours, I reinspected the tanks and released to 

production. 

(b) (6)
(b) (6)

(b) (6) (b) (6)

(b) (4) (b) (4) (b) (4) (b) (4)

(b) (4)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4)

(b) (4)

(b) (4) (b) (4)(b) (4)

(b) (4) (b) (4)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3622082 

515N-1 

08/15/2013 03J02 Slaughter HACCP C On 08/14/2013 at approximately 2000 hours while performing a HACCP Slaughter 

Record Review Task, I found the following: 1.- The Pre-shipment Record Review for 

the End of the Shift for CCP-1B ) for Plant #1 dated on 

08/10/2013 AM shift was signed at 0725 hours.The Pre-shipment Record Review 

for the End of Shift for CCP-1B ) Zero Tolerance for the 

Reprocessing Line in Plant #1 dated on 08/10/2013 AM Shift was signed at 

hours. The Pre-shipment Records Review for the End of the Shift for CCP-2B 

), Zero Tolerance for Line #1 and Line #2 in Plant #1 dated on 

08/10/2013 AM Shift was signed at hours. The signed document certifies that 

the product is ready to be shipped. The end of the shift for that day of 08/10/2013 

AM Shift was at hours. My findings indicate a noncompliance with the 

following regulatory requirements of regulation 9CFR 417.5 (c). 2.- The HACCP 

Monitoring Log -CCP 2B- (Plant 2) for Line and Line Organic 

Birds dated on 08/13/2013 AM Shift had the following Zero Tolerance Checks 

times: fist check at hours and hours, second check at 0001 hours and 

0007 hours, third check at 0123 hours and 0128 hours. The HACCP Plan states in 

part under monitor procedures 

. The second and the third 

Zero Tolerance check had a gap of on Line and 

on Line Mu findings indicate a noncompliance with the following 

regulatory requirements of regulation 9CFR 417.2 (c)(4). I notified 

of the noncompliance. 

5308 M6137 BXL3720085 

815N-1 

08/15/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 08/15/2013 while walking through the packaging department I observed the 

following noncompliance. At approximately 1746 hours at the bag fryer line , I 

observed that an employee was using scissors to cut open bagged whole birds that 

were in a grey plastic basket. The gray plastic baskets are not a product contact 

surface. The outside of the bags were not being washed before cutting them open 

with the scissors, and the scissors were not being washed after cutting open each 

bag. The Establishments SSOP states in part that "

 I informed 

and of the noncompliance. My findings indicate 

a noncompliance with the following regulatory requirements of regulations 9CFR 

416.1, 9CFR 416.14, 9CFR 416.12(a), and 9CFR 416.4(d). 

(b) (6)
(b) (6)

(b) (6) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN061408 

1415N-1 

08/14/2013 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1814 hours, while verifying the plant compliance with the 

operational sanitation procedures, I observed the following; there were three 

groups of plant employee’s unwrapping rework pouches of breast fillet. Each group 

had a plastic covered basket containing the wrapped product; which they were 

opening and emptying out over other wrapped products. The exterior of these 

pouches is not a food contact surface due to their unsanitary contact with the 

conveyors, which possibly had particles of chicken meat or juice, and cross 

contamination between the basket and actual pouch surface during the 

transportation process. Also I observed a plant employee with unwashed or gloved 

hands, was covering a basket with a plastic bag, and then touch the inner surface of 

the bag, which suppose to be a food contact surface. I immediately informed the 

of the noncompliance, and tagged the affected product 

with the U.S. retain tag # B43303598. At approximately 1930 hours, I checked and 

released the product after the plant corrective actions were found acceptable. 

5309 P6137A NJN561808 

2413N-1 

08/13/2013 06D02 Other Inspection 

Requirements 

C At 1336 hours, while performing a Presentation check on B-Line. At station # 3 the 

score was 67 points; this score represents two carcasses with viscera on shackle (16 

points), one carcass not hung by 2 legs (9 points), two carcasses has no viscera (40 

points) and one carcass not reflected (2 point). The establishment was running at 

the allowable line speed BPM (Birds per minute). I immediately informed Mr. 

, of the non-compliance and had him 

reduce the line speed . The line speed kept on BPM until the QC re-checks 

passed. The establishment failed to keep the conformance score with the allowable 

score, exceeding the score above 40 represent a non-compliance with 9 CFR 381.76 

(a) and b. 9 CFR 381.76 (a) states : "A post-mortem inspection shall be made on a 

bird-by-bird basis on all poultry eviscerated in an official establishment. No viscera 

or any part thereof shall be removed from any poultry processed in any official 

establishment, except at the time of post-mortem inspection, unless their identify 

with the rest of the carcass is maintained in a manner satisfactory to the inspector 

until such inspection is made. Each carcass to be eviscerated shall be opened so as 

to expose the organs and the body cavity for proper examination by the inspector 

and shall be prepared immediately after inspection as readyto- cook poultry. . 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE110808 

4412N-1 

08/11/2013 01C02 Operational SSOP 

Review and 

Observation 

C At 0445 hours while preforming Operational SSOP Review and Observation task in 

the Evisceration Department at the rehang area, I observed two large piles of birds 

approximately 150 total on the floor. There were no employees picking up the birds 

off the floor. I called and informed him of the 

forthcoming non-compliance. Mr had the two black hat leads to pick up and 

wash all the birds that were on the floor. No US Retained tag was applied. The 

establishments failure to meet the following regulations as stated constitute this 

non-compliance. 9CFR 416.4(d) states: "Product must be protected from 

adulteration during processing, handling, storage, loading, and unloading at and 

during transportation from official establishments." 9CFR 416.13(c) states:" Each 

official establishment shall monitor daily the implementation of the procedures in 

the Sanitation SOP's." 

5308 M6137 BXL3108083 

210N-1 

08/10/2013 04A06 Poultry Finished 

Product Standards 

C On 08/09/2013 at approximately 0030 hours while monitoring Post-Chill Finished 

Product Standards from product exiting Chiller #3 in Plant #2, I observed the 

following. After collecting a standard 10 bird sample, I accumulated 13 

nonconformance points from ingesta and black/brown specks and smears which 

exceeded the subgroup absolute limit of 10 points. I contacted and 

informed him of the noncompliance. A Quality Control recheck at 0036 hours failed 

with 12 nonconformance points. The limit for a recheck is Tolerance, 5 points. At 

this point the process is judged to be out of control. Product exiting the chiller was 

tanked and placed under QC hold pending rework. Quality Control rechecks at 0047 

and 0100 hours passed bringing the process back into control. My findings 

indicated a noncompliance with 9 CFR 381.76(b)(3)(iv)(e)(3). 

5308 M6137 BXL3408081 

810N-1 

08/10/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 08/10/2013 at approximately 0038 hours while monitoring Operational 

Sanitation Procedures in Packaging line I observed the following. Several of the 

first Organic carcasses arriving for cutup had black UFM (Unidentified Foreign 

Material) on the skin and connective tissue near the neck area of the carcasses. The 

specks and streaks measured up to approximately 1/2" by 3/8". From the location 

of the UFM on the carcasses the carcasses had been dragged across an insanitary 

surface. I contacted who stopped the line. A section of the drip 

pans after the unit was covered with a piece of plastic as a temporary 

corrective action. A tub of front halves (breast and wings) and a partial tub of half 

breasts were placed under QC hold until reconditioned. My findings indicated a 

noncompliance with 9 CFR 416.1 and 9 CFR 416.4(d). 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2409081 

308N-1 

08/08/2013 04A06 Poultry Finished 

Product Standards 

C On 08/08/2013 at approximately 0440 hours while monitoring facilities in Plant #2, 

I observed the following. Line broke down repeatedly and the carcasses at the 

kill/evisceration line rehang station were being collected on the transfer table and 

into tanks. I went to the paw collection room approximately 10 minutes later to see 

how many paws were being condemned. The establishment has an automated paw 

condemnation system that automatically condemns paws when a corresponding 

carcass at any inspection station is condemned and for tanked carcasses caused by 

break downs. The paws for Line take approximately 10 minutes to get to the 

collection station. Although the carcasses were being dropped no paws were being 

dropped in the paw room. I contacted and asked why the system 

was not dropping any paws. Line repairs were going to take some time so the 

slaughter process was switched to line . Before line was empties it also broke 

down. We watched the paw condemnation process for several more minutes until 

the line was empty and line paws had arrived at the collection station. Although 

both lines were broken no paws were being condemned by the system. 

All the paws were being collected into a plastic lined bin as edible product. I placed 

the bin of paws being collected when I first arrived and a second bin on hold. The 

paws were condemned by production and dumped into the condemned products 

room. On 08/10/2013 at approximately 0240 hours the birds on line had a high 

rate of disease resulting in multiply line stoppages and finally a line slowdown. Line

 was stopped so I went to the paw room to observed the paw system for 15 

minutes. Although it takes approximately for the affected paws to get 

to the paw collection room no paws were condemned. I contacted 

and told him of the paw system malfunction and that the tank of paws being 

collected was being tagged as US Retained product. The system was worked on by 

mechanics during the lunch break and appeared to be functioning normally after 

the lunch break. The bin of paws from before the lunch break was condemned by 

production and take to the PC plant for disposal. My findings indicated a 

noncompliance with 9 CFR 381.65(a) and 9 CFR 381.78(a). 

5308 M6137 BXL3003082 

008N-1 

08/08/2013 04A06 Poultry Finished 

Product Standards 

C On 08/08/2013 at approximately 0020 hours while monitoring Post-Chill Finished 

Product Standards from product exiting Chiller #3 in Plant #2, I observed the 

following. After collecting a standard 10 bird sample, I accumulated 19 

nonconformance points from ingesta and black/brown specks and smears which 

exceeded the subgroup absolute limit of 10 points. I contacted and 

informed him of the noncompliance. A Quality Control recheck at 0030 hours failed 

with 12 nonconformance points. The limit for a recheck is tolerance, 5 points. At 

this point the process is judged to be out of control. Product exiting the chillers was 

tanked and placed under QC hold pending reconditioning. Quality Control rechecks 

at 0038 and 0105 hours passed bringing the process back into control. My findings 

indicated a noncompliance with 9 CFR 381.76(b)(3)(iv)(e)(3). 

(b) (6)
(b) (6)

(b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3303083 

408N-1 

08/08/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 08/07/2013 at approximately 2217 hours while monitoring the Establishments' 

Pre-Operational Sanitation procedures in Plant #2, I observed the following. There 

was peeling paint on the guide bars on line and from the oil gland remover to 

past the backup eviscerators station. The guide bars are considered a non-product 

contact surface but are located directly above the carcasses. The carcasses are being 

opened at this location during production. At approximately 2218 hours the auto 

drawer for line had black UFM(Unidentified Foreign Material) and wear marks on 

the arms of the spoons that draw the contents from the abdominal cavity. There 

was also a thick layer of black UFM to approximately 1/8" on the inside of the 

metal and white nylon guide bar above the spoon assembly. The metal to metal 

contact between the arm and the guide bar is the source of the UFM. Sanitary 

conditions were restored by approximately 2224 hours. Also on line there was 

black UFM and wear marks on the arms of the suction assembly of the Lunger that 

when inserted into the carcass during production extracts the lungs. The UFM was 

also on the inside metal portion of the metal and white nylon portion of the guide 

bar above the arms. The UFM is being caused by the metal to metal contact 

between the guide bar and the stainless arms. Sanitary conditions were restored by 

approximately 2230 hours. My findings indicated a noncompliance with 9 CFR 

416.1, 9 CFR 416.2(b)(1), 9 CFR 416.2(a) & (b) and 9 CFR 416.13(c). 

5309 P6137A NJN060508 

1808N-1 

08/08/2013 01D01 SPS Verification C At approximately 0015, while performing a pre-operational inspection of the 

packaging area, the following noncompliance was noted. While inspecting the 

underside of the degree conveyor located in Area 2, Section C (Packaging: 

Segment Line & , I noticed fat pieces from previous usage hanging from 

the surface of the conveyor belt (non-product contact surface). After 

noticing the deficiency, I notified and showed the affected area to Mr. 

. I then applied US Reject tag B40191982 to the 

conveyor belt pending the implementation of corrective actions by the 

establishment. At approximately 0025, I was notified by Mr. that the 

corrective actions were completed and the equipment was ready for re-inspection. I 

re-examined the belt and determined that the equipment was acceptable for use. 

The establishment did not meet the requirements 9 CFR 416.4(b) which specifies 

that non-food-contact surfaces of equipment must be cleaned and sanitized as 

frequently as necessary to prevent the creation of insanitary conditions and the 

adulteration of product. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4)

(b) (4)

(b) (4)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0008084 

207N-1 

08/07/2013 03C02 Raw Intact HACCP C On 08/07/2013 at approximately 0230 hours while monitoring Operational 

Sanitation procedures in Packaging, I observed the following. was 

taking the temperature of product on Line I asker her for her 

thermometer and took the temperature of product on the inflow side of the line. 

The product temperatures registered to 64.2 degrees. The breast tenders and fillets 

were at the edge of the belt adjacent to the stainless portion of the line and on the 

end of the transfer belt caught in the space between the belt and the stainless 

chute. called who was informed of the 

noncompliance. Approximately 12 pieces of product was involved. The product was 

placed into a gray inedible container. A check of the establishments' computer 

revealed that the last check on Line was at hours and the product was 

found to be at 43.7 degrees. The room temperature at the inflow side of line was 

approximately 64.2 degrees. After break a check of product arriving at line from 

the Room showed temperatures consistently at approximately 45 degrees. A 

check of the Establishments' HACCP Plan - Raw Not Ground - Packaging Step #8

 However, CP-12 

is used by the establishment to monitor temperatures in 

the processing areas on product being packaged. The procedure states under 

Corrective Action Procedure that "Product >60 degrees will be condemned." The 

Establishments' HACCP Plan - Raw Not Ground - Packaging Step #1 

." My findings indicated a noncompliance with 9 CFR 

381.66(b) and 9 CFR 417.2(c)(4). 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6)

(b) (4)

(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3207081 

106N-1 

08/06/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 08/06/2013 at approximately 0340 hours while monitoring the establishments' 

Operational Sanitation procedures in Plant #2, I observed the following. Line was 

stopped due to a breakdown. I walked to the kill/evisceration auto transfer area 

and observed a large pile of birds on the floor, approximately 200. As birds 

continued to fall on the floor, was near the pile of birds 

rinsing them and returning them to production. The modified tank used with the 

reverse feature on the rehang belt was sitting nearby empty. The catch tray that 

captures birds that are not rehung and directs the rehang belt was full. The 

carcasses were falling from the top of the catch tray onto the floor. The tank 

normally located under the catch tray to catch the carcasses was adjacent to the 

pile of carcasses that were collecting on the floor. The tank was also empty. The 

modified tank and reverse feature on the rehang belt were used at approximately 

0349 hours at about the same time that line restarted. There was varying 

amounts of blood and other contaminants on the floor at this location from the kill 

process creating an insanitary condition. My findings indicated a noncompliance 

with 9 CFR 416.1 and 9 CFR 416.4(d). 

5308 M6137 BXL3422083 

906N-1 

08/06/2013 03C02 Raw Intact HACCP O On 08/06/2013 at approximately 0024 hours while conducting a Post-Chill Finished 

Products Standards check on Chiller #3 in Plant #2, I observed the following. After 

collecting a standard 10 bird sample, I observed one carcass with a shiny metal 

flake approximately 1mm by 3mm in size attached to the connective tissue near the 

junction of the wing and breast. I contacted and 

showed him the metal. I informed of the noncompliance. The 

metal flake was given to . Organic birds were exiting the chiller. 

According to PDD FSIS considers metal flakes of any size on a carcass to be an 

unacceptable contaminant that should be addressed by the establishments' Hazard 

Analysis. The Establishments' HACCP Plan - Raw Not Ground Packaging Step #1 

states

 The carcass contaminated with the metal flake had received its final 

microbial intervention and was on a rehang belt going into Packaging. There are no 

metal detectors in Packaging. The issue of metal contamination has been discussed 

at previous morning meetings with the establishment. My findings indicated a 

noncompliance with 9 CFR 416.4(d), 9 CFR 417.3(b)(1), 9 CFR 417.3(b)(2), 9 CFR 

417.3(b)(3) and 9 CFR 417.3(b)(4). 

(b) (6)
(b) (6)

(b) (6) (b) (4) (b) (4) (b) (4)

(b) (4)

(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN441708 

2006N-1 

08/06/2013 01D01 SPS Verification C At approximately 1055 hours, while verifying the plant compliance with the 

sanitation performance standard on the kill floor, I observed accumulations of black 

pasty material mixed with feathers on several areas of line (B) guide bar. The 

formation of this black residue is due to the friction between the metal of the 

shackles and the metal guide bar. This pasty black material increased and with the 

presence of water there is high probability that this accumulations of contaminant 

to fall on the carcasses cross contaminating them. I immediately showed Mr. 

, my finding and informed him of the 

forthcoming noncompliance documentation. 9 CFR 416.1 states: Each official 

establishment must be operated and maintained in a manner sufficient to prevent 

the creation of insanitary conditions and to ensure that product is not adulterated. 

5308 M6137 BXL1317080 

703N-1 

08/03/2013 03C02 Raw Intact HACCP C On 08/03/2013, at approximately 0925 hours while performing Raw Intact Task in 

Main Packaging, I found a noncompliance with the following regulatory 

requirements of regulations 9CFR 381.66 (b) and 9CFR 417.2 (c)(4). Using a 

company calibrated thermometer # 27 from Quality Control nightshift, I took a 

product temperature on Line . The first temperature on a whole wing was 60.2 

degrees. Since Quality Control was doing her temperature check, I showed her my 

findings. She called an employee and told him to add ice to the product, then she 

left. I took more product temperatures. The temperatures ranged from 60.2 

degrees to 64.5 degrees. I called and showed her my 

findings. She stopped the line and condemned the product due to high temperature 

failure, into a blue inedible barrel. The condemned product was approximately a 

half of a barrel. A review of the Establishments temperatures records on Line at

 hours revealed that the temperature was 53.1 degrees by Quality Control. The 

HACCP Plan -Raw Not Ground - Packaging Step #8 states in part 

". HACCP Supplements # 33 CP-12 

, states in part that 

. At approximately 0933 hours the Line was released 

back into production. 

(b) (6)
(b) (6) (b) (4) (b) (4)

(b) (4)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0012082 

402N-1 

08/02/2013 03C02 Raw Intact HACCP C While performing the Review of Establishment Data Task on 07/30/2013 and 

7/31/2013, I observed the following noncompliance. On the Thermometer 

Checkout Log dated 07/27/2013 there was an entry of thermometer #13 that had 

been checked out and returned by a Quality Control representative. On the 

Thermometer Calibration Log dated 07/27/2013 there was no calibration entry for 

thermometer #13. On futher investigation I saw that on 07/30/2013 thermometer 

#35 had also been checked out and returned, however there was no record of it 

being calibrated on the Thermometer Calibration Log. The HACCP 

Plan - Slaughter - Plant #1 and Plant #2, - Step #38 and #37, also 

-Step #46 and #45 for 

One of the Supplements listed is #20 CP-11 

, which lists under . My findings 

indicate a noncompliance with regulatory requirements of regulations 9CFR 

417.4(a)(2)(i) and 9CFR 417.5(a)(3). I informed of the 

noncompliance. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5808080 

202N-1 

08/02/2013 01D01 SPS Verification O On 08/02/2013 at approximately 0015 hours after completing Pre-Operational 

Sanitation in Packaging Area #1, I observed the following. Production was setting up 

in Packaging at the start of the shift. The dollies and baskets being removed from 

the elevator and the bulk products storage side of the crust tunnel and were being 

distributed to all the packaging lines. The wheels on the dollies being removed from 

the elevator were leaving a trail of brown UFM (Unidentified Foreign Material) on 

the floor. Hundreds of dollies are used during the shift and are brought down from 

the Weigh & Price Cooler on the elevator. The floor is normally not rinsed until 

lunch break at approximately 0430 hours. The heavy traffic will spread the UFM all 

over Packaging. The casters on the dollies are severely rusted with decaying product 

material adhering to the rust. The Dollies are a non-product contact surface and 

have not been cleaned for some time. I contacted and 

showed him the condition of the dollies and the insanitary condition they were 

creating. The dollies were collected and given a cold water rinse that had little 

effect. The dollies and baskets were placed into the elevator and storage side of the 

crust tunnel by sanitation to get them out of the way to facilitate Pre-Operational 

Sanitation cleaning procedures. Per a discussion at the morning meeting on 

07/24/2013 available dollies and baskets are cleaned nightly as part of 

Pre-Operational sanitation. was called and stated 

that there is only time to rinse the dollies daily but that 300 dollies were cleaned on 

07/27/2013. An acid cleaner is used that is not compatible with the daily sanitizer, 

so sanitation only uses the acid on Saturdays. He showed me several of the clean 

dollies and it was clear that the tops of the frame was cleaned and virtually free of 

the brown UFM but the bottoms of the frame and casters were still brown and 

rusted. I then showed the Crust Tunnel where the product 

racks made of the dollies and baskets are used to hold product during chilling. The 

tracks that the dollies run on are severely rusted. The crust tunnel is seldom 

cleaned as the floor is severely deteriorated. We proceeded to the Weigh & Price 

Cooler where the product is held in the racks until shipped. The cooler floor has a 

large area covered with liquefied brown UFM. The 'A' side of the cooler where the 

large liquefied brown area is located was cleaned on 7/27/2013 and will not be 

cleaned for another month. The floor in the elevator that is used to bring the dollies 

down stairs to Packaging is also cover with a similar brown UFM. At approximately 

2000 hours on 08/02/2013 I had clean a dolly using 

the foam cleaner available nightly. The cleaning process using the foam cleaner did 

not significantly reduce the brown UFM on the dolly. The establishments' SSOP 

states that " 

" No brushes are being utilized by 

(b) (6)
(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

sanitation to clean the dollies or baskets. My findings indicated a noncompliance 

with 9 CFR 416.1, 9 CFR 416.2(b)(1), ad 9 CFR 416.4(b). 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6)(b) (7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN581308 

2202N-1 

08/02/2013 04A06 Poultry Finished 

Product Standards 

C At approximately 0910 hours, I was performing a post-mortem inspection on line 

(A) when I observed a carcass which had already been marked with a vertical slash 

across the back. The carcass was re-hung on the line after it was taken down, rather 

than taken to the salvage station. I immediately showed Mr. 

, my finding and informed him of the forthcoming noncompliance 

documentation. 9 CFR 381.84 states: "Carcasses of poultry with evidence of 

extensive involvement of the air sacs with airsacculitis or those showing 

airsacculitis along with systemic changes shall be condemned. Less affected 

carcasses may be passed for food after complete removal and condemnation of all 

affected tissues including the exudates." 

5333 P7632 HYE091308 

5202N-1 

08/02/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 0940 hours, I was performing the Review and Observation 

component of a Zero Tolerance Task at Line 1 FPS (inspection station) prior to the 

carcasses entering the South chiller. While I was performing the Zero Tolerance 

verification, I observed a cloaca with a piece of intestine approximately 3 inches 

long attached to the tenth carcass from the ten carcass sample. After a closer 

observation, I noticed that the cloaca was draining a whitish paste like material 

consistent with fecal material (FSIS Directive 6420.2 Attachment 1). I took 

regulatory control action by retaining the affected carcass with U.S. Retain tag# 

B43303554. I showed my finding to 

Ms. initiated corrective actions as stated in the 

establishment’s HACCP plan. Mr. respectfully requested a second 

opinion from the IIC. At approximately 1040 hours SPHV, Dr. , 

confirmed that the material draining out of the end tip of the cloaca was fecal 

material. The affected carcass was reprocessed. The establishment failed to prevent 

fecal material from reaching the A line FPS inspection station with the potential of 

entering the chiller. Section 381.65(e) from the 9 Code of Federal Regulations 

requires that the establishments shall prevent contaminated carcasses with visible 

fecal material from entering the chiller. The finding of fecal material did not meet 

the requirements of the establishment’s HACCP plan. was informed 

of the forthcoming documentation for failure to comply with the regulatory 

requirements cited above. Two fecal failures occurred on 7/29/13 and 

8/01/13 . Previous preventive measures failed to stop reoccurrence of fecal 

material reaching the FPS station. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6)

(b) (6) (b) (6)

(b) (7)(C) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE240308 

3501N-1 

08/01/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 7/31/13 at approximately 2202 while performing the Pre-Operational SSOP 

Review and Observation task I, CSI , observed the following 

noncompliance. In Area #1 (B Line kill machine) I observed one fly, alive, on the 

product contact surface of the neck guide bar. The equipment was retained with the 

application of U.S. retain tag B38495422. killed 

the insect and showed me the remains. While the equipment was being washed and 

sanitized I investigated the kill room area further and found that the door to the 

live hang area was open and the air curtain machine was not working properly. 

After the equipment was washed and sanitized it was released at 2209 hours.

 were both informed of 

the noncompliance. Continuing my Pre-Operational Review and Observation task in 

Area IV, I inspected Unit #6 (Main Dark Meat Conveyors incline and decline belts. 

The Dark Meat Decline portion of the white conveyor had a greenish foreign 

material, with the consistency of machine grease, on the belt along with fat 

particles and a small winged insect. Also the white hard plastic guides that are 

bolted to the stainless steel frame of the conveyor had a gap between it and the 

frame of approximately 1/4 of an inch. This gap revealed a meat and fat residue 

built up on the white plastic guides. The conveyor was retained with the application 

of U.S. retain tag B38495429. I requested from a Bio Trace 

reading to be taken while waiting for maintenance employees to arrive to 

disassemble equipment, the reading was 774 bacteria count. had 

Establishment maintenance employees remove the guides for the purpose of 

thorough cleaning of the product contact surfaces. The backside surface of the 

guides had black mold on them, these findings were shown to 

. After all equipment of was washed, sanitized and reinspected 

the equipment was released at approximately 0042 hours. Upon reviewing the 

establishment's Pre-Operational SSOP records for the night in question I noted that 

Section #4 Segment Line 1/ Unit #12 incline conveyor belts was 

inspected and passed by the Establishment Q.C. personnel. 

were informed of the noncompliance 

for the failure to meet the regulatory requirements stated above. 

(b) (6)
(b) (6)

(b) (6)

(b) (6)

(b) (7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE580708 

1001N-1 

08/01/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C While performing a Zero Tolerance verification task in the Evisceration department 

on Evisceration line #1 I, CSI , observed the following noncompliance. At 

approximately 0546 hours I randomly selected ten chicken carcasses. The tenth 

carcass of the ten had two greenish brown fecal globs 1/4 of an inch in it's greatest 

diameter located inside the cavity on the left thigh. The fecal material smeared from 

inside to the left side leaf fat covering approximately 1 inch in length and 3/4 of an 

inch in width of the leaf fat. I took regulatory control of the product by applying U.S. 

retain tag B38495426 to the product. I then showed 

, my findings 

and informed them of the noncompliance. , 

performed the recheck as per the establishment's corrective actions passing two 

consecutive ten carcass checks and the carcass was released to 

at 0550 hours. This failure represents a noncompliance with 

regulation 9 CFR 381.65(e), which states: "Poultry carcasses contaminated with 

visible fecal material shall be prevented from entering the chilling tank." The failure 

also represents a deviation with the establishment's written HACCP plan, regulatory 

requirements of 9 CFR 417.2(c)(4), which states: "List the procedures, and 

frequency with which those procedures will be performed, that will be monitor each 

of the critical control points to ensure compliance with the critical limits. A fecal 

failure occurred on 7/29/13, previous preventive measures failed to stop 

reoccurrence of this noncompliance. 

(b) (6)
(b) (6)

(b) (6)

(b) (6)

(b) (6)

(b) (6)

(b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1205074 

131N-1 

07/31/2013 06D02 Other Inspection 

Requirements 

C On 07/31/2013 at approximately 0204 hours while performing the monthly 

Presentation procedure in Plant #1 Line #2, I observed the following. At a line speed 

of bpm(birds per minute) the third station had (1) viscera not uniform, (1) 

viscera attached to the carcass, (3) opening cuts, (3) parts inside and (1) 

contamination inside bird for a total of 32 nonconformance points. The fourth 

station had (1) viscera not uniform, (3) opening cut and (3) parts inside for a total of 

14 points. This exceeded the limits of 2 occurrences or 24 points for the process to 

be in control. A no viscera check as part of the Presentation check also failed with 

18 no viscera. At a line speed of bpm 13 no viscera are allowed. 

was informed. A recheck at approximately 0224 hours at a line speed of 

bpm the second station had (2) viscera attached to the carcass, (1) viscera swinging 

and (2) opening cut for a total of 34 points. The third station had (1) viscera not 

uniform, (1) viscera attached and (3) opening cut for a total of 23 points. The fourth 

station had (2) viscera not uniform, (1) viscera attached to carcass, (3) opening cut 

and (2) parts inside for a total of 33 points. was informed and the 

line was slowed to 126 bpm. Adjustments were made to the giblet turner during 

lunch. After lunch break a recheck at approximately 0339 hours the third station 

had (2) viscera not uniform and (2) viscera attached to carcass for a total of 40 

points. The fourth station had (2) viscera not uniform, (1) viscera attached to 

carcass, (1) viscera swinging and (1) opening cut for a total of 39 points. 

was informed and the line was slowed to 113 bpm. Rechecks at 

approximately 0357 and 0521 hours passed except for the no viscera portion of the 

Presentation check with the line speed being returned to 126 bpm. To pass the 

Presentation rechecks the establishment condemned the viscera attached to the 

carcass or on the shackles prior to the carcass being inspected throwing the viscera 

into the trough at the backup eviscerators station. Quality Control rechecks for no 

viscera failed at 0428 and 0639 hours so the line speed was kept at 126 bpm for 

the remainder of the shift. Three consecutive no viscera checks is an indication of a 

loss of process control. My findings indicated a noncompliance with 9 CFR 

381.76(a) & (b). 

5308 M6137 BXL2914075 

431N-1 

07/31/2013 01C02 Operational SSOP 

Review and 

O On 07/31/2013 at approximately 0933 hours, as I was about to perform a 

Post-Chill Finished Product Standards check on Chiller #4 in Plant #2, I observed the 

Observation following. I took the USDA stainless steel cart that was located next to Chiller #4, 

and I saw that there was a dead adult cockroach lying in it. I immediately tagged the 

cart with U.S. Rejected, U.S. Retained Tag # A 5324458. I showed 

my findings and informed him of the noncompliance. I removed the tag and

 took the cart and washed it and returned it to me. This restored 

sanitary conditions. My findings indicate a noncompliance with the following 

regulatory requirements of regulations 9CFR 416.1, 9CFR 416.4(a) and 9CFR 

416.2(a). 

(b) (6)
(b) (6) (b) (6)

(b) (6)

(b) (6) (b) (7)(C) (b) (4) (b) (4) (b) (4) (b) (4)

(b) (4)

(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4020071 

931N-1 

07/31/2013 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1525 hours, I was walking to the Rehang Area to perform the Post 

Chill Finished Product Standards Task, when I observed at the end of the Chiller #1 a 

stainless steel tank full of whole birds partial covered with a blue plastic. I saw one 

bird with numerous blacks specks UFM (Unidentified Foreing Material), I uncovered 

the entire tank and inspected several more birds and found more UFM on them. I 

immediately tagged the tank with U.S. Retained/Rejected Tag # B31 406696 and 

informed and of my findings. Since 

Quality Control was there I released the retained tank of product at approximately 

1532 hours to her. I removed my tag and Quality Control placed a red hold tag to 

the tank. At approximately 1625 hours, the birds where hung on Line in 

packaging for reprocessing. The birds went through the sprayers, rinse water 

sprayers and at the beginning of the line a company employee was spraying the 

birds with . Quality Control inspected the tubs with the reworked 

parts and found them to be acceptable. This is a noncompliance with the following 

regulatory requirements of regulations 9CFR 416.1 and 9CFR 416.4 (d). 

5308 M6137 BXL5018070 

930N-1 

07/30/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 07/25/2013 while performing Operational SSOP Review and Observation Task in 

Main Packaging and Room, I found a noncompliance with the following 

regulatory requirements of regulations 9CFR 416.2 (c), 9CFR 416.12 (a) and 9CFR 

416.13 (b). At approximately 1500 hours, I was inspecting product at the 

Reconditioning Station in the Room, I noticed that it was difficult to inspected 

the parts that were in a brown tub because one of the light tubes was off. I left to 

check the SSOP program to see if there was a requirement for lighting. The SSOP 

Plan stated in part that 

At approximately 1525 hours, I returned and there 

was new reconditioning product ready for inspection. I contacted 

and notified him of the SSOP requirements and asked him to have an 

electrician check the lighting. The electrician came and measure the foot candles of 

light at the Reconditioning Station. It was 107 foot candles of light intensity. I 

tagged the Reconditioning Station with U.S. Rejected/Retained Tag # B31 407099 

and informed that it was a noncompliance. He sent the 

product to another Reconditioning Station for rework and had an electrician work 

on the light. At approximately 1605 hours SCSI and the electrician 

measured the light intensity and it was 207 foot candles, he then released the area. 

(b) (6)
(b) (6)

(b) (7)(C)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN170707 

5530N-1 

07/30/2013 01D01 SPS Verification O At approximately 0059 hours, while entering the new room department through 

the east side entrance I observed the following non compliance: a beaded 

condensation on the ammonia pipes dripping on the entrance floor where the 

product passes through this entrance. I immediately rejected the area by applying 

U.S. Rejected tag No B38494918. 

were showed my 

finding and informed with the forthcoming noncompliance record. The area was 

rechecked found acceptable and released by Dr. , IIC establishment 

P-6137A, at 0155 hours. Upon review of the establishment daily implementation 

and monitoring log for operation, the last check at 2318 hours found acceptable”. 

The Requirements of 9 CFR 416.1, 9 CFR 416.2(d), Plant’s written SSOP, were not 

met 9CFR 416.2(d) Ventilation requirement states "Ventilation adequate to control 

odors, vapors, and condensation to the extent necessary to prevent adulteration of 

product, and creation of insanitary conditions must be provided" Establishment's 

SSOP Part 2- Operational Sanitation Section 6 New Product Room states: 

" 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN191207 

2431N-1 

07/30/2013 04A06 Poultry Finished 

Product Standards 

C At approximately 0835 hours, while performing finished product standards 

verification check on the reprocessing line, I observed the following noncompliance. 

Four of the ten randomly picked carcasses sample were contaminated with various 

amounts of ingesta in the lap area, on the lower back bone at the site of the 

kidneys, and on the fat close to the tail. Another three carcasses were contaminated 

with various sizes of gall stain on the lap and back skin as well as oil gland partially 

trimmed, two other carcasses had scabs and feathers on the skin of the lap area, 

and one carcass marked with split tail with the infected lungs not vacuumed, and 

dark blue bruises on the thigh. I immediately took regulatory control action by 

stopping the reprocessing line, and showed my findings to Mr. , 

, the and informed them of the 

forthcoming noncompliance. At approximately 0845 hours, I recorded my findings 

and released the line after the plant employees removed all the affected carcasses 

for rework. At approximately 0855 hours, The reprocessing line was rechecked and 

released after was found acceptable. The plant failed to keep the reprocessing line 

in control. 9 CFR 381.91(b) states: "Any carcass of poultry accidentally 

contaminated during slaughter with digestive tract contents shall not be 

condemned if promptly reprocessed under the supervision of an inspector and 

thereafter found not to be adulterated. Contaminated surfaces that are cut shall be 

removed only by trimming. Contaminated inner surfaces that are not cut may be 

cleaned by trimming alone, or at an approved reprocessing station away from the 

main processing line, by any method that will remove the contamination, such as 

vacuuming, washing, and trimming, singly or in combination. All visible specks of 

contamination must be removed, and if the inner surfaces are reprocessed other 

than soley by trimming, all surfaces of the carcass shall be treated with chlorinated 

water containing 20 ppm available chlorine." 9 CFR 381.84 states: "Carcasses of 

poultry with evidence of extensive involvement of the air sacs with airsacculitis or 

those showing airsacculitis along with systemic changes shall be condemned. Less 

affected carcasses may be passed for food after complete removal and 

condemnation of all affected tissues including the exudate." 9 CFR 381.89 

states: " Any part of a carcass which is badly bruised shall be condemned and, if the 

whole carcass is affected as a result of the bruise, the whole carcass shall be 

condemned." 

(b) (6)
(b) (6) (b) (6) (b) (6)

(b) (6)

(b) (6) (b) (7)(C) (b) (7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN350307 

1330N-1 

07/30/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 2400 hrs. I was performing the review and observation 

component of a Zero Tolerance task on evisceration A line at the pre chill inspection 

station prior to carcasses entering the chiller. I examined a sample set consisting of 

ten random carcass when I noted the following non compliance. One carcass of the 

ten sampled contained brown colored material, approximately 1/4 of an inch in 

diameter, located on the inside of the carcass below the tail in the pelvic area. This 

material is consistent with fecal material. was 

present during this check and shown this finding. I stopped evisceration line A, 

informed . Ms. initiated the establishment's corrective 

actions as stated in the HACCP plan once the line was restarted. 

was shown the finding and requested a disposition from 

PHV Dr. Upon examination of the carcass in question Dr. 

confirmed that it was fecal material. I informed plant management and Ms. of 

the documentation of this non compliance report. The Establishment failed to 

prevent fecal material from reaching the A line FPS inspection station. At this point 

in the evisceration process carcasses are on their way to enter into the chiller. At 

this point in the process the establishment has no further intervention steps. 9 CFR 

381.65(e) states: Poultry carcasses contaminated with visible fecal material shall be 

prevented from entering the chilling tank. 9 CFR 417.2(c)(4) states: List the 

procedures, and the frequency with which those procedures will be performed, that 

will be used to monitor each of the critical control points to ensure compliance with 

the critical limits. I reviewed the establishment's documentation associated with 

this HACCP failure. The establishment was able to show that the CCP was brought 

back under control and that no further product was affected by this failure. 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (7)(C)

(b) (4)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (4)

(b) (4)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE440407 

4829N-1 

07/29/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C While performing a Zero Tolerance verification task in the Evisceration department 

on Evisceration line #1 I, CSI , observed the following noncompliance. At 

approximately 0053 hours I randomly selected ten chicken carcasses. The third 

carcass of the ten had a greenish brown fecal smear approximately 1 1/2 inch in 

length and 3/4 of an inch in width located inside the cavity on the breast plate. I 

took regulatory control of the product by applying U.S. retain tag B38495421 to the 

product. I then showed 

my findings and informed them of the 

noncompliance. , performed the recheck as per the 

establishment's corrective actions passing two consecutive ten carcass checks and 

the carcass was released to at 0101 hours. This failure represents 

a noncompliance with regulation 9 CFR 381.65(e), which states: "Poultry carcasses 

contaminated with visible fecal material shall be prevented from entering the 

chilling tank." The failure also represents a deviation with the establishment's 

written HACCP plan, regulatory requirements of 9 CFR 417.2(c)(4), which states: 

5308 M6137 BXL0200073 

027N-1 

07/27/2013 03C02 Raw Intact HACCP C On 07/26/2013 at approximately 1947 hours while monitoring Packaging functions 

at end of the PM shift, I observed the following. The Packaging of product was 

completed on line and boneless skinless breast fillets were being removed and 

placed into a brown product tub. Using a company calibrated thermometer I took 

the temperature of the product still on the line product belt and temperatures 

registered to 64.3 degrees. was there and observed.

 was called and product on approximately the last 1' of the center 

and line side of the belt was over 60 degrees. I informed of the 

noncompliance and approximately 30 pounds of breast fillets were condemned and 

placed into a blue inedible product barrel. A check of the Establishments computer 

revealed that the last temperature check on line was at . The 

temperature of the Packaging area at the line location was approximately 80.4 

degrees. A check of the establishments' HACCP Plan - Raw Not Ground -Packaging 

Step #8 

However, CP-12 

is used by the establishment to monitor temperature in 

the processing areas on product being packaged. The procedure states under 

Corrective Action Procedure that My 

findings indicated a noncompliance with 9 CFR 381.66(b) and 9 CFR 417.2(c)(4). 

(b) (6)
(b) (6)

(b) (7)(C) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1405072 

227N-1 

07/27/2013 04A06 Poultry Finished 

Product Standards 

C On 07/20/2013 at approximately 0600 hours while monitoring Presentation in 

Plant #1, I observed the following. I informed Dr. that both lines were running 

at 102 bpm (birds per minute) at which time he reviewed the Presentation Logs for 

the shift. He said that the Paws should have been condemned when the line speed 

was slowed below bpm and that the paws being collected in the paw room 

should be condemned. I proceeded to the paw room but 

was already in the process of placing a QC hold tag a bin of paws. A computer 

printout was requested for the establishments Paw Verification procedure for lines 

1 & 2 for 7/20/2013. The establishment instead provided the Paw Rejection 

Verification Log that only has some of the paw verification results for the shift. The 

functions of the automatic paw condemnation system has been addressed at 

morning meetings in the past with the establishment stating that the automated 

system does not work properly when the line speed is below bpm so all paws 

are automatically condemned at that time. Presentation checks had failed for the 

shift and Line #1 was slowed to 113 bpm after a check at hours failed. Line #2 

was slowed to 113 bpm after a hours Presentation check failed. Yet according 

to the Paw Rejection Verification Log provided a QC check at hours on line #1 

passed and by that time line #1 was at 102 bpm. The last entry on the log was at

 hours and under Comments/Corrective Action says "N/A Paws being 

condemned on both lines per USDA." There is no log book maintained in the paw 

room that documents when or from which plant paws are received so it is 

impossible to determine if adulterated product entered commerce. My findings 

indicated a noncompliance with 9 CFR 381.65(a) and 9 CFR 381.78(a) . 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (7)(C) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1905075 

027N-1 

07/27/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 07/27/2013 at approximately 0135 hours while monitoring Packaging 

Department functions, I observed the following. The high speed line was running 

taking carcasses exiting Chiller #4 in Plant #2 to a rehang belt in plant #1. Sections 

of the chain associated with the line was covered with rust. I contacted S

 and showed him how easily the residue wiped from the chain. While 

monitoring the product on the exit conveyor belt from Chiller #4 there were brown 

specks of UFM (Unidentified Foreign Material) on several carcasses with a similar 

consistency as the rust on the chain. I removed the birds and showed them to 

. The line was stopped and the carcasses on the belt were tanked 

and placed on QC hold pending reconditioning. At break the high speed line was 

started to remove the remainder of the carcasses. The tray in Plant #1 that catches 

the carcasses and directs then to the rehang belt had a large area measuring several 

square feet of dried and semi dried brown UFM. As the birds exiting the high speed 

line come into contact with the brown UFM on the tray the carcasses were also 

placed into the reconditioning products cart. A placed tag #B31408046 on to the 

high speed line emergency disconnect switch in Plant #1 until the line could be acid 

washed. The line was released on 07/29/2013 at approximately 0855 hours by SCSI

 My findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.4(d) 

and 9 CFR 416.2(b)(1). 

5308 M6137 BXL2205070 

027N-1 

07/27/2013 01D01 SPS Verification O On 07/27/2013 at approximately 0103 hours while conducting a Finish Products 

Standards check on Line , I observed the following. There was a small shiny metal 

flake approximately 1mm in size attached to the connective tissue near the tip of 

the keel bone. I showed the flake to who said to give it to 

, he was not in his office. I returned at 

approximately 0220 hours and showed the metal and told him that 

the medal flake was found attached to the connective tissue near the keel bone at 

the abdominal opening and that because of the location on the carcass I would 

check the Line Body Opener. At the line Body Opener there was a piece of 

loose stainless steel curled up on one Guide Bar. The metal measured 

approximately 3 cm by 1 mm. A second Guide Bar had two small pieces of stainless 

loose that measured approximately 2-3 mm in length. The flaking metal is caused 

by contact between the stainless steel Guide Bars and the stainless steel product 

shackles. The carcasses are being opened at this point in the establishments 

process. With the guide bars directly above the carcasses, the introduction of metal 

creates a Physical Hazard. I contacted and showed him the 

noncompliance. My findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 

416.2(b)(1) and 9 CFR 416.4(d). 

(b) (6)
(b) (6) (b) (6)

(b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4)

(b) (4)

(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3403074 

225N-1 

07/25/2013 01D01 SPS Verification O On 07/24/2013 at approximately 2220 hours while conducting Pre-Operational 

Sanitation in Plant #2, I observed the following. There were pieces of stainless steel 

peeling off a guide bar associated with the line Body Opener. I called 

We checked the Body Opener for line and found more loose flaking 

stainless. I collected the metal as it was removed and gave it to 

. The stainless peels off in small pieces and strips. The metal 

pieces were approximately 2mm, 5mm, 7mm to larger pieces over 3 cm in length to 

approximately 1mm in width. The guide bars are on the out flow side of the 

machines. The carcasses are being opened at this point in the slaughter process. The 

metal flaking is caused by metal to metal contact between the guide bar and the 

carcass shackle. All the loose pieces were removed. It is impossible to gage the size 

of the flakes that occur as part of the natural deterioration process. With the guide 

bars directly above the carcasses the introduction of metal creates a Physical 

Hazard condition. On 07/26/2013 at approximately 0100 hours I returned to the 

Body Openers for line and found more loose flaking stainless. I contacted

 and showed him the noncompliance. Several 

pieces of stainless were removed so I could gage the size range that was similar to 

the sizes on the previous day. A mechanic was called and the sharp edges were 

rounded to stop the flaking process. My findings indicated a noncompliance with 9 

CFR 416.2(b)(1). 

5308 M6137 BXL3514073 

225N-1 

07/25/2013 03J02 Slaughter HACCP C While performing a HACCP Slaughter Record Review Task at approximately 1100 

hours, I observed the following; On 07/23/2013 at approximately 1235 hours Plant 

1, Line #2, PM Shift, had a Zero Tolerance Failure by USDA. Company started 

performing corrective actions as HACCP Plan for Slaughter-Plant 1 stated. The last 

passing check of Zero tolerance by Quality Control was at hours and the 

recheck passed at hours. HACCP Supplement 8, step 5 stated that 

The HACCP CCP 2B, 

Corrective action Log, Chiller Exit Log, had a suspect lot from 1404 hours to 1426 

hours. The correct suspect lot should have been from 1404 hours to 1436 hours. 

Quality Control performed the last post-chill check at 1429 hours. This leaves a 

period of seven minutes of suspect product that was not inspected according to the 

HACCP Plan. The Pre-Shipment Records Review CCP 2B ) End of 

Shift was signed by the Supervisor at hours and the corrective actions for the 

failure were not completed. The signed documented certifies that the product is 

ready to be shipped. My findings indicate a noncompliance with the following 

regulatory requirements of regulations 9CFR 417.5 (a)(3) and 9CFR 417.5 (c). I 

notified of the noncompliance. 

(b) (6)
(b) (6) (b) (6) (b) (6)

(b) (6)

(b) (6)

(b) (6)

(b) (7)(C)

(b) (7)(C)

(b) (7)(C)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN321607 

5525N-1 

07/25/2013 04C05 Poultry Good 

Commercial 

Practices 

C On July 25, 2013 at 1105n hrs I was notified by CSI that Inspector

 has hang back a suspect DOA at station B2; for veterinary disposition. When 

I went to the kill floor, I saw Mr. ; already at B2 

Station and looking at the carcass. The carcass had reddish discoloration, smelled 

putrid, with congested viscera and a friable and enlarged liver and spleen. The 

intestines were congested and reddened and the neck is limp and purplish in color. I 

confirmed the carcass as a DOA and notified Mr. of the disposition. I 

informed him that a NR will be generated as this was the second confirmed DOA for 

the week. The first confirmed DOA was found on Tuesday, July 23, 2013 at station 

B2 at approximately 1500 hrs. by Inspector . I also confirmed this DOA. 

Mr. was notified of this first 

confirmed DOA. Earlier NR NJN4211075618N/1 issued on July 18, 2013. The 

repetitive occurrence of DOAs entering the evisceration department demonstrates a 

loss of process control and the creation of insanitary conditions in accordance with 

9 CFR 381.71(a) and 416(d). 

5333 P7632 HYE002107 

1725N-1 

07/25/2013 01C02 Operational SSOP 

Review and 

Observation 

C When I was observing the process at the Rehang area, I observed a deficiency 

noncompliant with sections 416.4(a) and 416.4(d) of the Code of Federal 

Regulations. At approximately 1645 hours I observed a sanitation employee over 

spraying the reprocessing area while he was washing the giblets chiller exit. No 

product was on the cart for product to be reprocessed neither in the wash product 

sink at the moment of the incident. I informed 

. The establishment immediately restored sanitary conditions by cleaning 

and sanitizing the reprocessing area. , was 

informed of the forthcoming documentation for the failure to comply with the 

regulatory requirements of 416.4(a) (d). 416.4(a) (d) states, (a) all food-contact 

surfaces, including food-contact surfaces of utensils and equipment, must be 

cleaned and sanitized as frequently as necessary to prevent the creation of 

insanitary conditions and the adulteration of product. (d) Product must be 

protected from adulteration during processing, handling, storage, loading, and 

unloading at and during transportation from official establishments. 

5308 M6137 BXL1917075 

023N-1 

07/23/2013 03J02 Slaughter HACCP C On 07/23/2013 at approximately 1235 hours while performing a Pre-Chill Finished 

Products Standards Task in Plant # 1 on Line # 2, I observed the following 

noncompliance. I randomly removed a 10 bird sample and found one out of the ten 

birds with visible fecal contamination. The fecal was located inside the bird on the 

right side under the leaf fat. The fecal material was approximately 3/16" in diameter 

in size and olive green in color and pasty in texture. I informed 

, and the protocol for fecal failure was implemented. At approximately 1301 

hours, Quality Control performed a recheck and passed. The cause of the deviation 

was the Venter. This is a violation of the critical limits of CCP-2B, 

of the Plant's HACCP Plan for Slaughter. 

(b) (6)
(b) (6) (b) (6)(b) (6)

(b) (6) (b) (6) (b) (6) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN511107 

4324N-1 

07/23/2013 01D01 SPS Verification O On Tuesday July the twenty third at approximately 0930 hours, I walked close to 

the refrigerated trailers yard, South West area of the plant. While I was walking I 

smelled an offensive odor coming from the trailers yard. when I inspected the area 

closely, I found that the asphalt underneath the trailers was damaged with different 

sized pot holes ranged from approximately (10 feet long by three feet wide) to 

(three feet long by one foot wide). The damaged area was approximately one 

hundred feet long and fifty feet wide. The pot holes collected bloody water drained 

from the trailers. the bloody water was retained and putrefied in the pot holes, 

causing unpleasant odor. At approximately 0940 hours, I showed Mr. 

, my findings, and informed him of the 

noncompliance. 9 CFR 416.2(a) states; "Ground about an establishment must be 

maintained to prevent conditions that could lead to insanitary conditions, 

adulteration of product, or interfere with inspection by FSIS program employees 

5333 P7632 HYE120307 

2423N-1 

07/23/2013 04C05 Poultry Good 

Commercial 

Practices 

C On July 22, 2013 at approximately 0130 hours a chicken carcass was retained on 

Line 1, Station 3’s USDA rack for veterinary disposition. Upon examination the 

musculature and skin were a dark purplish-red, mainly along the dorsal surface of 

the carcass and had a limp neck. The lungs were congested and the liver was friable 

on palpation. There was also a slight putrid odor. I notified Mr. 

, N/S of my findings who then summoned Ms. 

, N/S to view the carcass. I presented 

the carcass and my findings to Ms. . At approximately 0150 hours another 

carcass was retained for veterinary disposition from the same line and station and 

appeared very similar to the carcass that was previously retained. I notified Ms.

 of my findings and presented the carcass to her for her observation. The 

dispositions of both carcasses were confirmed to be dead-on-arrival (DOA). I then 

informed her of the forthcoming noncompliance documentation. DOA carcasses 

entering into the evisceration department is in violation of 9 CFR 381.71(a) and 

creates an insanitary condition in the establishment. 

5308 M6137 BXL1312072 

922N-1 

07/22/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C While monitoring the Establishments' Pre-operational Sanitation Procedures in 

Plant #2, I found a noncompliance with the following regulatory requirements of 

regulations 9CFR 416.1, 9CFR 416.4 (a) and 9CFR 416.13 (c). At approximately 0710 

hours , I observed in Area #5 , Unit #1 the blue conveyor belt that catches the birds 

from Line had a plastic bristle from the brush that sanitation uses to clean the 

shackles. It measured approximately 1" long by 1/32" wide. Also in the same area 

the conveyor belt that leads to the chiller had another plastic bristle measuring 

approximately 5" long by 1/32" wide. These plastic bristles had UFM (Unidentified 

Foreing Material) on them and are insanitary. I informed 

about the noncompliance. Sanitation personnel removed the plastic bristles and 

rewashed the area, sanitary conditions were restored at approximately 0714 hours. 

(b) (6)
(b) (6)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1712072 

422N-1 

07/22/2013 03J02 Slaughter HACCP C While performing Pre-Chill Finished Products Standards Task, I observed a 

noncompliance with the following regulatory requirements of regulations 9CFR 

381.65 (e) and 9CFR 417.2 (c)(4). At approximately 0928 hours, I randomly 

removed a 10 bird sample from Line in Plant #2, I found one out of the ten birds 

with visible fecal contamination inside, on the right side, on the top of the leaf fat. 

The fecal material was a piece measuring approximately 1/8" diameter in size, dark 

green in color and pasty in texture. This exceed the limit of Zero Tolerance for the 

process to be in control. I informed 

of the noncompliance. The protocol for fecal failure was implemented. Quality 

Control did a recheck at approximately 0950 hours an it passed. The cause of the 

deviation was I/O Bird Washer. This is a violation of the critical limits of CCP-2B 

of the Plant's HACCP Plan for Slaughter. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (7)(C) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4022070 

422N-1 

07/22/2013 06D02 Other Inspection 

Requirements 

C On 07/20/2013 at approximately 0215 hours while monitoring line function in 

Plant #1, I observed the following. Dr. asked when a Presentation check was 

last performed as it appeared that the body openers were not working. I told him 

that I was unsure as it is a low priority item but that after performing a no viscera 

check there appeared to be a lot of giblets attached to the carcass or being hung on 

the carcass shackles and a lot of the giblets on the giblet shackles were turned away 

from the inspector. I performed a Presentation check on Line #2 at a line speed of

 bpm (birds per minute) at approximately 0221 hours and the second station 

failed with (1) viscera not uniform, (1) viscera on the shackle, (1) viscera swinging, 

(5) opening cut and (1) parts inside for a total of 36 points. The fourth station had 

(3) viscera not uniform, (5) opening cut and (1) parts inside for a total of 30 points. 

This exceeded the limits of 24 points or 2 occurrences of one error for the process 

to be in control. I proceeded to Line #1 and at approximately 0228 hours at a line 

speed of 126 bpm the first station had (3) viscera not uniform and (3) opening cut 

for a total of 27. The third station had (3) viscera not uniform, (4) opening cut, (2) 

vents attached and (1) parts inside for 33 points. Station #4 had (2) viscera not 

uniform, (1) viscera attached to carcass, (3) opening cut and (1) parts inside for 32 

points. I informed After break, I contacted 

who stated that Maintenance had made adjustments and that the lines were ready 

for a recheck. At approximately 0334 hours on line #2 the first station had (5) 

viscera not uniform, (1) viscera attached to the carcass and (4) opening cut for a 

total of 56 points. The second station had (2) viscera not uniform, (4) opening cut 

and (3) parts inside for a total of 24 points. The third station had (2) viscera not 

uniform, (7) opening cut, (3) parts inside for 27 points. The end station had (3) 

viscera not uniform, (4) opening cut and (2) parts inside for a total of 30 points. At 

approximately 0347 hours at Line #1 the first station had (1) viscera not uniform, 

(1) viscera attached to carcass and (3) opening cut for a total of 23 points. The 

second station had (1) front or side, (2) viscera attached to carcass and (4) opening 

cut for a total of 39 points. The third station had (1) not hung be 2 legs, (2) viscera 

not uniform and (2) opening cut for 27 points. The fourth station had (1) viscera 

attached to carcass, (1) viscera swinging, (2) opening cut and (2) parts inside for a 

total of 26 points. I contacted and the lines were slowed 10% with 

line #1 going to 113 birds per minute as the line was already at 126 birds per 

minute for an earlier QC no viscera failure. . At approximately 0434 hours line #2 

station one had (4) viscera not uniform, (1) viscera attached to carcass, (3) opening 

cut and (2) parts inside for a total of 49 points. The second station had (2) viscera 

not uniform and (3) opening cut for a total of 19 points. The third station had (3) 

viscera not uniform, (3) viscera attached to carcass and (4) opening cut for 64 

points. The fourth station had (3) viscera not uniform, (1) viscera attached to 

carcass, (2) opening cut and (2) parts inside for 40 points. At approximately 0441 

hours on line #1 the second station had (1) viscera not uniform, (2) viscera swinging 

and (2) opening cut for 30 points, The third station had (3) viscera not uniform, (3) 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

opening cut and (2) parts inside for 29 points. The fourth station dad (2) viscera not 

uniform, (1) viscera attached to carcass and (1) opening cut for 29 points. I 

informed and line #2 was slowed by to 113 bpm (birds per 

minute) and line #1 to 102 bpm. At approximately 0450 hours Line #2 the third 

station had (4) viscera not uniform, (1) opening cut and (1) parts inside for 34 

points. The fourth station had (4) viscera not uniform, (2) viscera attached to 

carcass, (2) opening cut and (1) parts inside for 59 points. I contacted 

and the line was slowed to 102 bpm. Rechecks at 0556 and 0647 hours both 

failed and the line speed for line #2 was maintained at 102 bpm for the remainder 

of the shift. At approximately 0547 hours a recheck on line 1 passed and the line 

speed was increased to 113 bpm. At approximately 0602 hours line #1 the third 

station had (2) viscera not uniform, (1) viscera attached to the carcass, (1) opening 

cut, (2) parts inside and (1) contamination for 37 points. The fourth station had (1) 

viscera not uniform, (1) viscera attached to carcass and (1) contamination inside 

bird for 26 points. The line speed was again reduced to 102 bpm. A recheck at 

approximately 0635 hours also failed and the line speed for line #1 was kept at 102 

bpm for the rest of the shift. My findings indicated a noncompliance with 9 CFR 

381.76(a) & (b). 

5309 P6137A NJN550707 

1422N-1 

07/22/2013 01D01 SPS Verification C I was in the evisceration department at 0428 hrs. when I observed the following 

non compliance. I noticed that the overhead unit used to clean the reprocessing line 

was in an insanitary condition. The brushes that are lowered into place to clean the 

reprocessing line shackles have metal guards that had numerous feathers on the 

inside and outside of the unit. There was also dried soap residue on the guard 

surfaces. Evisceration B-line is located just above this brush unit and the shackles 

where coming into contact with the brush guard as the line was moving along. I 

informed and of 

the non compliance of the above regulations. 

(b) (6)
(b) (6)

(b) (6)

(b) (7)(C)

(b) (4) (b) (4)

(b) (4)

(b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE350807 

5022N-1 

07/22/2013 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 0616 hours on July 22, 2013 in the chiller rehang area I, CSI 

, observed the following noncompliance. The cabinet, above the 

employee stand for the Segment line rehang belt, was dripping with heavily beaded 

condensation onto a uncovered tub of overflow product (approximately ten chicken 

carcasses) from the rehang belt. I immediately took regulatory control of the 

product and the tub with the application of U.S. Retain tag B38495424. 

ere 

informed of the noncompliance. Mr. took immediate action by having the 

condensation removed and the affected product was sent to the product wash 

station. The affected product was 

per establishment’s procedure. As per Step #6 of the establishments SSOP’s plan:” 

Upon reviewing the nightshift's SSOP records for 

General Evis Area Section #1 the last passing check for Step #6 was performed at

 and was found acceptable by Quality Control. 

5308 M6137 BXL1803075 

419N-1 

07/19/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 07/19/2013 at approximately 0010 hours while monitoring the Establishments' 

Pre-Operational Sanitation procedures in Packaging Area #1, I observed the 

following. At the Plant #1 Halver there were numerous black specks that smeared 

like grease on the top surface and side product contact surfaces of the large white 

wheel associated with line that holds the carcasses during the cutting process. 

There was a large piece of rail dust measuring approximately 1/4" on the upper blue 

belt that collects the carcasses. There was dried product residue on the stainless 

flashing (Packaging Side) at the end of the upper belt. The stainless flashing 

captures some of the front halves and directs them to the collection belt. The 

residue peeled off easily with a finger nail. There was dried product residue on the 

lower stainless collection assembly (Plant #1 Cooler Side) that weighs the product. 

There was beaded condensation on the upper drip pans associated with the unit. 

Sanitary conditions were restored by approximately 0020 hours. The Plant #1 

Halving Machine was checked in response to a Directed Task assigned after a 

previous noncompliance was written on the same piece of equipment. PreOp is 

scheduled for hours in Packaging, however after asking for more time PreOp 

did not start until approximately 0005 hours. Better lighting for this unit may make 

the cleaning process more effective. My findings indicated a noncompliance with 9 

CFR 416.1, 9 CFR 416.4(a) & (b), and 9 CFR 416.13(c). 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (7)(C) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5604073 

919N-1 

07/19/2013 03J02 Slaughter HACCP C On 07/19/2013 at approximately 0145 hours while performing a scheduled HACCP 

Slaughter fecal check in Plant #1 Reprocessing Line , I observed the following. 

After taking a standard 10 bird sample after the final house inspector's station, I 

observed one bird with visible fecal contamination. Dr. was nearby so I showed 

him the carcass and verified that the contamination was fecal material. The fecal 

contamination was on the inside of the carcass approximately 2" down from the tip 

of the keel bone on the right side of the carcass near the keel bone. The fecal 

material , a dark brown smear,was pasty in texture and measured approximately 

1/2" by 1/4". I stopped the line and contacted . I showed him 

the fecal contamination. He implemented the protocol for fecal failure. A QC 

recheck passed at 0205 hours. My findings indicated a noncompliance with 9 CFR 

381.65(e), 9 CFR 417.2(c)(4) and CCP-1B of the Plant's HACCP Plan for SlaughterPlant 1 -

5308 M6137 BXL4904074 

318N-1 

07/18/2013 04A06 Poultry Finished 

Product Standards 

O On 07/18/2013 at approximately 0033 hours while monitoring the Establishments' 

Post-Chill Finished Product Standards in Plant #1 Chiller #1, I observed the 

following. After taking a standard random 10 bird sample, I accumulated 20 

nonconformance points which exceeded the subgroup absolute limit of 10 points. I 

saved the birds and showed the brown residue on the cut and connective tissue of 

the carcasses to . While a recheck was being performed, I 

went to Packaging and informed of the residue on the birds. 

He observed the residue on the parts being packaged on line and placed the cut 

breasts on hold (9 racks) until the residue went away at approximately 0130 hours. 

A recheck on chiller #1 failed at 0054 hours with 6 nonconformance points which 

exceeded Tolerance (5) allowed for a recheck. At this point the process is judged to 

be out of control. Product was tanked (5) until a recheck passed at 0101 hours. The 

brown residue on the carcasses has been occurring periodically over the past 

several months in plant #1. It has been identified as high Manganese in the water 

by the Establishment in conjunction with City of Livingston officials. The 

establishments' SSOP Corrective Action logs under 'Preventative Measure' on 

several occasions has stated "Will continue to monitor the carcasses exiting the 

chillers." and on the 07/15/2013 SSOP Corrective Action Log that " Maintenance 

and refrigeration are working on a filtration system." This issue has been discussed 

since 1/2/2013 at weekly meetings. Although this is not a food safety issue, the 

Finish Product Standards still must be met. There were no supervisors monitoring 

the birds exiting the chillers. A QC post chill check passed at 0031 hours. My 

findings indicated a noncompliance with 9 CFR 381.76(b) and 9 CFR 416.15(a) & (b). 

(b) (6)
(b) (6) (b) (6) (b) (7)(C) (b) (7)(C) (b) (7)(C) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN421107 

5618N-1 

07/18/2013 04C05 Poultry Good 

Commercial 

Practices 

C On the morning of Thursday July 18, 2013 at approximately 0930 hours I was 

notified by CSI that she has hung back a suspected DOA carcass at station 

B1 while she was giving breaks; for veterinary disposition. I went back to the 

slaughter floor and confirmed the carcass hung back at station B1 as a DOA. The 

carcass had reddish discoloration and several hemorrhagic areas with a friable 

swollen liver and swollen dark red kidneys and a putrid smell. It has a limp neck. I 

informed Mr. of the DOA and shown him the carcass. I 

informed him that a NR will be generated as this is the second confirmed DOA for 

the week. The first DOA was found on Monday July 15, 2013 at approximately 1525 

hours at station B2 and was hung back by Inspector and was 

confirmed as a DOA by Dr. . The repetitive occurrence of DOAs entering 

the evisceration department demonstrates a loss of process control and the 

creation of insanitary conditions in accordance with 9 CFR 381.71(a) and 416.4(d). 

5308 M6137 BXL5504074 

417N-1 

07/17/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 07/15/2013 at approximately 2330 hours while monitoring the Establishments' 

Pre-Operational Sanitation Procedures in Packaging area #1, I observed the 

following. There was a heavy layer of pasty fat and tissue on the white nylon 

support brackets along the entire length of both of the lower conveyor belts from 

chillers 1 & 2. The belts are used to move carcasses to a second belt for rehanging 

for cutup on line I showed my findings. The lower belts were 

rewashed and released by approximately 0018 hours. At approximately 0005 hours 

there was black UFM (Unidentified Foreign Material) that appeared to be mold on 

the white plastic and stainless steel support brackets for the tray belt for line . An 

area approximately 12 feet long of the tray belt adjacent to the leg processors was 

affected. The UFM was in patches of varying size from small specks up to an area 

measuring approximately 1" by 12" in size. The area was cleaned and released by 

approximately 0020 hours. My findings indicated a noncompliance with 9 CFR 

416.1, 9 CFR 416.4(a) & (b), and 9 CFR 416.13(c). 

(b) (6)
(b) (6)

(b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE551107 

0916N-1 

07/16/2013 01D01 SPS Verification C . On Tuesday the 16th, 2013 the following noncompliance was observed in 

evisceration department. At approximately 0915 the liver harvester on line 2 was 

not properly washed down during the company break. The arms of the harvester 

were congested with intestines, livers and gizzards. 

) was informed of my findings. He had the livers on the line condemned 

until the harvester was rinsed properly. At approximately 0925 the harvester was 

released. Mr. was informed 

of the forth coming Noncompliance. 9CFR 416.1 states: Each official establishment 

must be operated and maintained in a manner sufficient to prevent the creation of 

insanitary conditions and to ensure that product is not adulterated. 9CFR 416.3(a) 

states: (a) Equipment and utensils used for processing or otherwise handling edible 

product or ingredients must be of such material and construction to facilitate 

thorough cleaning and to ensure that their use will not cause the adulteration of 

product during processing, handling, or storage. Equipment and utensils must be 

maintained in sanitary condition so as not to adulterate product. 9 CFR 416.4(a) 

states: (a) All food-contact surfaces, including food-contact surfaces of utensils and 

equipment, must be cleaned and sanitized as frequently as necessary to prevent the 

creation of insanitary conditions and the adulteration of product. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6)

(b) (4)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4)

(b) (4)

(b) (4) (b) (4)

(b) (4)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4622070 

911N-1 

07/11/2013 03J02 Slaughter HACCP C At approximately 1000 hours while performing a HACCP Slaughter Records Review 

Task, I observed the following; the HACCP Corrective Monitoring Log -CCP 

, dated on 07/08/13 was not there at the file 

cabinet, I asked and she provided me the 

record. As I reviewed the Log I noticed that at approximately 0924 hours, Quality 

Control had a failure , See Corrective 

Action Log. The HACCP Corrective Action Log stated under location and description 

of the deviation "Plant 1, Sprayer Line Off". The immediate Corrective 

action? "Stop L Inf. Pack Maint. Inf. ". Was product involved? "Yes, 

product was involved. Retained 4 racks of product". Quality Control placed the 

product under hold as documented on the Establishments "Hold & Release Form 

dated on 07/08/13 made by (initials), Tag #38296 at 0929 hours for Dept:

 Sprayers L " under Product Description "Thighs & Drumsticks" Quantity "4 

racks", under Reason "No " Corrective Action "Retained product, washed 

with ." Reviewing the Establishments HACCP Plan - Slaughter 

Plant 1, Step 28 under

 The Establishments' 

Pre-Shipment Records Review CCP-7B- dated on 07/08/13 PM 

shift was signed at hours by Under 

. Whole carcasses are hung on 

line and there is no documentation available for corrective action taken on the 

front halves (breast and wings) the other half of the carcass. With the sprayers off 

the carcasses received no as required by the 

Establishments' HACCP Plan for Slaughter allowing carcasses to enter commerce 

untreated. The Pre-Shipment Records Review CCP 7B (Plant 1) 

was signed before the corrective actions for the failure were completed. My findings 

indicated a noncompliance with the following regulatory requirements of 

regulations 9CFR 417.3(b)(1), 9CFR 417.3 (b)(2), 9CFR417.3(b)(4), 9CFR 417. 5(c), 

and 9CFR 417.6. was 

informed of the noncompliance. 

(b) (6)
(b) (6) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5012072 

911N-1 

07/11/2013 06D02 Other Inspection 

Requirements 

C At approximately 0833 hours, I performed a presentation check on Line at line 

speed of BPM (birds per minute). Station #1 had (2) not reflected, total of 4 

points. Station #2 had (1) viscera on shackle, (1) membrane, (1) opening cut and (1) 

not reflected, total of 13 points. Station #3 had (1) viscera not uniform, (3) viscera 

on shackle and (3) not reflected, total of 38 points. Station #3 failed, this exceed the 

limit of 25-39 points and (3) occurrences of one error. Quality Control performed a 

recheck at approximately 0849 hours and Station #2 failed with (4) not reflected. 

This exceed the limit of (2) occurrences of one error for the process to be in control.

 was informed and Line speed was reduced to 81 BPM 

(birds per minute). At approximately 0859 hours all rechecks passed, bringing the 

process back in control. This is a noncompliance with the following regulatory 

requirements of regulation 9CFR 381.76 (b). 

(b) (6)
(b) (4)

(b) (4)

(b) (4) (b) (4) (b) (4) (b) (4)

(b) (4)

(b) (4) (b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE181307 

0911N-1 

07/11/2013 03J02 Slaughter HACCP O During the FSA in June/July 2013, the EIAO observed at the 

step in the hazard analysis, the establishment identifies

 as hazards reasonably likely to occur. The 

justification provided states 

. 

9CFR 381.91(b)(1) allows for treatment of contaminated carcasses with chlorinated 

water containing > or = 20ppm available as an approved antimicrobial. Directive 

7120.1 allows for treatment with chlorinated water containing up to 50 ppm 

available chlorine. The control measures identified include “The risk is 

reduced/controlled at subsequent steps in the process. The Chlorine Pre-Requisite 

program monitors chlorine levels to ensure .” The 

establishment did not provide any documentation to demonstrate that 

would be effective to prevent pathogens such as Salmonella. In addition, 

whenever a hazard analysis reveals one or more food safety hazards that are 

reasonably likely to occur, every establishment shall develop and implement a 

written HACCP plan with critical control points that will eliminate or reduce the 

food safety hazard to acceptable levels in accordance with Title 9 CFR 417.2(b)(1). 

The establishment has not identified a point in the process that will eliminate or 

reduce in salvaged parts to control the hazard identified at the

 step. This is a noncompliance with 

417.2(b)(1). Additionally, on July 3, 2013, EIAO observed establishment personnel 

conduct monitoring of the concentration from the in the 

establishment, the and the 

systems. Establishment personnel followed the monitoring procedures as written in 

the Chlorine Pre-requisite program for both samples. When the monitor observed 

the concentration of one of the chlorine lines, the sample indicated that it was at 0 

ppm. Establishment personnel called maintenance to have chlorine added to the 

system and the system was rechecked 15 minutes later. However, no corrective 

actions were taken in regards to the product. The establishment cannot support the 

decisions made in the hazard analysis. This is a noncompliance in accordance with 

Title 9 CFR 417.5(a)(1). 9 CFR 417.2(b)(1) states: (b) The HACCP plan. (1) Every 

establishment shall develop and implement a written HACCP plan covering each 

product produced by that establishment whenever a hazard analysis reveals one or 

more food safety hazards that are reasonably likely to occur, based on the hazard 

analysis conducted in accordance with paragraph (a) of this section, including 

products in the following processing categories: (i) Slaughter—all species. (ii) Raw 

product—ground. (iii) Raw product—not ground. (iv) Thermally 

processed—commercially sterile. (v) Not heat treated—shelf stable. (vi) Heat 

treated—shelf stable. (vii) Fully cooked—not shelf stable. (viii) Heat treated but not 

fully cooked—not shelf stable. (ix) Product with secondary inhibitors—not shelf 

stable. 9 CFR 417.5(a)(1) states: (a) The establishment shall maintain the following 

records documenting the establishment's HACCP plan: (1) The written hazard 

(b) (6)
(b) (6)

(b) (6) (b) (6)

(b) (6)

(b) (6)

(b) (6)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

analysis prescribed in § 417.2(a) of this part, including all supporting 

documentation; 

5308 M6137 BXL4908072 

710N-1 

07/10/2013 01D01 SPS Verification C On 07/09/2013 at approximately 2215 hours while conducting Pre-Operational 

Sanitation in Plant #2, I observed the following. There was a piece of stainless steel 

flaking off a guide bar associated with the line Body Opener. I called 

who took pictures for maintenance and removed the metal. A piece of metal 

approximately 12mm long and 1mm thick was removed. The affected guide bar at 

the out flow side of the Body Opener is 1/2" thick and is worn approximately in 

half. Carcasses are being opened at this point and the introduction of metal creates 

a Physical Hazard condition. At approximately 2220 hours there were several pieces 

of stainless steel flaking from the guide bar at the inspectors helpers station for the 

middle inspection station on line The pieces varied in size from approximately 

2mm to 14mm in length and 1mm thick. The guide bar at this location is 5/8" thick 

and is worn approximately in half. I gave all the metal collected to 

My findings indicated a noncompliance with 9 CFR 416.1 and 9 CFR 

416.2(b)(1). 

5308 M6137 BXL2513075 

009N-1 

07/09/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 07/08/2013 at approximately 1020 hours, while passing by the ice machine 

chute in Plant #2, I observed the stainless steel tank collecting ice from the ice 

machine. I found a live insect approximately 1/4" diameter in size climbing on the 

ice inside the tank. was nearby and I showed him my findings. 

He scooped a handfull of ice with the insect and threw it in the drain that runs 

under Line as he walked away. I was not able to see the type of insect because

 disposed of it before I could investigate further. 

was informed about the noncompliance. She tagged the tank of ice 

with a Quality Control Red hold tag and had a company employee to condemned it. 

This is a noncompliance with the following regulatory requirements of regulations 

9CFR 416.1, 9CFR 416.2 (a) and 9CFR 416.4 (d). 

5308 M6137 BXL5604071 

709N-1 

07/09/2013 04A06 Poultry Finished 

Product Standards 

C On 07/09/2013 at approximately 0130 hours while conducting a Pre-Chill Finished 

Products Standards test on line in Plant #2, I observed the following. After 

removing a standard 10 bird sample I accumulated 40 Processing nonconformance 

points. This exceeded the limit of 30 points for the process to be in compliance. I 

informed . At 0139 hours a Quality Control recheck failed with 28 

nonconformance points. The limit for a recheck is 25 total points. At this point the 

process is judged to be out of control. Line was moving to Line however a 

series of Quality Control rechecks passed at the Post-Chill bringing the process back 

into control. My findings indicated a noncompliance with 9 CFR 381.76(b). 

(b) (6)
(b) (6) (b) (6)

(b) (6) (b) (7)(C)

(b) (6)

(b) (6)(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN462307 

5609N-1 

07/09/2013 03C02 Raw Intact HACCP C At approximately 2040 hours while performing the Review and Observation 

component of a Raw Intact Verification PHIS Task; I, CSI , observed 

multiple pieces of chicken tenders (fourteen pieces) that were on the top of the 

North/South 90 degree product conveyor's white plastic guide divider, which is an 

edible product contact surface, in the Fillet department. As part of the SIP Waiver 

that was granted to the establishment, I decided to take the temperature on the 

pieces of Chicken tenders. I requested that 

, to take the temperature with her calibrated thermometer #441. 

One piece registered its internal temperature at 63.6 F. 

as present and was shown the temperatures of this piece and two additional 

pieces also that Ms. thermometer registered at 61.5 F, 62.7 F. The finding of 

temperatures above degrees F does not comply with the SIP waiver granted to 

the establishment by USDA/FSIS and does not meet the regulatory requirements of 

sections 381.3 and 417.5(a) of the 9 Code of Federal Regulations. 9 CFR 381.3 

states, “Administration.(b) The Administrator may in specific classes of cases waive 

for limited periods any provisions of the regulations in order to permit appropriate 

and necessary action in the event of a public health emergency or to permit 

experimentation so that new procedures, equipment, and processing techniques 

may be tested to facilitate definite improvements: Provided, That such waivers of 

the provisions of the regulations are not in conflict with the purposes or provisions 

of the Act.” 9 CFR 417.5(a) states, “(1) the written hazard analysis prescribed 

in § 417.2(a) of this part, including all supporting documentation;(2) The written 

HACCP plan, including decision making documents associated with the selection 

and development of CCP's and critical limits, and documents supporting both the 

monitoring and verification procedures selected and the frequency of those 

procedures. The SIP protocol using the alternative chilling procedures in place of 9 

CFR 381.66(b), states, “...the alternative procedures in a HACCP, SSOP or 

prerequisite program to chill young chicken carcasses immediately after processing 

so that the internal temperature is reduced to 45 F or less within 6 hours and once 

product is chilled, the temperature may rise to a maximum of 60 F during further 

processing and packaging in place of 9 CFR 381.66(b)”. The establishment elected to 

condemn the affected product. Mr. 

and representive was informed of the forthcoming 

documentation for the failure to comply with the establishment’s SIP program and 

the regulatory requirements cited above. 

(b) (6)
(b) (6)(b) (6)

(b) (6)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5216070 

306N-1 

07/06/2013 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1150 hours while monitoring the Establishments Operational 

Sanitation Procedures in the Re-Wrap Room, I observed the following. A company 

employee was using a knife to open packages of party wings and drumettes for 

rewrap. The packages were in the gray plastic baskets that had varying amounts of 

dried tissue, and black and brown UFM (Unidentified Foreing Material). The gray 

plastic baskets are not a product contact surface. I watched her for a few minutes 

and noticed that she was touching the gray plastic baskets, cutting the packages 

with the knife, handling the product and placing the product in another gray plastic 

basket lined with blue plastic, not applying sanitizer to her gloves, knife or 

packages, creating and insanitary condition. I immediately tagged the product with 

U.S. Retained/Rejected Tag # B31 407096 and informed 

of the noncompliance. The Establishments SSOP 

states that " 

. 

had a company employee condemned the product. My findings indicate a 

noncompliance with the following regulatory requirements of regulations 9CFR 

416.1, 9CFR 416.4 (d), 9CFR 416.12 (a) and 9CFR 416.14. 

5308 M6137 BXL0109075 

105N-1 

07/05/2013 04A06 Poultry Finished 

Product Standards 

C On 07/05/2013 at approximately 0605 hours while monitoring Reprocessing Line

 in Plant #1, I observed the following. I took a ten bird sample and found three 

birds with varying amount of ingesta. One bird was highly contaminated with 

ingesta and rice hulls around the cut surfaces of the neck area. A second bird had 

numerous pieces of ingesta and a brown residue on the cut surfaces of the breast. 

The third had only a few pieces of ingesta and was of less concern. 9 CFR 381.91 

(b)(1) states "Any carcass of poultry accidently contaminated during slaughter with 

digestive tract contents shall not be condemned if promptly reprocessed under the 

supervision of an inspector and thereafter found not to be adulterated. 

Contaminated surfaces that are cut shall be removed only by trimming. ... and All 

visible specks of contamination must be removed,..." I stopped the line and 

contacted . Product was tanked until a QC recheck passed at 0616 

hours. The tanked product was placed under QC hold pending reconditioned. 

Virtually every shackle on the line was full. The line was minimally staffed with only 

one house inspector at the end. My finds indicated a noncompliance with 9 CFR 

416.1 and 9 CFR 381.91(b). 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4404075 

005N-1 

07/05/2013 01D01 SPS Verification C On 07/04/2013 at approximately 2225 hours while conducting Pre-Operational 

Sanitation in Plant #1, I observed the following. There was stainless steel flaking off 

along approximately a 3" long area of a guide bar associated with the assembly that 

drops the carcasses into the chiller #1. Carcasses are open at this point and the 

introduction of metal creates a Physical Hazard condition. Flaking metal will create 

a hazard on the product and/or fall into the chiller with the product. The metal 

pieces were removed and varied in size 1/8" to 1 1/2" in length by approximately 

less that 1mm to 1/8" thick. I collected the metal as it was removed and gave it to 

. At approximately 2240 hours while monitoring 

Facilities at startup, I observed approximately 20 pieces of stainless steel lacing on 

the Line #1 rehang belt that were damaged or missing. I showed 

the belt. He called a mechanic who removed the loose laces. Birds routinely are 

pilled up on this belt for varying periods of time awaiting rehanging with the belt 

running. The poor material condition of the lacing is creating a Physical Hazard 

condition. The establishment has no metal detection devises as part of the 

Slaughter or Packaging processes. The establishments' HACCP Plan - Slaughter Plant 

#1 under The establishments' HACCP 

Plan - Raw Not Ground Packaging under 

My findings indicated a noncompliance with 9 CFR 416.1 and 9 CFR 

416.2(b)(1). 

5308 M6137 BXL0523070 

203N-1 

07/03/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C On 07/03/2013 at approximately 0518 hours while conducting a Zero Tolerance 

check on line #2 in Plant #1, I observed the following. After taking a standard 

random ten bird sample, I observed one bird with visible fecal contamination. The 

fecal material was on the inside of the carcass on the right side where the leaf fat is 

normally located. The leaf fat had been removed. The fecal material was a smear 

approximately 1/2" in size, medium brown in color, and pasty in texture. I showed 

the carcass to . The protocol for fecal failure was implemented. A 

QC recheck passed at approximately 0548 hours. My findings indicated a 

noncompliance with 9 CFR 381.65(e) and 9 CFR 417.2(c)(4). 

(b) (6)
(b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4)(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3905072 

903N-1 

07/03/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 07/03/2013 at approximately 0002 hours while monitoring the establishments' 

Pre-Operation Sanitation Procedures in Packaging Area #1, I observed the following. 

There were numerous pieces of black UFM(Unidentified Foreign Material) that 

appeared to be a mixture of blackened grease and tissue from the previous days 

production on the guide bars for line . There was a dried yellowish substance on 

most of the shackles for line . The Lead Person mentioned they were having 

problems with the shackle washer. There were numerous pieces of black UFM on 

the mechanism at the end of line that drops the drums. Lockout/Tagout was 

removed so that the line could be run at a slow speed for cleaning. The line 

components were scrubbed with green pads, sanitized and rinsed with potable 

water. The line was released by approximately 0030 hours. My findings indicated a 

noncompliance with 9 CFR 416.1, 9 CFR 416.4(a) & (b), and 9 CFR 416/13(c). 

5308 M6137 BXL1418074 

502N-1 

07/02/2013 03J02 Slaughter HACCP C On 07/02/2013 while performing Pre-Chill Finished Products Standards Task, I 

observed a noncompliance with the following regulatory requirements of 

regulations 9CFR 381.65(e) and 9CFR 417.2(c)(4). At approximately 1529 hours, I 

randomly removed a 10 bird sample from Line in Plant #2. I found one out of 

the ten birds with visible fecal contamination inside the bird on the leaf fat and in 

the body cavity directly opposite of the leaf fat on the left side of the bird. The fecal 

material was a smear measuring approximately 1" in diameter in size and olive 

green in color and pasty in texture. I informed of the 

noncompliance, and the protocol for fecal failure was implemented. At 

approximately 1552 hours, Quality Control performed a recheck and passed. The 

cause of the deviation was the washer. This is a violation of the critical 

limits of CCP-2B, of the Plant's HACCP Plan for Slaughter. 

5308 M6137 BXL1614070 

102N-1 

07/02/2013 03J02 Slaughter HACCP C On 07/02/2013 while monitoring Post-Chill Finished Product Standards Task, I 

found a noncompliance with the following regulatory requirements of regulations 

9CFR 381.65(e) and 9CFR 417.2(c)(4). At approximately 1011 hours, I randomly 

selected a 10 bird sample from the exit of Chiller #4 in Plant #2. I found one out of 

the ten birds with visible fecal contamination inside the bird on the leaf fat on the 

left side of the bird. The fecal material was approximately 1/4" diameter in size, 

olive green in color and pasty in texture. This exceeds the limit of Zero Tolerance for 

the process to be in control. I informed of the noncompliance 

and they immediately started tanking the birds coming out of Chiller #4. Two and a 

half tanks were placed under QC red hold tags, pending rework. At approximately 

1015 hours Quality Control performed a recheck and passed. The cause of the 

deviation was the venter and a nozzle out of adjustment. This is a violation of the 

critical limits of CCP-2B of the Plant's HACCP 

Plan for Slaughter. 

(b) (6)
(b) (6) (b) (6) (b) (6)

(b) (6)

(b) (7)(C) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN420707 

4902N-1 

07/02/2013 03C02 Raw Intact HACCP C At approximately 0408 hours while performing the Review and Observation 

component of a Raw Intact Verification PHIS Task; I, CSI , observed 

multiple pieces of dark meat (boneless thighs) that were on the top of the product 

reprocessing cart which is an edible product contact surface, in the Packaging 

department. As part of the SIP Waiver that was granted to the establishment, I 

decided to take the temperature on the pieces of dark meat. I requested that 

, to take the temperature with her 

calibrated thermometer #425. One piece registered its internal temperature at 

66.5F. Mr. was present and took the 

temperature of two additional pieces with Ms. thermometer that 

registered at 61.2 F, 60.2 F. The finding of temperatures above degrees F does 

not comply with the SIP waiver granted to the establishment by USDA/FSIS and 

does not meet the regulatory requirements of sections 381.3 and 417.5(a) of the 9 

Code of Federal Regulations. 9 CFR 381.3 states, “Administration.(b) The 

Administrator may in specific classes of cases waive for limited periods any 

provisions of the regulations in order to permit appropriate and necessary action in 

the event of a public health emergency or to permit experimentation so that new 

procedures, equipment, and processing techniques may be tested to facilitate 

definite improvements: Provided, That such waivers of the provisions of the 

regulations are not in conflict with the purposes or provisions of the Act.” 9 CFR 

417.5(a) states, “(1) the written hazard analysis prescribed in § 417.2(a) of this part, 

including all supporting documentation;(2) The written HACCP plan, including 

decision making documents associated with the selection and development of 

CCP's and critical limits, and documents supporting both the monitoring and 

verification procedures selected and the frequency of those procedures. The SIP 

protocol using the alternative chilling procedures in place of 9 CFR 381.66(b), 

states, “...the alternative procedures in a HACCP, SSOP or prerequisite program to 

chill young chicken carcasses immediately after processing so that the internal 

temperature is reduced to or less within hours and once product is chilled, 

the temperature may rise to a maximum of during further processing and 

packaging in place of 9 CFR 381.66(b)”. The establishment elected to condemn the 

affected product. Mr. 

was informed of the forthcoming documentation for the failure to 

comply with the establishment’s SIP program and the regulatory requirements 

cited above. 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (7)(C) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN530507 

5401N-1 

07/01/2013 01D01 SPS Verification C On June 30, 2013 I, CSI , was performing CIP (Red water chiller) 

inspection at establishment P6137A Foster Farms at approximately 0945 hours. In 

the hallway that connects the Food Service department to the IQF department I 

observed multiple large gray product combo bins with approximately 12 insects 

(house flies) in them. I showed my findings to 

who offered immediate corrective actions that the establishment employees would 

move the bins outside and kill the insects. During the IQF department start of 

production, at approximately 2325 hours, and 

myself observed one fly on a stack of wooden pallets in the IQF department. Mr.

 attempted to kill the insect but failed to do so. S offered 

corrective actions that more fly bait stick tape would be hung in the hallway that 

connects this department to the others. While performing Good Commerical 

Practices verification task at approximately 0138 hours I observed that the boiler 

room door and the Maintenance large roll up door were open to the outside of the 

establishment, I inform of this and 

he immediately closed both doors. While at the carcass chiller exit I was performing 

a Finished Products Post Chiller check and observed one fly on the contaminated 

product loop. The insect flew from the loop to the chiller exit belt onto one carcass. 

From there the insect flew to somewhere in establishment. I took the only product 

affected from the belt and informed of my 

findings. sanitized the hang back loops and condemned the carcass. 

At approximately 0256 hours I informed 

of all my findings in this document and of the forthcoming 

noncompliance. 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (6) (b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE431307 

5402N-1 

07/01/2013 04A06 Poultry Finished 

Product Standards 

C I was performing a finished product standards verification task on the reprocessing 

line in the evisceration department at 0857 hours. I selected ten carcasses marked 

with a horizontal slash across the back indicating these carcasses had been 

identified by the on-line inspection team for cellulites salvage. One of the ten 

carcasses in the sample had cellulites lesions about 1 1⁄2” long and about 1/8” wide 

on lower left breast area. I showed 

did 

the required recheck of ten cellulite carcasses and the check was found acceptable 

at 900. I informed , of the 

forthcoming non compliance. Failure to meet the regulatory requirement cited 

above. In addition 9 CFR 381.86 states any organs or other parts of carcasses which 

is affected by inflammatory process shall be condemned 

5333 P7632 HYE280206 

3629N-1 

06/29/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 6/28/13 at approximately 2314 hours I observed the following while performing 

the Pre-Operational SSOP Review and observation task in area # III (North Chiller 

Exit ) . There was a thick build-up of fat and grease on the angle iron brackets that 

are positioned directly above the rehang belt . 

was notified of the noncompliance immediately . had one of his 

workers scrub and rinse the angle iron braces . The braces were reinspected and 

found in good sanitary condition . At approximately 2317 the drip pan directly 

above the Segment line cat walk was found to unexcitable . There was a build-up of 

grease and fat residue along the outer edge of the drip pan . Again

 was notified . had one of his workers get on top of the 

drip pan scrub the affected area along the side and rinse the entire drip pan . At 

approximately 2220 the Down Grade belts were inspected . There was pieces of fat 

found on both Down Grade flex belts . was informed of 

the noncompliance . had a member of his crew rinse and 

resanitized the Down Grade belts . My findings indicate noncompliance with 

regulations 9 CFR 416.4(a) which states all food contact surfaces must be cleaned 

and sanitized as frequently as necessary to prevent the creation of insanitary 

conditions and the adulteration of product and 9CFR 416.4(b) which states non 

food contact surfaces must also be cleaned and sanitized as frequently as necessary 

to prevent the creation of insanitary conditions and the adulteration of product . 

(b) (6)
(b) (6) (b) (6)

(b) (6) (b) (7)(C)

(b) (4)

(b) (7)(C) (b) (4) (b) (4) (b) (4)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0723065 

528N-1 

06/28/2013 01D01 SPS Verification C On 06/28/2013 at approximately 2002 hours while walking from the Rotisserie 

room to Plant 1 hanging area by Chillers 1 and 2, I observed the following. 

Sanitation was washing down the area and I saw that the door to the cooler by 

Plant 1 hanging and sorting area by Chillers 1 and 2 was open. I went inside the 

cooler, which was congested with tanks being brought in from an employee from 

Packaging and an employee from Rotisserie, and observed heavy fog and mist 

through out the entire cooler. I continued walking in the cooler to the other side 

where I observed that the cooler door that opens to the Packaging room was also 

open and Sanitation was also washing down the Packaging room. Regulation 

416.2(d) states that adequate Ventilation to control odors, vapors, and 

condensation to the extent necessary to prevent adulteration of product and the 

creation of insanitary conditions must be provided. I informed 

of the noncompliance. 

5309 P6137A NJN091606 

5428N-1 

06/28/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 1111 hours I was performing PHIS Finished Product Standards 

Inspection Procedure task at the Pre-chill Station on Evisceration Line “A”. After all 

plant interventions were allowed to occur, I randomly selected ten carcasses prior 

to entering the chilling process. I observed one out of the ten carcasses 

contaminated with visible feces. The fecal material was located inside the neck 

attachment in-between the pectoral muscle. It was yellowish in color and pasty in 

texture measuring approximately 1⁄2 inch in diameter and was confirmed by Dr.

 the . This exceeded the limit of Zero Tolerance for the process to 

be in control. I immediately took regulatory control action by stopping line “A” and 

showed my finding to 

. The protocol for fecal failure was implemented. A 

Quality Control recheck passed at 1123 hours. A preshipment review performed at 

1258. Mr. , were informed of the 

forthcoming NR. 

and in accordance with the regulations 9 CFR 

417.2© (4) and 9 CFR 381.65(e) which states: "poultry carcasses contaminated with 

visible fecal material shall be prevented from entering the chilling tank". The 

establishment's written HACCP Plan dated 4/18/2013 states: 

. Past similar NR’s was documented on 06/14/2013 # NJN 

4320065814 N/1 Ineffective Plant Response Action(s): “To prevent this situation 

from reoccurring, a check to verify that angle adjustment is correct was 

put in place on the I/O . Training was performed with the 

HACCP monitors on the updated version of the monitoring log and on how to check 

for the proper angle on the . Continued failure to comply with regulatory 

requirement(s) could result in additional regulatory or administrative action(s) as 

described in 9 CFR 500.4. 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6)

(b) (6)

(b) (7)(C) (b) (7)(C)(b) (4) (b) (4)

(b) (4)

(b) (4) (b) (7)(C) (b) (7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN200506 

4228N-1 

06/28/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On June 27, 2013 I, CSI , was in the Evisceration department performing 

Pre-Operational Sanitation verification task when I noted the following 

noncompliance. In Area 01 Evisceration Section D: Offline and Chiller Area I 

inspected Unit #15, A/B line bird unloader. The stainless steel chute that the 

chicken carcasses slide down into the carcass chiller on was covered in multiple fat 

particles and approximately five feathers from the previous days production. I 

retained the chute with the application of U.S. Retain tag B43303581 at 

approximately 2304 hours and showed my findings to 

. The chute was wiped clean and sanitized in my presents, no 

fat particles or feathers entered the chiller. At approximately 2321 hours sanitary 

conditions were restored and I released Unit #15 by removing the U.S. Retain tag.

 were informed of the 

noncompliance. 

5333 P7632 HYE320206 

5925N-1 

06/25/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 6/25/13 at approximately 0004 hours I observed the following noncompliance 

while conducting the Pre-Operational SSOP Review and Observation procedure in 

the packaging area . Unit # 1 the Body halvers had fat and debris on the Bird Indexer 

Chutes that transport product to the degree cooler , the white PVC pipe running 

along side the wall and over the halver had fat grease and unidentifyed foreign 

material on the exterior of the pipe . was notified of the 

noncompliance . had one of his workers rinse both Body 

Halvers and Bird Indexer Chutes . The area was reinspected at approximately 0018 

and found to be in sanitary condition . At 0009 unit #13 the # 1 Leg Processor 

(Manual Feeder ) was inspected . The Inside of the right panel was covered with 

pieces of fat . My findings were again reported to . 

had the inside of the panel rinsed and resanitized . Sanitary 

conditions were restored and the packaging area was released for production at 

approximately 0025 . My findings indicate noncompliance with regulations 9 CFR 

416.4(a) , 9 CRF 416.4(b) and 9 CFR 416.13(c) . 

5333 P7632 HYE340706 

1225N-1 

06/25/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

O . . On June 20, 2013, EIAO observed establishment personnel 

conduct preoperational sanitation check in the evisceration and rehang areas for 

the following production day (June 20,2 013 to June 21, 2013). After the 

establishments preoperational sanitation check was completed, EIAO observed the 

following: fat particles on the segment 1 return belt and conveyor; a 

piece of skin on the bag line rehang conveyor; and a piece of bone underneath the 

divider on the paw grading conveyor. Additionally, EIAO observed a hole 

containing cracks and jagged stuck up edges in the food contact portion of the 

Chute. EIAO also observed fat particles on the underside (non-food 

contact) of the conveyor. These findings are noncompliances in 

accordance with Title 9 CFR 416.13(c) and 416.3(a). . 

(b) (6)
(b) (6) (b) (6) (b) (7)(C) (b) (7)(C) (b) (7)(C) (b) (7)(C) (b) (7)(C) (b) (7)(C) (b) (7)(C) (b) (7)(C) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE340706 

1225N-2 

06/25/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

O During the FOOD SAFETY ASSESSMENT conducted on June 20, 2013, at 

approximately 2311 hours EIAO observed the following 

noncompliance while performing the Pre-Operational Review and Observation 

task . In the evisceration and rehang areas for the following production day (June 

20,2 013 to June 21, 2013) . After the establishments pre-operational SSOP 

monitoring check was conducted , EIAO observed the following : fat particles 

on the segment 1 return belt and conveyor ; a piece of skin on the bag 

line rehang conveyor ; and a piece of bone underneath the divider on the paw 

grading conveyor. EIAO also observed a hole containing cracks and jagged 

stuck up edges in the food contact portion of the Chute . EIAO 

observed fat particles on the underside (non-food contact) of the 

conveyor. EIAO notifyed Ms. all of the noncompliant areas 

observed. These findings are noncompliant in accordance with Title 9 CFR 416.13(c) 

and 416.3(a). EIAO observed establishment personnel rewash, rinse, sanitize, 

and reinspect the contaminated surfaces of the equipment. Additionally, EIAO 

observed establishment personnel repair the hole in the food contact portion of the

 Chute by welding the hole shut. Establishment personnel then 

rewashed, rinsed, sanitized, and reinspected all surrounding equipment 

surfaces . Once EIAO verified sanitary conditions were restored in the 

noncompliance areas , the area was released for production at approximately 0012 

hours . Title 9 CFR 416.13(c) states: “Each official establishment shall monitor daily 

the implementation of the procedures in the Sanitation SOP’s.” Title 9 CFR 416.3(a) 

states: “Equipment and utensils used for processing or otherwise handling edible 

product or ingredients must be of such material and construction to facilitate 

thorough cleaning and to ensure that their use will not cause the adulteration of 

product during processing, handling, or storage. Equipment and utensils must be 

maintained in sanitary condition so as not to adulterate product.” 

5309 P6137A NJN471606 

3524N-1 

06/24/2013 01D01 SPS Verification C At approximately 1349, while I was passing through the evisceration department 

employee break room, I observed the following non compliance: several flies flying 

in the break room, trash can over flowing with garbage, , bad odor smell, the floor 

had stagnant water, used paper towels and debris everywhere. Mr. 

was informed and he took corrective actions to restore sanitary condition and also 

notified of the forthcoming non-compliance record. The Requirements of 9 CFR 

416.1, 9 CFR 416.2(b) (2), 9 CFR 416.2 (a), and 9 CFR 416.2(h) (3) were not met. This 

document serves as written notification that your failure to comply with regulatory 

requirement(s) could result in additional regulatory or administrative action(s) as 

described in 9 CFR 500.4. 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN521506 

0824N-1 

06/24/2013 04A06 Poultry Finished 

Product Standards 

C At 1230 hrs. I was performing a zero tolerance verification task on the tubs of 

salvaged parts in the evisceration department. I randomly selected 5 pieces from 

each tub. I found one piece (thigh) affected with I.P (cellulitis) in a tub identified 

from B-line. I showed this finding to 

secured a QC hold tag on the tub after the 

corrective actions where proffered, which involved reworking the tub of product. I 

also informed of the non 

compliance with 9 CFR 381.86. The establishment condemned the affected part and 

reworked the remaining product in the tub. The finding of I.P. affected tissue on 

salvage parts constitutes a non compliance according to the regulations cited 

above. 9 CFR 381.86 states: “Any organ or other part of a carcass which is affected 

by an inflammatory process shall be condemned and, if there is evidence of general 

systemic disturbance, the whole carcass shall be condemned. There was a similar 

non compliance report issued for the same occurrence on 06/13/2013, 

NJN0616065213N/1. The establishment's response included immediate corrective 

actions of reprocessing the affected tub of product. The establishment responded 

with "Not applicable" for further planned action. It is unclear if the establishment 

included or enacted measures to prevent the reoccurrence of the same non 

compliance. 

5308 M6137 BXL0809061 

720N-1 

06/20/2013 01D01 SPS Verification C On 06/19/2013 at approximately 2300 hours while monitoring the Establishments' 

Operation Sanitation procedures in Plant #1 Line #1, I observed the following. There 

was a piece of shiny metal approximately 1/2" long and less than 1/16" thick 

attached to the guide bar at the out flow side of the Venter/Body Opening machine. 

The loose metal pieces directly above the open carcasses is causing an insanitatry 

condition. There were also several smaller pieces of metal flaking from the guide bar 

at the same location. I contacted and showed him my 

findings. A mechanic filed the guide bar to round off the flat sharp edges to stop the 

metal shedding process. My findings indicated a noncompliance with 9 CFR 

416.2(b)(1). 

(b) (6)
(b) (6) (b) (6)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2905062 

720N-1 

06/20/2013 01D01 SPS Verification C On 06/19/2013 at approximately 1940 hours while monitoring Facilities, I observed 

the following. There was a large puddle of water on the loading dock floor near 

Rotisserie creating an insanitary condition. The floor drain was clogged and the 

entire space was flooded to approximately 2" deep near the drain. The water had a 

black oily film on the surface. Pallets of materials around the outside walls of the 

space and trash near the empty dock truck door were wet. Rotisserie was still 

working and establishment personnel were walking through the puddle. Employees 

did not appear to be aware that they should not be walking through a flooded area. 

I do not know how long the drain was backed up but there were numerous black 

pallet jack wheel marks on the floor going into Rotisserie. I went to Rotisserie but 

no supervisor was available so using the laundry room phone I had 

called. Movement through the area was stopped. The pallets 

were moved. The drain was cleared. The floor was drained and a sanitizer was 

applied to the affected area restoring sanitary conditions by approximately 2015 

hours. My findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.2(e)(4), 

and 9 CFR 416.5(a). 

5308 M6137 BXL5808065 

420N-1 

06/20/2013 06D02 Other Inspection 

Requirements 

C On 06/20/2013 at approximately 0515 hours while monitoring Presentation of line 

#1 in Plant #1 at a line speed of BPM (Birds Per Minute), I observed the 

following. The second station had (1) bird front, (2) hung by one leg, (1) carcass 

swinging, (2) viscera attached to carcass and (1) parts inside for a total of 60 

nonconformance points. Once nonconformance points exceed 40 the process is 

judged to be out of control and a line reduction is required. 

was informed and the line was slowed to 113 BPM. The third station had (2) 

viscera not uniform and (1) viscera attached to the carcass for a total of 28 

nonconformances. Rechecks at 0543 hours returned the line speed to BPM 

where it stayed for the rest of the shift for high no viscera counts. A review of the 

Establishments' "No Viscera Log" for the shift revealed that Line #1 failed at 0056 

hours with 19 no viscera at BPM. 13 no viscera are allowed at BPM. A 

recheck failed at 0127 hours with 20 no viscera. The line speed was reduced to 126 

BPM. At 0407 hours there were 26 no viscera and 0613 hours 31 no viscera both 

rechecks failed and the line was kept at 126 BPM for the remainder of the shift. 11 

no viscera are allowed at 126 BPM. Three consecutive failures is considered as a 

loss of process control. On Line #2 at BPM at 0231 hours there were 18 no 

viscera. At 0400 hours a recheck failed with 23 no viscera. The line was slowed to 

126 BPM. At 0618 hours there were 18 no viscera at 126 BPM. The lines was kept 

at 126 BPM for the rest of the shift. My findings indicated a noncompliance with 9 

CFR 381.76(a) & (b). 

5308 M6137 BXL3907063 

919N-1 

06/19/2013 01D01 SPS Verification C 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3907063 

919N-2 

06/19/2013 01D01 SPS Verification C On 06/19/2013 at approximately 0300 hours while monitoring the establishments' 

Operational Sanitation procedures in the Weigh & Price Cooler, I observed the 

following. The floor on the 'A' side of the Weigh & Price Cooler is covered with a 

thick layer of liquefied brown UFM (Unidentified Foreign Material). I contacted

 and asked him when the cooler floor was last cleaned. He said he 

was not sure but that the cooler was normally cleaned every couple of months. I 

proceeded to Packaging and observed varying amounts of the same brown UFM at 

the end of the packaging lines where the racks of packaged products are made up 

before being Crusted (chilled) and sent by elevator to the Weigh & Price Cooler. The 

dollies, frames and wheel assemblies, being used in Packaging are covered with a 

similar brown UFM, the majority appears to be rust, and are the mode of transport 

of the brown UFM from the Weigh & Price Cooler to the Packaging floor. With 

hundreds of rust coated dollies being used during a shift the amount of filth being 

added to Packaging is considerable. I contacted and showed 

him a stack of dollies near line coated with the brown UFM and the insanitary 

condition on the floor. I asked him how often the floor is rinsed in packaging. His 

response was that the floor is . With the 

number of employees and the volume of work that is performed the brown UFM 

will be tracked all over packaging. I proceeded to Weigh & Price and informed

 that a noncompliance would be issued for the brown UFM on the 

cooler floor and because of the insanitary condition being created in Packaging. On 

06/20/2013 at approximately 0020 hours, I discussed the insanitary condition of 

the dollies with and he said he would address the 

rust and filth on the dollies. My findings indicated a noncompliance with 9 CFR 

416.1, 9 CFR 416.2(b)(2) and 9 CFR 416.4(a). 

(b) (6)
(b) (6) (b) (6) (b) (6)

(b) (6)

(b) (6)(b) (6) (b) (7)(C)

(b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN192006 

3019N-1 

06/19/2013 01C02 Operational SSOP 

Review and 

Observation 

C At 0950 hrs. I observed the following non compliance in the dark meat packaging 

area during bulk product packing operations. Employees were beginning to pack 

boneless skinless thighs into blue plastic lined boxes. I observed the employee 

assigned to operate the scale remove product with his gloved hands and place the 

product into the next box on the roller conveyer belt in order to attain the proper 

weight. The employee then secured the lid on the box and place the box on a 

wooden pallet. He then preceded to handle product from the next box without 

sanitizing his gloved hands. I also observed another employee putting the blue 

liners inside other boxes, preparing them to be filled with product. The employee 

had these blue lined boxes stacked on top of each other. The blue liners are product 

contact surfaces, whereas the outside of the cardboard boxes are not. I informed 

of my 

observations. Mr stopped the production to address each issue. Miss 

applied a QC hold tag on the one box of product and Mr. had 

that product sent to the establishment's reprocessing procedures. 9 CFR 416.4(d) 

states: product must be protected from adulteration during processing, handling, 

storage, loading, and unloading at and during transportation from official 

establishments. 

5309 P6137A NJN491906 

3619N-1 

06/19/2013 04C05 Poultry Good 

Commercial 

Practices 

C On June 18, 2013, Tuesday at approximately 1235 hours I was notified by a line 

inspector that a suspect dead-on-arrival carcass was hung back for veterinary 

disposition. The carcass was at the USDA rack behind Line B station # 3 with 

Inspector . The carcass was grossly reddish in color with a limp neck, 

friable liver and spleen and congected kidneys. I confirmed the carcass as a DOA. I 

informed of the 

findings. On the same day, at approximately 1450 hours another suspected DOA 

carcass was hung back at the USDA rack on Line a station # 3 . I confirmed the 

carcass as another DOA at approximately 1615 hours. I notified the 

, Mr. of the second DOA. The carcass was reddish in color 

with some areas of purplish discoloration. The liver, spleen and intestines were not 

present but the kidneys were dark-red to purple color and friable. The carcass had a 

limp neck and carcass had a putrid odor. I informed the establishment that these 

two incidences would be documented on a non-complince. The repetitive 

occurrence of DOAs entering the evisceratio department demonstrates a loss of 

process control and the creation of insanitary conditions in accordance with 9 CFR 

381.71 (a) and 416.4 (d). 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (7)(C) (b) (4) (b) (4) (b) (4) (b) (4) (b) (7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN240306 

0818N-1 

06/18/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 0059 hours while I was performing the Review and Observation 

component of a Zero Tolerance Task at the offline inspection station I observed the 

following noncompliance. On the ninth carcass from the ten carcass sample, I 

noticed a small amount (approximately 1/18 of an inch in diameter) of a 

greenish/brownish paste like material consistent with fecal material. The fecal 

material was located on the inside side the fold of the left wing tip. I took regulatory 

control action by stopping the offline and retaining the affected carcass with U.S. 

Retain tag# B43303582. I showed my finding to 

. Mr. requested disposition. IIC, 

Dr. confirmed the fecal material. Ms. initiated 

corrective actions as stated in the establishment’s HACCP plan. The affected carcass 

was released to passed the 

required recheck at 0112 hours. The establishment failed to prevent fecal material 

to reach the offline inspection station with the potential of entering the chiller. 

Section 381.65(e) from the 9 Code of Federal Regulations requires that the 

establishments shall prevent contaminated carcasses with visible fecal material 

from entering the chiller. The finding of fecal material did not meet the 

requirements of the establishments HACCP plan. The Supervisors and Q.C. 

representative mentioned in this document were informed of the forthcoming 

documentation for the failure to comply with the regulatory requirements cited 

above. Similar noncompliance was documented on May, 28,2013. Establishment's 

further planned action to take appropriate management steps with the final 

inspection employee failed to prevent reoccurrence. 

5308 M6137 BXL4317060 

217N-1 

06/17/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C While monitoring the Establishments' Pre-operational Sanitation Procedures in 

Main Packaging Area, I observed a noncompliance with the following regulatory 

requirements of regulations 9CFR 416.1, 9CFR 416.4 (b) and 9CFR 416.13 (c). At 

approximately 0837 hours while inspecting Line , I found numerous pieces of 

semi-dried fat, tissue and blood from the previous day production on the entire 

length of the gray conveyor belt. I found a piece of fat measuring approximately 2" 

long by 1/4" wide hanging on a shackle from the chain that brings product to this 

line. I immediately tagged the Line with U.S. Retained/Rejected Tag # B31 407280 

and informed of the 

noncompliance. had sanitation employee rewashed the 

entire line. I continued doing pre-operational sanitation procedures on Line and 

Line and then I came back to reinspected Line . At approximately 0859 hours 

sanitary conditions were restored, I then removed my tag and released the area 

back to production. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6)

(b) (6) (b) (4) (b) (4)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5222064 

017N-1 

06/17/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 06/15/2013 at approximately 0300 hours while monitoring the establishments 

Operational Sanitation procedures in the Paw Room for the Bulk Line product 

handing, I observed the following. Bagged bulk product was being packed into cases 

that weigh approximately 40 pounds. Product is placed in blue plastic bags in 

packaging. In Packaging the bags are twisted shut and placed with the twisted side 

down into gray plastic trays that are stacked to make racks which are then placed in 

the Crust Tunnel for chilling. The gray plastic trays being emptied along the bulk line 

were covered with varying amounts of dried tissue, and black and brown UFM 

(Unidentified Foreign Material). The trays are not treated as a product contact 

surface. To get the weight close as possible to 40 pounds at least one bag in every 

case was being opened and a piece(s) of product was being removed or added. The 

opened side of the bag is the end of the bag that is in direct contact with the 

insanitary gray plastic tray. Opening of the contaminated side of the blue plastic 

bag and then handling the product without applying a sanitizer was creating an 

insanitary condition. I watched for several minutes then contacted 

who was nearby and asked who the bulk line supervisor was? She said 

that a supervisor comes by about , that the employees are required to 

, and was there a problem. I 

showed her the trays and the cross contamination issue and had her call a 

supervisor. The line was stopped. 

was called and the issue was discussed. 29 cases of product that was 

processed in my presence was placed on QC hold pending reconditioning. The 

establishments SSOP states that 

There is a hand sanitizing 

machine approximately 30 feet away from the location of the bulk line operations 

but it would be very time consuming for an employee to have to sanitize their 

gloves after each case. The establishments HACCP Plan - Raw Not Ground Packaging 

does not address bulk packed product. After consulting with 

there is no procedure for handling bulk product on file. A temporary solution 

was implemented whereby the outside of packages to be opened will be sprayed 

with hand sanitizer before being opened. I talked to 

about the cleaning schedule for the gray baskets. said 

that s. 

My findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.4(d), 9 CFR 

416.5(a), 9 CFR 416.12(a) and 9 CFR 416.14. 

(b) (6)
(b) (6) (b) (6)

(b) (6) (b) (7)(C) (b) (7)(C) (b) (7)(C) (b) (7)(C) (b) (4) (b) (4) (b) (4)

(b) (6)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN412206 

1118N-1 

06/17/2013 03J02 Slaughter HACCP C When I was performing the Review and Observation/ Record Review component of 

a Slaughter HACCP Task at the Quality Control Lab I noted recordkeeping 

deficiencies noncompliant with sections 417.2(c)7, 417.5(a)3 of the 9 Code of 

Federal Regulations. While reviewing the CCP-2BC HACCP Form I noticed 

that the last check performed for the CCP-2BC was at 0247 hours, but the 

verification check for was not performed 

by the HACCP Monitor assigned for this verification task. The verification check was 

performed and found acceptable at hours; it was approximately 30 minutes 

after the due time. This deviation from the frequency ) 

established in the establishment’s HACCP plan did not meet the regulatory 

requirements mentioned in this document. 

, were informed of the forthcoming 

noncompliance 

5309 P6137A NJN570506 

0517N-1 

06/17/2013 01D01 SPS Verification C At approximately 2346 hours in the Evisceration department I was called to the "B" 

line station #3 by Inspector . Inspector had observed a leak from the 

ceiling. I, CSI , inspected the ceiling past the third inspection station and 

observed two leaks overhead. The first leak was from the ceiling dripping between 

the Evisceration "B" line and the Reprocessing Offline, no product affected. The 

second leak was from a white cross beam above the Reprocessing offline. I took 

regultory control of the Reprocessing line with the application of U.S. retain tag 

#B43303583.

 were shown the two leaks and informed of the noncompliance. After 

the establishment restored sanitary conditions by diverting the water from the 

leaks with a blue plastic liner that drained into a red trash barell all the offline 

shackles were washed and sanitized. I reinspected the area and offline then released 

the offline back to at approximately 0036 hours. 

5309 P6137A NJN230506 

5515N-1 

06/15/2013 01D01 SPS Verification C At approximately 0145 hours I, CSI , was performing a Good Commercial 

Practices verification task when I observed a insanitary condition noncompliant 

with 9CFR 416.1. In the trash dumping area behind the establishment there was 

multiple cardboard combo bins of trash (approximately twenty) most where 

overflowing with trash some were tipped over. The entire area was littered with 

used paper towels, product containers, broken pallets, used blue plastic liners. In 

the condemned product area I observed 27 large combo bins of condemned 

product from multiple departments and shifts of the establishment (carcasses from 

live hang, thigh bones from Packaging department, carcass backs from MSP 

department, wing tips from Fillet department) all uncovered. Also in this area 22 

gray trash barrels full of various condemned products. There was also a foul odor 

coming from the bins and the multiple pools of stagnant waste water leaking from 

the bins and barrels. 

was informed of the noncompliance. 

(b) (6)
(b) (6)

(b) (6) (b) (4)

(b) (7)(C) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN432006 

5814N-1 

06/14/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 1555 hours I was performing PHIS Finished Product Standards 

Inspection procedure task at the pre-chill station on evisceration line ‘A’. I randomly 

selected ten carcasses prior to their entry to the chiller and after all plant 

interventions were allowed to occur. When I observed the ninth carcass, I noticed 

that it was contaminated with visible fecal material approximately 1/8th inch in 

diameter, yellowish in color, paste-like in consistency, and located on the outer 

surface of the right thigh. Immediately, I took regulatory control action by stopping 

line ‘A’ and bringing notice t 

. The fecal finding was confirmed by Dr. 

. At approximately 1607 hours the establishment initiated corrective 

actions. Mr. , was informed of the forthcoming NR. 

The findings of fecal material on a carcass passed the final wash cabinet en route to 

the chilling system represents a as outlined in the 

establishment’s HACCP and in accordance with the regulations 9 CFR 381.65(e) 

which states: "poultry carcasses contaminated with visible fecal material shall be 

prevented from entering the chilling tank". The establishment's written HACCP Plan 

dated

 Past similar NR 

was documented on 06/13/2013 # NJN 3120064113 N/1- Previous Ineffective Plant 

Response Action(s): no plant response at this time. PHIS slaughter HACCP task 

performed to verify that all corrective and preventive measures were completed. 

Continued failure to comply with regulatory requirement(s) could result in 

additional regulatory or administrative action(s) as described in 9 CFR 500.4. 

(b) (6)
(b) (6)

(b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN061606 

5213N-1 

06/13/2013 04A06 Poultry Finished 

Product Standards 

C At 1250 hrs. I was performing a zero tolerance verification task on the tubs of 

salvaged parts in the evisceration department. I randomly selected 5 pieces from 

each tub. I found one piece (thigh) affected with I.P (cellulitis) in a tub identified 

from B-line. I showed this finding to 

. I secured U.S. Retain Tag # B43303543 to the tub. I also 

informed of the non compliance with 9 CFR 381.86. The 

establishment condemned the affected part and reworked the remaining product in 

the tub. At 1331 hrs. I reinspected the reworked product and found no further 

incidence of I.P. affected product. I removed the U.S. Retain tag and released control 

of the product back to the establishment. The finding of I.P. affected tissue on 

salvage parts constitutes a non compliance according to the regulations cited 

above. 9 CFR 381.86 states: “Any organ or other part of a carcass which is affected 

by an inflammatory process shall be condemned and, if there is evidence of general 

systemic disturbance, the whole carcass shall be condemned. There was a similar 

non compliance report issued for the same occurrence on 05/09/2013, 

NJN1916050109N/1. The establishment's response included immediate corrective 

actions of reprocessing the affected tub of product. The establishment responded 

with "Not applicable" for further planned action. It is unclear if the establishment 

included or enacted measures to prevent the reoccurrence of the same non 

compliance. 

(b) (6)
(b) (6)

(b) (6)

(b) (4) (b) (4)

(b) (4) (b) (4)(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN312006 

4113N-1 

06/13/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 1702 hours I was performing PHIS Zero-tolerance task, in the 

Evisceration Department on the reprocessing off-line, prior to the birds entering the 

chilling process, and all plant interventions were allowed to occur, when I observed 

two (2) carcasses in the ten (10) carcasses random sample with the following: the 

first carcass was contaminated with visible fecal material approximately 6 mm by 2 

mm in diameter, greenish in color, paste-like consistency, and located on the tail; 

The second carcass was contaminated with ingesta, the ingesta located in the pelvic 

area. I took regulatory control action by stopping the reprocessing line and applied 

US retain tag NO B43303501 on the affected carcasses. The findings were shown to

 At approximately 1711 the reprocessing line and the 

affected carcasses were released to the establishment allowing QC representative to 

perform corrective actions. Mr. was informed of the forthcoming NR. 

as outlined in the establishment’s 

HACCP and in accordance with the regulations 9 CFR 381.65(e) which states: 

"poultry carcasses contaminated with visible fecal material shall be prevented from 

entering the chilling tank". 9 CFR 417.2(c) (4) states: "List the procedures, and the 

frequency with which those procedures will be performed, that will be used to 

monitor each of the critical control points to ensure compliance with the critical 

limits". The establishment's written HACCP Plan dated 

A similar NR was documented on 

06/04/2013 # NJN 5607063704 N/1. Plant Response (Further Planned Action(s) 

states “upon review of the records, the records indicated that the Critical 

Limit on the was one or two deviations from being met for a majority of the 

evening. Training was held with the HACCP monitor and monitor on how to 

perform a proper check and to notify management of cp check results that 

are nearing the Critical Limit. PHIS slaughter HACCP task performed to verify that all 

corrective and preventive measures were completed. This document serves as 

written notification that your failure to comply with regulatory requirement(s) 

could result in additional regulatory or administrative action(s) as described in 9 

CFR 500.4. 

(b) (6)
(b) (6)

(b) (6) (b) (6)

(b) (6)(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1105060 

712N-1 

06/12/2013 01D01 SPS Verification C On 06/12/2013 at approximately 0215 hours while monitoring Operational 

Sanitation standards in Plant #2, I observed the following. There was a shiny piece 

of curled metal attached by one end to the guide bar at the Inspectors Helper 

station at the middle inspection station on line . The line was starting so I 

removed the piece of stainless steel and gave it to . The metal 

piece was approximately 1/2" long and 1/16" wide. Loose metal pieces directly 

above open carcasses is creating an insanitary condition. The guide bar at this 

location is a solid piece of stainless steel approximately 5/8" in size and is worn 

nearly in half. A check of the guide bars for all the lines in plant #2 revealed 

numerous places along the lines with similar wear conditions. After line was 

stopped and washed down, I observed a loose piece of metal measuring 

approximately 3" by 1/16" on a guide bar just prior to the first inspectors station 

for line . There was a sliver of metal attached by one end measuring 

approximately 1/4" long on a guide bar behind the mirror at the first inspection 

station for line The guide bar at this location is approximately 3/8" thick and is 

worn almost in half. There was a piece of loose metal measuring approximately 2" 

by 1/16" on the guide bar after the inspectors station on line . 

was shown my findings. A review of the HACCP Plan - Slaughter Plant #2 

under states My findings indicated a 

noncompliance with 9 CFR 416.2(b)(1). 

5333 P7632 HYE210306 

0312N-1 

06/12/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 6/12/ 13 at approximately 0009 hours I observed the following noncompliance 

while preforming the Pre- Operational SSOP Review and Observation task in the 

packaging area . The drip pan beneath the leg processor and above the blue flex 

transfer belt that carries product from the bin bumper to the thigh meat belt had a 

build-up of fat residue inside and around the edges . There was also pieces of fat 

inside the drip pan . After taking a regulatory control action and applying US 

Retained/Rejected # B38495456 , I presented my findings to 

had the drip pan and area below rinsed 

completely . The drip pan was reinspected and found to be in sanitary condition 

putting the establishment back in compliance . At 0017 hours unit # 16 was 

inspected , the Thigh Meat belt . The belt had black specks floating in the water 

on top . Again I presented my findings to 

had the entire belt rinsed of all visible black specks . The belt was reinspected an 

found to be in sanitary condition at approximately 0023 hours putting the 

establishment back in compliance and ready for production at approximately 0025 

hours . My findings indicate noncompliance with regulations 9 CFR 416.4(a) And 9 

CFR 416. 4(b) . 

(b) (6)
(b) (6) (b) (6)

(b) (6) (b) (6) (b) (4)

(b) (4)

(b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0705065 

811N-1 

06/11/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C On 06/11/2013 at approximately 0029 hours while performing a Zero Tolerance 

Verification task on line in Plant #2, I observed the following. After 

collected a random 10 bird sample, I observed one bird with visible fecal 

contamination. The fecal material was inside the carcass on the left side adjacent to 

the keel bone approximately 1" from the neck opening of the carcass. The fecal 

material consisted of seven small smears. The smears measured up to 

approximately 1/4" each and were in approximately a 1" area. The fecal material 

was olive green in color and pasty in texture. This exceeded the zero tolerance for 

the process to be in control. The protocol for fecal failure was implemented. A QC 

recheck passed at 0100 hours. My findings indicated a noncompliance with 9 CFR 

381.65(e), 9 CFR 417.(c)(4), and the critical limit of CCP-2B 

of the Plants' HACCP Plan for Slaughter. 

5309 P6137A NJN260506 

2411N-1 

06/11/2013 01D01 SPS Verification C At 0200 hours while I was walking through the evisceration department I observed 

deficiencies noncompliant with sections 416.1, 416.2(e)(3)(4) and 416.4(d) of the 9 

Code of Federal Regulations. At the rehang area I noticed that the entire area was 

overflowed with water, heads, feathers and debris scatter through the area from 

the drain that runs under the Head Puller, Washer, Head Cutter, line 

Auto Rehang and the Rehang table and belt, at the same time I observed 

approximately 15 carcasses on the floor piled up under the A line auto rehang and 

the Rehang table/belt from which some of the carcasses were over the standing 

water. The water was also covering the base of a stainless steel combo bin partially 

filled with carcasses (note that these combo bins have a drain in the base straight 

down to the floor and is approximately 2 inches above the floor). I also observed 

approximately 15 carcasses covered with blood and feathers from the kill line piled 

up on the Bird Catcher that is located prior to the Washer. All the 

deficiencies were creating insanitary conditions noncompliant with the regulations 

mentioned in this document. I showed my findings to 

. As immediate corrective action Mr. condemned the 

carcasses that were on the floor, in the combo bin and on the bird catcher. The 

establishment restored sanitary conditions immediately by unclogging the drain 

and cleaning up the debris from the floor. was informed of the 

forthcoming documentation for the failure to comply with the regulatory 

requirements cited above. 

(b) (6)
(b) (6)

(b) (6)

(b) (6)(b) (6)

(b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4411062 

310N-1 

06/10/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C At approximately 0702 hours while performing Pre Op SSOP Review and 

Observation task in Plant #1, I observed the following noncompliance. While 

inspecting the Liver Inspection Conveyor on Line #2 I observed numerous specks of 

black UFM (unidentified foreign material) all over the top and running the full 

length of the conveyor belt, on further inspection I also found numerous pieces of 

black UFM under the full length of the belt. I immediately took regulatory control 

and tagged the Conveyor with USDA Reject/Retain tag #B31 406261 and informed

 of the noncompliance. immediately 

instructed sanitation personnel to clean the conveyor and we continued with Pre 

Op inspection. Upon returning at approximately 0710 hours I reinspected the 

conveyor finding it clean, restoring sanitary conditions and I removed my tag at 

that time. My findings indicate a noncompliance with the Regulatory Regulations of 

9CFR 416.1, 416.4(a) and 416.13(c). 

5308 M6137 BXL5216061 

110N-1 

06/10/2013 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1003 hours while passing the Gib Chillers in Plant #2, I observed 

the following. The stack of small brown tubs being used by the company employee 

to collect the giblets were in an insanitary conditions. The tubs had black, white and 

brown dried crusty residue from the previous day production, I observed the tubs 

that were collecting the livers, gizzards and hearts and found the one being used for 

hearts unclean also. I inmediately tagged the tub with U.S.Retained/Rejected 

Tag # B31 407297 and the stack of tubs with U.S.Retained/Rejected Tag # B31 

407536. I informed and showed him my findings. 

had a company employee condemn the hearts and take the unclean 

tubs to the wash room. At approximately 1015 hours, I went to Plant #1 and 

inspected the stack of tubs in Gib Chiller Plant #1 and found them also in an 

insanitary conditions. The tubs had dried pieces of fat, black and brown dried crusty 

residue, a pieces of dried gizzards and hearts from the previous day production. 

Quality Control personnel was close by and tagged two stacks of tubs with a red 

hold tag and I tagged another stack of tubs with U.S. Retained/Rejected Tag # B31 

406857. I informed of the noncompliance. 

had a company employee take the tubs to the wash room. My findings 

indicated a noncompliance with the following regulatory requirements of 

regulations 9CFR 416.1, 9CFR 416.4 (a) and 9CFR 416.4 (d). 

(b) (6)
(b) (6) (b) (6) (b) (7)(C) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN350706 

0608N-1 

06/08/2013 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 0514 hours on June 8, 2013 I, CSI , was in the I.Q.F. 

New Products department performing a SSOP Review and Observation verification 

task when I noted the following noncompliance. The conveyor belt for the 

dip tank on Line #2 in the I.Q.F. department feeds product, skinless boneless 

chicken breast, to the Line #2 injection machine conveyor. I observed product over 

flow between these two conveyor belts. Product was continually falling on the floor 

into a pile of approximately thirty pieces. A gray trash barrel was in the center of 

this pile and filled with product, a second gray trash barrel was half full with 

product next to it. I took a regulatory control action by stopping the flow of product 

to the dip tank and tagging the conveyor belt for I.Q.F. Line #2 with U.S. 

retain tag B43303579. Continuing my inspection of the I.Q.F. department I noticed 

that at the Frigo exit there was approximately twenty frozen pieces of product, 

chicken strips, on the floor that had fallen from the overhead conveyor. I informed 

the of the 

noncompliance for the establishments failure to meet the regulatory requirement 

of 9CFR 416.4 (d) which states: " Product must be protected from adulteration 

during processing, handling, storage, loading, and unloading at and during 

transportation from official establishments." After sanitary condition were restored 

I released the product conveyor back to at 

approximately 0527 hours. 

5308 M6137 BXL1704060 

006N-1 

06/06/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 06/05/2013 at approximately 2210 hours while monitoring the Establishments' 

Pre-Operational Sanitation procedures in Plant #1, I observed the following. There 

was tissue sticking through the round hole in the cutting blade assembly on the 

venting machine for Line #1. Most of the cutting assemblies were in a similar 

condition with tissue packed into the space above the cutting blade. The tissue was 

up to approximately 1/1/2" in length. The tissue removed from the machine was 

coated with blackened UFM (Unidentified Foreign Material) with the consistency of 

grease. After the tissue was removed, the venting machine was rinsed with potable 

water and released by approximately 2231 hours. My findings indicated a 

noncompliance with 9 CFR 416.1, 9 CFR 416.4(a) and 9 CFR 416.13(c). 

(b) (6)
(b) (6) (b) (6) (b) (6)(b) (6) (b) (4) (b) (4) (b) (4) (b) (4)(b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5507064 

506N-1 

06/06/2013 06D02 Other Inspection 

Requirements 

C At approximately 0505 hours, I preformed a presentation check in plant 2 on line

 at a line speed of BPM (birds per minute). Station #3 had 1- viscera not 

uniformed, 2- Viscera on shackles, and 2- not reflected for a total of 28 

confirmation points. This exceeded the limit of 25-39 conformation points for the 

process to be in control. I informed . Quality 

Control performed a recheck at approximately 0523 hours and station #3 failed 

with 1- Viscera not uniformed, 1- Viscera on shackle, and 1- out of sequence for a 

total of 31 conformation points. This exceeded the limit of 25-39 conformation 

points for the process to be in control. was again 

informed of the failure and the line speed was reduced to 81 BPM. At 

approximately 0605 hours all rechecks passed, bringing the process back in control. 

5308 M6137 BXL2705064 

205N-1 

06/05/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 06/05/2013 at approximately 0005 hours while monitoring the establishments 

Pre-Operational Sanitation procedures in Packaging Area #1, I observed the 

following. There were numerous pieces of fat and tissue to approximately 1/4" on 

the inside surfaces of the cover for the tray dispenser for line . There were several 

pieces of fat and tissue to approximately 2" on the tray belt sprocket assemble at 

the same location. Also on line there was pasty fat and tissue on the white nylon 

and metal support brackets associated with the product tray belt. Appropriately 30 

feet of the plant #1 side of the line belt was affected. The area of the tray belt 

that passes under the breast processing product belts in addition to the pasty fat 

also had several areas of black UFM (Unidentified Foreign Material) that appeared 

to be mold. was informed of the noncompliance. The line was 

cleaned with green pads, rinsed with potable water and released by approximately 

0020 hours. In Packaging Area #2, the Deboning Room, there were two large 

pieces of tissue measuring approximately 4" by 1/2" inside the white product cones 

on line #1. There were also several pieces of fat and tissue to approximately 1" also 

on the inside surfaces of the product cones for line #1. There was also several cones 

with pasty fat and tissue stuck to the wear marks on the outside surfaces of the 

product cones. Most of the cones on all lines are in a deteriorated condition 

with scuff marks and deep cuts contributing to inefficient and ineffective cleaning. 

There were numerous pieces of fat and tissue on the inside surfaces of 

approximately an 8' section of the center breast fillet collection conveyor belt also 

in the line #1 area. was informed. The tissue was removed, areas 

were rinsed with potable water and the line was released by approximately 0036 

hours. My findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.2(b), 9 

CFR 416.4(a) & (b) and 9 CFR 416.13(c). 

(b) (6)
(b) (6) (b) (6)

(b) (6)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN560706 

3704N-1 

06/04/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 0540 hours while performing PHIS zero-tolerance task in the 

Evisceration Department on B line I noted the following noncompliance. I randomly 

selected a ten carcass sample set and observed fecal material in the third carcass of 

that sample. The bird's cloaca was still attached to the inside of the carcass. The 

fecal material was located inside the cavity near the cloaca. The fecal material was 

in the shape of a circular glob approximately 1/2 inch in it's greatest diameter, dark 

green in color with a paste like consistency. I immediately took regulatory control 

action and stopped "B" line then showed my findings to 

performed corrective actions as per establishment's HACCP plan.

 was notified of the noncompliance. The establishment did 

not meet the requirements of 9 CFR 381.65(e) which requires that the 

establishment prevents poultry carcasses contaminated with visible fecal material 

from entering the chilling system. The failure also represents a deviation from the 

establishment's written HACCP plan. Regulatory requirements of 417.2(c)(4) states 

"List the procedures, and the frequency with which those procedures will be 

performed, that will be used to monitor each of the critical control points to ensure 

compliance with the critical limits." This noncompliance has been linked to the 

following noncompliances. The establishment has stated in their responses that all 

noncompliances for these fecal failures were a result of mechcanical failures. 

NJN3007050722N-1, NJN5307054002N-1, NJN3120050529N-1, 

NJN0605052516N-1, NJN0605052516N-2 

5308 M6137 BXL1320060 

803N-1 

06/03/2013 03J02 Slaughter HACCP C While performing Pre- Chill Finished Products Standards Task, I observed a 

noncompliance with the following regulatory requirements of regulations 9CFR 

381.65 (e) and 9CFR 417.2 (c)(4). At approximately 1335 hours, I randomly 

removed a 10 bird sample from Line #2 in Plant #1, I found one out the ten birds 

with visible fecal contamination inside the bird on the left side under the leaf fat 

area close to the kidneys. The fecal material was three spots each one measuring 

approximately 1/8" diameter in size, dark green in color and pasty in texture. This 

exceed the limit of Zero Tolerance for the process to be in control. I informed

 of the noncompliance. The 

protocol for fecal failure was implemented. Quality Control did a recheck at 

approximately 1412 hours and it passed. The cause of the deviation was sprayer 

plugged up. This is a violation of the critical limits of CCP-2B 

of the Plant's HACCP Plan for Slaughter. 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (6)

(b) (6)

(b) (4) (b) (4)(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4816064 

003N-1 

06/03/2013 04A06 Poultry Finished 

Product Standards 

C On 06/03/2013 at approximately 1055 hours while monitoring the Establishments' 

Reprocessing Procedures on Line in Plant #2, I observed the following 

noncompliance. I randomly selected a 10 bird sample for my reprocessing check 

and found 2 birds with airsacculitis exudates remaining in the bird. I immediately 

took regulatory control action by stopping the line, and I informed 

. The line was started and product was retained while corrective actions 

were implemented. I performed a recheck at approximately 1110 hours and it 

passed, bringing the process back into control. I tagged the tank of retained birds 

with U.S. Retained/Reject Tag #A5324453 pending rework of the product. I 

informed of the noncompliance. I performed a recheck of 

the held product at approximately 1240 hours and it passed. I removed my tag and 

released the product back to production at that time. My findings indicate a 

noncompliance with 9CFR 381.76(b) and 9CFR 381.84. 

5308 M6137 BXL3018053 

530N-1 

05/30/2013 03J02 Slaughter HACCP C While performing Pre-Chill Finished Products Standards Task, I observed a 

noncompliance with the following regulatory requirements of regulations 9CFR 

381.65 (e) and 9CFR 417.2 (c)(4). At approximately 1514 hours, I randomly 

removed a 10 bird sample from Line in Plant #2, I found one out the ten birds 

with visible fecal contamination inside the bird in the kidney crypt area. The fecal 

material was a piece measuring approximately 5/16" diameter in size, olive green in 

color and pasty in texture. This exceed the limit of Zero Tolerance for the process to 

be in control. I informed of 

the noncompliance. The protocol for fecal failure was implemented. Quality Control 

did a recheck at approximately 1541 hours and it passed. This is a violation of the 

critical limits of CCP-2B of the Plant's HACCP Plan for 

Slaughter. 

5308 M6137 BXL4019054 

730N-1 

05/30/2013 01D01 SPS Verification C On 05/30/2013 at approximately 1400 hours while performing the Water Systems 

Food Defense Task, and I observed the following 

noncompliance. The long ice chute on the roof of Plant #1 that runs from the ice 

house, had a missing metal plate that covers the section where the pieces of metal 

meet on the top of the chute. The opening was approximately two inches wide and 

the auger and ice inside were visible and exposed to the outside elements. There 

were approximately five other metal plates covering other gaps in the 

chute,however they were attached by only one bolt apiece and did not seal out the 

outside elements. Upon further observation we also saw that the next chute that 

attaches to the ice machine on the roof of Plant #1 was open on the end where the 

first chute comes up to meet it. The opening was approximately six inches wide and 

the auger and ice were visible and exposed to the outside elements. Our findings 

indicate a noncompliance with the following regulatory requirements of regulations 

9CFR 416.1, 9CFR 416.2(b)(1), and 9CFR 416.2(g)(1). We informed 

of the noncompliance 

(b) (6)
(b) (6)

(b) (6) (b) (6)

(b) (7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN460905 

2930N-1 

05/30/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C At approximately 0710 hours in the Fillet Department on 5/30/13 I, CSI 

was conducting a Pre-Operational Sanitation verification task. On the product 

conveyors for cone lines #11 and 12, I observed multiple pieces of fat and meat 

from the previous day's production. The pieces of fat and meat varied in size, the 

larger pieces were approximately 3/4 of a inch in length and 1/2 an inch in width. 

Cone lines #11 and 12 were retained with the application of U.S. retain tag 

B43303568. and 

were informed of the noncompliance. After the establishment 

washed and sanitized cone lines #11 and 12 I reinspected and found the affected 

equipment to be acceptable. I then released cone lines #11 and 12 back to the 

establishment by removing U.S. retain tag B43303568 at approximately 0720 

hours. Similar noncompliance was issued on 4/24/13, in both incidents cone lines 

were observed in the same condition. The establishment failed to meet the 

regulatory requirements as per 9CFR 416.4(a) All food-contact surfaces, including 

food-contact surfaces of utensils and equipment, must be cleaned and sanitized as 

frequently as necessary to prevent the creation of insanitary conditions and the 

adulteration of product. 9CFR 416.13(c) Each official establishment shall monitor 

daily the implementation of the procedures in the Sanitation SOP's. 

5309 P6137A NJN312005 

0529N-1 

05/29/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 11:29, while performing an FPS verification procedure on “B” line, 

I observed one carcass of a ten carcass sample with visible fecal material. The fecal 

matter was located on the front portion of the right leg, below the hock area, and 

measured approximately one eighth of an inch in diameter. The fecal matter was 

brown in color and of a semi-solid consistency. After noticing the affected carcass, I 

stopped the slaughter line and showed the affected carcass to Mr.

 was also 

given the opportunity to examine the fecal matter on the carcass. After 

confirmation of the fecal finding by the IIC, corrective actions were initiated by the 

establishment including a recheck which was conducted, completed and passed on 

“B” line. The establishment did not meet the requirements of 9 CFR 381.65(e) which 

requires that the establishment prevent poultry carcasses contaminated with 

visible fecal material from entering the chilling system. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5108051 

328N-1 

05/28/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 05/27/2013 at approximately 2300 hours while monitoring Operational 

Sanitation at startup in Plant #2, I observed the following. There were varying 

amounts of brown dried and semi-dried tissue residue on the internal surfaces of 

the smaller size brown product tubs being used at the final trim station for lines 

and to collect salvaged parts. I placed the tubs, some with edible product, under 

USDA hold then contacted and showed him my findings. A 

small amount of product was reconditioned and returned to production. The tubs 

were replaced with gray tubs that are normally used at that location. I contacted

 in Packaging about dirty tubs. He said that Packaging had 

been informed and the affected pallets of tubs had been removed from the coolers 

and placed into the tub wash room. My finding indicated a noncompliance with 9 

CFR 416.1, 9 CFR 416.4(a) & (d). 

5308 M6137 BXL4708051 

623N-1 

05/23/2013 01C02 Operational SSOP 

Review and 

C On 05/23/2013 at approximately 0605 hours while performing Operational SSOP 

Review and Observation Task, I found at the end of the Giblets Chiller #4 in Plant #2, 

Observation the brown small tubs being used to collect the livers and gizzards dirty. The tubs 

had white and black dried crusty residue along the top inside the tub. I immediately 

placed a U.S. Retained/Rejected Tag # B31 4070537 to the product. I inspected a 

stack of small brown tubs that the Giblets Chiller employee have in the area staged 

to be used and found that they were dirty also with small pieces of dried fat and 

dried red residue. I tagged the tubs with U.S Retained/Rejected Tag # B31 407552. I 

informed of the noncompliance 

and showed them my findings. had a company employee 

working at the Giblets Chillers, condemned the gizzards and the livers and took the 

dirty tubs to the tub wash room. My findings indicated a noncompliance with the 

following regulatory requirements of regulations 9CFR 416.1, 9CFR 416.4(a) and 

9CFR 416.4 (d). 

5308 M6137 BXL4905050 

523N-1 

05/23/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 05/22/2013 at approximately 2224 hours while monitoring the Establishments 

Pre-Operational Sanitation procedures in Plant #1, I observed the following. There 

was heavy coating of black UFM (Unidentified Foreign Material) on the guide bars 

after the machine to a point where the bars intersect the chillers. The guide 

bars for lines 1, 2 and were in a similar insanitary condition. Contact between the 

shackles and guide bars during production would create an insanitary condition 

with the UFM falling onto the carcasses just prior to entering the chilling system. 

The access to the area for cleaning is a challenge due to the series of drip pans. 

Areas of the guide bars that obviously come into contact with the shackles were 

cleaned with a green pad, paper towels and a potable water rinse. The area was 

released by approximately 2235 hours. A more detailed cleaning will be performed 

after production. My findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 

416.4(a) and 9 CFR 416.13(c). 

(b) (6)
(b) (6)

(b) (6) (b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6) (b) (7)(C) (b) (7)(C)

(b) (7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN300705 

0722N-1 

05/22/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 0509 hours while I was performing the Review and Observation 

component of a Zero Tolerance Task at the offline inspection station I observed the 

following noncompliance. On the tenth carcass from the ten carcass sample, I 

noticed a small amount (approximately 1/2 of an inch in diameter) of a 

greenish/brownish paste like material consistent with fecal material. The fecal 

material was located on the inside side of the right wing between the drummette 

and wing tip. I took regulatory control action by stopping the offline and retaining 

the affected carcass with U.S. Retain tag# B43303564. I showed my finding to

 initiated corrective 

actions as stated in the establishment’s HACCP plan. The affected carcass was 

released to . The establishment failed to 

prevent fecal material to reach the offline inspection station with the potential of 

entering the chiller. Section 381.65(e) from the 9 Code of Federal Regulations 

requires that the establishments shall prevent contaminated carcasses with visible 

fecal material from entering the chiller. The finding of fecal material did not meet 

the requirements of the establishments HACCP plan. The Supervisors mentioned in 

this document were informed of the forthcoming documentation for the failure to 

comply with the regulatory requirements cited above. Similar non compliance was 

documented on 5/15/13 for an offline fecal failure. The Preventive measures of "An 

extra chlorine wash hose was installed, after the birds exit from the second body 

wash station before the final trimming area", failed to prevent reoccurrence. 

5333 P7632 HYE050705 

4621N-1 

05/21/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C On 5/20/13 at approximately 0433 hours I observed the following noncompliance 

while performing the Zero Tolerance verification task on line #2 . After pulling a ten 

bird random sample observing the fourth sample I noticed a large fecal smear in the 

pelvic cavity and another smear beneath the leaf fat . The fecal material was light 

yellow in color , pasty and smooth in texture . In size the fecal material in the pelvic 

cavity was approximately 1" by 1 " . The fecal material under the leaf fat was 

approximately 1⁄4” in width and 1 1/2" in length . I called my findings to the 

attention of who contacted 

. requested confirmation from 

PHV Dr. . Upon confirmation by Dr. a recheck was preformed by

 , which passed at approximately 0444 , putting the 

establishment back in compliance . The establishments fecal failure protocol was 

implemented by . My findings indicate a 

noncompliance with the following regulations 9CFR 381.65(e) which states that 

carcasses contaminated with visible fecal material shall be prevented from entering 

the chiller tank and 417.2(c)4 . The criteria for CCP-1B were also compromised . 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN140805 

2921N-1 

05/20/2013 01C02 Operational SSOP 

Review and 

Observation 

C When I was walking through the Packaging department I observed the following 

deficiency noncompliant with the 9 Code of Federal Regulations, Sections 416.2(a) 

and 416.4(d): At area 2 Section: A, I observed a winged insect (housefly) crawling 

over the dark meat (thighs) that was inside a combo bin that was staged close to 

the Delivery System# 2 & Drop Chutes (Unit# 15). At approximately 0425 hours I 

took regulatory control action by applying U. S. Retain tag# B43303555 to 

approximately 100 pounds of product. kill the 

fly when it was standing on the chute from the delivery system #2,

 tagged the piece of equipment for further cleaning 

and sanitizing. At approximately 0435 hours the establishment condemned the top 

layer from the pile of the affected product. , 

was informed of the forthcoming noncompliance. 

5308 M6137 BXL2507055 

817N-1 

05/17/2013 06D02 Other Inspection 

Requirements 

C On 05/16/2013 at approximately 0230 hours while monitoring the "No Viscera 

Log" for Line #2 in Plant #1, I observed a noncompliance with the following 

regulatory requirements of regulations 9CFR 381.76(a) and 9CFR 381.76(b). At 

2317 hours with line speed of BPM, Quality Control failed with 24 no viscera, 

13 are allowed. At 2347 hours at line speed of BPM, the recheck failed with 23 

no viscera, the line speed was slowed to 126 BPM. At 0120 hours with line speed of 

126 BPM, Quality Control failed with 17 no viscera and 11 no viscera are allowed. 

Three failures in a half-shift period is a noncompliance for lack of process control. 

The line speed stayed at 126 BPM and at 0411 hours Quality Control failed with 22 

no viscera and 11 no viscera are allowed. I informed of the 

noncompliance. 

(b) (6)
(b) (6)

(b) (6)

(b) (6)

(b) (6) (b) (7)(C) (b) (7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN540105 

0416N-1 

05/16/2013 01C02 Operational SSOP 

Review and 

Observation 

C At the start of Nightshift production I, CSI , and CSI 

were conducting a Operational Sanitation verification task in the Evisceration 

department at approximately 2327 hours. I observed above the carcass chiller a 

blue plastic liner that was tied to two over head support beams for the purpose of 

containing a leak from the ceiling. Approximately ten feet in front of this leak 

another leak had begun above the carcass chiller and was not contained. I 

immediately informed 

of the drip and the forthcoming noncompliance. I then tagged the chiller 

with the application of U.S. retain tag B43303566. stopped 

the production line and instructed maintenance personnel to contain the leak with 

another blue plastic liner. The carcass chiller was overflowed with water and 

chlorine was added to the water after the overflow process was completed. All 

affected product was condemned. With sanitary conditions restored I released the 

carcass chiller, at approximately 2335 hours back to production Supervisors. While 

continuing to verify that the establishment was containing the two drips above the 

carcass chiller, at approximately 0037 hours, I observed another leak above the 

offline from the ceiling. I immediately stopped the offline and retained it with the 

application of U.S. retain tag B43303563. I showed my findings to 

. In the presence of

 the establishment chose to condemn all affected 

product from the offline and divert the water from the leak in the ceiling with a blue 

plastic liner. After sanitary conditions were restored I released the offline back to 

production Supervisors. 

(b) (6)
(b) (6)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN060505 

2516N-1 

05/15/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 0243 hours while I was performing the Review and Observation 

component of a Finish Product Standards Task at the offline inspection station I 

observed the following noncompliance. On the fourth carcass from the ten carcass 

sample, I noticed a small amount (approximately 1/8 of an inch in diameter) of a 

greenish/brownish paste like material consistent with fecal material. The fecal 

material was located on the outer side of the left hock right below of the hock joint 

close to the shackle. I took regulatory control action by stopping the offline and 

retaining the affected carcass with U.S. Retain tag# B43303533. I showed my finding 

to

 initiated corrective actions as stated in the 

establishment’s HACCP plan. The affected carcass was reprocessed and found to be 

acceptable at 0247 hours. The establishment failed to prevent fecal material to 

reach the offline inspection station with the potential of entering the chiller. Section 

381.65(e) from the 9 Code of Federal Regulations requires that the establishments 

shall prevent contaminated carcasses with visible fecal material from entering the 

chiller. The finding of fecal material did not meet the requirements of the 

establishments HACCP plan. The Supervisors mentioned in this document were 

informed of the forthcoming documentation for the failure to comply with the 

regulatory requirements cited above. 

(b) (6)
(b) (6)

(b) (6)

(b) (6)

(b) (6) (b) (7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN060505 

2516N-2 

05/15/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 0510 hours while I was performing the Review and Observation 

component of a Finish Product Standards Task (FPS) at A Line inspection station. 

While I was performing the FPS verification, I observed the cloaca with a piece of 

intestine approximately 2 inches long attached to the tenth carcass from the ten 

carcass sample, after a closer observation, I noticed that the intestine was draining 

a Brownish paste like material consistent with fecal material inside the carcass on 

the pelvic area. I took regulatory control action by retaining the affected carcass 

with U.S. Retain tag# B43303533. I showed my finding to 

requested a second opinion from Dr. which confirmed that it was 

fecal material. Ms. initiated corrective actions as stated in the 

establishment’s HACCP plan. The affected carcass was reprocessed and found to be 

acceptable at 0520 hours. When I informed Online IPP about the zero tolerance 

failure, they communicated to me that they informed the establishment’s 

management of finding carcasses with cloacas attached and high amounts of 

contamination. At 0243 hours the establishment had a zero tolerance failure on the 

Reprocessing Offline. The establishment failed to prevent fecal material to reach the 

A line FPS inspection station with the potential of entering the chiller. Section 

381.65(e) from the 9 Code of Federal Regulations requires that the establishments 

shall prevent contaminated carcasses with visible fecal material from entering the 

chiller. The finding of fecal material did not meet the requirements of the 

establishment’s HACCP plan. The Supervisors mentioned in this document were 

informed of the forthcoming documentation for the failure to comply with the 

regulatory requirements cited above. 

5333 P7632 HYE040005 

1215N-1 

05/15/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C On Friday May 9, 2013 at approximately 0450 hours, I was conducting a Poultry 

Zero Tolerance Verification Procedure at the finished product standard (FPS) station 

for Line 1. I had selected a random ten carcass sample from the line and observed a 

fecal smear approximately 1⁄2” x 1⁄4” in size within the carcass cavity. The fecal 

material was brownish-green in color with a pasty consistency and was located 

under the left side of the keel bone. I notified 

of my findings and the forthcoming documentation. Ms.

 then summoned Quality Control personnel to perform a recheck at the Line 1 

FPS station. The prevention of carcasses with fecal contamination to reach the FPS 

station prior to entering the chiller represents a noncompliance with regulation 9 

CFR 381.65(e) which states "Poultry carcasses contaminated with visible fecal 

material shall be prevented from entering the chilling tank". 

(b) (6)
(b) (6)

(b) (6)

(b) (6)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1904054 

214N-1 

05/14/2013 03J04 Poultry Zero 

Tolerance 

C On 05/14/2013 at approximately 0014 hours, while performing the Zero Tolerance 

Task in Plant #1 on Line #2, I found visible fecal contamination on one of the ten 

Verification birds I randomly removed. The fecal was located inside, above the kidney on the 

right side on the bird. The fecal material measured approximately 1/8" in size, olive 

green in color and pasty in texture. This exceeds the limit of Zero Tolerance for the 

process to be in control. I informed 

of the noncompliance and the protocol for fecal failure was implemented. 

Quality Control performed the recheck at approximately 0047 hours and failed with 

one bird out of ten that had visible fecal contamination. The bird had a vent with 

approximately 1 1/2" of intestine, attached by connective tissue on the left side of 

the bird. The fecal material was inside the bird on the kidneys in the middle 

measuring approximately 1/2" long, dark green in color and slightly runny in 

texture. 

were informed of the failure. Quality Control performed the recheck at 

approximately , after the company break, and passed. The cause of the 

deviation was the guide bar of the inside outside bird washer. Quality Control 

performed Post Chill checks from 0126 till 0246, all checks passed. My findings 

indicate a noncompliance with 9CFR 381.65(e), 9CFR 417.2(c)(4), and the critical 

limit of CCP2B, of the Plant's HACCP Plan for Slaughter. 

5308 M6137 BXL4504050 

611N-1 

05/11/2013 04A06 Poultry Finished 

Product Standards 

C On 05/10/2013 at approximately 0139 hours, I randomly removed a 10 bird 

sample from Line in Plant #2 for a Pre-Chill Finished Product Standard Check. I 

documented 33 points on the Processing Nonconformances from the 10 bird 

sample. This exceeds the subgroup absolute limit of 30 points for the Processing 

Nonconformances to be in control. I informed Quality Control of the failure and at 

approximately 0150 I performed a recheck. I documented 31 points on the 

Processing Nonconformances, this exceeds the limit of the 25 points allowed for the 

recheck, at this point the process is considered out of control. I informed 

of the noncompliance. Line had finished running the Organic birds 

after I had performed the recheck and had moved to Line . Quality Control 

performed rechecks at Post-Chill and at 0325 hours, all Post-Chill checks had 

passed. My findings indicate a noncompliance with 9CFR 381.76(b). 

(b) (6)
(b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4508050 

011N-1 

05/11/2013 04A06 Poultry Finished 

Product Standards 

C On 05/11/2013 at approximately 0515 hours while monitoring evisceration line 

processes in Plant #1, I observed the following. The automatic rehang feature that 

transfers carcasses from the kill line to the evisceration line was not working for line 

#1 causing all the carcasses to be dropped onto the belt at the rehang station. The 

establishment has an automatic paw condemnation system that drops the paws 

automatically when a carcass is condemned at any inspection station. The system 

was not functioning when the association between the carcass and the paws was 

lost as the carcasses were being manually rehung on a random basis by five 

employees. I went to the paw collection room and observed that paws were being 

collected from lines 1 & 2 into a single plastic lined bin which is how the 

establishment treats edible product. I contacted who condemned 

by approximately 0550 hours the paws that had collected before break. The 

automatic rehang machine could not be repaired during the 0530 hour break so the 

paws from line #1 were condemned for the rest on the shift. This is a loss of process 

control. My findings indicated a noncompliance with 9 CFR 381.65(a) and 9 CFR 

381.78(a). 

5308 M6137 BXL1505052 

710N-1 

05/10/2013 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 0210 hours while passing by the Gib Chiller in Plant #2, I noticed 

the following noncompliance. The brown tub that was being used to collect the 

gizzards looked dirty. On closer inspection I saw that the tub had dried crusty 

residue along the top inside of the tub. Upon further inspection I observed that the 

other brown tubs being used to collect the liver, gizzards and hearts on both Chiller 

#3 and Chiller #4 also had dried residue and fat on the top inside of the tubs. I 

observed a stack of brown tubs in the area and I asked the employee working at the 

Gib Chiller if those tubs were clean and he answered that they were. I inspected the 

tubs and found that they were also dirty with dried residue and fat. I took 

regulatory control action and tagged the tubs with USDA Reject/Retain tag 

B31408043, I then informed of the noncompliance and 

showed him my findings. He immediately took the tubs to the wash room to be 

rewashed and he brought clean tubs. He then had the employee working at the Gib 

Chiller condemn the gizzards, livers and hearts that were in the dirty tubs, restoring 

sanitary conditions at approximately 0230 hours. My findings indicate a 

noncompliance with 9CFR 416.1, 9CFR 416.4(a) and 9CFR 416.4(d). 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (7)(C) (b) (7)(C) (b) (7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN000105 

3010N-1 

05/10/2013 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 0730 in the Fillet Department on 5/09/13 I, CSI was 

conducting a Operational Sanitation verification task. On the product conveyor for 

cone line #7, I observed multiple pieces of fat and skin from the previous days 

production. The pieces of fat and skin varied in size, the larger pieces were 

approximately 3/4 of a inch in length and 1/2 an inch in width. The product 

conveyor did not have product on it because this was observed at start up for the 

Fillet department. Cone line #7 was retained with the application of U.S. retain tag 

B43303550. The Fillet Department, 

were informed of the noncompliance. After the 

establishment washed and sanitized cone line #7 CSI reinspected and 

found the affected equipment to be acceptable. CSI then released cone line 

#7 back to the establishment by removing U.S. retain tag B43303550 at 

approximately 0811 hours. 

5309 P6137A NJN191605 

0109N-1 

05/09/2013 04A06 Poultry Finished 

Product Standards 

C At 0839 hrs. I was performing a zero tolerance verification task on the tubs of 

salvaged parts in the evisceration department. I randomly selected 5 pieces from 

each tub. I found one piece (thigh) affected with I.P (cellulitis) in a tub identified 

from A-line. I showed this finding to . I secured U.S. Retain 

Tag # B43303542 to the tub. I also informed 

of the non compliance with 9 CFR 381.86. The establishment condemned the 

affected part and reworked the remaining product in the tub. At 0945 I reinspected 

the reworked product and found no further incidence of I.P. affected product. I 

removed the U.S. Retain tag and released control of the product back to the 

establishment. The finding of I.P. affected tissue on salvage parts constitutes a non 

compliance according to the regulations cited above. 9 CFR 381.78(a) states in part: 

“At the time of any inspection under this subpart each carcass, or any part thereof, 

which is found to be adulterated shall be condemned, except that any such articles 

which may be made not adulterated by reprocessing.” 9 CFR 381.86 states: “Any 

organ or other part of a carcass which is affected by an inflammatory process shall 

be condemned and, if there is evidence of general systemic disturbance, the whole 

carcass shall be condemned. 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (6)

(b) (6) (b) (6)

(b) (6) (b) (7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE590205 

0909N-1 

05/09/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On the 8 May, 2013 at approximately 0008 hours, after Sanitation and QC 

Performed Pre-Operational Sanitation and released area IV for operations, I 

performed Pre-operational Sanitation Inspection and observed the following 

Noncompliance: there was black greasy water with spots of foreign material in the 

immediate area” approximately an area 6 x 6 square “on the Conveyor Belt below 

the Chute. I immediately took a regulatory control action by placing U.S Rejected 

Tag # B39415929 on the affected area and informed Mr. 

of the noncompliance and forthcoming Non Compliance Record. With 

the aid of a ladder I climbed to a better vantage point after the belt was cleaned and 

before the area was released to possibly see were the grease was coming from. The 

motor housings/cover and drive line/cogs had excessive grease, both mechanical 

and animal as well as excessive condensation “ beaded and dripping “ on the ceiling 

directly above Ln 1 & 2 Body Halvers; Ln 1 & 2 Bird Indexers; the Chute and 

Conveyor. At that point I informed Mr. that the area was not released and I 

would be in the USDA office waiting until sanitary conditions had been restored to 

my satisfaction. Approximately a half hour later Mr. retrieved me from the 

office to reinspect the area in question. I reinspected the area and found the area to 

be acceptable with sanitary conditions restored, I removed the U.S. rejected Tag at 

approximately 0040 hours. Upon review of the SSOP Implementation and 

Monitoring Log Checklist, QC had found Unit #1 of Area #4 acceptable at 2333 

hours. 

5309 P6137A NJN250505 

3208N-1 

05/08/2013 04A06 Poultry Finished 

Product Standards 

C At approximately 0239 hours I, CSI , was in the Evisceration Department 

performing a Finished Product Standards verification task on the offline. I selected a 

random ten carcass sample to verify the establishments reconditioning procedure 

for contaminated product. Three carcasses of the ten had various amounts of 

ingesta, two of the carcasses had large amounts of ingesta in the neck/crop area of 

the carcass, one had ingesta located inside the cavity on the rib cage. Production 

employee stopped the offline, I informed 

of the failure and showed him my findings. Then I informed

 that I would conduct the establishment required recheck. After selecting ten 

carcasses, I observed two of the ten to have ingesta in the neck/crop area. I took 

regulatory control action with the application of U.S. retain tag B43303544 to the 

offline e-stop and informed 

r of my findings and the forthcoming noncompliance for the 

establishment's failure to meet the regulatory requirements. Then I released offline 

and immediately began the establishment's recheck and 

corrective actions. 

(b) (6)
(b) (6) (b) (6) (b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (7)(C) (b) (7)(C) (b) (4)

(b) (4) (b) (4)

(b) (7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5217053 

607N-1 

05/07/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C While performing Zero Tolerance Verification Task, I observed a noncompliance with 

the following regulatory requirements of regulations 9CFR 381.65 (e) and 9CFR 

417.2 (c)(4). At approximately 1457 hours, randomly 

removed a 10 bird sample from Line # in Plant #2, I found the second bird 

inspected with visible fecal contamination inside the bird at the right side next to 

the tail-vent area, what looked to be a venter missed cut. The fecal material was a 

piece measuring approximately 1/4" long by 3/16" wide, green olive in color and 

pasty in texture. This exceed the limit of Zero Tolerance for the process to be in 

control. I informed of the 

noncompliance. The protocol for fecal failure was implemented. At approximately 

1521 hours, Quality Control performed a recheck and it passed. The cause of the 

deviation was the venter. This is a violation of the critical limits of CCP-2B, 

of the Plant's HACCP Plan for Slaughter. 

5308 M6137 BXL3712053 

606N-1 

05/06/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C While performing Pre Operational inspection in the Packaging area, I found a 

noncompliance with regulatory requirements of regulations 9 CFR 416.4(a) and 

416.14. At approximately 0837 hours, while inspecting The 

located by the bag fryer lines in the packaging area, I noticed the 

following insanitary condition: There were several rough surface inside of the 

hoppers. The yellowish and scabby residue came off easily when I scratched it. The 

hoppers are a product contact surface utilized to load product into tubs. I showed 

my finding to The . I then, proceeded to place 

a rejected/retained tag N0 B31 407702 on the effected equipment. Sanitation 

employees scrubbed and washed the affected product contact surfaces. At 

approximately 0855 hours, I reinspected the equipment finding it clean. I then, 

remove the US reject tag, releasing the equipment to production. 

was notified of the noncompliance. 

5333 P7632 HYE430605 

1606N-1 

05/06/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C On 5/5/13 at approximately 0215 hours I observed the following noncompliance 

while performing the Zero Tolerance procedure on line #2 . After pulling a ten bird 

random sample and observing the third sample , I noticed a large fecal smear just 

below the leaf fat . The fecal material was light green in color , pasty and smooth in 

texture approximately 3/8” in width and 3⁄4” in length . I reported my findings to of

 who was performing a check on line #1 . 

contacted 

requested confirmation from PHV Dr. . Upon confirmation by Dr.

 a recheck was preformed by , which passed at approximately 

0222 hours then establishments protocol for fecal failure was implemented by

 . My findings indicate noncompliance with the 

following regulations 9CFR 381.65(e) which states that carcasses contaminated 

with fecal material shall be prevented from entering the chiller tank and 417.2(c)4 

and the criteria for CCP-1B were also compromised . 

(b) (6)
(b) (6)

(b) (6) (b) (6)

(b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1305050 

202N-1 

05/02/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 05/02/2013 at approximately 0100 hours while monitoring the establishments' 

Operational Sanitation procedures in Packaging Area #1, I observed the following. 

There was an off colored film of UFM (Unidentified Foreign Material) on the 

stainless surfaces that support the brown product belts for line . I wiped some of 

the UFM from Line off onto a white product soaker pad and showed it to 

. The UFM showed up black on the white pad. Line was not yet in 

use. I proceeded to line the 'A' side was in use and was clean. I found the same 

UFM on the 'B' side which was not in use. The UFM was also on most of the small 

tables that are part of the bagging system for lines and . 

was called. A review of the establishment 

Pre-Operational Sanitation documents for the shift revealed that Line was 

checked by a General Sanitation employee as part of the establishments 

Pre-Operational Sanitation check and found to be acceptable at 2300 hours. Line 

was found to be acceptable at 2304 hours. Quality Control personnel according to 

the establishments' SSOP Pre-Op Daily Implementation and Monitoring Log for 

Packaging found Line belt acceptable at 2318 hours and select units for 

lines & were found to be acceptable by 2317 hours. The establishment uses a 

cleaner as part of their pre-operational cleaning procedure manufactured by Supply 

Systems coded A-433 that is a mixture of and . 

According to the label the product only requires a .

 was given a sample of the UFM. had production sanitation 

personnel clean the affected surfaces. The UFM wiped off easily with a paper towel. 

A followed per establishment policy restoring sanitary 

conditions by approximately 0200 hours. My findings indicated a noncompliance 

with 9 CFR 416.1, 9 CFR 416.3(a), 9 CFR 416.4(a) and 9 CFR 416.14. 

(b) (6)
(b) (6) (b) (6)

(b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN530705 

4002N-1 

05/02/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 0458 hours while performing PHIS zero-tolerance task in the 

Evisceration Department on B line I noted the following noncompliance. I randomly 

selected a ten carcass sample set and observed fecal material in the third carcass of 

that sample. The fecal material was located inside the cavity on the left side flap, 

approximately 1/2 in length and 1/4 in it's greatest diameter, dark green in color 

with a paste like consistency. I immediately took regulatory control action and 

stopped "B" line then showed my findings to 

performed corrective actions as per establishment's HACCP plan. 

was notified of the noncompliance. The establishment 

did not meet the requirements of 9 CFR 381.65(e) which requires that the 

establishment prevents poultry carcasses contaminated with visible fecal material 

from entering the chilling system. The failure also represents a deviation from the 

establishment's written HACCP plan. Regulatory requirements of 417.2(c)(4) states 

"List the procedures, and the frequency with which those procedures will be 

performed, that will be used to monitor each of the critical control points to ensure 

compliance with the critical limits." 

5333 P7632 HYE370005 

3002N-1 

05/02/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 5 /1 /13 at approximately 2158 hours I observed the following noncompliance 

while performing the Pre-orerational SSOP Review and Observation procedure in 

the picking room . On the way to perform the lock-out and tag-out procedure with

 I observed a piece of fiberglass paneling attached to the 

south wall . The paneling covered an area approximately 7’ by 8’ . Upon closer 

observation I noticed what appeared to be several pieces of paneling bonded 

together covering the area . All four sides of the area were covered with black 

mold . The three pieces of paneling jointed with caulking contained mold as well . I 

took a regulatory control action and immediately informed of 

the noncompliance . My findings also indicate noncompliance with 9CFR 416.1 and 

9 CFR416.2 (b)2 . 

5308 M6137 BXL0122054 

701N-1 

05/01/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 04/30/2013 at approximately 2350 hours while monitoring the establishments' 

Pre-Operational Sanitation procedures in Packaging, I observed the following. There 

were several pieces of fat approximately 1/4" to 1" and a blood clot approximately 

1/4" under the brown product belt on Line , closest to Line . I informed

 of the noncompliance.The area was rewashed, restoring 

sanitary conditions. My findings indicate a noncompliance with 9CFR 416.1, 9CFR 

416.4(a), 9CFR 416.14, and 9CFR 416.13(c). 

(b) (6)
(b) (6) (b) (6) (b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6) (b) (7)(C) (b) (7)(C) (b) (7)(C) (b) (4)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3908054 

001N-1 

05/01/2013 01D01 SPS Verification C On 05/01/2013 at approximately 0535 hours in Plant #1 Evisceration Department, 

USDA GS7 Inspector saw a live cockroach on the wall where employees 

hang their aprons, directly behind USDA Inspection Station #6 on Line #2. He killed 

the cockroach with a paper towel and then showed it to me and I took it to

 and informed him of the noncompliance. At 

approximately 2306 hours in Plant #1 Evisceration, Inspector saw another 

cockroach on a metal pole directly behind USDA Inspection Station #5 on Line #2. 

Inspector killed the cockroach with a paper towel then gave it to me and I 

showed it to . This was the second incident with a 

cockroach on the same day. 

5308 M6137 BXL4604050 

401N-1 

05/01/2013 04C05 Poultry Good 

Commercial 

Practices 

C On 05/01/2013 at approximately 0216 hours while performing Good Commercial 

Practices in Plant #1 Live Hanging area, I observed the following. On Line #2, the 

stainless steel tank marked "USDA CONDEMN" which is used for DOA birds, there 

was one bird lying on top of approximately 20 dead birds that was breathing and 

slightly moving it's head. I immediately informed and 

the bird was removed from the tank and put on Line #2 kill line, to go through 

stunning and the automatic kill machine. This noncompliance is linked to NR 

BXL3313020527N/1 on 2/27/2013 for the same root cause. I informed 

of the noncompliance. 

5333 P7632 HYE060705 

4601N-1 

05/01/2013 01C02 Operational SSOP 

Review and 

Observation 

C While performing an Operational Sanitation Review and Observation task in Area 

#3, Chick Weight/Bag Line at 0345 hours I observed the following noncompliance; 

Above the Chick Weight /Bag line from the bottom of the Cabinet, heavy 

beaded condensation was present and dripping onto the product contact surface 

below. I took immediate regulatory control action by stopping the production line 

with U.S. Retain tag # B 39757011 and informed Mr. 

N/S of the Noncompliance and the forthcoming Non Compliance Record. I also 

informed Miss. of the situation and the noncompliance 

action. Mr. took immediate action by having the condensation removed and 

the affected product retained and sent to the product wash station. Control of the 

Chick Weight/Bag Line was relinquished at 0351 hours after the product contact 

surface was resanitized and sanitary conditions were restored. The affected product 

was put back into circulation after it was reprocessed per establishment’s 

procedure. As per Step #6 of the establishments SSOP’s plan:” 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE260804 

2729N-1 

04/29/2013 04A06 Poultry Finished 

Product Standards 

O On 4/28/13 I observed the following noncompliance while preforming a Poultry 

Finished Product standard verification task on the reprocessing line in the 

evisceration department at approximately 0216 . Selecting ten birds 

randomly , marked with split tails for vacum I observed one out of the ten with air 

sac exudate . The air sac was yellow in color , watery in texture locataed on the left 

side of the opening cut below the leaf fat . was informed her of the 

noncompliance . preformed the recheck immdiately . The recheck 

passed putting the establishment back in compliance . My findings indicate a 

noncompliance with regulation 9CFR 381.83 which states that evidence of extensive 

involvment of air sac or showing systemic changes shall be conedmn ed . Less 

effected carcasses may be passed for food after complete removal and 

condemnation of all affected tissues including the exudate . 

5333 P7632 HYE260804 

2729N-2 

04/29/2013 04A06 Poultry Finished 

Product Standards 

O On 4/28/13 I observed the following noncompliance while preforming a Poultry 

Finished Product standard verification task on the reprocessing line in the 

evisceration department at approximately 0216 . Selecting ten birds randomly 

marked with split tails for vacum I observed one out of the ten with air sac 

exudate . The air sac was yellow in color , watery in texture locataed on the left side 

of the opening cut below the leaf fat . was informed of the 

noncompliance and preformed the recheck immdiately . The recheck passed putting 

the establishment back in compliance . My findings indicate a noncompliance with 

regulation 9CFR 381.83 which states that evidence of extensive involvment of air 

sac or showing systemic changes shall be conedmned . Less effected carcasses may 

be passed for food after complete removal and condemnation of all affected tissues 

including the exudate . 

(b) (6)
(b) (6)

(b) (6)

(b) (4) (b) (4)

(b) (4)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN032004 

0025N-1 

04/25/2013 04A06 Poultry Finished 

Product Standards 

C I was performing a Poultry Finished Product Standards verification task at 1141 

hours on the reprocessing line in the evisceration department when I observed the 

following noncompliance: The establishment failed to remove airsacculitis tissue 

and exudates from carcasses identified by USDA for air sac removal. (7) Carcasses of 

the (10) carcasses sample identified for air sac removal contained air sac exudates. 

The establishment’s written procedure for 

t) states: 

. I initiated regulatory control by 

stopping the reprocessing line and applied U.S. Retained tag NO B38495187 on the 

affected carcasses. Mr. 

were informed of my finding and forthcoming non compliance. At 

1148 hours I released the affected carcasses to the establishment for rework and 

the regulatory control was relinquished to the Quality control so that to start the 

establishment corrective actions to regain process control and perform rechecks to 

identify all affected products associated with the failure. Ms performed a 

recheck on the reprocessing line. The recheck failed by one carcass out of ten 

carcasses sample had airsacculitis on the pelvic cavity. She performed another 

recheck; the recheck passed at 1154 hours. The requirements of 9 CFR 381.84 and 

the purpose of Plant’s written procedure were not met 9 CFR 381.84 

which states: 

Plant’s written 

Airsacculitis procedure document number IX.m dated 8/15/2012. The purpose: 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6)

(b) (4)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN531104 

4425N-1 

04/25/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 04/24/2013 at 1040 hrs I was walking in the fillet department on the north side 

next to wing singulators line 4 and 6 when I noticed that there was liquid dripping 

from the drain hole of the catch pan above the line onto the product (wings) being 

conveyed on the line below. This catch pan houses the product belt sprayers and 

did not have the drain hose attached. The blue flexible drain hose is used to direct 

the flow from the drain onto the floor and away from the product. I immediately 

got the attention of and had him stop the wing 

singulator belt that was affected by this drip. I informed Mr. of my 

observations and secured U.S. Reject Tag #B39415848 to the framework of the 

singulator line. I informed of the non 

compliance to the regulation sited above. The immediate corrective action by the 

establishment was to reattach the drain hose to the drain and wash and sanitize 

the affected product belt. The establishment determined that the drain hose had 

been in place at 0945 hrs. The establishment retained approximately two combo 

bins of wings and one rack of bulk bagged wings. After the belt was washed and 

sanitized I removed the reject tag at 1157 hrs. 9 CFR 416.4(d) states: product must 

be protected from adulteration during processing, handling, storage, loading and 

unloading at and during transportation from official establishments. 

5308 M6137 BXL1016042 

624N-1 

04/24/2013 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1053 hours while performing scheduled Operational SSOP Review 

and Observation task, I observed the following noncompliance. While walking 

through the Room I stopped at the sink used to recondition product to ensure 

that the product there was iced. While I was there I observed several pieces of 

product in a brown tub staged on the right side of the sink under the "clean 

product" sign that had multiple specks of black UFM (unidentified foreign material) 

on them. The Establishment's SSOP's state tha

 and that 

". I immediately tagged the tub with USDA Retain Tag #B31406330 and 

informed of the noncompliance. The lead person 

immediately started reconditioning the product. I did a recheck of the product and 

found it to be clean restoring sanitary conditions and removed my tag at 

approximately 1215 hours. My findings indicate a noncompliance with the 

regulatory regulations of 9CFR 416.1 and 9CFR 416.4(d). 

(b) (6)
(b) (6) (b) (6)

(b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN122204 

3424N-1 

04/24/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C At approximately 0720 hours while performing the Review and Observation 

component of a Pre-Operational Sanitation PHIS task, I observed the following 

deficiencies at the Fillet Room Section F Wings: At Unit# 21 North Side Sizing 

Stations (3 stations) on the first sizing station adjacent to the incline conveyor to 

sizing from the cone lines had fat residue from the previous day’s production along 

the white plastic guide bars and in the interior side of the conveyor. At Unit# 8, 

North/South KVP Incline conveyor (line diverts product to packaging line (Ossid# 1), 

on this unit I observed a piece of fat from the previous day’s production. The piece 

of fat had an approximate measurement of 1.5 inches long and 1⁄4 of an inch wide. 

At unit# 2, Product Transfer Incline belt, I observed a piece of skin lodged in 

between the wheels located at the lower side of the belt. The piece of skin was from 

the previous day’s production and it had an approximate measurement of 3 inches 

long and 1 inch wide. The Lock Out/Tag out procedure remained in place until the 

establishment restored sanitary conditions. I showed the deficiencies to 

The establishment implemented immediate corrective 

actions by cleaning and sanitizing the affected equipment. Once sanitary conditions 

were restored and the units were reinspected and found acceptable, I relinquished 

the units to production at 0730. The finding of pieces of fat and skin from previous 

day’s production on product contact surfaces represents a failure to meet the 

regulatory requirements of sections 416.4(a) and 416.13(c) of the 9 Code of Federal 

Regulations. and 

, were informed of the forthcoming documentation for the failure to 

comply with the regulatory requirements cited above. 

5309 P6137A NJN122204 

3424N-2 

04/24/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C At approximately 0725 hours, while performing the Review and Observation 

component of a Pre Operational Sanitation PHIS task in the Fillet Room I observed 

the following non compliance: Cone line # 5: There were considerable amounts of 

fat and skin pieces along the entire length of the conveyor belt, cones, chutes, dip 

pans, stands and the lines metal frame. The approximate sizes are 1/2” – 1 1⁄2” and 

1/4“– 1/2“in width. I showed the deviations to 

and informed him of the noncompliance. The establishment implemented 

immediate corrective actions. All affected areas were cleaned and sanitized. Once 

sanitary conditions were restored and the area was found acceptable the area was 

released at 0730. The establishment failed to meet regulatory requirements as per 

9CFR 416.4(a) All food-contact surfaces, including food-contact surfaces of utensils 

and equipment, must be cleaned and sanitized as frequently as necessary to 

prevent the creation of insanitary conditions and the adulteration of product. 9 CFR 

416.13(c) Each official establishment shall monitor daily the implementation of the 

procedures in the Sanitation SOP's. 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN560704 

1124N-1 

04/24/2013 01D01 SPS Verification C At approximately 00:43 in the New Room (IQF), while performing an SPS review and 

observation PHIS task, I observed the following non compliance. There were three 

stacks of brown baskets. Several of the baskets had dried fat pieces with an 

approximate measurement of 1⁄2”-2” long and 1⁄4” – 1⁄2” wide. I took regulatory 

control by applying U.S. retain tag #B38495403. I then notified 

of my findings and of the forthcoming noncompliance. 

She acknowledged and verified the dirty baskets. At this point plant employees 

were still getting baskets from the stacks and applying blue plastic liners to the 

baskets. She then addressed the findings with , who then 

tagged the baskets that were being staged by the plant employees. Ms. 

then instructed another employee to take the remaining basket out of the 

production area. Once these corrective actions were implanted and sanitary 

conditions were restored, I removed my U.S. retain tag. The establishment failed to 

comply with regulatory requirements 9CFR 416.1Each official establishment must 

be operated and maintained in a manner sufficient to prevent the creation of 

insanitary conditions and to ensure that product is not adulterated.9 CFR 416.4(b) 

Non-food-contact surfaces of facilities, equipment, and utensils used in the 

operation of the establishment must be cleaned and sanitized as frequently as 

necessary to prevent the creation of insanitary conditions and the adulteration of 

product. 

5333 P7632 HYE480804 

0324N-1 

04/24/2013 04A06 Poultry Finished 

Product Standards 

O ON 4/24/13 at approximately 0333 hours I observed the following noncompliance 

while conducting a Poultry Finished Product Standards verification task . The task 

was preformed on the bag line due to the amount of contamination found in an 

earlier verification check at the AQL table . Pulling a sample of approximately ten 

gizzards from a tan product tub which had been staged to be the next tube of 

gizzards to be used , I noticed ingesta , grit and black flakes of ( UMF ) Unidentified 

Foreign Material in approximately 50% of the sample . Selecting another sample of 

approximately ten gizzards for further observation I found 50% of that sample to be 

contaminated as well . Taking a regulatory control action I had the tub removed 

from circulation . was in the area and was informed 

of the noncompliance . Mr. placed a QC hold tag on the product which was 

condemned at approximately 0620 hours . My findings indicate noncompliance 

with the following regulations 9CFR 318.76(b) and 9CFR 416.4(d) which states that" 

the product must be protected from adulteration during processing , handling 

,storage , loading and unloading at and during transportation from official 

establishments " . 

(b) (6)
(b) (6)

(b) (6) (b) (6)

(b) (6)

(b) (6) (b) (6)

(b) (6) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN500304 

1523N-1 

04/22/2013 04A06 Poultry Finished 

Product Standards 

C When I was performing the Review and Observation component of a Finish 

Products Standard PHIS task at the chiller exit (post chill inspection station) I noted 

the following deficiency. One carcass from a ten carcass sample was marked for 

airsacculitis (split tail). This carcass had airsacculitis exudates, pieces of lung in the 

thoracic area and the cloaca with a piece of intestine still attached to it. I show the 

carcass to . The approximate time of 

this incident was 0119 hours. A minute later I found another carcass with 

airsacculitis exudates in the thoracic and pelvic area, this carcass was also marked 

for airsacculitis (split tail). I showed my finding to 

t. At 0123 hours I performed an offline vacuum verification. I 

collected a sample consisting of 10 carcasses from which 6 carcasses marked with 

split tail had airsaccullitis exudates in the rib cage. I showed my finding to 

According to the establishment’s vacuum 

procedure 3 carcasses with vacuum defects requires retention and rework of the 

affected product. , initiated 

immediate corrective actions as prescribe in the establishment’s vacuum 

procedure. The establishment failed to remove airsaccullitis exudate from carcasses 

marked by USDA online inspection personnel. 9 CFR 381.84 requires that 

establishments completely remove and condemn tissues affected with airsacculitis, 

including exudates, in carcasses not condemned. Mr.

 were informed 

of the forthcoming documentation for the failure to comply with the regulatory 

requirements cited above. 

5333 P7632 HYE042004 

4422N-1 

04/22/2013 04A06 Poultry Finished 

Product Standards 

C At 1331 hours I performed the Review and Observation of a Finish Product 

Standards task at the salvaged parts station in the degree cooler. The product 

had already went through all interventions during the slaughter process and was 

inspected and released by Quality Control personnel. While performing my 

verification in a tub of salvage thighs, I noticed that one of the thighs had cellulitis 

exudate attached to the meat approximately a 1/2 inch by 1/4 inch in size. I took 

regulatory control action by applying US Retained tag #B38494104 to the affected 

tub of product. I showed my finding to Ms

 and 

informed them of the forthcoming noncompliance. Upon reviewing the 

establishment records, I noted that Quality Control personnel released and found 

acceptable the affected product at 1129 hours. The finding of cellulitis exudate in 

finish product represents a noncompliance as per 9 CFR 381.86 which states, “Any 

organ or other part of a carcass which is affected by an inflammatory process shall 

be condemned and, if there is evidence of general systemic disturbance, the whole 

carcass shall be condemned”. At approximately 1337 I released the product to Mr.

 so he could initiate corrective actions. 

(b) (6)
(b) (6) (b) (6)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN400704 

1722N-1 

04/21/2013 01C02 Operational SSOP 

Review and 

Observation 

C I was walking through the Packaging department at the start up of operations and 

before product reached the product contact surfaces, when I observed the following 

noncompliance: At Section A: Marination line, I observed in the Incline Conveyor 

Out of Hopper (Unit #7) pieces of fat, with an approximate measurement of 5mm, 

from the previous day’s production and residue from spice ingredients, reddish in 

color, that are used to marinate the product that is processed in this units. At 0101 

hours I tagged the unit with retain tag #B303531. On the transfer conveyor belt 

under the delivery system #1 drop chute I noticed a piece of meat from the 

previous day’s production, with an approximate measurement of 1 inch long 

and 1⁄2 inch wide. I tagged the unit with retain tag #B303531. I showed my findings 

to 

They also were informed of the forthcoming documentation for the 

failure to comply with the regulatory requirements of Sections 416.4(a) and 

416.13(c) of the 9 Code of Federal Regulations. After the establishment restored 

sanitary conditions on the affected equipment, I released the units to production at 

0146 hours. 

5308 M6137 BXL4605045 

118N-1 

04/18/2013 03J02 Slaughter HACCP C On 04/18/2013, while monitoring Post-Chill Finished Product Standards Task, I 

found noncompliance with the following regulatory requirements of regulations 

9CFR 381.65 (e) and 9CFR 417.2 (c)(4). At approximately 0140 hours, I randomly 

selected a 10 bird sample from the exit of the Chiller #2 in Plant #1, I found one out 

of the ten birds with visible fecal contamination inside the bird under the leaf fat 

area, close to the tail. The fecal material was a smear measuring approximately 1/4" 

diameter in size, green in color and watery in texture. This exceed the limit of Zero 

Tolerance for the process to be in control. I informed 

a of the noncompliance. 

They immediately started tanking the birds coming out of the Chiller #2. Two tanks 

were placed under QC red hold tags pending for rework. At approximately 0151 

hours Quality Control did a recheck and it passed. The cause of the deviation was 

the Inside/Outside Bird Washer. This is a violation of the critical limits of CCP-2B

 of the Plant's HACCP Plan for Slaughter. 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4905043 

218N-1 

04/18/2013 04A06 Poultry Finished 

Product Standards 

C On 04/16/2013 at approximately 2300 hours while monitoring the Plant #2 

slaughter functions at startup, I observed the following. Due to disease and 

contamination the establishment had the line speed on line reduced to 56 bpm 

(birds per minute) and line was at bpm. The establishment has an automated 

paw condemnation system that drops the paws automatically when a carcass is 

condemned at any station. The system does not work properly if the line speed is 

below bpm and the paws are supposed to be automatically condemned. I went 

to the paw collection room to verify the process and found that paws were on the 

collection belt and in an edible product bin. The paws were being collected and not 

automatically condemned as was USDA understanding of the systems function. I 

contacted to verify that the process had not 

changed and that the paws were supposed to be condemned per policy. I proceeded 

to the paw room and monitored paws that were collected as edible being placed 

into a U.S.D. A. Condemned barrel. The paws being collected were directed to a 

condemn barrel until the line speed was increased. This ia a loss of process control. 

My findings indicated a noncompliance with 9 CFR 381.65(a) and 9 CFR 381.78(a). 

5309 P6137A NJN080804 

1116N-1 

04/16/2013 01D01 SPS Verification C While walking through the Food Service department I noticed a blue plastic liner 

affixed to the glue box of the box sealing machine. I investigated the purpose of this 

blue plastic liner and found that it was to prevent water, from a leak in the ceiling, 

from falling onto the finished boxed product conveyor belt. Observing the boxed 

product flow I determined that this corrective action implemented by the 

establishment failed to prevent the creation of an insanitary condition and did not 

protect the boxed product. I observed that water was dripping onto one box and 

the conveyor, I then took an immediate regulatory control action and retained the 

conveyor with the application of U.S. retain tag B43303552 at approximately 0236 

hours. I informed 

of the noncompliance. After sanitary conditions were restored the boxed 

product conveyor was released at approximately 2328 hours 4/16/13. 

5308 M6137 BXL1009041 

911N-1 

04/11/2013 06D02 Other Inspection 

Requirements 

C On 04/11/2013 while monitoring line functions at the start of the shift at 

approximately 2300 hours there appeared to be an excessive number of viscera 

missing from line #2. I waited for mechanics to make startup adjustments to the 

machines on line #2. At approximately 2322 hours, I performed a standard three 

minute no viscera check at bpm (birds per minute) on line #2 and found 18 no 

viscera. At bpm 13 no viscera are allowed. I informed of the 

failure. At 2355 hours QC personnel performed a recheck of line #2 and got 25 no 

viscera. The line was slowed to 126 bpm. At 0202 hours a QC recheck failed at 126 

bpm with 26 no viscera. At 126 bpm 11 no viscera are allowed. Subsequent checks 

at 126 bpm failed and the line was kept at 126 bpm for the rest of the shift. This is 

a loss of process control and failure to take proper corrective action. My findings 

indicated a noncompliance with 9 CFR 381.76(a) & (b). 

(b) (6)
(b) (6)

(b) (6)(b) (6)

(b) (6)

(b) (6) (b) (6) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN281004 

2511N-1 

04/11/2013 01C02 Operational SSOP 

Review and 

Observation 

C I was in the evisceration department at 0758 hours when I noticed an employee 

dumping a fiber (cardboard) bin of ice into the paw chiller. The wood pallet that the 

bin was on was not shrink wrapped with plastic. I looked in side the paw chiller and 

noticed a piece of foreign material imbedded in the ice. 

etrieved the material which was a wood sliver 

approximately one and a half inches in length. I informed , 

who then applied a hold tag on the paw chiller. I informed Mr. of the 

issuance of the non compliance report. The establishment chose to implement 

corrective actions including emptying the paw chiller to wash and sanitize the inside 

product contact surfaces. The paws that were in the chiller where put on hold by 

the establishment, waiting further disposition. There was a similar non compliance 

issued on 02/05/2013, NR #NJN4816025405N/1 for the same occurrence. The 

establishment's stated further planned actions for this non compliance: "In order to 

prevent this situation from reoccurring, plastic bins will be used to ice into the paw 

chiller. In the event that a fiber bin needs to be used, the pallet will be shrink 

wrapped prior to placing it on the bin dumper. Training was completed with 

Evisceration management on both night and day shift." These stated corrective 

actions to prevent a reoccurrence where not implemented. 

5308 M6137 BXL0705045 

910N-1 

04/10/2013 03J02 Slaughter HACCP C On 04/10/2013 at approximately 0229 hours while monitoring the establishments' 

Operational Sanitation procedures in Packaging, I observed the following. I was 

checking the birds for UFM (Unidentified Foreign Material) on Line at a point just 

before the giblets are added back into the carcass before bagging. The third bird 

that I checked had visible fecal contamination. There was a cloacae and 

approximately 3 inches of intestine inside the carcass. The intestine was attached at 

a point approximately 3 inches inside the carcass by a piece of connective tissue 

near the kidney area. The fecal contamination was dark greenish brown in color, 

measured approximately 1/2" by 1/8" and was located inside the carcass on the left 

fat flap. A second piece of fecal material was also located inside the carcass on the 

left lung which was still intact. The second piece of fecal contamination measured 

approximately 1/4" by 1/4" and was the same dark greenish brown color. There is 

no procedure for a fecal failure in Packaging so 

was called and I showed him the carcass. A review of the 

establishments' records showed that the plant #1 venter checks for lines 1 & 2 were 

found to be acceptable for the first half of the shift. However, at 

0113 hours found (2) cloaca from the 10 birds sampled during the Finished Product 

Standards check from line #2. At 0029 hours also found (2) cloaca of 

the 10 birds sampled and at 107 hours (1) cloaca was found of the 10 birds 

sampled during the Finished Products Standards checks from line #1. My findings 

indicated a noncompliance with 9 CFR 381.65(e), 9 CFR 417.2(c)(4) and the critical; 

limit of CCP-2B of the Plants' HACCP Plan for 

Slaughter. 

(b) (6)
(b) (6) (b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4)

(b) (6)

(b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN151604 

4909N-1 

04/09/2013 04A06 Poultry Finished 

Product Standards 

O I noted the following non compliance during a finished product standards 

verification check of the establishment's off-line reprocessing process. At 1335 

hours I randomly selected ten carcasses from the off line after the final wash 

cabinet. Two of the ten had visible ingesta material inside the body cavity of the 

carcass. I stopped the off line and showed these findings to 

and informed . The line was restarted, I then 

performed the required recheck at 1345 hours. Of the ten carcasses examined for 

the recheck two carcasses had visible ingesta on the outside of the bird at the crop 

area. The line was immediately stopped. was once again shown these 

findings, was informed as was . 

The establishment initiated their written corrective procedures for an off line 

contamination failure. These procedures included a recheck, marking the chiller 

with a red net and initiating post chill checks on the affected lot.

 was informed of the documentation of the non compliance 

of the regulation cited above as was . 

5308 M6137 BXL4209040 

408N-1 

04/08/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 04/08/2013 at approximately 0650 hours while monitoring the establishments 

Pre-Operational Sanitation procedures in Plant 2, I observed the following. In Area 

1, Unit 29, Line in the Bleeding room I observed the Picker Brushes had an 

accumulation of numerous feathers on both sides of the unit, and on the motor. I 

immediately informed of the noncompliance. Sanitation 

rewashed the brushes and motor restoring sanitary conditions. I continued with the 

Pre-Operational Sanitation procedure and I observed the following at Area 2, Unit 

11, the 1/2 of Picker 1, Line , closest to the scalder of Line There were several 

feathers inside the picker, underneath the black rubber fingers. I informed 

, and Sanitation rewashed the Picker, restoring sanitary 

conditions. My findings indicate a noncompliance with 9CFR 416.13(c), 9CFR 

416.14, 9CFR 416.1 and 9CFR 416.4(a). 

(b) (6)
(b) (6)

(b) (6)

(b) (6)

(b) (4)

(b) (4)

(b) (4)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN281404 

2608N-1 

04/08/2013 04A06 Poultry Finished 

Product Standards 

C On 04/05/2013 and at approximately 1410 hours while performing a Poultry 

Finished Product Standards verification task I observed the following 

noncompliance: five carcasses out of my ten carcasses sample that randomly 

selected, and after Inside Outside washing and before the carcasses entering the 

chiller, were marked with a split tail for air sac vacuum, two of these carcasses had 

full kidney and three of them had parts of the kidney not vacuumed. I immediately 

applied U.S. Retained tag NO B38495185 on the affected carcasses. 

, was informed of my finding and forthcoming non 

compliance. Mr. immediately stopped the reprocessing line and tanked off 

the affected carcasses. At 1418 hours I performed recheck on the reprocessing line, 

the recheck passed and the line was released. The affected carcasses released to the 

company for rework and found acceptable by QC technician. The requirements of 9 

CFR 381.84, 9 CFR 381.76 and the Plant’s written procedure were not 

met 9 CFR 381.84 which states: "

 9 CFR 381.76 

which states “........Lesion/ condition subject to removal following an approved 

cleanout process. Examples: airsaculitis, salpingitis, nephritis, spleen or liver 

conditions requiring removal of the kidneys” Plant’s written procedure 

document number IX.m dated 8/15/2012. The purpose : 

5309 P6137A NJN250804 

1808N-1 

04/07/2013 01C02 Operational SSOP 

Review and 

Observation 

C When I was standing observing the employees performing the midshift clean up at 

the north side wall of the Packaging Department by the dumper (unit #28) for the 

dark meat deboning line, I noticed a cart that contained yellow styrofoam trays, 

which are product contact surface, that are used to pack finished edible product. 

The trays were covered with a blue liner to protect them from being over sprayed 

while the midshfit clean up is performed. Upon a closer inspection, I noticed that 

the liner was not covering the stacks of trays completely allowing pieces of fat and 

water from the floor to be over sprayed onto the trays. At approximately 0528 

hours I tag the affected trays with retain tag # B43303532. The establishment’s 

SSOP program, Section 2, Packaging & Food Service, states, 

Because product contact surface was contaminated, the establishment 

failed to meet the regulatory requirements of sections 416.13(c) and 416.4(a) of the 

9 Code of Federal Regulations. 

were 

informed of the deficiency and the forthcoming documentation of the 

noncompliance cited in this document. To restore sanitary conditions the 

establishment condemned the affected trays at 0533 hours. 

(b) (6)
(b) (6)

(b) (6) (b) (6)

(b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN120204 

1705N-1 

04/05/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C While conducting the Review and Observation component of the Pre-Operational 

task I noted the following noncompliance. At approximately 2305 hours I inspected 

the offline bird unloader (Unit #12). The offline bird unloader is located above the 

south/east portion of the carcass chiller. The product contact surface guide bars 

that push the product off the shackle and into the carcass chiller was covered in fat 

pieces and feathers from the previous day's production. Also the large coupling that 

holds the guide bars in place had a black grime like foreign material built up on it. I 

showed my findings to and informed him of the 

noncompliance. With sanitary conditions restored I released the area at 

approximately 2320 hours. I then went to the Q.C. office and informed 

of the noncompliance and requested to see the Pre-Op records for the 

Evisceration department. Unit #12, Offline bird unloader, was inspected and found 

acceptable by a Q.C. technician at 2228 hours. 

5309 P6137A NJN410604 

1105N-1 

04/05/2013 04A06 Poultry Finished 

Product Standards 

C At approximately 0410 hours in the Evisceration department I performed the PHIS 

Finished Product Standards task at the salvage parts inspection station. The tub of 

parts I inspected was labeled "drums, B-line, 0315 hours." I checked five random 

pieces, two pieces had small amounts of yellow and green ingesta. The last drum 

stick had a large yellow piece of cellulitis exudate between the skin and muscle 

tissue, approximately 3/4 inch in length and 1/2 inch in width. I retained the tub of 

drums with U.S. retain tag B43303547 and informed 

of the noncompliance for the 

establishment failure to meet 9CFR 381.86. At approximately 0600 hours I 

reinspected the retained tub of drums and found it acceptable and released it back 

to . 

(b) (6)
(b) (4)

(b) (4)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN171204 

3404N-1 

04/04/2013 03J02 Slaughter HACCP C During the Food Safety Assessment (FSA), at the “Live Receiving” step in the 

“Evisceration” hazard analysis, the establishment identifies “pathogens,” with 

Salmonella provided as an example, as a biological hazard reasonably likely to 

occur. The justification provided states:

 The establishment has 

The establishment indicated that they 

apply a . However, the establishment indicated 

during the food safety assessment (FSA) that 

.” Therefore, the 

establishment has no antimicrobial intervention in place for the salvaged parts to 

support the statement at the “Live Receiving” step in the “Evisceration” hazard 

analysis that “pathogens” will be addressed with “subsequent anti-microbial 

interventions and processing steps.” This is a noncompliance with Title 9 CFR 

417.5(a)(1). In addition, whenever a hazard analysis reveals one or more food safety 

hazards that are reasonably likely to occur, every establishment shall develop and 

implement a written HACCP plan with critical control points that will eliminate or 

reduce the food safety hazard to acceptable levels in accordance with Title 9 CFR 

417.2(b)(1). The establishment has not identified a point in the process that will 

eliminate or reduce “pathogens” in salvaged parts to control the hazard identified 

at the “Live Receiving” step. This is a noncompliance with 417.2(b)(1). 

(b) (6)
(b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4)

(b) (4)

(b) (4)(b) (4)

(b) (4) (b) (4)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN171204 

3404N-2 

04/04/2013 03J02 Slaughter HACCP C During the Food Safety Assessment (FSA),the EIAO found that the establishment is 

unable to demonstrate that their HACCP program 

reflects all current practices and identifies procedures for 

. Specifically, on February 28 and March 6, 2013, the EIAO observed the 

designated HACCP monitoring employee examine and document the 

concentration and verification reading ) from the read 

out display on the computer system. The establishment’s HACCP program 

does not identify that a verification reading of the will be observed and 

documented during a monitoring procedure. Additionally, the establishment’s 

HACCP program does not contain written procedures for their automatic 

. Ms. clarified during the food safety assessment that 

the establishment does not have written procedures on file for their 

. Ms. did provided a document from their 

manufacturer, 

which describes the methodology of the system and 

how the operates. This document was not observed to 

be referenced anywhere in the establishment’s Poultry Slaughter HACCP program. 

The establishment is required to list all monitoring and verification procedures and 

frequencies which will be used in accordance with Title 9 CFR 417.4 and support 

compliance with the critical limits. This is a regulatory noncompliance with Title 9 

CFR 417.2(c)(4) and 417.2(c)(7). 

(b) (6)
(b) (4)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN171204 

3404N-3 

04/04/2013 03J02 Slaughter HACCP C During the Food safety Assessment (FSA), the EIAO observed that the establishment 

is referencing the implementation of their Salmonella Initiative Program (SIP) 

waiver to support the decisions in the Slaughter hazard analysis that Salmonella is 

not reasonably likely to occur. 

The establishment is unable to demonstrate how 

random sampling will be achieved to cover all lines and all shifts as is necessary to 

meet the requirements of their Salmonella Initiative Program. During the FSA, the 

EIAO observed that the carcasses exit the chiller and then plant employees sort and 

rehang carcasses on the Sizing line or one of the two Segment lines which each run 

through separate cabinets and then a potable water rinse is applied. The 

EIAO observed that the establishment collects “post chill” carcass samples only 

from the Sizing line. The EIAO observed that carcasses from the sizing line appeared 

different than carcasses from the segment lines in that they did not display torn 

skin or other damage to the carcass. Furthermore, the establishment is utilizing the 

“post chill” results obtained only from carcasses on the Sizing line to support 

decisions made in their “Evisceration” and “Offline Reprocessing” hazard analyses 

that biological hazards are being reduced or controlled in their poultry slaughter 

process. The establishment is unable to demonstrate that sampling only one of the 

three carcass rehang lines, which does not include the potentially higher risk 

damaged carcasses, is adequate to address biological hazards of concern. The 

establishment is required to maintain documentation to support decisions made in 

their hazard analysis. This is a regulatory noncompliance under Title 9 CFR 

417.5(a)(1). 

(b) (6)
(b) (4)

(b) (4)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN171204 

3404N-4 

04/04/2013 03J02 Slaughter HACCP C During the Food Safety Assessment (FSA) the EIAO observed at the 

The justification provided states: 

The EIAO observed 

in reviewing the establishment’s SIP Waiver dated February 7, 2012, that there is 

no waiver to support the justification that on-going Salmonella verification results 

will validate that regulatory requirements under Title 9 CFR 416.2(g)(3) have been 

met. To comply with Title 9 CFR 416.2(g)(3), an establishment must consider the 

effects of reusing the water in the hazard analysis and support all decisions made 

regarding this reuse. FSIS expects that an establishment would take measures 

necessary to ensure that their products are not contaminated. Failure to consider 

the effects of reusing water within the chill system raises concerns about the 

adequacy of the hazard analysis. The establishment is unable to support decisions 

made in their hazard analysis at the “Red Water” steps. This is a regulatory 

noncompliance under Title 9 CFR 417.5(a)(1). 

5309 P6137A NJN351204 

0604N-1 

04/04/2013 03B02 Raw Non-Intact 

HACCP 

C In reviewing the establishment’s Raw Ground Chicken hazard analysis during the 

Food Safety Assessment (FSA), Enforcement Investigations and Analysis Officer 

(EIAO) found that the hazard analysis identifies “Pathogen Growth (Ex. Salmonella)” 

as a biological hazard not reasonably likely to occur at the “From Raw Not Ground 

Fillet Process Flow Chart” step, the “Intra Company Transfers” step, and the 

“Shipping” step. However, the establishment does not identify any potential 

biological hazards in the hazard analysis at steps where ground product is being 

produced (after receiving raw intact product to be ground from the Fillet process 

and prior to shipping the ground product) in the hazard analysis. It is unclear how 

the hazard “Pathogen Growth” identified at a previous step is not identified as a 

potential hazard at subsequent process steps such as “Grinding.” The establishment 

is not able to support that there are no potential biological hazards in the Raw 

Ground Chicken hazard analysis during the production of ground product. This is a 

noncompliance with Title 9 CFR 417.2(a)(1) and 417.5(a)(1). 

5309 P6137A NJN431204 

5304N-1 

04/04/2013 03C02 Raw Intact HACCP C During the Food Safety Assessment (FSA), in reviewing the establishment’s Raw Not 

Ground hazard analysis for the Individually Frozen (IF) Chicken products, 

Enforcement Investigations and Analysis Officer (EIAO) found that hazard analysis 

identifies “overexposure to ” as a chemical hazard. However, the hazard 

analysis does not specify whether it is reasonably likely to occur or not. Every 

official establishment shall conduct a hazard analysis to determine the food safety 

hazards reasonably likely to occur in the production process. This is a 

noncompliance with Title 9 CFR 417.2(a)(1). 

(b) (6)
(b) (4)

(b) (4)

(b) (4) (b) (4) (b) (4) (b) (4)

(b) (4)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (4)

(b) (4)

(b) (4) (b) (4) (b) (4)

(b) (4)

(b) (4) (b) (4)

(b) (4)

(b) (4) (b) (4) (b) (4) (b) (4)

(b) (4)

(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN431204 

5304N-2 

04/04/2013 03C02 Raw Intact HACCP C In reviewing the establishment’s Raw Not Ground hazard analysis and flow charts 

during the FSA, EIAO found that the establishment identifies “allergens” as a 

chemical hazard not reasonably likely to occur at certain process steps. However, 

the establishment does not identify “allergens” as a potential chemical hazard at all 

steps in the hazard analysis where allergenic ingredients are handled or stored. The 

establishment is not able to support that allergens are not a potential chemical 

hazard at multiple process steps. For example, the hazard 

analysis does not identify allergens as a potential chemical hazard at the “ 

” step, the “ ” step, and the “ ” step where allergens can be 

handled. Similarly, the analysis only identifies allergens as a 

chemical hazard at the “ ” step and the “ 

” step; the hazard analysis does not identify allergens as a potential chemical 

hazard at the “ ” step, “ ” step, “ ” 

step, the “ ” step, the other “ step, the “ 

” step, and the machine/ ” step where 

allergens can be handled. Additionally, the New Products Room – Line 

hazard analysis only identifies allergens as a chemical hazard at the “ 

” step; the hazard analysis does not identify allergens as a potential 

chemical hazard at the “ ” step, “ 

” step, “ ” step, and the “Reprocessing” step where 

allergens can be handled or stored. Furthermore, the New Products Room – IF 

Chicken hazard analysis only identifies allergens as a chemical hazard at the 

“ ” step, the “ ” step, and 

the “ ” step; the hazard analysis does not identify allergens as a potential 

chemical hazard at the “ ” step, the 

” step, the “ ” step, and the “ ” step 

where allergens can be handled or stored. The establishment is unable to support 

that allergens are not a potential chemical hazard of concern in the hazard analysis 

at all steps where allergens are handled and stored and where there is potential for 

allergen cross-contamination. This is a noncompliance with Title 9 CFR 417.2(a)(1) 

and 417.5(a)(1). 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4)

(b) (4)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN431204 

5304N-3 

04/04/2013 03C02 Raw Intact HACCP C During the Food Safety Assessment, in reviewing the establishment’s Raw Not 

Ground – New Products Room – flow chart EIAO found that there is an 

” step that does not come from any other step and that 

leads to the ” step, which leads to the “ ” 

step. EIAO discussed this finding with , who 

clarified that allergens from storage come from the “ ” step. 

EIAO found that this product flow described by Ms. is not represented in the 

flow chart. The flow chart also indicates that allergen ingredients or 

allergen-containing products can go through the injector. However, EIAO observed 

during the FSA that allergen ingredients are typically applied on product after the 

injection process. In addition, in reviewing the Raw Not Ground – Individually 

Frozen (IF) Chicken flow chart, EIAO found that the process flow indicates that 

allergens are used in the IF process. For example, at the “ 

” step indicates that allergen ingredients are handled at the . 

However, EIAO did not observe any allergens being handled at the , and

 clarified that there are no allergens handled 

at the . She also clarified that allergens are not handled anywhere in the 

IF area except for the tumbler. She indicated that allergens can be used in the 

tumbler only if the Marination line’s tumbler breaks down. However, the IF Chicken 

flow chart does not reflect this process. The flow chart shows that the product flow 

goes from the “ ” step through to the end of 

the line, indicating that allergens are being tracked throughout the IF line. However, 

EIAO observed during the FSA that there are no allergens utilized and handled on 

the IF line. clarified that no allergens are 

handled anywhere on the IF line. The flow charts for the New Products Room – IF 

Chicken line and for the New Products Room – line do not accurately 

reflect the establishment’s product flow. This is a noncompliance with Title 9 CFR 

417.2(a)(2). 

(b) (6)
(b) (6)

(b) (6)

(b) (4)

(b) (4)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN431204 

5304N-4 

04/04/2013 03C02 Raw Intact HACCP C In reviewing the Raw Not Ground hazard analysis during the Food Safety 

Assessment (FSA), EIAO found that the hazard analysis reference the 

HACCP Verification & Validation for 

Foster Farms Cherry Plant (Est. 6137A), Fresno, CA, dated 12/01/2005, to support 

the decision that “Pathogen Growth (Ex. Salmonella)” is a biological hazard not 

reasonably likely to occur at multiple process steps, including the “ ” 

steps. clarified that the establishment is 

currently utilizing the “ ” section of the study to support 

decisions in the Raw Not Ground hazard analysis. This “ ” 

section of the study references a “Reprocessing Station treatment” was applied. 

However, the study does not specify what the “treatment” was, what the 

parameters of the treatment were, and how the treatment was used or applied at 

the reprocessing station/salvage stations during the study. Therefore, it is unclear 

how the results of this study are utilized to support the establishment’s process 

and decisions in the hazard analysis. In addition, it is unclear which “Reprocessing 

Stations” in the establishment that the study is referring to; the study utilizes the 

terms “salvage stations” and “reprocessing stations” interchangeably, making it 

unclear whether the “reprocessing stations” in the study are for the establishment’s 

Raw Not Ground process or Slaughter process. This specific information is 

important in order for the establishment to demonstrate that they are able to 

achieve the same effect (in bacterial reductions) at the establishment’s 

“ ” as the study. During the FSA, Ms. 

indicated that the establishment does not 

consider . 

The establishment is not able to support the decision in their Raw Not Ground 

hazard analysis that “Pathogen Growth (Ex. Salmonella)” is not reasonably likely to 

occur at multiple process steps, including the “ ” steps, using the 

study on file. This is a noncompliance with Title 9 CFR 417.5(a)(1). 

(b) (6)
(b) (6) (b) (4)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (4)(b) (4)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN431204 

5304N-5 

04/04/2013 03C02 Raw Intact HACCP C In reviewing the establishment’s Raw Not Ground operations during the Food 

Safety Assessment, the EIAO found that the establishment is maintaining and 

implementing a Daily Temperature Summary Standard Operating Procedure 

(SOP)whose purpose is 

” as stated in the SOP. The 

establishment stores raw poultry products in these coolers and freezers. In 

reviewing the establishment’s Raw Not Ground hazard analysis, the EIAO found that 

the establishment does not identify any potential biological hazards at process 

steps where the raw products are stored. While the establishment is currently 

monitoring storage temperatures under the Daily Temperature Summary SOP, it is 

not referenced in the hazard analysis and the establishment is not able to support 

that there are no potential biological hazards in the hazard analysis at process steps 

where the establishment stores raw meat. This is a noncompliance with Title 9 CFR 

417.2(a)(1) and 417.5(a)(1). 

5309 P6137A NJN431204 

5304N-6 

04/04/2013 03C02 Raw Intact HACCP C In reviewing the establishments Raw Not Ground – New Products 

Room – Individually Frozen (IF) Chicken hazard analysis during the Food Safety 

Assessment, the EIAO found that the establishment identifies no potential hazards 

at the Injector step and the step in the hazard analysis. However, on 

03/11/2013, EIAO discussed these process steps with 

When they reviewed the 

Raw Not Ground process, the establishment determined that the injected products 

might be a higher risk product. Therefore, the establishment implemented the

 and dip application systems on the IF-2 line. EIAO 

reviewed the establishment’s 

. EIAO also reviewed the 

establishment’s 

Based on the Salmonella prevalence prior to the treatment, the 

establishment is not able to support the decision in the hazard analysis that there 

are no potential biological hazards at the Injector step and at the step. This 

is a noncompliance with Title 9 CFR 417.2(a)(1) and 417.5(a)(1). In addition, since 

the parts that enter the IF Chicken line come from other Raw Not Ground 

departments in the establishment’s facility as indicated in their flow chart, the 

establishment is not able to support the decisions that Salmonella is not reasonably 

likely to occur throughout the establishment’s Raw Not Ground process. This is a 

noncompliance with Title 9 CFR 417.5(a)(1). 

(b) (6)
(b) (6)

(b) (6)

(b) (7)(C) (b) (7)(C) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1118043 

602N-1 

04/02/2013 06D02 Other Inspection 

Requirements 

C On 04/02/2013 at approximately 1545 hours while monitoring the "No Viscera 

Log" for Line #1 in Plant #1, I observed a noncompliance with the following 

regulatory requirements of regulations 9CFR 381.76 (a) and 9CFR 381.76 (b). At 

1238 hours with line speed of BPM, Quality Control failed with 19 no viscera, 

13 no viscera are allowed. At 1301 at line speed BPM, the recheck failed with 

28 no viscera, the line speed was slowed to 126 BPM. At 1457 hours with line 

speed of 126 BPM, Quality Control failed with 18 no viscera and 11 no viscera are 

allowed. Three failures in a half-shift period is a noncompliance for lack of process 

control. I informed of the noncompliance. 

5309 P6137A NJN490304 

4502N-1 

04/02/2013 01D01 SPS Verification C At approximately 2320 hours I, CSI , and CSI observed 

an insanitary condition while we were walking from the Food Service department to 

the IQF department. In the hallway that connects the two departments the 

ventilation fan for the Food Service department was covered in gray debris, the 

debris had a constancy of a lent like material. The cover of this fan was also covered 

with the same material and an accumulation of feathers. This exhaust fan is located 

adjacent to the open entrance to the IQF department. The overhead light for this 

area also had black mold covering the length of the light cover, and was the width 

of approximately one inch. Under this overhead light was a pile of product from the 

previous days production, wet paper towels, and pieces of wood from a broken 

pallet. The drains in the hallway had old discarded labels and paper towels clogging 

the drains. In front of the entrance to the staging cooler there was a half chicken 

carcass, the back and rib cage, covered in black residue that forms from the traffic 

of palletjacks on the floor of the hallway. I informed 

of the noncompliance. 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (6) (b) (6) (b) (6)

(b) (7)(C)

(b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN190504 

1901N-1 

03/31/2013 01D01 SPS Verification C At approximately 2318 hours five minutes after start up, Food Inspector, 

called me to her inspection station to inform me that the shackles from A 

and B line had grease. I informed 

, of the grease on the shackles. Upon closer 

observation, I noticed that 100% of the shackles had beaded black water and solid 

black residue spots on the frame of the shackles. All the shackles were 

contaminated in the same area starting at approximately 6 inches away from the 

hocks of the carcasses and going up close to the rail. The establishment stopped 

hanging carcasses until sanitary conditions were restored. Although product was 

not cross-contaminated and no findings of grease or UFM (unidentified foreign 

material) during the FPS checks performed by quality control and I, the presence of 

dirty water and foreign material residue on the shackles created an insanitary 

condition were product potentially could have gotten adulterated. At approximately 

0100 hours sanitary conditions were restored. The finding of foreign material 

(grease) on the shackles represents a noncompliance with sections 416.1 and 416.4 

(a) of the Code of Federal Regulations. , was 

informed of the forthcoming documentation for the failure to comply with the 

regulatory requirements cited above. 

5309 P6137A NJN572304 

3201N-1 

03/31/2013 01D01 SPS Verification C While in the Evisceration Department at approximately 0024 hours I observed an 

insect on the side panel of the offline final wash cabinet. The insect was a large 

mosquitohawk. The for the offline area killed the insect and we showed 

it to . I than began to inspect the rest of the 

department to determine if there were anymore insects present. On the wall next 

to the Inspection station for salvage parts I found a small gray moth and also 

showed my findings to . Then while continuing my inspection I 

observed feathers and dried blood spots from the previous days production on the 

wall near the salvage cone station behind USDA station #3 for "A" line. At 

approximately 0032 hours I informed of the noncompliance for 

the deficiency stated in this document. was also notified. 

(b) (6)
(b) (6)

(b) (6)

(b) (6)

(b) (6) (b) (6) (b) (7)(C) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN520503 

1929N-1 

03/29/2013 01D01 SPS Verification C While in the Packaging Department at approximately 0250 hours I observed the 

following noncompliance: An establishment employee moved one large gray combo 

bin of product, salvaged poultry backs, for mechcanically separated poultry away 

from the product conveyor. Then the employee replaced it with another large gray 

combo bin with a blue plastic liner that was torn from the top of the bin to the 

bottom of the bin exposing the inside of the combo bin. Product from the conveyor 

began to flow as normal into the combo bin and I tagged the bin with U.S. retain tag 

B43303534. CSI went an found establishment 

, as I observed the product flow. stopped the product conveyor 

and elected to condemn all of the product in the bin. I then informed 

of the noncompliance. 

The establishment does not consider the inside of these combo bin a sanitary 

product contact surface. The establishment uses the blue plastic liners as a product 

contact surface in these combo bins to maintain sanitary conditions. The ripped 

blue plastic liner represents a noncompliance with the following regulations: 9 CFR 

416.1 which states: "Each offical establishment must be operated and maintained 

in a manner sufficient to prevent the creation of insanitary conditions and to ensure 

that product is not adulterated." CFR 416.3(a) States: "Equipment and utensils used 

for processing or otherwise handling edible products or ingredients must be of such 

material and construction to facilitate thorough cleaning and to ensure that their 

use will not cause the adulteration of product during processing, handling, or 

storage. Equipment and utensils must be maintained in sanitary condition so as not 

adulterate product." CFR 416.4(d) states: "Product must be protected from 

adulteration during processing, handling, storage, loading, and unloading at and 

during transportation from official establishment." 

5308 M6137 BXL2514030 

728N-1 

03/28/2013 01D01 SPS Verification C At approximately 1100 hours while performing scheduled Sanitation Performance 

Standards task in Plant #2, I observed the following noncompliance. While I was 

walking past the sizing lines I observed heavy beaded condensation on one of the 

drip pans directly above one of the lines. Upon further investigation I observed 

heavy beaded condensation on all the drip pans in the area, I also observed the 

condensation actually dripping between the lines and around two tanks of 

uncovered product that were staged near the machine. There was no 

Supervisor in the area so I immediately had a company employee start cleaning the 

drip pans. I went and found and informed 

them of the noncompliance. came to the area and I showed 

him where there was still heavy beaded condensation, he had the employee 

continue cleaning the drip pans restoring sanitary conditions. My findings indicate a 

noncompliance with 9CFR 416.1, 9CFR 416.2(d) and 9CFR 416.4(b). 

(b) (6)
(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5308030 

028N-1 

03/28/2013 06D02 Other Inspection 

Requirements 

C On 03/28/2013 at approximately 0400 hours while performing an Other Inspection 

Requirements procedure in Plant #1, I observed the following. A review of the 

establishments Lines - No viscera Monitoring Log for the shift revealed that 

both lines had been slowed due to no viscera failures. Line #1 failed at 0153 hours 

at bpm (birds per minute) with 17 no viscera. At bpm 13 no viscera are 

allowed. A recheck at 0223 hours failed with 18 no viscera at which time the line 

was slowed to 126 bpm. The line failed at 126 bpm at 0336 hours with 17 no 

viscera. At 126 bpm 11 no viscera are allowed. The line stayed at 126 bpm for the 

rest on the shift due to repeated failures. Line #2 failed at 2325 hours at bpm 

with 19 no viscera. At 0003 hours the line again failed with 18 no viscera and the 

line was slowed to 126 bpm. At 0157 hours at 126 bpm the line failed with 15 no 

viscera. The only time that line #2 passed was at 0611 hours at 126 bpm, however a 

subsequent check at bpm failed and the line was returned 126 bpm at 0617 

hours. This is a noncompliance due to a loss of process control and a failure to take 

proper corrective action. My findings indicated a noncompliance with 9 CFR 

381.76(a) & (b). 

5308 M6137 BXL5608032 

828N-1 

03/28/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 03/27/2013 at approximately 2355 hours while monitoring the establishments' 

Pre-Operational Sanitation procedures in Packaging Area #1, I observed the 

following. There were several pieces of fat and tissue to approximately 3" on the 

brown product belt under leg processor #4. Most of the white rollers associated 

with the product belts for leg processors 1-6 were coated with white pasty fat. 

There was one white roller under leg processor #6 that does not turn resulting in 

the roller having approximately a 1/2" flat spot exposing the inside surfaces of the 

roller. The inside of the roller was completely filled with fat and tissue that gave off 

a strong putrid odor. As the roller does not turn this putrid material is in constant 

contact with the product contact surface of the belt during production. There was 

black UFM (Unidentified Foreign Material) that appeared to be mold on the 

stainless support brackets under leg processors 4-6. These stainless brackets are 

not considered a product contact surface and will be cleaned during the enhanced 

cleaning conducted on Saturday. Sanitary conditions were restored by 

approximately 0015 hours. The roller was removed and discarded. My findings 

indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.4(a) & (b) and 9 CFR 

416.14. 

(b) (6)
(b) (6)(b) (6)

(b) (6)

(b) (6)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN280303 

5728N-1 

03/27/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C When I was at the Packaging department performing the Review and Observation 

component of a Pre-operational Sanitation PHIS task I observed the following 

noncompliances: At Section C: Segment Line & Multivac, I observed specks and 

pieces of fat, from the previous day’s production, scattered on the product contact 

surfaces of the hoppers (Unit #26). The pieces of fat had an approximate 

measurement of 1mm to 5 mm in diameter. At approximately 0040 hours I took 

regulatory control of the unit with retain tag #B303503. At Section A: Marination 

line, I observed in the interior side of the lower part of the Incline Conveyor Out of 

Hopper (Unit #7) pieces of fat, with an approximate measurement of 5mm, from 

the previous day’s production and residue from spice ingredients, reddish in color, 

that are used to marinate the product that is processed in this units. I tagged the 

unit with retain tag #B303508. At section B: Dark Meat Deboning, I noticed that the 

Portable Incline Transfer Conveyor (Unit #5) had the same reddish residue of 

marinated mixture covering an area approximately 4 inches long and 1 inch wide on 

one of the conveyor’s belt hard white plastic guide bars, Upon a closer look I 

noticed the entire conveyor had specks of spice mixture along the two guide bars 

and in the inner side of the conveyor. I showed the deficiencies to 

. I tagged the unit with retain tag #B303508. At 0055 hours 

after the establishment restored sanitary conditions, the affected units were 

released to production. The finding of pieces of fat and spice mixture on product 

contact surfaces represents a failure to meet the regulatory requirements of 

sections 416.4(a) and 416.13(c) of the Code of Federal Regulations. Mr. 

, was informed of the forthcoming documentation for the 

failure to comply with the regulatory requirements cited above. 

5308 M6137 BXL1604032 

326N-1 

03/26/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C While performing Zero Tolerance Fecal Task, I observed a noncompliance with the 

following regulatory requirements of regulations 9CFR 381.65 (e) and 9CFR 417.2 

(c)(4). On 03/26/2013 at approximately 0123 hours, 

randomly removed a 10 bird sample from Line # in Plant #2, I found one out of 

the ten birds with visible fecal contamination inside the bird located at the left side 

below the kidneys. The fecal material was a spot measuring approximately 3/16" 

diameter in size, brownish green in color and pasty in texture. This exceed the limit 

of Zero Tolerance for the process to be in control. I informed 

of the noncompliance. The protocol for fecal 

failure was implemented. Quality Control could not performed a recheck due to 

completion of organic birds at approximately 0142 hours. The cause of the 

deviation was the bird washer. Quality Control doubled their procedures at 

the Post-Chill to ensure the product was in compliance. Post-Chill checks were 

performed from 0237 hours to 0322 hours. This is a violation of the critical limits of 

CCP-2B, of the Plant's HACCP Plan for Slaughter. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (6) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1916031 

626N-1 

03/26/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C At aproximately 1230 hours while performing a Zero Tolerance fecal check on line 2 

of plant 1, I found one out of the 10 birds contaminated with feces. The fecal 

material was located inside of the carcass, on the right side near the tail. It was 

greenish brown in color and pasty in texture measuring approximately 1/4" in 

diameter. This exceeded the limit of Zero Tolerance for the process to be in control. 

I immediately notified of the noncompliance. The 

protocol for Fecal Failure was implemented. A Quality Control recheck passed at 

1256 hours. Post chill checks were performed on the suspect lot from 1308 hours 

to 1431 hours. All product exiting chiller 2 was found acceptable. My findings 

indicate a noncompliance with 9 CFR 381.65(e) and 9CFR 417.2(c)(4), and the 

critical limit of CCP-2B, of he plant’s HACCP Plant for 

Slaughter. 

5308 M6137 BXL2303033 

026N-1 

03/26/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 03/25/2013 at approximately 2347 hours while monitoring the establishments' 

Pre-Operational Sanitation Procedures in Packaging Area #1, I observed the 

following. There was dried and semi-dried fat and tissue residue on the stainless 

portions of the overhead wing and breast fillet conveyor belts that transfer product 

from the Deboning Room to Packaging. The residue was up to approximately 

1/16" thick and to approximately 2" high on the stainless portion above the 

product belt. The length of the two breast belts with the residue measured 

approximately 50 feet. The two wing belts are approximately 80 feet long. The belts 

were cleaned with a green pad and potable water then treated with an 

antimicrobial and a potable water rinse restoring sanitary conditions by 

approximately 0025 hours. My findings indicated a noncompliance with 9 CFR 

416.1, 9 CFR 416.4(a), 9 CFR 416.13(c) and 9 CFR 416.14. 

5308 M6137 BXL4905034 

223N-1 

03/23/2013 06D02 Other Inspection 

Requirements 

C On 03/23/2013 while performing "No Viscera" checks in Plant #1, Line 1, I observed 

a noncompliance with the following regulatory requirements of regulations 9CFR 

381.76 (a) and 9CFR 381.76 (b). At 0203 hours, I documented 19 no viscera and 

only 13 are allowed at line speed of BPM. I informed 

of the failure. After lunch at 0330 hours I performed a recheck and failed with 16 no 

viscera and only 13 no viscera are allowed. I informed of the 

failure. The line speed was reduced to 126 BPM. At 0408 hours Quality Control 

performed a no viscera check and failed with 17 no viscera and only 11 no viscera 

are allowed at the line speed of 126 BPM. I informed 

of the noncompliance. 

(b) (6)
(b) (6) (b) (6)

(b) (6)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1418034 

622N-1 

03/22/2013 06D02 Other Inspection 

Requirements 

C At approximately 1539 hours while performing "No Viscera" Checks for Line #1 and 

Line #2 in Plant #1, I observed a noncompliance with the following regulatory 

requirements of regulations 9CFR 381.76 (a) and 9CFR 381.76 (b). Line #2 had five 

failures documented by Quality Control. 1.- At 0816 hours at line speed of 

BPM, 18 no viscera and only 13 no viscera are allowed. 2.- At 0846 hours at line 

speed of BPM, recheck failed with 19 no viscera. Line speed slowed down to 

126 BPM. 3.- At 1009 hours at line speed of 126 BPM, 16 no viscera and only 11 no 

viscera are allowed. 4.- At 1246 hours at line speed of 126 BPM, 20 no viscera, only 

11 no viscera are allowed. 5.- At 1503 hours at line speed of 126 BPM, 15 no 

viscera, only 11 no viscera are allowed. Three failures in a half -shift period is a 

noncompliance for lack of process control. I informed of 

the noncompliance. 

5308 M6137 BXL1709034 

622N-1 

03/22/2013 04A06 Poultry Finished 

Product Standards 

C On 03/22/2013 at approximately 0503 hours while conducting the weekly Finished 

Products Standards check on Reprocessing Line I observed the following. After 

taking a random 10 bird sample from a point on the line after the final house 

inspector, I observed two birds wit untrimmed Inflammatory Process (cellulitis) and 

one bird with a large gall stain on the inside of the carcass. At this point the process 

is judged to be out of control. All three birds were marked with a slash on the back 

which according to the establishments' marking system indicates that the bird 

needs trimming or salvaging. I informed of the failure. The 

line was running at a slow speed and less then half the shackles were full. The end 

of the line house inspector was changed which was the only corrective action taken. 

A QC recheck passed at 0511 hours. My findings indicated a noncompliance with 9 

CFR 381.76(b). 

5308 M6137 BXL4811035 

122N-1 

03/22/2013 03J02 Slaughter HACCP C At approximately 0800 hours while performing Pre-Chill Finished Products 

Standards Task in Plant #2, on Line I observed the following noncompliance. I 

randomly selected a 10 bird sample from Line and found one of the ten birds 

with visible fecal contamination. The fecal material was located on the back of the 

tail near the oil gland and measured approximately 1/4" x 1/16" in size, it was 

brownish green in color and pasty in texture. This exceeded the limit of Zero 

Tolerance for the process to be in control. I immediately informed

 of the noncompliance. The protocol for fecal failure 

was implemented. Quality Control did a recheck at 0826 hours and it passed. All 

Post Chill rechecks performed between 0919 hours and 1004 hours also passed. 

The cause of the deviation was the sprayers being out of adjustment. This is a 

deviation from the critical limits of CCP-2B 

of the Plant's HACCP Plan for slaughter. 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6)

(b) (6)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1116031 

120N-1 

03/20/2013 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 0918 hours I was walking to Chiller #1 in Plant #1 to performed a 

Post-Chill Finished Product Standards Task. I observed at the rehang area a stainless 

steal tank under the cabinet. The tank was staged there for dumping onto 

the rehang tables. The tank was uncovered and full of whole body birds. I saw one 

bird with numerous black specks (Unidentified Foreing Material), I inspected several 

more birds and found UFM material on them. I immediately tagged the tank # N-18 

with U.S. Rejected/Retained Tag # B31 407930 and Informed 

of my findings. called 

. took the tank to the 

Rehang area in Plant #2. Two employees began to reworked the product, I 

reinspected several birds that had been reworked and they were acceptable. Since 

Quality Control was monitoring the reworking of the product, I released the retain 

tank of product to Quality Control at approximately 0947 hours. I removed U.S. 

Retained/Rejected Tag and Quality Control placed a red hold tag to the tank. Quality 

Control reinspected and released the product back to production at approximately 

1030 hours. This is a noncompliance with the following regulatory requirements of 

regulations 9CFR 416.1 and 9CFR 416.4 (d). 

5308 M6137 BXL2317035 

320N-1 

03/20/2013 03J02 Slaughter HACCP C At approximately 1222 hours while performing Pre-Chill Finished Products 

Standards Task in Plant #2 on Line , I observed the following noncompliance. I 

randomly selected a 10 bird sample from Line # and found one of the ten birds 

with visible fecal contamination. The fecal material was located on the back of the 

tail near the oil gland and measured approximately 1/4" x 1/8" in size, it was 

brownish green in color and pasty in texture. This exceeded the limit of Zero 

Tolerance for the process to be in control. I immediately informed 

of the noncompliance. The protocol for fecal failure was 

implemented. Quality Control did a recheck at 1248 hours and it passed. The cause 

of the deviation was the bird turner not turning the birds properly and line was 

moved to Line # so that the bird turner could be replaced. All Post Chill rechecks 

performed between 1355 hours and 1425 hours passed. This is a violation of the 

critical limits of CCP-2B of the Plant's 

HACCP Plan for Slaughter. 

(b) (6)
(b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2808033 

620N-1 

03/20/2013 06D02 Other Inspection 

Requirements 

C On 03/20/13 at approximately 0450 hours while monitoring the “No Viscera Log” 

for Line #1 and Line #2 in Plant #1, I observed a noncompliance with the following 

regulatory requirements of regulations 9CFR 381.76 (a) and 9CFR 381.76 (b). On 

Line #1 at 2324 hours with line speed of BPM, Quality Control failed with 25 no 

viscera, 13 no viscera are allowed. At 2354 at line speed BPM, the recheck 

failed with 18 no viscera ,the line speed was slowed to 126 BPM. At 0138 hours 

with line speed of 126 BPM, 19 no viscera and 11 no viscera are allowed. On 

Line # 2 at 2320 hours with line speed of BPM, Quality Control failed with 35 

no viscera and 13 no viscera are allowed. At 2359 hours at line speed of BPM, 

the recheck failed with 23 no viscera and the line speed was slowed to 126 BPM. At 

0143 hours with line speed of 126 BPM, 21 no viscera and 11 no viscera are 

allowed. Three failures in a half-shift period is a noncompliance for lack of process 

control. I informed of the noncompliance. 

5308 M6137 BXL0608035 

619N-1 

03/19/2013 06D02 Other Inspection 

Requirements 

C At approximately 0550 hours while monitoring the "No Viscera Log" for Line #1 and 

Line #2 in Plant #1, I observed a noncompliance with the following regulatory 

requirements of regulations 9CFR 381.76 (a) and 9CFR 381.76 (b). Line # 1 had 

three failures documented by Quality Control. At 2330 hours at line speed of 

BPM, 19 no viscera and only 13 no viscera are allowed. At 0008 hours at line speed

 BPM, recheck failed with 24 no viscera. The line speed was slowed down to 126 

BPM and at 0140 hours Quality Control failed with 23 no viscera, 11 no viscera are 

allowed. On Line #2 at 2335 hours at line speed of BPM, 32 no viscera and only 

13 no viscera are allowed. At 0018 hours at line speed BPM, recheck failed with 

31 no viscera. The line speed was slowed to 126 BPM and at 0148 hours Quality 

Control failed with 25 no viscera and only 11 no viscera are allowed. Three failures 

in a half-shift period is a noncompliance for lack of process control. I informed

 of the noncompliance. 

(b) (6)
(b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5504031 

916N-1 

03/16/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 03/15/2013 at approximately 2330 hours while monitoring the establishments' 

Pre-Operational Sanitation procedures in the Plant #1 hanging area of Packaging, I 

observed the following. There were numerous black specks of UFM (Unidentified 

Foreign Material) in a puddle of water in the center of the drip pan approximately 

10 ' from the spray cabinet for line #1 & 2. There 

were also numerous pieces of dried and semi-dried fat and tissue to approximately 

1/16" along the entire length of the same drip pan that measure approximately 4' 

by 45'. There was also a heavy layer of dried and semi dried fat and tissue to 

approximately 1/8" along the drip pan associated with the spray cabinet for 

lines The drip pans are approximately 4' by 30 '. said 

that drip pans are cleaned during the enhanced cleaning that is performed on 

. He was informed that the drip trays were product contact surfaces as 

they drained back into the cabinets and needed to be cleaned before 

startup. The area was cleaned, sanitized and released by approximately 0008 hours. 

At approximately 2340 hours in the Plant #2 hanging area of Packaging there were 

several pieces of black UFM (Unidentified Foreign Material) with the consistency of 

rail dust on the drip pans and in the spray cabinet for lines #1 & 2. The drip 

pans are approximately 20" by 15' long. There was a layer of dried and semi-dried 

fat and tissue to approximately 1/8" on the drip pans for line 3 & 4. The drip pans 

are approximately 20" by 6'. There was a brown film on the interior sides and 

bottom surfaces of the spray cabinet for line . There was a 10" adjustable 

wrench in the bottom of the same spray cabinet that was severely rusted. The drip 

pans for the cabinet for Line was covered with a layer of brown film and 

numerous pieces of fat to 1/8". The drip pans are approximately 20" by 8'. The 

plant#2 unit was already filled and ready for use. The cleaning on the spray 

cabinets and drip pans drain into the unit so the tank was dumped and the unit was 

rinsed with . asked so I showed him that just the 

portions of the drip pans that drain back into the spray cabinets needed to 

be cleaned daily. My findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 

416.4(a), 9 CFR 416.13(c) and 9 CFR 416.14. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE160903 

1815N-1 

03/15/2013 03J02 Slaughter HACCP C . On 3/15/13 at approximately 0446 hours , I observed the following 

noncompliance while performing a finished Product Standard Task on the North 

Chiller ( Post Chill ) . After selecting a ten bird random sample I observed one out of 

ten with an attached cloaca with a 2" – 3" portion of intestine . The fecal material 

was approximately 1 cm by 1 cm in size , watery in texture and geeenish - brown in 

color flowing from the cloaca . I immediately notified who was 

standing nearby . contacted 

who initiated the establishment’s fecal failure protocol . The establishment's 

rechecks passed at approximately 0507 hours putting the establishment back in 

compliance . My findings indicate a noncompliance with regulations 9CFR 381.65(e) 

which states that "carcasses contaminated with visible fecal material shall be 

prevented from entering the chiller tank " and 9CFR 417.2(c)4 , The criteria for 

CCP-1B were also compromised . 

5308 M6137 BXL2009034 

714N-1 

03/14/2013 03J02 Slaughter HACCP C On 03/14/2013 at approximately 0610 hours while performing a Pre-Chill Finished 

Product Standards check on Line #1 in Plant #1, I observed the following. After 

taking a random 10 bird sample, I observed one bird with visible fecal 

contamination. There was a cloacae with approximately 5" of intestine inside the 

bird. The intestine was attached to the carcass at a point approximately 2" inside 

the carcass by a piece of connective tissue. The entire intestine was a dark gray 

color. There was fecal material visible at both the cloacae end and at the cut end of 

the intestine. The fecal material had leaked from the cut end of the intestine inside 

the carcass into a crease at the end of the fat flap near the kidneys on the left side. 

The fecal material was dark brown in color, pasty in texture and measured 

approximately 1/4" by 1/8" in size. This exceeded the zero tolerance for the process 

to be in control. I contacted and showed him my findings. The 

protocol for fecal failure was implemented. A QC recheck passed at 0633 hours. My 

findings indicated a noncompliance with 9 CFR 381.65(e), 9 CFR 417.2(c)(4) and the 

critical limit of CCP 2B of the Plants' HACCP 

Plan for Slaughter. 

(b) (6)
(b) (6)

(b) (6)

(b) (4) (b) (4)(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN271803 

3913N-1 

03/13/2013 01C02 Operational SSOP 

Review and 

Observation 

C At 1548 hrs. I observed the following non compliance in the food service area 

during bulk drumstick packing. The employee assigned to work the scale was 

handling the outside of the cardboard fiber boxes. When a box was under weight 

the employee proceed to handle product (drumsticks) to add to the box. He would 

then physically move the box down the line and continue to weigh the next box. The 

employee was not sanitizing his gloves after coming into contact with the outside 

of the box, a non food contact surface, before returning to handle product. At this 

time the employees in the area went on a break. I informed 

of the issuance of the non 

compliance report. I retained the pallet of cases that had already been packed, 27 

cases in total, with U.S. retain tag #B39415846. The establishment's corrective 

actions included placing a tub of sanitizer solution in close proximity to the scale 

operator and sending the affected cases of product to their rework procedure. After 

the product was reworked per the establishment's procedures I removed the retain 

tag at 1731 hrs. returning the product to control of the establishment. 

5308 M6137 BXL0418035 

108N-1 

03/08/2013 06D02 Other Inspection 

Requirements 

C At approximately 1500 hours while monitoring the "No Viscera Log" for Line #1 and 

Line #2 in Plant #1, I observed a noncompliance with the following regulatory 

requirements of regulations 9CFR 381.76 (a) and 9CFR 381.76 (b). Line #1 had three 

failures documented by Quality Control. 1.- At 0817 hours at line speed of 

BPM, 21 no viscera and only 13 no viscera are allowed. 2.- At 0843 hours at line 

speed of BPM, recheck failed with 28 no viscera. Line speed slowed down to 

126 BPM. At 1003 hours Quality Control did a regular check and passed at line 

speed of 126 BPM with 11 no viscera and 11 no viscera are allowed, line speed 

increased to BPM. 3.- At 1008 hours at line speed of BPM, 20 no viscera 

and only 11 no viscera are allowed the line slowed down to 126 BPM. Three failures 

in a half-shift period is a noncompliance for lack of process control. I informed

 of the noncompliance. 

(b) (6)
(b) (6)

(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1007031 

008N-1 

03/08/2013 03J02 Slaughter HACCP C On 03/08/2013 at approximately 0046 hours while monitoring the establishments' 

Operational Sanitation procedures in Packaging, I observed the following. I was 

checking the birds for UFM (Unidentified Foreign Material) on Line just prior to 

the point where the giblets are added to the carcass prior to bagging. The fourth 

bird that I checked had a cloacae attached inside the carcass at the tail with 

approximately 4" of intestine. There was fecal material on the right side leaf fat. The 

fecal material was dark brown in color, pasty in texture and measured 

approximately 1/2" by 1/4" in size. As there are no procedures for a packaging 

department fecal failure, I had th

 called. I showed them my findings. A review of 

the establishments' computer records for the shift shows that Line #1 venting 

machine failed QC checks for 'improper venting' at 2345 hours, 0036 hours, 0118 

hours and 0207 hours with a note 'Informed Production Supervisor'. My findings 

indicate a noncompliance with 9 CFR 381.65(e), 9 CFR 417.2(c)(4) and the critical 

limit of CCP 2B of the Plants' HACCP Plan for 

Slaughter. 

(b) (6)
(b) (6)

(b) (6) (b) (6)

(b) (6)

(b) (4)

(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN310503 

2508N-1 

03/08/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C I was conducting the Review and Observation component of Pre-Operational 

Sanitation in area #3 the Mechanically Separated Poultry department when I noted 

the following noncompliance. I inspected unit #11, the Pump (east), 

including all of the stainless parts associated with the pump. I found inside both of 

the stainless steel cork screw augers that the black rubber gaskets had a poultry 

paste like substance from the previous day’s production on them. I then retained 

the augers with U.S. retain tag B43303518 at 0023 hours and informed 

of the noncompliance. At approximately 0035 hours I 

reinspected the augers and verified that sanitary conditions were restored and 

released the area and equipment. In the Food Service Department I continued the 

Pre-Operational task and inspected area #4 unit #5 Injector and needles. I requested 

to see the inside of the injector and opened it. I 

observed inside the injector a white in color watery in texture fat residue covering 

the motor, hoses and inside surfaces of the injector. I also saw that the gray rubber 

seal of the injector door was in poor condition. It was covered with black mold and 

held together with glue at the seams that had come apart. 

r was notified of the noncompliance. I retained the injector 

with U.S. retain tag B43303517 at approximately 0040 hours. At approximately 

0115 hours I reinspected the injector, the establishment chose to remove the entire 

gray rubber seal to eliminate the presence of mold, and the Sanitation department 

in my presence resanitized the inside and outside of the injector. With sanitary 

conditions restored I released the injector at 0120 hours. After my inspection was 

complete I went to the Q.C. office to inform the lead of 

the noncompliance and too review the Q.C. documents of the nights 

Pre-Operational Inspection performed by Quality Control. Pre-Op was conducted in 

the Mechanically Separated Poultry Department unit #11 ( Pump A east) 

and was found acceptable by the Q.C. tech at 2346 hours. The establishment's SSOP 

program states in Part 1 Pre-operational Sanitation/Daily, Section 4 Further 

Processing " 

". This failure represents a 

noncompliance as per the regulatory requirements of sections 416.1, 416.4(b) and 

416.13 (c) of the Federal Code of Regulations. The presence of mold, fat residues 

and particles on non-food contact surfaces represents a noncompliance with 

Section 9 CFR 416.1 states, "Each official establishment must be operated and 

maintained in a manner sufficient to prevent the creation of insanitary conditions 

and to ensure that product is not adulterated." Section 9 CFR 416.4(b) states, 

“Non-food-contact surfaces of facilities, equipment, and utensils used in the 

operation of the establishment must be cleaned and sanitized as frequently as 

necessary to prevent the creation of insanitary conditions and the adulteration of 

product.” Section 9 CFR 416.13 (c) states, "Each official establishment shall monitor 

daily the implementation of the procedures in the Sanitation SOP's". 

(b) (6)
(b) (6)

(b) (6)

(b) (6)

(b) (6)

(b) (4)

(b) (4)

(b) (4)

(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE490703 

2108N-1 

03/08/2013 04A06 Poultry Finished 

Product Standards 

C On Thursday 03/07/2013 night shift there was a high percentage of birds presented 

for post-mortem inspection that where identified by the on line inspectors for 

airsaculitis removal. The establishment had initiated their alternative 

procedure. At 0212 hours I elected to verify the 

effectiveness of the alternative procedure. I went to the FPS Pre-Chill Station on line 

1 and collected a ten (split tail) bird sample. One of the ten birds had a horizontal 

slash across the back with a split tail; the carcass had cellulitis in the left flap of the 

leaf fat area. According to Document Number: E-14, 

. The finding of this bird at 

the FPS station is a failure to follow the establishments written procedures, 

. Also the establishment’s 

failure to prevent cellulitis from entering the chill system. QC performed a ten bird 

retest, there where no further findings on the retest. I notified 

of the forthcoming 

documentation for the failure to comply with the regulations cited above. 

5333 P7632 HYE581603 

4408N-1 

03/08/2013 04A06 Poultry Finished 

Product Standards 

C I was performing a finished product standards verification task on the reprocessing 

line in the evisceration department at 1215 hours. I selected ten carcasses marked 

with a horizontal slash across the back for cellulitis salvage. Two of the ten 

carcasses in the sample had cellulitis lesions on the leg quarters. I showed 

. Then she 

performed the required recheck of ten cellulitis carcasses and the recheck was 

found acceptable at 1222. I informed day shift

 of the failure to meet the 

regulatory requirement cited above. In addition 9 CFR 381.86 states any organs or 

other parts of carcasses which is affected by inflammatory process shall be 

condemned. 

5308 M6137 BXL1409033 

007N-1 

03/07/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C On 03/07/2013 at approximately 0550 hours while performing a Zero Tolerance 

fecal check on Line in Plant #2, I observed the following. After the line 

supervisor took a 10 bird random sample, I observed one bird with visible fecal 

contamination. The fecal material was a smear measuring approximately 1/2" by 1" 

in size, olive green in color and pasty in texture. The fecal material was located 

inside the carcass on the left side under the leaf fat on the thigh. This exceeded the 

Zero Tolerance for the process to be in control. I showed my 

finding. The protocol for fecal failure was implemented. A QC recheck at 0619 hours 

passed. My findings indicated a noncompliance with 9 CFR 381.65(e), 9 CFR 

417.2(c)(4) and the critical limit of CCP-2B of the 

Plants' HACCP Plan for Slaughter. 

(b) (6)
(b) (6) (b) (6) (b) (6)

(b) (6)

(b) (6)

(b) (6)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4)(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1609035 

707N-1 

03/07/2013 04A06 Poultry Finished 

Product Standards 

C On 03/07/2013 at approximately 0401 hours after performing a Pre-Chill Finished 

Product Standards check on line in Plant #2, I observed the following. While 

entering my findings from the check onto the establishments' logs there was an 

entry made by at 0332 hours of 32 points indicating that the 

line had failed. 9 CFR 376.76(b) states that "If all the past 5 prechill subgroups are 

at or below the start number, the establishment shall 'immediately' conduct a 

retest..." Instead of performing a recheck 'immediately' performed a check 

on Line that passed at 339 hours. I went to the QC Supervisors office but no one 

was there. I went back to Plant #2 and contacted who had a radio and 

asked her to contact the QC Supervisor and inform her that line had failed and 

that no recheck had been performed. I returned later and reviewed the log with 

to show her that a recheck was not performed until 0412 hours 

and that a noncompliance would be written for the recheck not being performed 

'immediately'. My findings indicated a noncompliance with 9 CFR 

381.76(b)(iv)(d)(2)(i). 

5308 M6137 BXL4018030 

407N-1 

03/07/2013 06D02 Other Inspection 

Requirements 

C At approximately 1535 hours while monitoring the "No Viscera Log" for Line #1 and 

Line #2 in Plant #1, I observed a noncompliance with the following regulatory 

requirements of regulations 9CFR 381.76 (a) and 9CFR 381.76 (b). Line #1 had three 

consecutive failures documented by Quality Control. 1.- At 1237 hours at line speed 

of BPM, 20 no viscera and only 13 no viscera are allowed. 2.- At 1306 hours at 

line speed of BPM, 30 no viscera and only 13 no viscera are allowed. Recheck 

failed and the line speed slowed down to 126 BPM. 3.- At 1456 hours at line speed 

of 120 BPM, 15 no viscera and only 11 no viscera are allowed. Three consecutive 

failures in a half-shift period is a noncompliance for lack of process control. The line 

speed remained at 126 BPM the rest of the shift. was 

informed about the noncompliance. 

5308 M6137 BXL0818031 

406N-1 

03/06/2013 03J02 Slaughter HACCP C At approximately 1330 hours while performing a HACCP Slaughter Record Review 

Task, I observed the following; Quality Control or designee documented on the 

HACCP Monitoring Log CCP-2B (Plant #2) dated on 03/06/2013 

PM shift, Direct Observation on Line # at 0744 hours. The time enter on 

verification activities (Direct Observation) did not corresponded with any of the 

monitor procedure entries. Records Review for that CCP-2B was 

performed by Quality Control or designee at 1306 hours. My findings indicate a 

noncompliance with the following regulatory requirements of regulations 9CFR 

417.5 (a)(3) and 9CFR 417.5 (b). I notified 

of the noncompliance. 

(b) (6)
(b) (6)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5415032 

706N-1 

03/06/2013 03J02 Slaughter HACCP C While performing Pre-Chill Finished Products Standards Task, I observed a 

noncompliance with the following regulatory requirements of regulations 9CFR 

381.65 (e) and 9CFR 417.2 (c)(4). At approximately 0800 hours, I randomly 

removed a 10 bird sample from Line #2 in Plant #1, I found one out of the ten birds 

with visible fecal contamination inside the bird on the right side under the leaf fat 

area (no fat attached). The fecal material was a piece measuring approximately 1/4" 

wide and 3/8" long in size, green olive in color and pasty in texture. This exceed the 

limit of Zero Tolerance for the process to be in control. I informed 

of the noncompliance. The protocol for fecal failure was 

implemented. Quality Control did a recheck at approximately 0834 hours and it 

passed. The cause of the deviation was the water sprayers plugged. This is a 

violation of the critical limits of CCP-2B of the Plant's 

HACCP Plan for Slaughter. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN130303 

0105N-1 

03/05/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C I was conducting the Review and Observation component of Pre-Operational 

Sanitation in area #1 of the Evisceration department when I noted the following 

noncompliance. I inspected unit #6, the paw incline conveyor, I found a flakey white 

residue built up on the paw conveyor. I then retained the conveyor with U.S. retain 

tag B39415840 at 2242 hours and informed 

of the noncompliance. At approximately 2304 hours I reinspected the conveyor and 

verified that sanitary conditions were restored. In the Packaging Department I 

continued the Pre-Operational task and inspected area #2 unit #22 East/West 

product conveyor to I requested to 

turn over the product conveyor so I could observe the under side of the conveyor. I 

observed on that surface fat and meat particles from the previous day’s production 

as well as a bio film residue, yellow and greenish in color the length of the conveyor. 

I applied U.S. retain tag B39415839 to the conveyor at 0033 hours and informed

 of the forthcoming noncompliance. At 

approximately 0054 hours I reinspected the product conveyor and verified sanitary 

conditions were restored. After my inspection was complete I went to the Q.C. 

office to inform the of the noncompliance and too 

review the Q.C. documents of the nights Pre-Operational Inspection performed by 

Quality Control. Pre-Op was conducted in the Evisceration Department area #1 unit 

#6 and found acceptable by Q.C. tech at 2219 hours. Pre-Op was also conducted in 

the Packaging Department in area #2 unit #22 the East/West product conveyor to 

at 0006 hours and found acceptable by Q.C. tech. The establishment's SSOP 

program states in Part 1 Pre-operational Sanitation/Daily, Section 3 Packaging 

" 

". This failure represents a noncompliance as 

per the regulatory requirements of sections 416.4 (a), 416.4(b) and 416.13 (c) of 

the Federal Code of Regulations. The presence of fat and meat particles on a food 

contact surface represents a noncompliance with Section 9 CFR 416.4(a) which 

states, "All food-contact surfaces, including food contact surfaces of utensils and 

equipment, must be cleaned and sanitized as frequently as necessary to prevent the 

creation of insanitary conditions and the adulteration of product". Section 9 CFR 

416.4(b) states, “Non-food-contact surfaces of facilities, equipment, and utensils 

used in the operation of the establishment must be cleaned and sanitized as 

frequently as necessary to prevent the creation of insanitary conditions and the 

adulteration of product.” Section 9 CFR 416.13 (c) states, "Each official 

establishment shall monitor daily the implementation of the procedures in the 

Sanitation SOP's". 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE360003 

0705N-1 

03/05/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 3/4/13 at approximately 2208 hours I observed the following noncompliance 

while preforming the SSOP Pre-Op Review and Observation Task . While inspecting 

Unit # 40 of area II ( the Neck and Giblet chiller ) I observed the following . There 

was a white build-up of grease on the upper rim of the bottom hopper and there 

was also a support bracket approximately 3” – 4” in width and approximately 1’ 

-15” in length covered with fragments of liver product . I immediately informed

 of the non-compliance . Retained/Rejected tag 

B38-495466 was applied . instructed a member of the 

clean-up crew to scrub and rinse the affected areas . A recheck was performed at 

approximately 2214 hours . The Neck and Giblet chiller was found to be in sanitary 

condition and the area was released and resanatized , putting the establishment 

back in compliance and ready for production . At 2216 hours unit #10 of area II was 

inspected ( Line # 1 Salvage Station ) . While inspecting the knife holder in the area I 

observed fat and meat particles in the plastic insert , as well as black unidentified 

foreign fiber material in the corners of the metal bracket that holds the plastic 

insert . U.S. REJECTED/RETAINED tag B38-495465 was applied to the area and

 was once again notified . instructed 

a member of his crew to remove the plastic insert and rinse it with a high pressure 

nozzle and the bracket was hand scrubbed and rinsed on the inside . A recheck was 

preformed at approximately 2222 hours . The area was found to be in sanitary 

condition putting the establishment back in compliance and ready for 

production . The contamination of product contact surfaces are violations of the 

following regulations 9CFR 416.1 , 9CFR 416.4(a ) , 9CFR 416.4 (d) ,9CFR 

416.13(a) , 9CFR 416.14 and 9CFR 416.13 . 

5308 M6137 BXL1518030 

604N-1 

03/04/2013 06D02 Other Inspection 

Requirements 

C At approximately 1330 hours while monitoring the "No Viscera Log" for Line #1 and 

Line #2 in Plant#1, I observed a noncompliance with the following regulatory 

requirements of regulations 9CFR 381.76 (a) and 9CFR 381.76 (b). Line #1 had 4 

consecutive failures by Quality Control. At 0818 al line speed of 111 BPM, Quality 

Control documented 16 no viscera, only 10 are allowed. At 0846 hours at line speed 

of BPM the check failed with 20 no viscera only 11 are allowed. At 1010 hours 

at line speed of BPM the check failed with 17 no viscera, only 11 are allowed. 

At 1304 hours the check failed with 18 no viscera at the same line speed of 

BPM. Three consecutive failures in a half-shift period is a noncompliance for lack of 

process control. I informed of the noncompliance. The line 

speed remaind at BPM the rest of the shift. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6)

(b) (4)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4405030 

602N-1 

03/02/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 03/02/2013 at approximately 0019 hours while monitoring the Establishments' 

Post-Chill Finished Product Standards for Chiller #2, I observed the following. After 

taking a random 10 bird sample, I observed on bird with a shiny metal flake on the 

left side of the carcass on the connective tissue associated with the cut skin near 

the neck area. was there taking temperatures so I showed her the 

carcass. I then took the carcass to the Pre-Chill Finished Product Standards table 

and called . At approximately 0158 hours while performing a 

Pre-Chill Finished Product Standards check on Line #1, I observed the following. 

After taking a standard 10 bird random sample, I found one bird with a shiny metal 

flake on the exterior left side of the carcass on the breast near where the wing is 

attached. The carcass was mutilated. A second shinny metal flake was found inside 

the skin on the right side of the breast near the wing. The wing had been removed. I 

again showed the bird to . The metal flakes were of similar size 

approximately 1mm by 1/2mm. Although the metal flakes were not large enough 

to be a Health Hazard, metal is still a contaminant. The Establishments SSOP for 

Operational Sanitation: Daily Procedures under Corrective Action states under 

" 

" My findings indicated a 

noncompliance with 9 CFR 416.1, 9 CFR 416.2(b)(1), and 9 CFR 416.14. 

5308 M6137 BXL5617031 

501N-1 

03/01/2013 06D02 Other Inspection 

Requirements 

C On 03/01/2013, The No Viscera log in plant one, lines 1, reflected 5 

consecutive failures during the production day. Two checks failed at birds per 

minute, which allows 13 nonconformances and four checks failed at line speed of 

126 BPM, which allows 11 nonconformances. The viscera checks that were 

performed at 126 BPM did not meet the required standards; however, the line 

speed remained at 126 BPM. This scenario reflects a lack of control in the process. 

Line 1 At 0818 hours, failed with 32 nonconformances at line speed of BPM (13 

nonconformances are allowed) At 0847 hours, the recheck failed with 32 

nonconformances at line speed of BPM. Line speed was slowed down to 126 

BPM. At 1019 hours, failed with 21 nonconformances at line speed of 126 BPM (11 

nonconformances are allowed). At 1300 hours, failed with 25 nonconformances at 

line speed of 126 BPM. At 1500 hours, failed with 15 nonconformances at line 

speed of 126 at line speed of 126 BPM This is a noncompliance with regulatory 

requirement of regulation 9 CFR 381.76. was notified of the 

noncompliance. 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2817024 

828N-1 

02/28/2013 06D02 Other Inspection 

Requirements 

C On 02/28/2013, The No Viscera log in plant one, lines 1, reflected 5 

consecutive failures during the production day. Two checks failed at birds per 

minute, which allows 13 nonconformances and three checks failed at line speed of 

126 BPM, which allows 11 nonconformances. The viscera checks that were 

performed at 126 BPM did not meet the required standards; however, the line 

speed remained at 126 BPM. This scenario reflects a lack of control in the process. 

Line 1 At 0815 hours, failed with 17 nonconformances at line speed of BPM (13 

nonconformances are allowed) At 0847 hours, the recheck failed with 32 

nonconformances at line speed of BPM. Line speed was slowed down to 126 

BPM. At 1018 hours, failed with 24 nonconformances at line speed of 126 BPM (11 

nonconformances are allowed). At 1238 hours, failed with 24 nonconformances at 

line speed of 126 BPM. At 1458 hours, failed with 17 nonconformances at line 

speed of 126 BPM. This is a noncompliance with regulatory requirement of 

regulation 9 CFR 381.76. was notified of the noncompliance. 

5308 M6137 BXL2913023 

827N-1 

02/27/2013 06D02 Other Inspection 

Requirements 

C At approximately 0834 hours, I performed a presentation check on Line " " at line 

speed of BPM (birds per minute). Station #1 had (4) viscera on shackle, (2) not 

reflected and (2) parts inside, total of 38 points. Station #2 had (2) viscera on 

shackle, (1) no viscera and (1) not reflected, total of 38 points. Station #3 had (1) 

viscera on shackle, (2) not reflected and (1) parts inside, total of 13 points. Station 

#1 failed with 38 points, this exceed the limit of 25-39 points and (3) occurrences of 

one error, Station #2 also failed with 38 points. Quality Control performed a recheck 

at approximately 0848 hours and Station #2 failed with (3) viscera on shackle. This 

exceed the limit of (2) occurrences of one error for the process to be in control. 

was informed and line speed was reduced to 81 BPM. At 

approximately 0909 hours all rechecks passed, bringing the process back in control. 

At approximately 0840 hours, I performed a presentation check on Line " at line 

speed of BPM (birds per minute). Station #1 had (1) viscera on shackle, (1) not 

reflected and (1) contamination inside the bird, total of 16 points. Station #2 had 

(1) not reflected and (3) parts inside, total of 5 points. Station #3 had (1) viscera on 

shackle, (1) not reflected and (2) parts inside, total of 12 points. Station #2 failed 

with (3) occurrences of one error, this exceed the limit of (3) occurrences of one 

error. Quality Control performed a recheck at approximately 0854 hours and 

Station #1 failed with (3) not reflected. This exceed the limit of (3) occurrences of 

one error for the process to be in control. was 

informed and line speed was reduced to 81 BPM. At approximately 0924 hours all 

rechecks passed, bringing the process back in control. This is a noncompliance with 

the following regulatory requirements of regulation 9CFR 381.76 (b). 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3313020 

527N-1 

02/27/2013 04C05 Poultry Good 

Commercial 

Practices 

C While performing Good Commercial Practices Task, at approximately 1050 hours in 

Plant #2 Live Hanging Area, I found a noncompliance with the following regulatory 

requirements of regulations 9CFR 381.65 (b). On Line the stainless steel tank 

marked "USDA CONDEMN" which is used for DOA birds was approximately half full 

of dead birds. While making my observations I shined my flashlight in the tank and 

found one bird with his eyes open. The bird was on the top and started moving his 

wings, I then placed my hand on his breast and it was breathing. A company 

employee, was near me. He took the bird from the condemn tank and 

placed in the live hanging line for me. I informed 

of the noncompliance. 

5308 M6137 BXL4408020 

427N-1 

02/27/2013 04A06 Poultry Finished 

Product Standards 

C On 02/27/2013 at approximately 0354 hours, I randomly removed a 10 bird 

sample from Line in Plant #2 for a Pre-Chill Finished Product Standard Check. I 

documented 32 points on the Processing Nonconformances from the 10 bird 

sample. This exceeds the subgroup absolute limit of 30 points for the Processing 

Nonconformances to be in control. I informed of the failure 

and approximately 0410 hours Quality Control performed a recheck. Quality 

Control documented 26 points on the Processing Nonconformances, this exceeds 

the limit of the 25 points allowed for the recheck, at this point the process is 

considered out of control. I informed of the noncompliance. 

Quality Control performed rechecks at Pre-Chill and Post-Chill. At approximately 

0515 hours the process was back in control. This is a noncompliance with the 

following regulatory requirements of regulation 9CFR 381.76(b). 

5308 M6137 BXL0005023 

226N-1 

02/26/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 02/26/2013 at approximately 0013 hours while monitoring the Establishments' 

Pre-Operational Sanitation procedures in Packaging Area #2, the Room, after 

establishment SSOP monitors completed their inspections, I observed the following. 

There was a thick continuous layer of fat and tissue on approximately a 20 foot 

section of the white support brackets, at a point where the brackets contact the 

product belt, for the overhead wing line. There were numerous specks of black UFM 

(Unidentified Foreign Material) that appeared to be mold on the white sprocket at 

the end of the line. The affected portion of the line is nearest the door to Packaging 

Area #1. The affected area was cleaned with a green scouring pad and given a rinse 

with potable water restoring sanitary conditions per establishment procedure by 

approximately 0026 hours. My finding indicated a noncompliance with 9 CFR 416.1, 

9 CFR 416.4(a), 9 CFR 416.13(c) and 9 CFR 416.14. 

(b) (6)
(b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2014023 

426N-1 

02/26/2013 03J02 Slaughter HACCP C While performing a HACCP Slaughter Record Review Task at approximately 1050 

hours, I found a noncompliance with the following regulatory requirements of 

regulation 417.5 (c). The CCP-2B Pre-Shipment Records Review 

End of Shift, dated on 02/23/2013 AM shift, Plant #1 was signed at 0900 hours 

(first page) and 0903 hours (second page). The CCP-2B 

Monitoring Log Line #1 had last Zero Tolerance check at 0904 hours and Line #2 had 

last Zero Tolerance check at 0908 hours. The signed document certifies that the 

product is ready to be shipped. The Pre-Shipment Records Review, End of Shift was 

signed before the last Zero Tolerance checks on Line #1 and Line#2 were performed. 

I informed of the noncompliance. 

5308 M6137 BXL2108020 

926N-1 

02/26/2013 06D02 Other Inspection 

Requirements 

C On 02/26/2013 at approximately 0344 hours while monitoring slaughter line 

processes in plant #1, I observed the following. There appeared to be a lot of viscera 

missing from line #2. There were a number of off color birds (dehydrated) passing 

down the line and the birds are often condemned as without the viscera it is 

difficult to determine a cause. A check of the Lines No-Viscera Monitoring 

Log for the shift showed that line #1 was in a failed status but that line #2 was in 

compliance. I performed a standard 3 minute no viscera check on Line #2 and found 

that there were 34 no viscera at bpm (birds per minute). At bpm 13 no 

viscera are allowed. I informed A QC recheck failed at 0410 hours 

and the line was slowed to 126 bpm. Another QC check at 0613 hours also failed at 

126 bpm. A QC no viscera check of Line #1 failed at 0140 hours. A QC recheck at 

0204 hours failed with 23 no viscera and the line was slowed to 126 bpm. QC 

rechecks at 0358 and 0609 hours failed with 39 no viscera at 126 bpm. At 126 bpm 

11 no viscera are allowed. The three consecutive failures on line #1 is also a 

noncompliance for failure by the establishment to take proper corrective action. My 

findings indicated a noncompliance with 9 CFR 391.76(a) & (b). 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3319024 

826N-1 

02/26/2013 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1030 hours, at the packaging re hang area for plant 1, I observed 

a noncompliance with regulations 416.1 and 416.4(a). There was three stainless 

steel tanks align right next to chiller 2 re hang line. These tanks were coming from 

the Rotisserie Room. The employee collecting ice grabbed a hose and rinsed them 

with hot water. As he was ready to push them to the ice collection area, I stopped 

him with the purpose of inspecting the sanitary conditions of these tanks. I found 

them with chunks of fat and what seemed to be a brownish residue built up on the 

inside bottom of the tanks. Rinsing with hot water was not sufficient to clean the 

brownish residue on the bottom of the tanks. I immediately place retained tags on 

the affected edible containers (US Tag N0. B31 407786, B31 407787 and B31 

407788). was notified of the noncompliance. I also 

observed a couple of stainless steel tanks brought out of plant 1 cooler. These tanks 

were covered with blue liners. When I uncovered them, I noticed the same type of 

brownish residue building up inside of the tanks. I also placed rejected US tags on 

both tanks ( B31 407949 and B31 407950). I then, contacted 

and notified him of the insanitary condition. He took immediate corrective action 

by assigning employees to the edible condemn room to wash these tanks by 

applying soap, scrubbing and rinsing each one of them with hot water. I released 

the stainless steel containers back to production after sanitary conditions were 

restored. was also notified of the noncompliance. 

mentioned his intention to keep these employees at the edible dump room so that 

all stainless steel tanks are properly cleaned. My finding represent a noncompliance 

with Pre Operational and Operational sanitary practices. 

5308 M6137 BXL5720023 

326N-1 

02/26/2013 06D02 Other Inspection 

Requirements 

C On 02/26/2013, The No Viscera log in plant one, lines 1, reflected 3 

consecutive failures during the first four hours of production. Two checks failed at

 birds per minute, which allows 13 nonconformances and one check failed at 

line speed of 126 BPM, which allows 11 nonconformances. The no viscera checks 

that were performed at 126 BPM did not meet the required standards; however, 

the line speed remained at 126 BPM. Latter on during the day, line one was slowed 

down to 100 birds per minute due to pathology. This scenario reflects a lack of 

control in the process. Line 1 At 0815 hours, failed with 17 nonconformances at line 

speed of BPM (13 nonconformances are allowed) At 0848 hours, the recheck 

failed with 14 nonconformances at line speed of 140 BPM. At 0902 hours, Line 

speed was slowed down to 126 BPM untill further notice. At 1031 hours, failed with 

13 nonconformances at line speed of 126 BPM (11 nonconformances are allowed). 

At 1312 hours, failed with 20 nonconformances at line speed of 126 BPM. At 1500 

hours, passed with 7 nonconformances at line speed of 100 BPM (9 

nonconformances are allowed) This is a noncompliance with regulatory 

requirement of regulation 9 CFR 381.76. was notified of the 

noncompliance. 

(b) (6)
(b) (6) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3600020 

823N-1 

02/23/2013 01D01 SPS Verification C On 02/22/2013 at approximately 0315 hours while performing a Raw Intact HACCP 

procedure in Packaging, I observed the following. There was a piece of stainless 

steel lacing on a thigh being collected in brown product tubs near line for further 

processing. I showed my finding to . The lacing is used to hold 

the cloth belts together. A lace is approximately 1" long. The metal piece was to 

large to be considered a safety hazard and would probable have been found during 

the deboning and final trim process. To determine a source, we checked the belts 

for leg processors 7-12 that were in use and found 4 laces missing on the belt that 

collects the legs associated with Leg Processors 7-9. There were also several laces 

that have wear marks that are normally associated with a rubbing action. There 

were 2 laces missing on the thigh collection belt associated with Leg Processors 

7-12. A check of the other cloth belts in Packaging revealed that 3 laces were 

missing on the leg collection belt associated with Leg Processors 1-3. There is also 

wear marks on the rest of the laces on this belt.The main product belt associated 

with Line that collects half breasts and takes them to the point where they are 

packaged was missing at least 15 laces in four separate places. One belt that 

collects the wings from under the Breast Processors was missing 4 laces and a 

second belt that also collects wings from the Breast Processors was missing 6 laces. 

There are also wear marks on the rest of the lacing on these belts. The lacing is 

deteriorating either through wear or by separation from the belt with the metal 

contaminating the finished product just prior to packaging. The response to 

NR#BXL708013131N/1 dated 1/31/2013 under 'Immediate Action' states 

"Maintenance replaced the lacing for the belts." The response to NR 

#BXL4004023609N/1 dated 2/9/2013 for a similar observation under 'Immediate 

Action' stated that "Maintenance replaced the lacing for the belts, tightened the 

rollers, and verified the clearance." No mention was made of a preventative 

measure to prevent reoccurrence. The Establishment is either unable or unwilling to 

address this issue. My findings indicate a noncompliance with 9 CFR 416.1, 9 CFR 

416.4(d) and 9 CFR 416.2(b)(1). 

(b) (6)
(b) (6) (b) (6)

(b) (6)

(b) (6) (b) (7)(C) (b) (7)(C) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3604025 

023N-1 

02/23/2013 04A06 Poultry Finished 

Product Standards 

C On 02/22/2012 while monitoring the Establishments' Reprocessing Procedures on 

Line in Plant #1, I observed a noncompliance with the following regulatory 

requirements of regulation 9CFR 381.84 (Airsacculitis). At approximately 2337 

hours, I randomly removed a 10 bird sample for my reprocessing test, I found one 

out of six birds with splits tails in the sample that contained Airsacculitis exudates 

by the kidney area. I performed a recheck at approximately 2344 hours, in which 

three out of the ten birds sample contained Airsacculitis exudates. I immediately 

informed of the noncompliance and he immediately took 

action by stopping the line and retained the product into a tank. Quality Control 

placed a red hold tag to the tank. At approximately 2355 hours Quality Control 

performed a recheck and it passed. I released the product to Quality Control. The 

retained product was reworked and released by Quality Control at approximately 

0030 hours. 

5333 P7632 HYE110202 

3422N-1 

02/22/2013 01D01 SPS Verification C At approximately 03:36 am while performing the Review and Observation 

component of the Operational Sanitation PHIS task, the following noncompliance 

was noted: At the the end of the rotisserie packing line ten stacks of baskets were 

staged, five with product and five without. All ten stacks of baskets were 

contaminated with foreign residue of black consistency and 1⁄2 - 21⁄2 inches of fat. 

Inspector CSI took regulatory control of the affected product and 

baskets by applying USDA retain tags. CSI then informed 

of the forthcoming noncompliance. Mr. 

took immediate action by removing all products and washing all affected baskets.

 was informed of the noncompliance and he placed Q.C. 

retain tags to affected baskets for recheck. Regulatory control of the area was 

released at 03:47 am once sanitary conditions were restored. This failure represents 

a noncompliance with regulations: 9 CFR 416.1 which states “Each official 

establishment must be operated and maintained in a manner sufficient to prevent 

the creation of insanitary condition and to ensure that product is not adulterated.” 

9 CFR 416.4 (b) which states “Non-food-contact surfaces of facilities, equipment, 

and utensils used in the operation of the establishment must be cleaned and 

sanitized as frequently as necessary to prevent the creation of insanitary 

conditions. 

(b) (6)
(b) (6)

(b) (6)(b) (6)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1700023 

721N-1 

02/21/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 02/20/2013 at approximately 0040 hours while monitoring the establishment's 

Operational Sanitation procedures in Packaging, I observed the following. I checked 

five birds from a group of the first birds hung and found three birds on Line 

that had black and brown UFM (Unidentified Foreign Material) on the three 

carcasses as follows: on the tissue left hanging from the neck, on the skin flap and 

on the fat and tissue in the area of the neck, and on the skin flap that included 

approximately a 3/4" piece of neck bone. From the location of the UFM the birds 

must have been dragged across a contaminated surface. I contacted 

and showed him my findings. We observed the line operation along the 

drip pans in packaging but found no issues. We proceeded to the Plant #2 and 

found birds dragging on the drip pans before the machine on Line . These 

drip pans are not treated as product contact surfaces. Birds were also dragging on 

the the Chick/Weight line at the bottom of the incline between stations WX and 

AABB, and along the overhead drip pans for line #2. The drip pans are not treated as 

a product contact surface and the overhead drip pans were coated with a heavy 

layer of black UFM contaminating the birds that came into contact with the UFM 

on the drip pan surface. The Chick/Weight line was stopped. An attempt was made 

to scrub and wash the line but with no soap available and only cold water, the 

green scrub pad used just smeared the UFM around. A plastic sheet was applied to 

the drip pans as a temporary solution and the line was restarted after 

approximately 30 minutes. A work order was submitted. My findings indicated a 

noncompliance with 9 CFR 416.1, 9 CFR 4(d), 9 CFR 416.2(b)(1), and 9 CFR 416.14. 

5308 M6137 BXL2404024 

521N-1 

02/21/2013 03J02 Slaughter HACCP C On 02/21/2013 at approximately 0015 hours while performing the weekly 

monitoring of Reprocessing Line , I observed the following. After taking a 

standard 10 bird sample, I observed one bird with visible fecal contamination on 

the right side where the leaf fat would be located. The leaf fat is removed as part of 

the reprocessing line function. The fecal material was a smear measuring 

approximately 1/2", medium brown in color, pasty in texture, and gave off a 

distinctive odor. I contacted who called 

. Approximately 50 birds were tanked. A recheck passed at 

approximately 0022 hours. A review of the Off Line & Inspection Form for the 

shift showed that Line was running at birds per minute at 2303 hours. There 

was one house inspector at the end of the line. My findings indicated a 

noncompliance with 9 CFR 381.65(e), 9 CFR 417.2(c)(4) and the critical limit of 

CCP-1B - (Reprocess) of the Plants' HACCP Plan for 

Slaughter. 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (7)(C) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN110502 

2521N-1 

02/21/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C I, CSI , was performing the review and observation component of 

Pre Operational Sanitation PHIS task at 00:46 in Area 4 Food Service, I noted the 

following noncompliance: While checking the return bird slide and north/south 

rehang belt area I observed excessive amount of fat pieces along the length of the 

belt, the inner and outer metal ends of belt, the dip pans directly above the belt and 

the WOG drop slide. I took regulatory control by applying US retain tag B43303504. 

were notified of the forthcoming noncompliance. Once corrective actions 

were implemented and sanitary conditions were restored the area was released at 

00:52 The establishment failed to meet the requirements of CFR 9 416.4 (a) All 

food-contact surfaces, including food-contact surfaces of utensils and equipment, 

must be cleaned and sanitized as frequently as necessary to prevent the creation of 

insanitary conditions and the adulteration of product.(b) Non-food-contact surfaces 

of facilities, equipment, and utensils used in the operation of the establishment 

must be cleaned and sanitized as frequently as necessary to prevent the creation of 

insanitary conditions and the adulteration of product. CFR9 416.13 (c)Each official 

establishment shall monitor daily the implementation of the procedures in the 

Sanitation SOP's. 

5308 M6137 BXL2222024 

420N-1 

02/20/2013 06D02 Other Inspection 

Requirements 

C On 02/20/2013 while performing 'No Viscera' checks in Plant #1, line #1 and line 

#2, I observed a noncompliance with the following regulatory requirements of 

regulations 9CFR 381.76 (a) and 9CFR 381.76 (b). -Line #2 At 0114 hours, I 

documented 19 no viscera and only 13 are allowed at line speed of BPM, I 

informed of the failure. At 0144 hours, Quality Control 

performed a recheck and failed with 22 no viscera and only 13 no viscera are 

allowed at line speed of BPM. was informed and line speed 

was reduced to 126 BPM. Line speed remained at 126 BPM the rest of the shift. 

-Line #1 At 0431 hours, I documented 16 no viscera and only 13 are allowed at line 

speed of BPM, I informed of the failure. At 0459 hours, 

Quality Control performed a recheck and failed with 16 no viscera and only 13 no 

viscera are allowed at line speed of BPM. was informed and 

line speed was reduced to 126 BPM. Line speed remained at 126 BPM the rest of 

the shift. was informed about the noncompliance. 

(b) (6)
(b) (6) (b) (4) (b) (4)

(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0507023 

719N-1 

02/19/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 02/19/2013 at approximately 0330 hours while monitoring the establishments' 

Operational Sanitation procedures in Packaging, I observed the following. The birds 

on the high speed line from Plant #2 to Plant #1 were dragging on the catwalk 

located to the right as the line exits the tunnel into Plant #1. The birds also drag on 

the drip trays as they turn the corner on their approach to the spray cabinet 

for line . Tthe catwalk and drip pans are not treated as a product contact surface 

and are adding contaminants to the product upon contact. The chain associated 

with the high speed line is heavily rusted and needs reconditioning or replacement. 

I showed my findings. Hanging of birds on the line was 

stopped. The birds on the line were tanked and placed under QC hold for 

reconditioning. A review of the establishments' 

shows that no Chemical, Physical or Biological Hazards were 

identified. Under 'Justification for Decision' it states ' 

" My finding indicated a 

noncompliance with 9 CFR 416.1, 9 CFR 416.4(d), 9 CFR 416.2(b)(1) and 9 CFR 

416.14. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4)

(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4708024 

516N-1 

02/16/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 02/16/2013 at approximately 0215 hours while monitoring the establishments 

Operation Sanitation procedures in Packaging, I observed the following. There were 

several oily black specks of UFM (Unidentified Foreign Material) approximately 6-10 

per tray to approximately 1/16" on the product tray and absorbent pads on 

packaging line just prior to the product being added. The side of the line adjacent 

to the packaging supervisors office was involved. I watched for approximately a 

minute and every third or fourth tray was being contaminated. I contacted 

. A mechanic was called. The auto padder unit used to cut and 

dispense absorbent pads was tipped over by the mechanic and repairs were made. 

A large piece of black UFM (Unidentified Foreign Material) approximately 1/2" and 

several small pieces that appeared to be clumps of blackened padding residue 

appeared on the belt that holds the packaging trays. The line was cleaned. Several 

attempts were made to repair the auto padder. I continued to remove 

contaminated trays during this process. After break at approximately 0300 hours a 

final attempt was made resulting in the same black specks on the packaging trays.

 had the absorbent pads placed on the trays manually until repairs 

could be made at a later time. At the 0300 hour, I removed several trays from Line 

at the point where product was being added. Four of the trays had the blackened 

dust like material on the trays measuring approximately 1/4" by 1/16". I showed 

the trays, one with product already being packed, to . I 

contacted the Lead Mechanic who informed me that the establishment used only 

. A review of the establishments' 

hows that no Chemical, Physical or Biological 

Hazards were identified. Under Justification for decision it states " 

." My 

findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.2(b)(1), 9 CFR 

416.4(d) and 9 CFR 416.14. 

(b) (6)
(b) (6)

(b) (6) (b) (6)

(b) (6)

(b) (4)

(b) (4)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN261902 

2216N-1 

02/16/2013 03C02 Raw Intact HACCP O At approximately 0855 hours, while performing the PHIS task for Operational 

Sanitation in the second processing area, I observed two bins filled with chicken 

back bones staged in the re-hang area of the food service floor. The first, 

bin # 22420, weighed 1,879 lbs; from kill date 2/14/2013. The second, bin # 32277, 

was filled with 2,420 lb; kill date 2/15/2013 Thursday. I asked 

to use his thermometer to check the temperature of the products. The 

maximum temperature for bin #22420 was 44.7 degrees Fahrenheit, and for 

bin # 32277 was 42 degrees Fahrenheit. I immediately retained the products by 

placing retained tags NO. B34776900 and NO. 40266747 on each bin respectively. I 

informed Ms. , of my findings and 

forthcoming noncompliance. At approximately 0910 hours, the product was 

released to Ms. who condemned the product in my presence. Upon review 

the thermometer calibration log entry for thermometer# 467 was documented as 

acceptable at 2328 hours. Failure of the establishment to maintain a maximum 

internal temperature of the product at 40 degrees Fahrenheit or less is a 

noncompliance in accordance with 9 CFR 381.66(a) and 9CFR 381.66(c) (3). 9 CFR 

381.66(a) states in part " Temperature and procedures that are necessary for 

chilling and freezing ready-to-cook poultry, including all edible portions thereof, 

must be in accordance with operating procedures that ensure the prompt removal 

of the animal heat, preserve the condition..." 9CFR 381.66(c) (3) states “Previously 

chilled poultry carcasses and major portions must be maintained constantly at 40 

degrees F or below until removed from the vats or tanks for immediate packaging 

.... " 

5308 M6137 BXL2207021 

115N-1 

02/15/2013 03J02 Slaughter HACCP C On 02/15/2013 at approximately 0215 hours while monitoring the establishments' 

Operational Sanitation procedures in Packaging on line , I observed the 

following. I was monitoring birds for UFM (Unidentified Foreign Material) just prior 

to the point where the giblets are added to the carcasses prior to begging. The 

fourth bird that I checked had a cloacae attached inside at the tail with 

approximately 3" of intestine. There was fecal material leaking from the cut end of 

the intestine into the left side kidney area. As there is no procedure for a packaging 

department fecal failure, I had Quality Control and 

called. The fecal material was olive green in color, pasty in texture and 

measured approximately 1/2" by 1/8". Two racks of packaged birds were held for 

further inspection by Quality Control. Fecal material normally contains a large 

number of microbes. A review of the Establishments' 

states " 

." My findings indicated a noncompliance with 9 CFR 381.65(e), 9 CFR 

417.2(c)(4) and the critical limit of CCP 2B of 

the Plants' HACCP Plan for Slaughter. 

(b) (6)
(b) (6) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3013021 

915N-1 

02/15/2013 04A06 Poultry Finished 

Product Standards 

C While monitoring the Establishments’ Reprocessing Procedures on Line in Plant 

#2, I observed the following noncompliance. At approximately 1050 hours, I 

randomly selected a 10 bird sample for my reprocessing check. I found 2 birds with 

airsacculitis exudates remaining in the bird. I immediately took regulatory action by 

stopping the line and I informed of the noncompliance. 

The line was started and product was retained while corrective actions were 

implemented. I performed a recheck at approximately 1104 hours and it passed, 

bringing the process back into control. I tagged the tank of retained birds with U.S. 

Retained/Rejected Tag #B31407602 pending rework of the product. I performed a 

recheck of the held product at approximately 1259 hours and it passed. I removed 

my tag and released the product back to production at that time. My findings 

indicate a noncompliance with 9CFR 381.76(b) and 9CFR 381.84. 

5308 M6137 BXL3504022 

315N-1 

02/15/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 02/14/2013 at approximately 2350 hours while monitoring the Establishments' 

Pre-Operational Sanitation procedures in Packaging Area #1, I observed the 

following. There was a thin layer of pasty fat and issue on the stainless steel sides of 

both overhead breast fillet transfer belts that carry finished product from the 

Deboning room to packaging lines. The affected belts run parallel to the Crust 

Tunnel and are approximately 60 feet long. The pasty tissue was up to 

approximately 2" high in places and cover areas that were several feet long. There 

were numerous pieces of semi-dried fat and tissue on the internal surfaces and 

metal support brackets associated with the short transfer belt that carries breast 

fillets rejected by the X-Ray machine to a belt that takes them to a deboning 

station. The tissue had been there for some time as the product residue gave off a 

strong sour offensive odor. Sanitary conditions were restored by approximately 

0025 hours. My findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 

416.4(a) & (b), 9 CFR 416.13(c), and 9 CFR 416.14. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE450002 

0115N-1 

02/15/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 2/14 at approximately 2204 hours I observed the following while preforming 

the SSOP Review and Observation Task in Area II .The paddles and upper frame 

work on the outer portion of the North Chiller ( east section from center ) had a 

build-up of grease left from the previous shifts production . I immediately informed

 of my findings . had one of his 

workers wipe the paddles down and the affected areas of the frame work . The area 

was reinspected and found to be in sanitary condition putting the establishment 

back in-compliance . At approximately 2210 hours Unit # 14 of Area # II was 

inspected . The cabinet on the South West Wall that houses the company computer 

used to retrieve establishment data had a build-up of black mold 

and ( UMF ) Unidentified Foreign Material on the in side of the flip-up cover to the 

cabinet and outer portions around one fastener . was 

immediately informed of the non-compliance and US Rejected/Retained 

tag # B38495468 was applied . had one of his workers clean 

the the in side of the cabinet door and the area inside surrounding the computer 

.The cabinet was reinspected at approximately 2217 and sanitary conditions had 

been restored . The tag was removed and Area # II was ready for production . My 

findings indicate non-compliances with the following regulations 9CFR 

416.13(a) , 9CFR 416.4(b) , 9CFR 416.14 , 9CFR 416.13(c) , 9CFR 416.4(a) and 9CFR 

416.1 . 

5308 M6137 BXL2813020 

114N-1 

02/14/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 02/14/2013 at approximately 1039 hours while monitoring the establishments' 

Operational Sanitation procedures in the Packaging Department, I observed the 

following. Between the Bag Fryer Line and the Bag Fryer Line at the final tie 

station where rework is done and before the tied bag fryers go on to the revolving 

table to be put on racks. There were two birds that were not in bags, that had fallen 

on the floor close to Line and I witnessed an employee walk over to the two 

birds on the floor and using her feet she kicked the two birds approximately two 

feet towards Line . The employee then picked up the two birds and holding them 

in one hand she took a hose and sprayed the two birds. She then put the two birds 

in a stainless steel rework cart that was at the end of Line by the final tie station. 

I immediately went over to the cart with the two birds inside it and I observed UFM 

approximately 1/32" in size embedded in the skin. I took regulatory control action 

and tagged the two birds with USDA Reject/Retain tag #B31407603. I then informed

 and of the noncompliance. I 

removed my retain tag at 1050 hours and condemned 

the two birds. washed the stainless steel cart restoring 

sanitary conditions at 1052 hours. 

(b) (6)
(b) (6)

(b) (6)

(b) (4)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3003022 

914N-1 

02/14/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 02/13/2012 at approximately 2310 hours while monitoring the Establishments' 

Pre-Operational Sanitation procedures in the Rotisserie Room, I observed the 

following. There was a coating of pasty fat and tissue to approximately 1/4" with 

pieces of tissue to approximately 1/2" on the sprockets, and along the entire length 

of the white nylon and stainless support brackets for the product belt associated 

with the injection machine. Sanitary conditions were restored by approximately 

2335 hours. My findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 

416.4(a), 9 CFR 416.13(c) and 9 CFR 416.14. 

5308 M6137 BXL3203023 

614N-1 

02/14/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C On 02/14/2012 at approximately 0036 hours while performing a Zero Tolerance 

fecal check on Line #1 in Plant #1, I observed the following. After taking a random 

ten bird sample, I observed one bird with visible fecal contamination. The fecal 

material was a smear measuring approximately 1/2" by 3/4" in size, medium brown 

in color and pasty in texture. The fecal material was located in the area of the keel 

bone inside of the carcass approximately 1-1/2 inches from the abdominal cut. This 

exceeded the zero tolerance for the process to be in control. I showed

 my findings. The protocol for fecal failure was implemented. It took over 30 

minutes for maintenance personnel to clean the spray heads on the bird washer. A 

QC recheck passed at 0115 hours. My findings indicated a noncompliance with 9 

CFR 381.65(e) and 9 CFR 417.2(c)(4), and the critical limit of CCP-2B

 of the Plants' HACCP Plan for Slaughter. 

5308 M6137 BXL4208020 

914N-1 

02/14/2013 06D02 Other Inspection 

Requirements 

C On 02/14/2013, at approximately 0504 hours, I performed a presentation check on 

Line . Station #1 failed with (2) viscera on shackle, (2) not reflected and (1) 

contamination inside the bird, total of 26 points. Station #2 failed with (2) viscera 

on shackle and (3) not reflected, total of 22 points. Station #3 had (1) viscera on 

shackle and (1) not reflected, total of 10 points at line speed of BPM (Birds Per 

Minute). This exceed the limit of (3) occurrence of one error and (25-39) points. At 

approximately 0523 hours Quality Control performed a recheck and Station #1 

failed with (1) viscera not uniform, (2) viscera on shackle and (2) not reflected, total 

of 28 points. Station #2 had (2) not reflected, total of 4 points. Station #3 failed 

with (1) viscera not uniform, (1) viscera on shackle and (4) not reflected total of 24 

points. This exceed the retest conformances levels of 3 occurrences of one error and 

25 points for the process to be in control. was informed 

and the line speed was reduced to BPM. At approximately 0552 hours Quality 

Control performed a recheck at line speed of BPM and it passed. At 

approximately 0557 hours at line speed of BPM, Quality Control performed a 

recheck and passed it, bringing the process back in control. This is a noncompliance 

with the following regulatory requirements of regulation 9CFR 381.76 (b). 

(b) (6)
(b) (6)

(b) (6)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4216024 

014N-1 

02/14/2013 06D02 Other Inspection 

Requirements 

C On 02/14/2013, The No Viscera log in plant one, lines 1 and 2, each 

reflected 6 consecutive failures during the production day. Two checks failed at 

birds per minute, which allows 13 nonconformances and four checks failed at line 

speed of 126 BPM, which allows 11 nonconformances. The viscera checks that were 

performed at 126 BPM did not meet the required standards; however, the line 

speed remained at 126 BPM. This scenario reflects a lack of control in the process. 

Line 1 At 0759 hours, failed with 22 nonconformances at line speed of BPM ( 

nonconformances are allowed) At 0828 hours, the recheck failed with 27 

nonconformances at line speed of BPM. Line speed was slowed down to 126 

BPM. At 1100 hours, failed with 22 nonconformances at line speed of 126 BPM (11 

nonconformances are allowed). At 1321 hours, failed with 20 nonconformances at 

line speed of 126 BPM. At 1503 hours, failed with 25 nonconformances at line 

speed of 126 BPM. At 1632 hours, failed with 22 nonconformances at line speed of 

126 BPM This is a noncompliance with regulatory requirement of regulation 9 CFR 

381.76. Line 2 At 0813 hours, failed with 25 nonconformances at line speed of 

BPM (13 nonconformances are allowed) At 0842 hours, the recheck failed with 18 

nonconformances at line speed of BPM. Line speed was slowed down to 126 

BPM. At 1107 hours, failed with 19 nonconformances at line speed of 126 BPM (11 

nonconformances are allowed). At 1325 hours, failed with 19 nonconformances at 

line speed of 126 BPM. At 1509 hours, failed with 20 nonconformances at line 

speed of 126 BPM. At 1720 hours, failed with 18 nonconformances at line speed of 

126 BPM. This is a noncompliance with regulatory requirement of regulation 9 CFR 

381.76. was notified of the noncompliance. 

5308 M6137 BXL5008022 

814N-1 

02/14/2013 03J02 Slaughter HACCP C On 02/14/2013 at approximately 0200 hours while performing a HACCP Slaughter 

Record Review Task, I found the following. Quality Control or designee documented 

on the HACCP Monitoring Log -CCP 1B- , Line (Plant #2) dated 

on 02/12/2013 PM shift, Direct Observation at 0951 hours. The time enter on 

verification activities (Direct Observation) did not corresponded with any of the 

monitor procedure entries of 0751 hours, 0859 hours and 0958 hours. My findings 

indicate a noncompliance with the following regulatory requirements of regulations 

9CFR 417.5 (a)(3) and 9CFR 417.5 (b). I informed 

of the noncompliance. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6)

(b) (6)

(b) (6)

(b) (6)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0505021 

513N-1 

02/13/2013 04C05 Poultry Good 

Commercial 

Practices 

C On 02/13/2013 at approximately 0130 hours while monitoring the Establishments' 

Good Commercial Practices in Plant #1 Live Hang area, I observed the following. 

There was a bird hanging by it neck at the end of the dumping belt for Line #1. It's 

head was caught behind a piece of stainless that was loose. The stainless sheet is 

used to direct the birds off the dumping belt. The birds neck was bent at almost a 

180' angle. It was not moving. I went to the office but no supervisor was available 

so I had and the employee doing the dumping release the bird. The 

bird was dead so I attached U.S. Retained Tag #B31407772 to the carcass. Except for 

the injuries to the neck the bird appeared normal. There were no signs that it 

struggled. There was very little blood. I found in the Plant #1 

Supervisors Office in a meeting with the other Plant #1 Supervisors. I told him 

about the bird. We proceeded to the hanging area and I showed him the loose piece 

of stainless near the end of the right side of the dumper belt. 

called a mechanic who used a tie wrap to hold the metal in place until a more 

permanent repair could be made. I informed that a 

noncompliance would be issued for 'Death Other Than By Slaughter. My findings 

indicated a noncompliance with 9 CFR 381.65(b). 

5308 M6137 BXL1105021 

113N-1 

02/13/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 02/13/2013 at approximately 0005 hours while monitoring the establishments 

Pre-Operational Sanitation procedures in Packaging Area #1, I observed the 

following. There were numerous pieces of fat and tissue, and black UFM 

(Unidentified Foreign Material) that appeared to be mold on the internal stainless 

and white nylon support brackets associated with Trim Conveyor Belt #2 for line #1. 

There are small access ports on both sides of the belt, however, the access does not 

allow for a thorough cleaning or visual inspection to the ends of the belt. 

will be submitting a work order to modify the belt design. My findings 

indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.3(b), 9 CFR 416.4(a) and 9 

CFR 416.13(c). 

5308 M6137 BXL2217022 

213N-1 

02/13/2013 06D02 Other Inspection 

Requirements 

C While monitoring The no viscera in line 1 of plant 1, I found a 

noncompliance with regulatory requirement of regulation 9 CFR 381.76 At 

approximately 0910 hours, I performed a no viscera check on line 1 at line speed of

 birds per minute(BPM). My check failed with 18 nonconformances out of 13 

nonconformances allowed at BPM. I notified . At 

1029 hours, line speed BPM, QC performed a recheck failing with 20 

nonconformances out of 13 nonconformances. At this point a non compliance is 

issued. Line speed was slowed down to 126 BPM which allows 11 

nonconformances. At approximatelly 1325 hours, at 126 BPM line speed, QC 

performed a passing recheck with 8 out of 11 nonconformaces. Line speed 

remained at 126 the rest of the day. At approximately 1505 hours, 

was notified of the noncompliance. 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6)

(b) (6)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2217022 

213N-2 

02/13/2013 06D02 Other Inspection 

Requirements 

C On 02/13/2013, a second noncompliance was issued in plant 1 due to no viscera 

failures during the day. The Line 2 No Viscera log reflected 5 consecutive 

failures during the production day. Two checks failed at birds per minute, which 

allows 13 nonconformances and three checks failed at line speed of 126 BPM, 

which allows 11 nonconformances. The viscera checks that were performed at 126 

BPM did not meet the required standards; however, the line speed remained at 126 

BPM. This scenario reflects a lack of control in the process. At 0802 hours, failed 

with 17 nonconformances at line speed of BPM (13 nonconformances are 

allowed) At 0816 hours, the recheck failed with 15 nonconformances at line speed 

of BPM. Line speed was slowed down to 126 BPM. At 1011 hours, failed with 

26 nonconformances at line speed of 126 BPM (11 nonconformances are allowed). 

At 1244 hours, failed with 25 nonconformances at line speed of 126 BPM. At 1500 

hours, failed with 25 nonconformances at line speed of 126 BPM. This is a 

noncompliance with regulatory requirement of regulation 9 CFR 381.76 At 

approximately 1505 hours, was notified of the 

noncompliance. 

5308 M6137 BXL5015024 

713N-1 

02/13/2013 04A06 Poultry Finished 

Product Standards 

C While monitoring the Establishments' Reprocessing Procedures on Line in Plant 

#2, I observed the following noncompliance. At approximately 1020 hours, I 

randomly selected a 10 bird sample for my reprocessing check. I found 1 bird with 

airsacculitis exudates remaining in the bird. I immediately informed 

and told her I would have to perform a recheck. I again randomly 

removed a 10 bird sample at approximately 1030 hours and found 2 birds with 

airsacculitis exudates remaining. I immediately took regulatory action by stopping 

the line and informed of the noncompliance. The line 

was started and product was retained while corrective actions were implemented. I 

performed a recheck at approximately 1046 hours and it passed. bringing the 

process back into control. I tagged the tank of retained birds with U.S. 

Retained/Rejected Tag #B39 554619 pending rework of the product. I performed a 

recheck of the held product at approximately 1247 hours, finding 2 birds with 

airsacculitis exudates remaining. I informed of my 

findings and told her that the product would have to be reworked a second time. I 

rechecked the tank again at approximately 1325 hours and it passed, I removed my 

tag and released the product back to production at that time. My findings indicate a 

noncompliance with 9CFR 381.76(b) and 9CFR 381.84. 

5308 M6137 BXL5104020 

013N-1 

02/13/2013 01D01 SPS Verification C At approximately 0232 hours, I observed a live juvenile cockroach on the wall 

between the hand wash sink and the drinking fountain in the body opening area of 

Plant #2. The cockroach was caught and immediately shown to 

. He said that he would imform . This is a 

noncompliance with the following regulatory requirements of regulations 9CFR 

416.1 and 9CFR 416.2(a). 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE270102 

0513N-1 

02/13/2013 01C02 Operational SSOP 

Review and 

Observation 

C On February 11, 2013 at approximately 2235, I was performing a Zero Tolerance 

task at the Pre-chill station on line one. The first two birds I pulled off had grease 

smears on the keel bone area approximately 1⁄2 inch square. I then noticed all the 

birds going down the line had grease smears from 1⁄4 inch to 1⁄2 inch. I immediately 

stopped the line and informed ) of 

the problem. I released control of the line at 2239 after extra employees were 

placed at the final trim station to trim the grease from the affected carcasses. At 

2245 the line was back in compliance. 9CFR 416.1 states “Each official 

establishment must be operated and maintained in a manner sufficient to prevent 

the creation of insanitary conditions and to ensure that product is not adulterated.” 

9CFR 416.4(a) states “All food-contact surfaces, including food-contact surfaces of 

utensils and equipment, must be cleaned and sanitized as frequently as necessary 

to prevent the creation of insanitary conditions and the adulteration of product.” 

9CFR 416.4(d) states “Product must be protected from adulteration during 

processing, handling, storage, loading, and unloading at and during transportation 

from official establishments.” 

5308 M6137 BXL2713022 

712N-1 

02/12/2013 04C05 Poultry Good 

Commercial 

Practices 

C On 02/12/2013 at approximately 0840 hours while performing Good Commercial 

Practices in Plant 2 Live Hanging area I observed the following. On Line the 

stainless steel tank marked "USDA CONDEMN" which is used for DOA birds in the 

live hanging area there were approximately 18 dead birds in the tank and one bird 

that was alive and lying on it's back at the bottom of the tank. The bird was 

breathing and had it's eyes open and was lifting it's head and moving it's legs. I 

immediately informed who in turn, using his radio, 

notified The bird was removed from the tank and 

placed on the live hanging line. I informed both and

 that this was a noncompliance with CFR 381.65(b) 

Good Commercial Practices. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4814022 

312N-1 

02/12/2013 06D02 Other Inspection 

Requirements 

C While monitoring The no viscera in line 2 of plant 1, I found a 

noncompliance with regulatory requirement of regulation 9 CFR 381.76 At 

approximately 0913 hours, I performed a no viscera check on line 2, at line speed of

 birds per minute(BPM). My check failed with 43 nonconformances out of 13 

nonconformances allowed at BPM. I notified . At 

0950 hours, at line speed BPM, QC performed a recheck failing with 22 

nonconformances out of 13 nonconformances. At this point a non compliance is 

issued. Line speed was slowed down to 126 BPM which allows 11 

nonconformances. At approximately 1245 hours, at 126 BPM line speed, QC 

performed a passing recheck with 10 out of 11 nonconformaces. Line speed was 

increased to BPM. At approximately 1301 hours, at BPM line speed, QC 

performed a passing recheck with 10 out of 13 nonconformances bringing the 

process back in control. was notified of the 

noncompliance. 

5308 M6137 BXL4814022 

312N-2 

02/12/2013 06D02 Other Inspection 

Requirements 

C On 02/12/2013, a second noncompliance was issued to line 2 in plant 1. During the 

afternoon there were 3 consecutive failures recorded on the no viscera 

log. One checks failed at birds per minute, which allows 13 nonconformances 

and two checks failed at line speed of 126 BPM, which allows 11 nonconformances. 

The viscera checks that were performed at 126 BPM did not meet the required 

standards during the afternoon; however, the line speed remained at 126 BPM. This 

scenario reflects a lack of control in the process. At 1326 hours I performed a no 

viscera check on line 2, at BPM line speed. I failed with 34 nonconformances 

out of 13 allowed. I notified who, decided to slow the line 

down to 126 BPM. At 1454 hours, QC performed a no viscera check at 126 birds per 

minute. She failed with 18 nonconformances out of 11 nonconformances allowed. 

At 1646 hours QC performed another failing no viscera check at line speed of 126 

BPM. She recorded 23 nonconformances out of 11 nonconformances allowed. This 

scenario represents a noncompliance with regulatory requirement of regulation 9 

CFR 381.76 

(b) (6)
(b) (6)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN340302 

4912N-1 

02/12/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C I was conducting the Review and Observation component of Pre-Operational 

Sanitation in area #2 of the Packaging department when I noted the following 

noncompliance. I inspected unit #30, the overhead incline transfer conveyor to dark 

meat deboning, I found 4 paint chips white in color approximately 1/8 of an inch in 

diameter continuing my inspection I also observed on the conveyor fat and meat 

particles from the previous days production. In between the white hard plastic side 

barriers of the conveyor fat was also present. The drip pan underneath the 

conveyor was covered with large pieces of fat, one measuring approximately 3 

inches in length and 1 1/2 inches width. I then retained the conveyor with the 

application of U.S. Retain tag B39415838 at 0040 hours and informed 

of the forthcoming noncompliance. At approximately 0051 

hours I reinspected the conveyor and verified that sanitary conditions were 

restored and released the conveyor. The establishment's SSOP program states in 

Part 1 Pre-operational Sanitation/Daily, Section 3 Packaging " 

. This failure represents a noncompliance with as per the 

regulatory requirements of sections 416.4 (a) and 416.13 (c) of the Federal Code of 

Regulations. The presence of fat and meat particles on a food contact surface 

represents a noncompliance with Section 9 CFR 416.4(a) which states, "All 

food-contact surfaces, including food contact surfaces of utensils and equipment, 

must be cleaned and sanitized as frequently as necessary to prevent the creation of 

insanitary conditions and the adulteration of product". Section 9 CFR 416.13 (c) 

states, "Each official establishment shall monitor daily the implementation of the 

procedures in the Sanitation SOP's". 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (6)

(b) (6)

(b) (4)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (4)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN390702 

4913N-1 

02/12/2013 04A06 Poultry Finished 

Product Standards 

C At approximately 0450 hours I performed the Review and Observation component 

of a Finish Products Standards Directed PHIS Task. At the offline inspection station I 

collected a sample consisting of 10 carcasses from which 4 carcasses marked with 

split tail had airsaccullitis exudate. Two of the affected carcasses had airsac in the 

thorax area; the other two had airsac on the left and right side of the kidney area. I 

showed my findings to 

. At 0457 hours 

, failed the required recheck on a 10 carcass sample from 

which 2 carcasses had airsacculitis exudate in the rib cage also. According to the 

establishment’s vacuum procedure part A-

. Part B states, “ 

”. 

, initiated immediate corrective actions as prescribe in the 

establishment’s vacuum procedure. The establishment failed to remove 

airsaccullitis exudate from carcasses marked by USDA online inspection personnel. 

Section 381.84 of the 9 Code of Federal Regulations requires that establishments 

completely remove and condemn tissues affected with airsacculitis, including 

exudates, in carcasses not condemned. Mr. 

, were informed of the 

forthcoming documentation for the failure to comply with the regulatory 

requirements cited above. 

5308 M6137 BXL0413020 

211N-1 

02/11/2013 06D02 Other Inspection 

Requirements 

C While monitoring The no viscera in line 2, plant 1, I found a 

noncompliance with regulatory requirement of regulation 9 CFR 381.76(a) and (b) 

At approximately 0816 hours, Line 2 was running at birds per minute(BPM) line 

speed which allows 13 nonconformances. I performed a check failing line 2 with 19 

nonconformances out of 13 nonconformances allowed. I notified 

. At 0837 hours, at line speed of BPM, QC performed a recheck failing 

with 19 nonconformances out of 13 nonconformances. At this point a non 

compliance is issued. The line speed was slowed down to 126 BPM which allows 11 

nonconformances. At approximately 0952 hours, at 126 BPM line speed, QC 

performed a passing recheck finding 10 out of 11 nonconformaces. The line speed 

was increased to BPM. At approximately 0959 hours, at BPM line speed, 

QC performed another passing recheck (10 out of 13 nonconformances) which 

brought the process back in control. was notified of the 

noncompliance. 

(b) (6)
(b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2708021 

011N-1 

02/11/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 02/11/201 at approximately 0507 hours while monitoring the establishments 

Pre-Operational Sanitation Special Units procedures in Plant 2, I observed the 

following. There was a deteriorating chicken foot from Saturday mornings 

production inside of Line scalder at the west end next to the Line picker.I also 

observed a clump of feathers approximately 4 inches long, in a crease on the 

bottom of Line scalder on the east end where the scalder rounds to head back 

west. Approximately one foot away from the clump of feathers, on the south side of 

Line scalder I observed numerous spots of dried crusty UFM approximately 1/8" 

in size and several feathers approximately 1/2" long at the scalder water level. I 

informed of 

the noncompliance. I released the area at approximately 0515, after recleaning and 

sanitary conditions were restored. 

5308 M6137 BXL5712022 

011N-1 

02/11/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C While performing a scheduled Zero Tolerance check on line 2 of plant 1, I found a 

noncompliance with regulatory requirement of regulation 9 CFR 381.65(e) and 

417.2 (c)(4). At approximately 1000 hours, I randomly removed 10 birds from line 2 

finding one out of ten birds contaminated with feces. The fecal contamination was 

located inside of the bird on the right side near the tail area. It was pasty in texture 

and light yellow in color, measuring approximately 1/4" in diameter. This is a 

violation of the critical limit of CCP-2B of the plant's 

HACCP plan for slaughter. were 

notified of the noncompliance. The establishment's fecal protocol was 

implemented. According to QC records the cause of deviation was "one of the water 

sprayers was plug up". At approximately 1025 hours, QC performed a passing 

recheck bringing CCP 2B back in control. Post chill checks were performed from 

1054 hours to 1200 hours. All product coming out of the chiller was found 

acceptable. 

(b) (6)
(b) (6)

(b) (6)

(b) (7)(C) (b) (7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN190202 

4112N-1 

02/11/2013 01C02 Operational SSOP 

Review and 

Observation 

C I, CSI, and CSI, were performing the Review and 

Observation component of a Sanitation Performance Standards PHIS Task. At 

approximately 2320 hours, seven minutes after the start of the official hours of 

operation, we observed at the North/East Carcass Chiller, Unit#10 (Area 1 Section 

D: Offline & Chiller Area) that two of the chiller’s paddles had fat residue from the 

previous day’s production on the support bars and on the paddles’ bars. The 

paddles at the moment of our observation were above the chiller’s water level. The 

first paddle had fat residue along the support bar surface and on the first bar of the 

paddle had a smear of fat approximately 5 inches long, 1 inch wide and 1⁄2 inch thick. 

The second paddle had a piece of fat with an approximate measurement of 3 inches 

long, 1 inch wide and 1⁄2 inch thick. We showed our findings to 

We took control of the affected area until the establishment 

restored sanitary conditions by cleaning and sanitizing the affected pieces of 

equipment. At 0045 hours approximately 2000 carcasses (5 combo bins) were 

retained and reprocessed. The establishment failed to clean the affected product 

contact surfaces during the general sanitation. This failure represents a 

noncompliance as per the regulatory requirements of sections 416.4(a), 416.4(d) 

and 416.13(c) of the Federal Code of Regulations. Section 9 CFR 416.4(a) states, “All 

food-contact surfaces, including food-contact surfaces of utensils and equipment, 

must be cleaned and sanitized as frequently as necessary to prevent the creation of 

insanitary conditions and the adulteration of product”. Section 9 CFR 416.4(d) 

states, Product must be protected from adulteration during processing, handling, 

storage, loading, and unloading at and during transportation from official 

establishments. Section 9 CFR 416.13(c) states, “Each official establishment shall 

monitor daily the implementation of the procedures in the Sanitation SOP's”. 

were informed of the forthcoming documentation for the failure to 

comply with the regulatory requirements cited above. 

(b) (6)
(b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3804022 

509N-1 

02/09/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 02/07/2013 at approximately 2255 hours while monitoring the establishments' 

Operational Sanitation procedures in Plant #2, I observed the following. The plant 

was running Organic birds when Line broke down. Line was being stopped 

repeatedly due to pathology (airsacculittis, inflammatory process, and 

contaminants). I walked to the kill line/evisceration auto transfer area and observed 

a large pile of birds on the floor, approximately 200. The three tanks , conveyor belt 

and catch trays were all also full. The birds that were on the floor were under the 

transfer machines and along the catch trays. The tank under the transfer unit for 

line was full so another tank was brought up. Birds that had collected on the 

floor, approximately 35, while the tanks were being transferred were run over by 

the replacement tank adding more contaminants to the product. About 2300 hours

 arrived. The kill was stopped, however it still took until 

approximately 2315 hours to get the birds off the floor. The conveyor belt for line 

is not setup to be used as a means of filling tanks with excess product as is line 

This requires the birds to be removed by hand. The available tank storage at the 

point of transfer is inadequate to collect the 15 minutes of birds from the kill line 

during a breakdown. My findings indicated a noncompliance with 9 CFR 416.1 and 9 

CFR 416.4(d). 

5308 M6137 BXL4004023 

609N-1 

02/09/2013 01D01 SPS Verification C On 02/09/2013 at approximately 0115 hours while monitoring Facilities in 

Packaging Area #1, I observed the following. The stainless steel lacing that holds the 

cloth belt together on the belt that collects the thighs under Leg Processors 7-12 

has deteriorated. Approximately 5 laces are worn with 2 that are completely worn 

off to the belts surface. One lace is approximately 1" long. The lacing was replaced 

soon after NR # BXL1708013131N/1 dated 1/31/2013 was written, however, the 

wear issue that is causing the lacing to deteriorate rapidly was not addressed. The 

lacing for the cloth belt that collects the legs for Leg Processors 7-9 has four missing 

laces. The main collection belt for Line that carries legs to the point where they 

are packaged has approximately 15 laces that have separated with 4 of the half 

laces on one side missing. The lacing on line that carries wings to the point of 

packaging has two laces separated with 3 of the 4 half laces missing. The belt that 

carries the wing sections and runs under the breast processors has wear marks on 

most of the laces on the entre length of the lacing. There are also four laces missing 

from that belt. As the lacing deteriorates either through wear or separation there is 

potential for stainless steel to attach to the product as it passes down the belts just 

prior to packaging. My findings indicated a noncompliance with 9 CFR 416.1 and 9 

CFR 416.2(b)(1). 

(b) (6)
(b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4)

(b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0419023 

408N-1 

02/08/2013 06D02 Other Inspection 

Requirements 

C At approximately 1630 hours, while monitoring the "No Viscera Log" for 

plant 1, lines 1 and 2, I observed a noncompliance with regulatory requirements of 

CFR 381.76 (a) and (b). Lines 1 and 2, each had three consecutive failures during the 

four hour period before lunch. Two checks failed at the line speed of birds per 

minute, which allows 13 nonconformances and the third check failed at the line 

speed of BPM, which allows 11 nonconformances. This reflects a lack of process 

control. Line 1 At 0813 hours, the check failed with 16 nonconformances at the line 

speed of BPM (13 nonconformances are allowed) At 0839 hours, the recheck 

failed with 14 nonconformances at the line speed of BPM. The line speed was 

slowed down to 126 BPM. At 1028 hours, the check failed with 13 

nonconformances at the line speed of 126 BPM (11 nonconformances are allowed) 

Line 2 At 0817 hours, the check failed with 28 nonconformances at the line speed of

 BPM ( 13 nonconformances are allowed) At 846, the recheck failed with 20 

nonconformances at the line speed of BPM. The line speed was slowed down to 

126 BPM. At 1036 hours, the check failed with 16 nonconformances at the line 

speed of 126 BPM ( 11 nonconformances are allowed). I informed 

about the noncompliance. 

5308 M6137 BXL4105020 

106N-1 

02/06/2013 03J02 Slaughter HACCP C On 02/06/2013 at approximately 0202 hours while monitoring the establishments' 

Finished Product Standards in Plant #2 Line , I observed the following. After 

taking a random 10 bird sample, I observed one bird with visible fecal 

contamination. There was a partial stomach attached to the carcass with an intact 

gizzard and approximately 8" of intestine attached to the stomach. The fecal 

material was leaking from the cut end of the intestine into the area of the kidneys. 

The fecal material was medium yellow in color, with a creamy texture and measured 

approximately 3/8" by 1/4" in size. This exceeded the Zero Tolerance for the 

process to be in control. was contacted and the protocol for fecal 

failure was implemented. A QC recheck at 0224 hours passed. My findings indicated 

a noncompliance with 9 CFR 381.65(e), 9 CFR 417.2(c)(4) and the critical limit of 

CCP 2B of the Plants' HACCP Plan for Slaughter. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (4) (b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4405020 

306N-1 

02/06/2013 01C01 Operational SSOP 

Record Review 

C On 02/06/2013 at approximately 0320 hours while conducting a SSOP records and 

associated documents review, I observed the following. The establishments' HOLD 

and Release Form for 02/04/13 indicated that at 1055 hours 2814 pounds of 

product at Packaging Line was condemned for being contaminated with 'foreign 

material'. At 1935 hours in Packaging Line two racks were held for being 

contaminated with 'foreign material'. At 1956 hours several tanks in PLT #1 were 

held for being contaminated with 'foreign material'. A review of the Establishments' 

SSOP for Operational Sanitation under Monitoring states 

." A 

review of the establishments' SSOP Daily Implementation and Monitoring Log for 

Operations in the affected areas for the shift under Operational SSOP indicated that 

conditions were found to be acceptable. The SSOP Daily Implementation and 

Monitoring Log for Operations was not used per the SSOP to record product 

contaminated during production. Under Corrective Actions the requirements for 

documentation concerning 'Restoration of Sanitary Conditions or Prevention of 

Recurrence which are to be documented by the 'Appropriate Plant Management 

Team Member were also not documented. My findings indicated a noncompliance 

with 9 CFR 416.4(d), 9 CFR 416.13 (b) & (c) and 9 CFR 416.16(a). 

5309 P6137A NJN481602 

5405N-1 

02/05/2013 01C02 Operational SSOP 

Review and 

Observation 

C I had just completed performing a zero tolerance check on the paws when I noticed 

at the paw chiller the ice dumper was in the upright position. While in the upright 

position there was a cardboard bin on a wooden pallet in the dumper restrainer. I 

looked inside the paw chiller and noticed a piece of what appeared to be foreign 

material floating on the ice. I informed of what I found.

 retrieved the material in question, which at 

this point was adhered to the inside wall of the chiller. The material was a wood 

sliver approximately 1 1⁄2 inches in length. At 0948 hours I tagged the paw chiller 

with U.S. Retain tag # B39415845. The establishment chose to implement 

corrective actions including emptying the paw chiller to wash and sanitize the inside 

product contact surfaces. The paws that were in the chiller where bagged and boxed 

and put on hold by the establishment, waiting further disposition, eleven cases in 

total. I informed of the 

documentation of the non compliance with the regulations cited above. After the 

chiller and belts where washed and sanitized I removed the U.S. Retain tag at 1048 

hours. 

(b) (6)
(b) (6) (b) (6) (b) (7)(C) (b) (7)(C) (b) (7)(C) (b) (7)(C) (b) (7)(C) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1219020 

901N-1 

02/01/2013 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1640 hours SCSI was called to the Plant 2 

evisceration line by the USDA Inspectors. The inspectors informed him that there 

was a high amount of birds with pathology (airsacculitis) being run on Line . SCSI

 observed that evisceration Line was continually stopping due to 

pathology. The reprocessing line, off/line reprocessing stations and reprocessing 

hang back racks were all full of birds being held for reprocessing. SCSI 

and I walked to the kill line/evisceration auto transfer area. We observed the Line 

transfer table, where birds collect when the evisceration lines stop. The table was 

overflowing and we could see approximately 10 birds on the floor around the Line 

transfer table. At approximately 1645 hours while we were observing the process in 

this area, evisceration Line stopped. This caused the chute that moves birds 

from the Line transfer machine to the transfer table to become congested. We 

observed approximately 25 birds overflow from the side of the congested chute and 

fall on the floor. On his way to inform of the 

insanitary condition in the re-hang area, SCSI passed by evisceration 

Line . He observed that Line was stopped and all inspection stations had hang 

back racks full. He also noticed that on Station 3 birds marked for reprocessing 

were hanging on the rack designated for “hang high” birds that have not been 

inspected. The reprocessing birds and hang high birds were comingled on the rack. 

This caused Line to be stopped for several minutes, while the reprocessing was 

being performed. At approximately 1650 hours while SCSI was observing 

the process of evisceration Line , I remained in the auto transfer area. I observed 

evisceration Line stop and because the Line transfer table was already full of 

birds this caused approximately 15 birds to fall on the floor at the transfer chute on 

Line automatic transfer machine. An employee brought a smaller metal tank 

over to the transfer chute to catch the birds that were falling on the floor, however 

in doing so he ran over the birds that had fallen on the floor. The wheels and the 

underside of the tank came in contact with the birds on the floor causing the birds 

to become more contaminated and created an insanitary condition. My 

observations reflect a noncompliance with regulations 9CFR 416.4(d) and 416.1. We 

notified of the noncompliance. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1708013 

131N-1 

01/31/2013 01D01 SPS Verification C On 01/31/2013 at approximately 0145 hours while monitoring Operational 

Sanitation procedures in Packaging Area #1, I observed that the stainless steel 

lacing that hold the brown cloth product belts together under Leg Processors 7-12 

have deteriorated. One wire piece of the lacing on the belt under the Processors 

that collect the legs is worn off level with the top of the belt material. One lace is 

approximately 1 inch long. There are wear marks that are normally caused by a 

rubbing motion on the product contact side along most of the length on the lacing. 

The lacing on the belt under the Processors that collect the thighs is missing three 

wire laces that are worn off level with the top of the cloth belt. The lacing on the 

thigh belt has wear marks on the product contact side that are much deeper than 

the wear marks on the leg belt. I showed my findings. My findings 

indicated a noncompliance with 9 CFR 416.1 and 9 CFR 416.2(b)(1). 

5308 M6137 BXL3422011 

331N-1 

01/31/2013 01C02 Operational SSOP 

Review and 

C On 01/31/2013 at approximately 0030 hours while monitoring the Establishments' 

Post-Chill Finished Product Standards in Plant #1 Chiller #2, I observed the 

Observation following. One carcass had a shiny metal flake approximately 1 1/2mm by 1mm 

between the tissue and skin surface near the neck area. was 

nearby so I showed her my finding. I took the metal flake to the Production office 

and showed . While checking for possible sources 

for the metal contaminant, I observed the chiller operation from the platform at the 

product inflow side. Each chiller paddle has a solid side and a forked side. The solid 

sides alternate with each chiller paddle. The backside of the chiller paddle has a 

ridge approximately 2" high. Near the rounded end of the solid side of the paddle 

that is submerged when the paddle is in use, there are worn areas on top of the 

ridge that vary in size with each paddle. The wear spots are several inches in length 

and up to approximately 1/4" in depth. All the paddles in both Chillers #1 & #2 that 

I observed have a similar wear spot in approximately the same location on both the 

right and left sides of the alternating solid portion of the paddles. On the edge of 

most of the wear spots that I observed there are metal shards of varying size.

 agreed that the metal flake on the carcass looks 

the same as the shards on the chiller paddles. My findings indicated a 

noncompliance with 9 CFR 416.1, 9 CFR 416.2(b)(1) and 9 CFR 416.4(d). 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN080901 

1331N-1 

01/31/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 0622 hours while performing PHIS zero-tolerance task in the 

Evisceration Department on B line I noted the following noncompliance. I randomly 

selected a ten carcass sample set and observed fecal material in the forth carcass of 

that sample. The fecal material was located inside the cavity on the right side thigh 

and also the right side leaf fat, approximately 1/4 in diameter on the inside and 1/4 

of an inch on the leaf fat, dark green in color with a paste like consistency. I 

immediately took a regulatory control action and stopped "B" line then showed my 

findings to . 

Ms. performed corrective actions as per establishment's HACCP plan and

 was notified of the noncompliance. The 

establishment did not meet the requirements of 9 CFR 381.65(e) which requires 

that the establishment prevents poultry carcasses contaminated with visible fecal 

material from entering the chilling system. The failure also represents a deviation 

from the establishment's written HACCP plan. Regulatory requirements of 

417.2(c)(4) states "List the procedures, and the frequency with which those 

procedures will be performed, that will be used to monitor each of the critical 

control points to ensure compliance with the critical limits." 

5308 M6137 BXL1617014 

230N-1 

01/30/2013 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1120 hours whilen performing scheduled Operational SSOP 

Review and Observation task I observed the following noncompliance. While 

walking through the Packaging area I walked into the Plant #2 Aged Breast Cooler 

where I found two pallets of brown tubs and lids, marked as clean, contaminated 

with numerous pieces of splintered wood up to approximately 1 1/4" by 1/8" in 

size, up to about three feet from the floor. I immediately took regulatory control 

action and tagged both pallets with USDA Reject/Retain tags #B31406328 and 

#B31406329, I then informed of the noncompliance 

and showed him my findings. He immediately took corrective action and had a 

company employee come with a pallet jack to take the pallets of tubs to the wash 

room to be rewashed. The two pallets of tubs were rewashed and sanitary 

conditions were restored by approximately 1240 hours. My findings indicate a 

noncompliance with 9CFR 416.1, 9CFR 416.4(a) and 9CFR 416.4(d). 

(b) (6)
(b) (6)

(b) (6)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4)(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1313012 

429N-1 

01/29/2013 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1010 hours while performing scheduled Operational SSOP Review 

and Observation task I observed the following noncompliance in the Packaging area. 

I walked between Line and the Leg Processor machines to look at the Leg Halver 

machine area and found condensation dripping into a brown tub staged for use at 

the Leg Halver machines. The condensation was dripping from the drip pan that is 

under a large exhaust fan on the ceiling just above the end of the halvers. I 

immediately notified of the noncompliance. He 

immediately removed the brown tub to be washed and called 

who immediately removed all product from the line and cleaned the 

condensation from the drip pan, restoring sanitary conditions by 1022 hours. My 

findings indicate a noncompliance with the regulatory requirements of 9 CFR 416.1, 

9 CFR 416.2(d) and 9 CFR 416.4(a). 

5308 M6137 BXL3618015 

728N-1 

01/28/2013 06D02 Other Inspection 

Requirements 

C On 01/28/2013, The "No Viscera Log" for plant 1, lines 1 and 2 reflected a 

noncompliance with regulatory requirement of 9 CFR 381.76 (a) and (b). Line 1 and 

2, each had three consecutive failures during the morning time. Two checks failed at 

line speed of birds per minute, which allows 13 nonconformances and the third 

check failed at line speed of 126 BPM, which allows 11 nonconformances. At this 

point production decided to continue running the lines at 126 BPM until further 

notice; however, the no viscera checks that were performed at 126 BPM did not 

meet the required standards during the afternoon. The line speed did not slowed 

down. This scenario reflects a lack of control in the process. Line 2 At 0805 hours, 

failed with 24 nonconformances at line speed of BPM (13 nonconformances are 

allowed) At 0823 hours, the recheck failed with 28 nonconformances at line speed 

of BPM. At 0835 Line was slowed down to 126 BPM until further notice. At 

1030 hours, failed with 15 nonconformances at line speed of 126 BPM (11 

nonconformances are allowed). At 1339 hours, failed with 30 nonconformances at 

line speed of 126 BPM. At 1500 hours, failed with 19 nonconformances at line 

speed of 126 BPM. Line 1 At 0800 hours, failed with 22 nonconformances at line 

speed of BPM (13 nonconformances are allowed) At 0819 hours, the recheck 

failed with 20 nonconformances at line speed of BPM. At 0825 Line was slowed 

down to 126 BPM until further notice. At 1025 hours, failed with 26 

nonconformances at line speed of 126 BPM (11 nonconformances are allowed). At 

1310 hours, failed with 31 nonconformances at line speed of 126 BPM. At 1449 

hours, the check passed with 8 nonconformances. Line speed was increased from 

126 BPM to BPM. At 1454 hours, the check passed with 13 nonconformances 

at line speed of BPM. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE030101 

0028N-1 

01/28/2013 01D01 SPS Verification C On 1/27/13 at approximately 2245 I observed the following while preforming the 

SPS task . The Blast Tunnel in the degree cooler . Lines 1 2 & had debris on the 

floor including old frozen exposed paws a large package of Skin on Jumbo Breast 

and soaker pads . Lines had frozen exposed drums , thighs and paws on 

the floor as well . Regulation 416. 2(b)2 states walls,floors,and ceilings within the 

establishment must be built of durable materials impervious to moisture and be 

cleaned and sanitized as necessary to prevent adulteration of product or the 

creation of insanitary conditions . My observation also indicates a non-compliances 

with regulation . was working close to the 

area so he was informed of the non-compliance . assured 

me the situation would be taken care of immediately . My findings indicate 

non-compliances with the following regulations 9CFR 416.2(b)2 , 9CFR 416.1 and 

9CFR 416.4d . 

5309 P6137A NJN360101 

3629N-1 

01/27/2013 04A06 Poultry Finished 

Product Standards 

C While I was giving breaks to online inspection personnel, I noticed an increment of 

birds with airsacculitis being hanged on the offline. After the breaks were done, I 

decided to perform a directed task to verify if the establishment was implementing 

its written procedures. At approximately 0700 hours I performed the 

Review and Observation component of a Finish Products Standards Directed PHIS 

Task. At the offline inspection station I collected a sample consisting of 10 carcasses 

from which 2 carcasses marked with split tail had airsacculitis exudates in the rib 

cage. At 0709 hours I performed a recheck on a 10 carcass sample from which 1 

carcass had airsacculitis exudates in the rib cage also. I showed my findings to 

. According to the establishment’s 

vacuum procedure part A- Plant Standard Criteria for Critical Control Points, states, 

“ ”. Part 

B states, “ 

. , 

initiated immediate corrective actions as prescribe in the establishment’s vacuum 

procedure. The establishment failed to remove airsacculitis exudates from carcasses 

marked by USDA online inspection personnel. Section 381.84 of the 9 Code of 

Federal Regulations requires that establishments completely remove and condemn 

tissues affected with airsacculitis, including exudates, in carcasses not condemned. 

Mr. , was informed of the forthcoming 

documentation for the failure to comply with the regulatory requirements cited 

above. 

(b) (6)
(b) (7)(C) (b) (7)(C) (b) (6)

(b) (6)

(b) (6)

(b) (6)

(b) (6) (b) (7)(C) (b) (7)(C) (b) (4) (b) (4) (b) (4) (b) (4)

(b) (4)

(b) (4)

(b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4222010 

825N-1 

01/25/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 01/24/2013 at approximately 0215 hours while monitoring the establishments' 

Operational Sanitation procedures in the Packaging Department, I observed the 

following. On the rehang belt adjacent to the plant #2 unit there were 

several uncut gizzards mixed in with the Organic birds being hung on a line going to 

the halving machine in Packaging. As the Organic birds at this point in the process 

have received their final microbial intervention, I collected several of the gizzards 

and found that some of the gizzards were still full of ingesta and intestinal digestive 

juices, some had partial stomachs attached, and one had a piece of intestine 

approximately 6" long with fecal material still present inside. The conveyor belt and 

birds were potentially cross contaminated by the contents of the uncut gizzards, 

stomachs and intestine which are normally contaminated with various bacteria i.e. 

Salmonella, and are normally removed by step #31 according to the establishments' 

Hazard Analysis Flow Chart of the slaughter process. The conveyor belt was 

emptying off so I continued to collect the gizzards when arrived I 

explained to him the cross contamination issue and had him call 

who was informed of the noncompliance. The belt was 

rinsed with restoring sanitary conditions. There were 

approximately 90 uncut gizzards collected from the belt that had been there for an 

undetermined period of time. Birds normally exit the chillers at approximately 0025 

hours and start to collect on the rehang belts. The birds remain on the belt for 

varying periods of time until selected for hanging. I proceed to line in Packaging 

which was being used to manually cutup Organic carcasses into parts for packaging. 

These birds come from the same chiller. There was a uncut gizzard on a pile of half 

breast collected at that location. was nearby. The 

gizzard with a partial stomach attached was removed. The gizzard was full of 

ingesta and digestive juices. The breast halves near the location of the gizzard were 

reconditioned and returned to production. The area was rinsed with . 

I proceeded to the Superintendents office and discussed the issue with the 

. I informed him of the possible cross 

contamination issue and that I would place product that may have come into 

contact with the bacterial source, the gizzards and intestine, on hold. I proceeded to 

the Staging Cooler and placed USDA hold tags on 27 pallets of Organic Front halves 

by approximately 0315 hours. I proceeded to the USDA Office and informed SCSI 

and SVMO of the issue and that product was involved.

 and Dr. discussed the issue and I was told by Dr.

 to release the product. All product was released by approximately 0340 

hours. A review of the establishments' SSOP - under Daily 

Procedures states " 

" and 

" A review of the 

states 

(b) (6)
(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

." My finds 

indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.4(d), and 9 CFR 416.14. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5608014 

725N-1 

01/25/2013 01D01 SPS Verification C On 01/24/2012 at approximately 2240 hours while monitoring Operational 

Sanitation procedures at startup in Plant #2, I observed the following. There was a 

shiny metal flake approximately 2mm by 1mm in size on the Transfer Belt for line 

. At this point in the process the birds are being moved from the kill line to the 

evisceration line. As the birds were arriving at the automatic re-hang machine for 

the line and with the potential of a physical hazard being added to the product, I 

removed the metal flake and showed it to who was monitoring the 

rehang equipment in the same location. A row of metal pins is used to hold the 

fabric of the belt together. I showed the condition of the metal 

pins associated with the transfer belt. The stainless pins on both transfer belts for 

lines were in similar condition. There appeared to be one to four pins missing 

on the both ends of both transfer belts. Several more pins on both belts were 

separated from one end of the belt material. The tops of many of the pins have 

wear marks that are normally caused by a rubbing action and is a possible source of 

the metal flake. A review of the HACCP plan - Slaughter plant 2 under (P) Physical 

Hazards has "None Identified". Under 'Justification for Decision' there are no 

reasons listed or supplemental documents listed as support for the decision. My 

findings indicated a noncompliance with 9 CFR 416.1 and 9 CFR 416.2(b)(1). 

5308 M6137 BXL1105010 

424N-1 

01/24/2013 06D02 Other Inspection 

Requirements 

C On 01/24/2013 at approximately 0032 hours while monitoring Presentation on line

 in Plant #2, I observed the following. At a line speed of bpm (birds per 

minute) station #1 had (2) viscera not uniform, (1) viscera on the shackle, (5) 

membranes, (3) not reflective for a total of 40 weighted nonconformance points 

from a standard 10 bird check. An accumulation of 40 or more nonconformance 

points requires an immediate line speed reduction to 81 bpm. I contacted

 and the line was slowed The 2nd station had (3) membranes, (3) 

not reflective, and (2) parts inside. Station #3 had (3) viscera on the shackle, (1) 

membrane, (2) not reflective and (1) contamination inside for a total of 36 

nonconformance points. Three occurrences for the same error or more then 25 

total points are also failures requiring a recheck. was informed 

that all three stations on line had failed. A Quality Control recheck at 0057 hours 

failed at 2nd of the 3rd stations with (4) not reflective at station #2, and (3) no 

viscera and (3) not reflective for 30 total points at station #3. The line was slowed 

to 71 bpm. QC rechecks at 0107 hours, 0121 hours and 0127 hours all passed 

bringing the line back into compliance. My findings indicated a noncompliance with 

9 CFR 381.76(b). 

(b) (6)
(b) (6)

(b) (6)

(b) (6)

(b) (7)(C) (b) (7)(C) (b) (7)(C) (b) (4) (b) (4) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN500201 

0824N-1 

01/24/2013 01D01 SPS Verification C At approximately 2354 hours I, CSI , and CSI were in 

the Wet cooler performing the review and observation element of the Sanitary 

Performance Standards task. In the Wet cooler I observed six racks of product, code 

#920 in dirty baskets. On the baskets I observed pieces of fat and muscle tissue, 

dried blood, and black spots of foreign material. Upon further inspection the 

product's immediate packaging, individually sealed plastic containers, was also 

covered in black foreign material. The racks had a written temporary labels that 

read, "#920, back to cherry, date 1/23/13". I then retained the six racks with the 

U.S. retain tags sited in section 9B of this document, and informed Fillet Swing Shift

 of the noncompliance. 

was also informed of the noncompliance. After I verified that sanitary 

conditions were restored by the baskets and product's immediate packaging being 

cleaned of the visible foreign material, product was released to be repacked in new 

containers. The dirty packages and baskets represent a noncompliance with 

417.4(d) which states: Product must be protected from adulteration during 

processing, handling, storage, loading, unloading at and during transportation from 

official establishments. 

5308 M6137 BXL0808011 

024N-1 

01/23/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 01/24/2013 At approximately 0135 hours while performing a scheduled 

Operational SSOP Review and Observation task, SCSI and I were 

walking in Plant One around the back side (south end) of rehang weight chute area 

next to Line We observed condensation dripping from an unsanitary structure, a 

catwalk, into a large metal tank of product. I immediately tagged the tank with 

retain tag #B31407307, and notified . 

Product was reworked and placed into a sanitized tank and covered with plastic to 

prevent any further contamination. Product was released at 0205 hours. My 

findings indicate a noncompliance with the regulatory requirements of 9CFR 

416.2(d) and 9 CFR 416.4(d). 

5308 M6137 BXL1112015 

923N-1 

01/23/2013 03J02 Slaughter HACCP C While performing a Finished Products Standards Task, I found a noncompliance 

with the following regulatory requirements of regulations 9CFR 381.65 (e) and 9CFR 

417.2 (c)(4). At approximately 0823 hours, I randomly removed a 10 bird sample 

from Line #2 in Plant #1, I found one out the ten birds with visible fecal 

contamination outside of the bird located on the back of the tail in the right side. 

The fecal material was spot measuring approximately 1/8" diameter in size, green 

olive in color and pasty in texture. This exceed the limit of Zero Tolerance for the 

process to be in control. I informed 

of the noncompliance. The protocol for fecal failure was implemented. 

Quality Control performed a recheck at approximately 0855 hours and it passed. 

The cause of the deviation was the water pressure. This is a violation of the critical 

limits of CCP-2B, of the Plant's HACCP Plan for Slaughter. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (7)(C) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1718013 

222N-1 

01/22/2013 01D01 SPS Verification C At approximately 1440 hours, CSI's and I observed a live 

juvenile cockroach on the wall between the hands wash sink and the paper towels 

dispenser in the body opener area in Plant #2. The cockroach was caught and 

immediately shown to the . He immediately called

 and informed him about our findings. This is a 

noncompliance with the following regulatory requirements of regulations 9CFR 

416.1 and 9CFR 416.2 (a). 

5333 P7632 HYE310201 

1122N-1 

01/22/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 1/21 /13 at approximately 2315 hours I observed the following while 

preforming the SSOP Review and Observation task . Unit # 3 of area 3 the incline 

conveyor flex belt had a build-up of yellowish/brown UMF (unidentified forigen 

material ) underneath the frame between the flex belt and the inner portion of the 

frame . The area was approximately 2” in width and approximately 8” to 10” in 

length I immediately applied U.S . Retained/Rejected tag # B38493695 on the 

conveyor and brought my finding to the attention of 

who was standing near . Had 2 of his workers scrub and rinse 

the bottom and the inside of the frame work .The area was reinspected at 

approximately 2325 hours . Sanitary conditions were restored and the tag was 

removed . The conveyor was resanitized and the area was ready for production. My 

findings indicate non-compliances with the following regulations 9CFR 

416.4(b) , 9CFR 416.14 , 9CFR 416.4(a) , 9CFR 416.13 and 9CFR 416.13(c) . 

5308 M6137 BXL2320010 

721N-1 

01/21/2013 06D02 Other Inspection 

Requirements 

C At approximately 1544 hours while monitoring the "No Viscera Log" for Line #1 and 

Line #2 in Plant #1, I observed a noncompliance with the following regulatory 

requirements of regulations 9CFR 381.76 (a) and 9CFR 381.76 (b). Line #2 had five 

consecutive failures by Quality Control. At 0802 hours at line speed of BPM, 

Quality Control documented 25 no viscera only 13 are allowed. At 0825 hours the 

recheck failed with 24 no viscera. Line Supervisor was informed and at 0841 hours, 

the line speed was reduced to 126 BPM. At 1031 hours at line speed of 126 BPM 

Quality Control documented 16 no viscera and only 11 are allowed. Three 

consecutive failures in a half- shift period is a noncompliance for lack of process 

control. I informed of the noncompliance. Two more 

consecutives checks failed, one at 1334 hours with 24 no viscera and another one 

at 1533 hours with 18 no viscera at the same line speed of 126 BPM. 

(b) (6)
(b) (6)(b) (6)

(b) (6)

(b) (7)(C) (b) (7)(C)

(b) (4)

(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN130301 

3022N-2 

01/20/2013 03C02 Raw Intact HACCP C At approximately 0245 hours while performing the Review and Observation 

component of a Raw Intact Verification PHIS Task; CSI, and I, CSI 

, observed approximately 7 pieces of dark meat (boneless thighs) 

that were on the top of the cover of the #1, which is not edible product 

contact surface, in the Packaging department. As part of the SIP Waiver that was 

granted to the establishment, we decided to take the temperature on the pieces of 

dark meat. We requested to , to take 

the temperature with her calibrated thermometer #471. One piece registered its 

internal temperature at 61.3 F. Mr. , 

requested to take the temperature one more time. On the second recheck, the 

internal temperature registered was 63.1 F. The finding of temperatures above 

degrees F does not comply with the SIP waiver granted to the establishment by 

USDA/FSIS and does not meet the regulatory requirements of sections 381.3 and 

417.5(a) of the 9 Code of Federal Regulations. 9 CFR 381.3 states, 

“Administration.(b) The Administrator may in specific classes of cases waive for 

limited periods any provisions of the regulations in order to permit appropriate and 

necessary action in the event of a public health emergency or to permit 

experimentation so that new procedures, equipment, and processing techniques 

may be tested to facilitate definite improvements: Provided, That such waivers of 

the provisions of the regulations are not in conflict with the purposes or provisions 

of the Act.” 9 CFR 417.5(a) states, “(1) the written hazard analysis prescribed 

in § 417.2(a) of this part, including all supporting documentation;(2) The written 

HACCP plan, including decisionmaking documents associated with the selection and 

development of CCP's and critical limits, and documents supporting both the 

monitoring and verification procedures selected and the frequency of those 

procedures. The SIP protocol using the alternative chilling procedures in place of 9 

CFR 381.66(b), states, 

. The establishment elected to 

condemn the affected product. Mr. 

, was informed of the forthcoming documentation for the failure to 

comply with the establishment’s SIP program and the regulatory requirements 

cited above. 

(b) (6)
(b) (6) (b) (6) (b) (6)

(b) (6)

(b) (4) (b) (4)

(b) (4)

(b) (4)

(b) (7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN420501 

5718N-1 

01/18/2013 03C02 Raw Intact HACCP C On 1/17/13 I was in the Fillet Department and observed numerous tray pack racks 

lined up to be sent into the crust tunnel. I then used my sanitized digital 

thermometer to measure the temperature of one package of boneless skinless 

breast, the temperature was 61.0 F. I then retained the rack from which the tray 

pack was retrieved with U.S. retain tag B38495476. I showed 

my findings and requested a Q.C. Technician to take a temperature 

measurement with a calibrated thermometer.

 used calibrated thermometer # 427 and measured the temperature of the 

product to be 60.4 F. I then requested more readings from the same rack and we 

found two packages at the following temperatures: 58.7 F and 59.5 F. I informed 

of the forthcoming noncompliance for product exceeding 60 F. The last 

passing temperature check for boneless skinless breast was taken at 2037 hours, 

temperature measurement was 38.8 F. Establishment P-6137 A was granted a 

Salmonella Initiative Program Letter issued on September 9, 2011. The SIP program 

allows establishment P-6137A to use alternative chilling procedures in place of 9 

CFR 381.66(b), provided the establishment: Assesses, modifies and validates as 

appropriate, the Hazard Analysis and Critical Control Points (HACCP) plan according 

to 9 CFR 381.22 and 417.4. The establishment failed to implement their SIP 

program by allowing the internal temperature of their product to rise above 60 

degrees F. SIP protocol states: “ 

.” In 

addition establishment P 6137 A prerequisite CP-4B SOP states: " 

. 

5308 M6137 BXL4718010 

317N-1 

01/17/2013 03J02 Slaughter HACCP C At approximately 1550 hours while performing a HACCP Slaughter Record Review 

Task, CSI and I found the following; the HACCP Monitoring Log - CCP 

2B, Line # dated on 01/16/2013 AM shift had a failure at 

approximately 0633 hours. Corrective actions were performed and finished at 

approximately 0850 hours. The Pre-Shipment Records Review CCP 2B 

End of Shift, was signed at 0800 hours. The signed documented certifies 

that the product is ready to be shipped. The Pre-Shipment Records Review, End of 

Shift was signed before the corrective actions for the failure were completed. This is 

a noncompliance with the following regulatory requirements of regulations 9CFR 

417.5 (c). I informed of the 

noncompliance. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6)

(b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE030501 

4817N-1 

01/17/2013 04A06 Poultry Finished 

Product Standards 

C On Wednesday 01/16/2013 night shift there was a high percentage of birds 

presented for post-mortem inspection that where identified by the on line 

inspectors for airsaculitis removal. The establishment had initiated their alternative 

On-line Vacuuming/Air sac Removal procedure. At 0230 hours I elected to verify the 

effectiveness of the alternative procedure. I went to the FPS Pre-Chill Station on line 

1 and collected a ten (split tail) bird sample. Three of the ten birds exhibited air sac 

exudate on the left side along the ribcage area; one of the ten birds had intact 

kidneys indicating that the vacuum procedure was ineffective. QC performed the 

required ten bird retest, there where no failure findings on the retest. I notified 

of the 

forthcoming documentation for the failure to comply with the regulations cited 

above. 

5309 P6137A NJN062201 

1116N-1 

01/16/2013 04A06 Poultry Finished 

Product Standards 

C At approximately 0455 hours I was performing the Review and Observation 

component of a Finish Products Standards PHIS Task. At the offline inspection 

station I collected a sample consisting of 10 carcasses from which 1 carcass marked 

with split tail had airsaccullitis exudate in the rib cage. I showed my finding to 

. I initiated a recheck of 10 carcasses marked with a split tail and 

again 1 carcass had airsaccullitis exudate in the rib cage. 

began immediate corrective actions as prescribed in 

the establishment’s vacuum procedure. I informed 

of the forthcoming noncompliance. The establishment failed to 

remove airsaccullitis exudate from carcasses marked by USDA online inspection 

personnel. 9 CFR 381.84 requires that establishments completely remove and 

condemn tissues affected with airsacculitis, including exudates, in carcasses not 

condemned. Two noncompliances were documented for the same cause on 

11/23/2012 NR# NJN0409114623N/1 and on 1/15/2013 NR# NJN3407011415N/1. 

5308 M6137 BXL0309014 

715N-1 

01/15/2013 04A06 Poultry Finished 

Product Standards 

C On 01/15/2013 at approximately 0025 hours while monitoring the Establishments' 

Post-Chill Finished Product Standards in Plant 1 from Chiller #1, I observed the 

following. After collecting a random 10 bird sample, I accumulated 21 

nonconformance points which exceeded the subgroup absolute limit of 10 points. I 

informed . A QC recheck failed with 14 points at 0032 

hours. The limit at the Post-Chill for a recheck is Tolerance which is 5 points. At this 

point the process is judged to be out of control. Production was aware and had 

tanked the failing product since the initial birds exited the chiller. A QC recheck 

failed again at 0109 hours with 8 nonconformances. A recheck at 0259 and 0512 

hours brought the process back into control. A total of 8 tanks of carcasses were 

placed on QC hold pending rework. My findings indicated a noncompliance with 9 

CFR 381.76(b)(3)(iv)(e)(3). 

(b) (6)
(b) (4) (b) (6)

(b) (6)

(b) (6) (b) (6)

(b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2914012 

015N-1 

01/15/2013 04A06 Poultry Finished 

Product Standards 

C While monitoring the Establishments' Reprocessing Procedures on Line in Plant 

#2, I observed a noncompliance with the following regulatory requirements of 

regulation 9CFR 381.84. At approximately 0900 hours, I randomly removed a 10 

bird sample for my reprocessing check, I found three out the eight birds with split 

tails in the sample that contained Airsacculits exudates. I immediately took 

regulatory control action by stopping the line and informed the 

and also . The line was started and the product 

retained while corrective actions were being implemented. I performed a recheck at 

approximately 0910 hours and it passed bringing the process back in control. I 

tagged the tank containing the product with U.S. Retained/Rejected Tag # B31 

406714. After the product was reworked, I performed a recheck and released it , at 

approximately 0940 hours. 

5309 P6137A NJN340701 

1415N-1 

01/15/2013 04A06 Poultry Finished 

Product Standards 

C At approximately 0505 hours I was performing the Review and Observation 

component of a Finish Products Standards PHIS Task. At the offline inspection 

station I collected a sample consisting of 10 carcasses from which 4 carcasses 

marked with split tail had airsaccullitis exudate in the rib cage. I showed my finding 

to . According to the establishment’s 

vacuum procedure 3 carcasses with vacuum defects it requires retention and 

rework of the affected product. , 

initiated immediate corrective actions as pescribe in the establishment’s vacuum 

procedure. The establishment failed to remove airsaccullitis exudate from carcasses 

marked by USDA online inspection personnel. 9 CFR 381.84 requires that 

establishments completely remove and condemn tissues affected with airsacculitis, 

including exudates, in carcasses not condemned. Mr. 

, was informed of the forthcoming documentation for the failure to 

comply with the regulatory requirements cited above. 

(b) (6)
(b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0918013 

011N-1 

01/11/2013 06D02 Other Inspection 

Requirements 

C At approximately 1445 hours, while monitoring the "No Viscera Log" for Line #1 

and Line #2, I observed a noncompliance with the following regulatory 

requirements of regulations 9CFR 381.76 (a) and 9CFR 381.76 (b). --Line #1 had 

three consecutive failures by Quality Control in a four hours period, before lunch 

time break. At approximately 0816 hours at line speed of BPM, Quality Control 

documented 36 no viscera and only 13 no viscera or less are allowed. At 

approximately 0842 hours, Quality Control recheck failed with 26 no viscera at line 

speed of BPM. Line Supervisor was informed and at approximately 0851 hours 

the line speed was reduced to 126 BPM. At approximately 1018 hours at line speed 

of 126 BPM, Quality Control did her regular check and failed with 19 no viscera. At 

this line speed only 11 no viscera or less are allowed. --Line #2 had also three 

consecutive failures by Quality Control in a four hours period, before lunch time 

break. At approximately 0811 hours at line speed of BPM, Quality Control 

documented 21 no viscera and only 13 no viscera or less are allowed. At 

approximately 0838 hours, Quality Control recheck failed with 21 no viscera at line 

speed of BPM. Line Supervisor was informed and at approximately 0846 the 

line speed was reduced at 126 BPM. At approximately 1031 hours at line speed of 

126 BPM, Quality Control did her regular check and failed with 19 no viscera. At this 

line speed only 11 no viscera or less are allowed. At this point both lines were out 

of control. Three consecutive failures is a noncompliance for a failure to take proper 

corrective actions. was informed about the noncompliance. 

Line #1 was back in control at approximately 1455 hours and Line #2 remained at 

126 BPM till the end of the shift. 

(b) (6)
(b) (6)

(b) (6)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1409010 

711N-1 

01/11/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 01/11/2013 at approximately 0630 hours while reviewing the establishment 

SSOP records and associated documents, I observed the following. On 12/31/2012 

a noncompliance BXL4107122331N/1 was written for product from plant #1 being 

contaminated with UFM (Unidentified Foreign Material). On 01/02/13 at 0028 

hours the establishment retained product contaminated with UFM that was exiting 

the plant #1 chillers. The cause of the contamination was determined to be dirty 

city water. At the weekly meeting on 01/02/2013 the issue of contaminated 

product with dirty city water was discussed with plant management and 

documented on MOI BXL3019012102G. Maintenance was to contact the city to 

solve the problem. On 01/09/2013 at 1320 hours the establishment shutdown 

plant #1 as a result of dirty city water contaminating product. At 1353 hours on 

01/09/2013 product exiting the giblet chillers was found to be contaminated with 

foreign material. The cause again was determined to be dirty city water. On 

01/10/2013 at 0025 hours product exiting the Plant #1 chillers was retained for 

being contaminated with foreign material. On 01/11/2013 at 0025 hours product 

exiting the Plant #1 chillers was retained for being contaminated with foreign 

material. A review of the establishments Operational Sanitation SSOP 'Corrective 

Action' states in part under " 

." No 

effective preventative measure has been established as the contamination of 

product in Plant #1 from dirty city water continues. My findings indicated a 

noncompliance with 9 CFR 416.15(b) which states in part 'Corrective Actions 

include... appropriate reevaluation and modification of the Sanitation SOP's and the 

procedures specified therein or appropriate improvements in the execution of the 

Sanitation SOP's or the procedures specified therein.' 9 CFR 416.4(d), 9 CFR 416.14 

and 9 CFR 416.1. 

5308 M6137 BXL5409013 

011N-1 

01/11/2013 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1400 hours, while walking through the Room, I observed a 

brown tub on the reprocessing station. This tub was located on the right side of the 

reprocessing station next to a conspicuous "clean product" red sign. I removed the 

lid and found the tub full with product. I proceeded to verify compliance with the 

establishment's Product reconditioning Procedure. I inspected the already 

reconditioned product, finding one fillet and two half breast contaminated with 

several small specks of freing material. I immediately place a US. Rejected/Retained 

tag N0. B31 407744 on the affected product. I notified and 

of the noncompliance. All products was reconditioned again. At 

approximately 1500 hours, I re-inspected the reconditioned product finding it 

acceptable. I then, remove the USDA hold tag. My findings represent a 

noncompliance with regulation 9 CFR 416.4(d); 416.14 and 416.1 

(b) (6)
(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5804013 

911N-1 

01/11/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 01/10/2013 at approximately 2210 hours while monitoring the establishments' 

Pre-Operational Sanitation procedures in Plant #2, I observed the following. There 

were numerous specks to approximately 1/8" of black UFM(Unidentified Foreign 

Material) on the transfer table for line . The guide bars for lines adjacent 

to the transfer table were coated with a thick layer of fat, blood, tissue and 

feathers. There is a section of guide bar approximately 5' long on line located 

along the wall just before the line transfer table that is worn half away. The 

internal surfaces of the guide bar were partially filled with sour fat & tissue from 

previous days production. This deteriorating maternal condition is creating an 

insanitary condition. There are several short sections of the rail at the same location 

for lines that are deteriorating into layers of flaky rust. The rail is directly 

above the birds during production potentially contaminating product. There was 

numerous pieces of welding slag to approximatekly 1/4" on the top of the sprocket 

associated with the oil sack cutter for line . The support brackets above the line

 oil sack cutter were coated with a greasy film of brown UFM. There is no catch 

tray associated with the unit that would protect the product during production. 

There was a thin coating of brown UFM with the consistency of dry rust on the 

shaft and kickout assembly for the second station on line The kickout is directly 

above the carcasses which are open at this point in the process. There was peeling 

paint & rust on the support brackets associated with sprocket directly above the 

gizzard puller assembly on line Carcasses run directly under the unit and are 

open at this point in the process. There was a black powdery UFM with small shiny 

specks that could be metal directly under the chain drive portion of the gizzard 

puller on line There is no catch pan associated with the gizzard puller units 

creating a potential for the UFM to contaminate carcasses during production. My 

findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.4(a) & (b), 9 CFR 

416.2(b)(1), 9 CFR 416.13(c) and 9 CFR 416.14. 

(b) (6)
(b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3617010 

910N-1 

01/10/2013 06D02 Other Inspection 

Requirements 

C While performing No Viscera Check on Line #1 and Line #2 at approximately 1351 

hours, I found a noncompliance with the following regulatory requirements of 

regulations 9CFR 381.76 (a) and 9CFR 381.76 (b). Line #2 had three consecutive 

failures by Quality Control in a four hours period before lunch break. At 

approximately 0811 hours at line speed of BPM, Quality Control documented 

21 no viscera and only 13 no viscera or less are allowed. At approximately 0840 

hours at line speed of BPM, Quality Control recheck failed with 18 no viscera. 

Line Supervisor was informed and at approximately 0847 hours, line speed was 

reduced to 126 BPM. At approximately 1027 hours at line speed of 126 BPM, 

Quality Control documented 12 no viscera and only 11 no viscera or less are 

allowed. At this point the process is out of control. Three consecutive failures is a 

noncompliance for a failure to take proper corrective action. At approximately 1320 

hours at line speed of 126 BPM, Quality Control documented 13 no viscera, only 11 

no viscera or less are allowed. At approximately 1501 hours at line speed of 126 

BPM the check passed with 11 no viscera. At approximately 1509 hours at line 

speed of BPM the check passed with 9 no viscera, bringing the process back in 

control. I informed of the noncompliance. 

5308 M6137 BXL5717011 

910N-1 

01/10/2013 01D01 SPS Verification C At Approximately 1037 hours while performing scheduled Operational SSOP Review 

and Observation task I was walking into the packaging area from Plant #2, I 

observed the following noncompliance. I was looking down the Cut Up Line when 

I looked up and noticed heavy beaded condensation covering the bottom of the 

drip pan that is below the large exhaust fan on the ceiling. The drip pan is directly 

above the line of carcasses that go to Line in packaging. I immediately notified

 of my findings and showed him the condensation. He 

immediately had a sanitation employee get a ladder to reach the affected area and 

had another Supervisor stop employees from hanging on that line to create a gap in 

the carcasses, when the gap reached the affected area the line was stopped and 

sanitation cleaned the drip pan without affecting product. Sanitary conditions were 

restored by approximately 1049 hours. My findings indicate a noncompliance with 

the Regulatory requirements of 9 CFR 416.2(d) and 9 CFR 416.1. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (6)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN291801 

1110N-1 

01/10/2013 03C02 Raw Intact HACCP C On January 9, 2013 at approximately 1736 hours, while performing PHIS procedure 

Raw Intact in Packaging Department, while the establishment was processing and 

packaging Buffalo Chicken Breasts with a marinade that declares in the label to 

contain allergens (dry milk), I observed the following non compliance: Allergen 

residue inside a tote that was half full of product of boneless thigh meat next to the 

dark meat conveyor. The ice inside the tote covering the product, had visual traces 

of allergen residue. I immediately placed U.S. Retained Tag #B39415825 to the 

product and informed Mr. of the non 

compliance. Mr. elected to condemn the product intead of rework. At 

approximately 1835 hours, I decided to inspect the process again and observed at 

the end of the dark meat conveyor line, just prior to the , a strip of plastic (14 

to 15 inches long) that was smeared with the allergen marinade and was resting on 

top of boneless thighs, (10 to 15 lb). Closer inspection revealed that the boneless 

thigh meat table that runs parallel to Buffalo Chicken Breasts had specs of marinade 

all along that specific side. I immediately showed my findings to and

 and informed them that this instance would be added to 

the forewarned non compliance. Mr. elected to condemn the product 

immediately so no tag was applied and to seize production for the day. Boneless 

dark meat product on the table is retained by the establishment. Establishments 

hazard analysis address allergens as not reasonably likely to occur because of their 

Pre-requisite program which states: 

The establishment’s Pre-requisite program failled to 

determine the unforeseen hazard of allergenic cross-contamination. 

(b) (6)
(b) (6)

(b) (6) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE310401 

5911N-1 

01/10/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C At approximately 2345, I began a preoperational inspection of the establishment’s 

2nd processing area. This inspection began after I was notified by the designated 

establishment employee that the area was ready for inspection. While inspecting a 

blue product transfer belt, I found fat residue build-up from previous usage on the 

product contact surface side of the belt. Mr. 

was in the vicinity at the time of my finding and was both informed of 

and given the opportunity to observe the condition of the product transfer belt. 

Immediate corrective actions were then taken by establishment personnel to 

restore the sanitary condition of the belt. After the establishment’s corrective 

actions were completed, I re-inspected the product belt and determined that it was 

acceptable for use The establishment did not adequately monitor the 

implementation of the Sanitation SOP resulting in noncompliance with 9 CFR 

416.13(c). In addition, the establishment did not meet the requirements of 9 CFR 

416.1 which requires that each official establishment must be operated and 

maintained in a manner sufficient to prevent the creation of insanitary conditions. 

Finally, 9 CFR 416.4(a) requires that all food contact surfaces must be cleaned and 

sanitized as frequently as necessary to prevent the creation of an insanitary 

condition. 

5308 M6137 BXL0613013 

209N-1 

01/09/2013 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 1022 hours, I found a noncompliance with regulatory 

requirement of regulation 9 CFR 381.65(e) and 9 CFR 417.2(c)(4). I randomly 

removed 10 birds from line in Plant 2 to perform a Zero Tolerance Fecal check, 

finding one out of ten birds contaminated with feces. The fecal material was located 

inside of the carcass by the vent area. It was dark brown in color and pasty in 

texture measuring approximately 1/16" in diameter. I immediately notified

 of the noncompliance. The Fecal Protocol was 

implemented. The cause of deviation was the sprayers. At approximately 1043 

hours, after the sprayers were adjusted, QC performed a passing recheck which 

brought CCP 2B back in control. From 1122 hours to 1222 hours, Post Chill checks 

were performed on the suspect lot. All product coming out of chiller 3 was found 

acceptable. 

(b) (6)
(b) (6) (b) (6)(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1215012 

209N-1 

01/09/2013 06D02 Other Inspection 

Requirements 

C On 01/7/2013 The Line 1 and 2 NO VISCERA MONITORING LOG records 

reflected a noncompliance with regulatory requirement of 9 CFR 381.76(a)(b). At 

1318 hours QC performed a no viscera check in line 1, failing with 19 no viscera 

nonconformances. The line was running at BPM (birds per minute) which 

allows 13 or less no viscera to be in compliance. Maintenance was notified. At 1341 

hours, QC performed a recheck at BPM, failing with 17 no viscera 

nonconformances. The line speed was reduced to 126 BPM. At 126 BPM 11 or less 

no viscera nonconformances are allowed. At 1538 hours QC performed a recheck at 

line speed 126 BPM failing the line with 13 no viscera nonconformaces. Production 

continued running line 1 at 126 BPM the remainder of the day with out any further 

corrective action. At 1345 hours QC performed a no viscera check in line 2, failing 

with 33 no viscera nonconformances. The line was running at BPM (birds per 

minute) which allows 13 or less no viscera to be in compliance. Maintenance was 

notified. At 1402 hours, QC performed a recheck at BPM, failing with 24 no 

viscera nonconformances. The line speed was reduced to 126 BPM. At 126 BPM 11 

or less no viscera nonconformances are allowed. At 1530 hours, QC performed a 

recheck at line speed 126 BPM failing the line with 23 no viscera nonconformaces. 

Production continued running line 2 at 126 BPM the remainder of the day without 

any further corrective action. My findings reflect the establishment's failure to 

correct the deficiency and therefore, lack of control in the process. On 01/09/2013,

 was notified of the noncompliance. 

5308 M6137 BXL2014013 

609N-1 

01/09/2013 06D02 Other Inspection 

Requirements 

C On 01/05/2013 The LINE #2 - NO VISCERA MONITORING LOG records 

reflected a non compliance with regulatory requirement of 9 CFR 381.76(a)(b). At 

0817 hours QC performed a no viscera check in line 2, failing with 27 no viscera 

nonconformaces. The line was running at 126 BPM (birds per minute) which allows 

11 or less no viscera to be in compliance. Maintenance was notified. At 0852 hours 

QC performed a recheck at 126 BPM, failing with 18 no viscera nonconformances. 

Lead person was notified as well as maintenance once again. Despite the 

establishment's failure to meet the standards at 126 BPM, line speed remained at 

126 BPM. At 1028 QC performed another recheck at 126 BPM, failing with 19 no 

viscera nonconformances. All these failures represent the establishment's lack of 

control in their process. After 5 1/2 hours, the process was brought back in control 

with two passing rechecks. First passing recheck at 1319 hours at 126 BPM line 

speed and the second passing recheck at 1336 hours at BPM line speed. On 

01/09/2013, was notified of the noncompliance. 

(b) (6)
(b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3408010 

209N-1 

01/09/2013 03J02 Slaughter HACCP C On 01/09/2013 at approximately 0130 hours while monitoring the Establishments' 

Finished Product Standards in Plant #2 line I observed the following. After 

removing a 10 bird random sample, I observed two birds with visible fecal 

contamination. There was a cloacae with approximately 6" of intestine attached 

inside the carcass at the base of the tail. The fecal material was leaking from the cut 

end of the intestine into the left kidney area. The fecal material was olive green in 

color, pasty in texture and approximately 1/8" in size. I washed my gloves 

thoroughly before examining the remaining four carcasses for FPS standards. The 

last carcass of the ten bird sample also had visible fecal contamination on the front 

of both legs approximately 2" from the hock. The fecal material was olive green in 

color, pasty in texture and measured approximately 1/4" by 1/8" on the left leg and 

approximately 1/8" by 1/8" on the right leg. was informed. The 

protocol for fecal failure was implemented. A QC recheck passed at 0156 hours. My 

findings indicated a noncompliance with 9 CFR 381.65(e), 9 CFR 417.2(c)(4) and the 

critical limit of CCP 2B Zero Tolerance Fecal Contamination of the Plant's HACCP 

Plan for Slaughter. 

5308 M6137 BXL4008010 

009N-1 

01/09/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 01/09/2013 at approximately 0030 hours while monitoring Operation 

Sanitation Standards in the Plant #2 Multi-Vac cooler, I observed the following. 

There was a partial pallet of brown product tubs with product giving off a strong 

odor. The partial pallet was made up tubs labeled 090294 Keel Cartilage 

020-0342-1361, 12/7 salvage keel bone, and 12/5 AM shift. It was impossible to 

tell how many of the 9 total tubs were stored under which dated label. The cooler 

was at approximately degrees. The product was very slimy and gave off a very 

strong pungent odor that was evident immediately upon entering the cooler. I 

noticed previously on 01/02 in the same cooler a similar odor with decaying 

product being condemned by an establishment supervisor on that date. I believed 

the problem to be solved however the odor kept getting stronger as the days 

passed. A review of the Establishments' Operational Sanitation procedures SSOP 

Daily Implementation Monitoring Logs for the past week indicate that the coolers 

are monitored by QC personnel and are always 

found to be 'Acceptable'. A total of approximately 250 pounds in 9 partial tubs was 

condemned in the edible dump room. I monitored the washing and sanitizing of the 

stainless tank involved with being applied

 before releasing it. My findings indicated a noncompliance with 9 CFR 416.1, 

9 CFR 416.2(d), and 9 CFR 416.4(d) 

(b) (6)
(b) (6)

(b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4916013 

009N-1 

01/09/2013 06D02 Other Inspection 

Requirements 

C On 01/08/2013 The LINE 2 - NO VISCERA MONITORING LOG records 

reflected a non compliance with regulatory requirement of 9 CFR 381.76(a) and (b). 

At 0818 hours QC performed a no viscera check in line 2, failing with 18 no viscera 

nonconformances. The line was running at BPM (birds per minute) which 

allows 13 or less no viscera to be in compliance. Maintenance was notified. At 0843 

hours, QC performed a recheck at BPM, failing with 32 no viscera 

nonconformances. The line speed was reduced to 126 BPM. At 126 BPM 11 or less 

no viscera nonconformances are allowed. At 1021 hours QC performed a recheck at 

line speed 126 BPM failing the line with 17 no viscera nonconformaces. Production 

continued running line 2 at 126 BPM the remainder of the day. There were two 

more failures during the afternoon at 126 BPM. At 1302 hours, 16 no viscera 

nonconformances out of 11 no viscera allowed and at 1509 hours, 19 no viscera 

nonconformances out of 11 no viscera allowed. There was a total of 5 consecutive 

failures during the day. My finding reflect the establishment's failure to correct the 

deficiency and therefore, lack of control in the process. On 01/09/2013, 

was notified of the noncompliance. 

(b) (6)
(b) (6) (b) (6)

(b) (6)

(b) (4)

(b) (4)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0822014 

505N-1 

01/05/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 01/05/2013 at approximately 1815 hours while monitoring Operational 

Sanitation procedures in Plant #1 at the end of the shift, I observed the following. A 

sanitation employee in the Line room area was washing tanks as they were being 

emptied by production. The cleaning process was taking 1-2 minutes per tank as 

the employee was keeping up with production. As production emptied a tank the 

one being washed was covered with blue plastic and pushed into the Plant #1 

cooler. The blue plastic is the establishments way of identifying that a tank is clean 

and ready for use. Tanks 14-L, 4-L, #123, #112, N-4, #20, 81-L, 39L, N-3, 1-L, #102, 

64-L, #72, 58-L, #125, 63-L and #124 were all cleaned in a 30 minute period while I 

observed. The Establishments' Pre-Operational Sanitation procedure under 'Wet 

Clean-Up (food contact surfaces)' states in part " 

" The employee was adding the 

foam cleaner to the tanks with varying amounts of necks, giblets, fat and bloody 

fluids still inside. I was told previously by that to 

be effective the Foam Cleaner that the establishment uses must be in contact with 

the product contact surface for a minimum of 5 minutes. The employee washing 

the tanks was rinsing off the foam cleaner immediately after it was applied not even 

waiting for the foam cleaner to run down the inside surfaces to the bottom of the 

tank before rinsing it off. 

." There appeared to be no 'Check' step being performed as the tanks 

being covered still had pasty fat on the inside surfaces of the tanks to 

approximately 1/4". " ." I went to the office 

but could not find a Sanitation Supervisor, however, was nearby 

so I had him observe the process being used. He agreed that established procedures 

were not being followed. My findings indicated a noncompliance with 9 CFR 416.1, 

9 CFR 416.4(a), 9 CFR 416.13(c), and 9 CFR 416.14. 

5308 M6137 BXL2717011 

105N-1 

01/05/2013 03J02 Slaughter HACCP C At approximately 1240 hours, I found a noncompliance with regulatory 

requirement of regulation 9 CFR 381.65(e) and 9 CFR 417.2(c)(4). I randomly 

removed 10 birds from line 1 in Plant 1 to perform a Finish Product Standard check, 

finding one out of ten birds contaminated with feces. The fecal material was located 

on the right flap of the bird. It was dark brown in color and pasty in texture 

measuring approximately 1/8" in diameter. I immediately notified 

of the noncompliance. The Fecal Protocol was implemented. The 

cause of deviation was a loose guide rail inside the cropper. At approximately 1310 

hours QC performed a passing recheck which brought CCP 2B back in control. Post 

Chill checks were performed from 1400 hours to 1445 hours. All product coming 

out of chiller 1 was found acceptable. 

(b) (6)
(b) (6) (b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6)

(b) (6)

(b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3609010 

805N-1 

01/05/2013 06D02 Other Inspection 

Requirements 

C On 01/04/2013 at approximately 2248 hours while monitoring Plant #1 at startup, 

I observed the following. There was approximately half the viscera missing on line 

#2. The line was stopped and called a mechanic. Adjustments 

were made to the PMT machine. I waited several minutes for the line to settle out 

after being restarted then performed a standard three minute no viscera check. The 

line failed with 49 no viscera at approximately 2302 hours at bpm (birds per 

minute). At bpm 13 no viscera are allowed. was informed. A 

recheck by Quality Control failed at 0107 hours with 45 no viscera at bpm. The 

line was slowed to 126 bpm. A Quality Control recheck at 0159 hours at 126 bpm 

again failed with 39 no viscera. At 126 bpm 11 no viscera are allowed. The line was 

kept at 126 bpm for the rest of the shift. This is a failure by the establishment to 

take proper corrective action. My findings indicated a noncompliance with 9 CFR 

381.76(a) & (b). 

5309 P6137A NJN321601 

5805N-1 

01/05/2013 01C02 Operational SSOP 

Review and 

Observation 

C While performing an Operational Sanitation SSOP, at approximately 0756 hours, in 

Area #2-Packaging Section C, by the tub conveyor of Body Halver #2, and next to 

product conveyor for #4, I observed the following non compliance: A stream 

of liquid overflowing drip pan that runs underneath the line that supplies product 

to that unit, onto a bin that was staged by the Drum and Thigh conveyor. After 

closer inspection I noticed the bin was 1⁄4 full of thighs and the liquid was splashing 

directly on the exposed product. I immediately took regulatory control of the 

product with USDA Retained Tag #B39415871, and showed and informed Mr. 

and of the non 

compliance. Mr. climbed the latter for body halver #2 and removed a whole 

front plugging the drain line restoring sanitary conditions. Product was reworked, 

inspected and released by USDA at approximately 0944 hours, and preventive 

measures were proffered. 

5333 P7632 HYE440901 

4105N-1 

01/05/2013 04A06 Poultry Finished 

Product Standards 

C On 1/03/13 at 1040 hours, I was performing a finished product standards 

verification task, to verify the establishment's alternative online vacuum procedure 

on line one in the evisceration department. I selected ten carcasses marked for 

vacuum by a split tail. One out of the ten carcass sample had two full kidneys inside 

the carcass. I informed and 

of my findings. I then performed the required recheck and found lung 

tissue and airsacculitis adhered to the rib cage of one of the carcasses. I informed

 and of the 

noncompliance for the failure to meet the regulatory requirement cited above. No 

further rechecks were performed because the establishment chose to stop the 

alternative online vacuum procedure. In addition 9 CFR 381.76 table 1 #7 states: 

Lesions/conditions subject to removal following an approved cleanout process: 

Airsacculitis condition requiring removal of the kidneys. 

(b) (6)
(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3004013 

604N-1 

01/04/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 01/03/2013 at approximately 2350 hours while monitoring the Establishments' 

Pre-Operational Sanitation procedures in Packaging Area #1, I observed the 

following. There were several pieces of fat, blood and tissue to approximately 1/4" 

from the previous days production on a portable FPS table located between chillers 

3 & 4. At the same location there was a portable tray that is used to direct product 

exiting the chillers to a rehang belt. The tray was stored on the floor. This is used as 

a product contact item and needs to be stored in a sanitary manner. Sanitary 

conditions were restored by approximately 2355 hours. At approximately 0105 

hours there were numerous pieces of fat and tissue to approximately 1" on the 

overhead belt that transports wings to the packaging area. The section of the belt 

affected runs adjacent to the elevator. Approximately 20' of the belt was rewashed 

by approximately 0018 hours. In Packaging Area #2 the Deboning room there 

was fat and tissue to approximately 3" on two cutting wheels associated with the 

third machine along line #1 that makes the initial wing cuts. The machine was 

recleaned by approximately 0115 hours. My findings indicated a noncompliance 

with 9 CFR 416.1, 9 CFR 416.4(a), and 9 CFR 416.13(c). 

(b) (6)
(b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0204011 

403N-1 

01/03/2013 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 01/02/2013 at approximately 2303 hours while monitoring Pre-Operational 

Sanitation Procedures in the Rotisserie Room, I observed the following. There were 

three pallet jacks with pasty fat and tissue,and dried and semi-dried tissue to 

approximately 1/2" on the stainless product contact portion of the units. The 

affected arms of the pallets jacks which extend into the product during use were 

recleaned with green scouring pads, brown paper towels and a potable water rinse 

then released by approximately 2311 hours. In Packaging area #1 at approximately 

2355 hours a section of approximately 15 stainless pins are missing on the half 

breast collection belt for line . The affected area appears to rub on a white nylon 

divider at that location. This deteriorating belt condition has the potential of adding 

metal flakes to the product. There were several gray flakes from approximately 1/8" 

to 1/2" in size that appeared to be paint on the stainless and white nylon portions 

of Leg Processor #8. The paint on the overhead pipes above Leg Processors #7 , 8 

and 9 has severely deteriorated with numerous large areas of flaking paint. At 

approximately 0005 hours there were numerous pieces of dried and semi dried 

pieces of fat and tissue on the covers to the tray dispenser units for lines . 

The items were rinsed and returned to service by approximately 0010 hours. At 

approximately;y 0016 hours in Processing area #2 the Room there was a red 

flake approximately 1/2" in size on the wing section collection belt neat line #1 that 

appeared to be paint. There was also two small red flakes on the collection belt for 

the carcass shredder. that appeared to be paint. The red paint on the fire fighting 

system piping attached to the ceiling in the area from line #1 to the carcass 

shredder is deteriorated with numerous large areas of visible loose flakes. At 

approximately 0015 hours there was a large piece of tissue to approximately 4" on 

the blade of the carcass shredder. The unit gave off a strong offensive odor. A

 and potable water rinse was applied to the shredder and 

associated belt restoring sanitary conditions by approximately 0035 hours. My 

findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.2(b)(2), 9 CFR 

416.4(a) and 9 CFR 416.13(c). 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4)

(b) (4)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1709012 

203N-1 

01/03/2013 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 0035 hours in Plant #1 at the end of the chiller out flow belt from 

chiller #2 an establishment employee was sorting contaminated carcasses from a 

stainless tank. The empty tank N-15 had up to approximately a 2" layer of 

contaminated ice and tissue in the bottom and numerous pieces of fat and tissue 

on the inside surfaces of the tank. The empty tank was pushed into the tank wash 

area by another establishment employee who rinsed it with potable water at 

approximately degrees and applied a spray of . 

The tank was then moved to the Check/Weight line area and used to collect WOG's 

(With Out Giblets) for Rotisserie. The tank still had numerous pieces of fat and 

tissue to approximately 1/2" and a puddle of brown fluid in a large depression in 

the bottom of the tank to approximately 1/2" deep. As the WOG's are finished 

product and were being cross contaminated by the residue in the tank, I applied US 

Retained tag B31406750 to the partially filled tank. I contacted 

and showed him the reside on the tank from the previous days production. The 

affected birds were rinsed with a rinse and returned to production. The 

tank was recleaned and released by approximately 0356 hours. A review of the 

Establishments Operational Sanitation SSOP Corrective Action Log for 01/02/2012 

documented that 24 tanks of contaminated product was collected at 0047 hours. 

Tank N-15 was one of the affected tanks of contaminated product that was still 

being reworked. The Establishments SSOP under 'Operational Sanitation' 

Implementation states " 

." The 

Operational Sanitation SSOP does not say how this is to be accomplished. Also 

under 'Corrective Action' the Operational Sanitation SSOP states "

 This action is to be accomplished by the "Plant Management Team 

Member". As I could not find any documentation in the daily SSOP file, I contacted 

. agreed that the 24 tanks should 

have been treated as a contaminated product contact surface, had seen no 

'documented actions' entries on any logs, and was not aware of whom the night 

shift "Plant Management Team Member' was. My findings indicated a 

noncompliance with 9 CFR 416.1 , 9 CFR 416.4(a) & (d), 9 CFR 416.12(a), 9 CFR 

416.13(c), 9 CFR 416.14 and 9 CFR 416.16(a). 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6)(b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5722014 

302N-1 

01/02/2013 01C02 Operational SSOP 

Review and 

Observation 

C On 01/02/2013 at approximately 1930 hours while monitoring Operational 

Sanitation Procedures in the Plant #2 Aged Breast Cooler, I observed the following. 

There was a partial pallet of brown product tubs with product giving off a strong 

odor. The partial pallet was made up of mixed product (legs, breast halves, front 

halves) with the majority of the pallet consisting of front halves. The front halves 

were a pale green color and gave off a strong pungent odor. There was no label on 

the product of any kind. I contacted who condemned the product 

which weighed pounds and disposed of it in the edible dump room by 

approximately 1940 hours. My findings indicated a noncompliance with 9 CFR 

416.1, 9 CFR 416.4(d), and 9 CFR 381.145(b) which states that products need to be 

identified in some manner (not full label) such that inspection program personnel 

can re-inspect at any time or as often as they deem necessary to assure the 

products are not adulterated or misbranded. 

5308 M6137 BXL4107122 

331N-1 

12/31/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 12/31/2012 at approximately 0044 hours while monitoring the establishments 

Operational Sanitation procedures in Plant #1, I observed the following. There was 

brown UFM (Unidentified Foreign Material) specks and smears on the birds exiting 

Chillers #1 & #2. The UFM was on the cut surfaces of the breast, on the fat, skin and 

tissue around the neck area, and on the tissue at the abdominal opening at the tip 

of the keel bone. The amount of UFM varied from approximately 1" to several 

square inches in size. I took several samples from both chillers and from the bag 

fryer line going into packaging and contacted . As product had 

been going into Packaging for approximately 15 minutes I requested that she call

 for guidance. arrived and 

was shown the UFM on the product. I returned at approximately 0115 hours and as 

no corrective action was in progress I contacted 

and showed him the product that I had retained earlier. I went to Packaging and 

found the birds being packaged on line to be acceptable. I proceeded to the 

Plant #1 Cooler and checked the first tanks of WOG's(With Out Giblets) that had 

been collected for Rotisserie and the first pallets of front halves that were collected 

for the Deboning room placing the product on hold. Having found the same 

brown UFM, I contacted and showed him the contaminated 

carcasses and product. He said that production was told that there might be a 

water quality problem in Plant #1. had the first birds exiting both 

chillers tanked. However, Establishment QC personnel found the birds acceptable 

and released them. Three pallets of front halves labeled PLANT #1 12:31 hours, 

12:54 hours and 12:57 hours were later placed under QC hold pending 

reconditioning. Four tanks of WOG's labeled 18073 at 12:47 hours weighing 

pounds, 18072 at 1242 hours weighing pounds, 18071 at 1239 hours 

weighing hours, and 18079 at 1250 hours weighing pounds were also 

placed on QC hold pending reconditioning. My findings indicated a noncompliance 

with 9 CFR 416.1, 9 CFR 416 4(d) and 9 CFR 416.14. . 

(b) (6)
(b) (6)

(b) (6)

(b) (6)(b) (6)

(b) (6) (b) (6) (b) (6) (b) (7)(C) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3204122 

429N-1 

12/29/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 12/28/2012 while performing Pre-operational Sanitation SSOP Procedures in 

Main Packaging, I found a noncompliance with the following regulatory 

requirements of regulations 9CFR 416.1, 9CFR 416.2(d) and 9CFR 416.13(c). At 

approximately 2348 hours, while inspecting the halvers machine for plant #1, I 

observed numerous beads of condensation formed on the ceiling above the halvers 

machine. I immediately informed of the noncompliance. He 

then sent sanitation personnel to wipe off the condensation. I then went to 

inspected Line and Line and found heavy beads of condensation on the ceiling 

above where these two lines start at the west wall till the middle of the lines and 

also on the drip pans that are above these two lines. On the ceiling above Line ,

 along the west wall, it was also covered of condensation. I informed 

of the noncompliance. He sent sanitation personnel to wipe 

off the condensation, sanitation personnel used the air hose and the squeegee to 

restore sanitary conditions. At approximately 0021 hours, I reinspected and 

released the area. 

5308 M6137 BXL1800121 

828N-1 

12/28/2012 01D01 SPS Verification C On 12/27/2012 at approximately 0700 hours a live cockroach was observed on the 

right leg of a carcass on line in Plant #2 at the end inspection station #12 by 

Inspector . The line was stopped and the live cockroach was caught and 

removed from the product. Three affected birds was removed from the line to be 

reprocessed. The roach was shown to and 

. Cockroaches spread disease and filth. This is a noncompliance with 9 CFR 

416.1 and 9 CFR 416.2(a). 

5309 P6137A NJN371612 

3328N-1 

12/28/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 1411 hours while performing PHIS task for Zero tolerance on the 

Reprocessing Line, I observed one of the ten carcass sample with visible fecal 

material on the inside of the cavity adjacent to the right thigh of the bird. The fecal 

material was approximately one inch radius dark green in color and had a paste-like 

consistency. I immediately took regulatory control action by stoping the 

reprocessing line and notified Mr. and Mr.

 and the 

assigned to the area, showed them my findings and informed them of the 

forthcoming non compliance. That the establishment failed to prevent fecal 

material from entering the chilling system represents noncompliance with 9 CFR 

381.65(e). The failure also represents a deviation from the establishment's written 

HACCP plan, regulatory requirement of 9 CFR 417.2(c)(4) that states: List the 

procedures and the frequency with which those procedures will be performed, that 

will be used to monitor each of the critical control points to ensure compliance with 

the critical limits. 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6)

(b) (6)

(b) (6)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN201612 

0027N-1 

12/27/2012 01C02 Operational SSOP 

Review and 

Observation 

C While performing PHIS task Sanitary Operational Procedure (SSOP) at 

approximately 1034 hours in the Fillet Department, I observed the following non 

compliance: Unidentified foreign material on styrofoam plates on line #2, Sliced 

Breast Packing Conveyor. The plates had the soaking pad in them and were 

traveling on the line ready to be packed with sliced fillet. I pulled six empty plates 

from the line with foreign material in them, (plates in the line are Product Contact 

Surface) and placed Retained tag #B39415855 on them. The foreign material ranged 

in size from black specks and smears to approximately 1/8 inch in diameter. I 

showed my findings to Mr. and 

. Mr. pulled out another 15-20 plates with the same kind of 

unidentified foreign material from the pile of styrofoam plates that were staged to 

be used to be packed and added an employee to double check plates as preventive 

measures and to restore sanitary conditions. I continued my inspection procedure 

same department, Area 6: Unit 23; Product Chute to Bin from delivery system at 

approximately at 1049 hours and observed a pile of whole breast fillets on the floor 

(approximately 40-45 pieces) next to a plastic bin that was being filled with the 

same kind of product. I waited to see if anybody was taking action on this situation 

and no one was around. I took regulatory control of the product with USDA 

Retained tag #B39415854 and informed Ms. and 

that this situation would be documented in the 

fore-mentioned SSOP non compliance. Ms. mentioned she did not know how 

long the product had been on the floor, so she elected to condemn the product in 

my presence. Plants SSOP’s #XV Post chill Reprocessing of parts and carcasses step 

10 states: 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6)

(b) (6)

(b) (6) (b) (7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE301312 

3727N-1 

12/27/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C I was in the Evisceration department performing a Zero Tolerance verification task 

at the line one pre-chill evaluation station at 1049 hours when I observed fecal 

material on one of the ten randomly selected carcasses. The fecal material was 

located in the cavity of carcass under the kell bone. It was oval shaped 

approximately .5mm in length 0.2mm in width, dark green in color, with a paste like 

consistency. I took regulatory control of the product with the application of U.S. 

retain tag B39757046. I informed and 

of my finding. Mr. contested that the material was fecal, and 

requested veterinary disposition. FSIS IIC Dr. confirmed the 

material was fecal. was informed of the 

forthcoming noncompliance. performed the recheck 

as per establishment's corrective actions, the recheck passed. This failure 

represents a noncompliance with regulation 9 CFR 381.65(e), which states: "Poultry 

carcasses contaminated with visible fecal material shall be prevented from entering 

the chilling tank. The HACCP plan is not ensuring compliance with the critical limits 

for fecal contamination. Regulation 9 CFR 417.2(c)(4), states: "The HACCP plan shall, 

at minimum:" "(4)List the procedures, and frequency with which those procedures 

will be performed, that will be used to monitor each of the critical control points to 

ensure compliance with the critical limits." There has been four fecal failures on line 

one in the past two and half months. The first, NR # HYE213104603 was on 

10/19/12, the second, NR# HYE3415125103N occurred on 12/03/12 and the third 

NR# HYE4815124218 N/1 on 12/18/12, the last NR# HYE3013123727N/1 occurring 

on 12/27/12. On 12/19/12 FSIS IPP shared their concerns about the fecal failures 

on line #1 with the establishment's management at the weekly meeting. 

5333 P7632 HYE220712 

5424N-1 

12/24/2012 04A06 Poultry Finished 

Product Standards 

C There was a high percentage of birds presented for post-mortem inspection that 

where identified by the on line inspectors for airsaculitis removal. The 

establishment had initiated their alternative On-line Vacuuming/Air sac Removal 

procedure. At 0454 hours I elected to verify the effectiveness of the alternative 

procedure. I went to the FPS Pre-Chill Station on line 1 and collected a ten (split tail) 

bird sample. Two of the ten birds had intact kidneys indicating that the vacuum 

procedure was ineffective in the proper removal of the tissue and one bird exhibited 

air sac exudate on the right side along the ribcage area. The required ten bird retest 

passed as there where no failure findings. I notified 

and of the forthcoming 

documentation for the failure to comply with the regulations cited above. 

(b) (6)
(b) (6) (b) (6)

(b) (6) (b) (6) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2612120 

520N-1 

12/20/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C On 12/20/2012, while performing a zero Tolerance fecal check, I found a 

Noncompliance with regulatory requirement of regulation 9 CFR 381.65(e) and 

417.4(c)(4) At approximately 0900 hours, I randomly removed 10 birds from line 2 

in plant 1, finding one carcass contaminated with feces. The fecal material was 

pasty in texture and dark yellow in color. It was located under the right leaf fat area 

measuring approximately 1/4" in diameter. I immediately notified 

of the noncompliance. The fecal Protocol was implemented. The 

cause of deviation was due to shower heads plugged on the first cabinet. QC 

performed a passing re check at approximately 0925 hours putting the process back 

in control. Post-Chill checks were performed from 1004 hours to 1104 hours. This is 

a violation of the critical limit of CCP-2B, of the plant's 

HACCP Plan for Slaughter. 

5308 M6137 BXL3722122 

719N-1 

12/19/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 12/19/2012 at approximately 0650 hours, while monitoring the Establishments' 

Operational Sanitation Procedures in Main Packaging, I observed a company 

employee grasping halves of birds from the drip pan that is next to the chute of the 

halvers machine in Plant #2. Company employee direct those halves of birds to the 

chute. This drip pan it's not a food product contact surface. As per company 

procedure written in the SSOP Plan the employee failed to follow the product 

reconditioning procedure and contaminated the product that it was going through 

the chute. I attached a U.S. Retained/Rejected Tag # B31 406711 to the product that 

it was coming out from the chute, 8 brown tubs in total. I informed 

and of the noncompliance.

 informed me that the product will be reconditioning as per 

company procedure, I removed the U.S. Retained /Rejected Tag and released the 

product to Quality Control. Quality Control attached red hold tag on the product 

pending for reconditioning. At approximately 0840 hours after the product was 

reconditioned, Quality Control inspected the product and released. My findings 

indicate a noncompliance with the following regulatory requirements of regulations 

9CFR 416.1, 9CFR 416.4 (d), 9CFR 416.13 (b) and 416.13 (c). 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (7)(C) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0309120 

818N-1 

12/18/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C While performing Zero Tolerance Fecal Task, I observed noncompliance with the 

following regulatory requirements of regulations 9CFR 381.65 (e) and 9CFR 417.2 

(c)(4). On 12/18/2012 at approximately 0616 hours, 

randomly removed a 10 bird sample from Line in Plant #2, I found the last bird 

inspected with visible fecal contamination inside the bird located at the middle of 

the kidney area. The fecal material was a smear measuring approximately 1/2" long 

and 1/4" wide, dark green in color in pasty in texture. This exceed the limit of Zero 

Tolerance for the process to be in control. I informed 

and of the noncompliance. The protocol for fecal failure 

was implemented. Quality Control performed a recheck at approximately 0644 

hours and it passed. The cause of the deviation was the bird washer. This is 

a violation of the critical limits os CCP-2B, of the Plant's 

HACCP Plan for Slaughter. 

5333 P7632 HYE481512 

4218N-1 

12/18/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C I was in the Evisceration department performing a Zero Tolerance verification task 

at the line one pre-chill evaluation station at 1334 hours when I obsevred fecal 

material on one of the ten randomly selected carcasses. The fecal material was 

located on the left side leaf fat of the carcass. It was oval shaped approximately 1cm 

in length 0.3cm in width, dark green in color, with a paste like consistency. I took 

regulatory control of the product with the application of U.S. retain tag B38495479. 

I informed and of my 

finding. Mr. contested that the material was fecal, and requested veterinary 

disposition. FSIS IIC Dr. confirmed the material was fecal. First

 was informed of the forthcoming 

noncompliance. performed the recheck as per 

establishment's corrective actions, the recheck passed. This failure represents a 

noncompliance with regulation 9 CFR 381.65(e), which states: "Poultry carcasses 

contaminated with visible fecal material shall be prevented from entering the 

chilling tank." The failure also represents a deviation with the establishment's 

written HACCP plan, regulatory requirements of 9 CFR 417.2(c)(4), which states: 

"List the procedures, and frequency with which those procedures will be performed, 

that will be monitor each of the critical control points to ensure compliance with 

the critical limits." There has been three fecal failures on line one in the past two 

months. The first was on 10/19/12, the second occurred on 12/03/12 and this 

being the last on 12/18/12. 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6)

(b) (4)

(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE530212 

4318N-1 

12/18/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C After QC had performed the pre-operational inspection and released area 3 as 

acceptable, I performed the hands on observation component of the Preoperational 

Sanitation Inspection procedure. The following non compliance was noted: At area 

3, unit #5, the stainless steel cover of the dumper's hydraulic assembly had pieces 

of fat and particles of product residue built up on all four inside surfaces. These 

pieces of fat and particles varied in size and where too numerous to count. I also 

observed at unit #3 a portable metal grate stand that had numerous pieces of fat 

with the largest approximately three inches long on the bottom surfaces. I showed 

these findings to and 

, and informed them of the documentation of the non 

compliance. This finding represents a non compliance with 9 CFR 416.4(b) which 

states: "Non-food contact surfaces of facilities, equipment, and utensils used in the 

operation of the establishment must be cleaned and sanitized as frequently as 

necessary to prevent the creation of insanitary conditions and the adulteration of 

product." In addition the establishment's Pre-Op SSOP, Part 1-

y, step #2 Equipment(including conveyors, shackles and floors) will 

be completely . 

The establishment's failure to implement the SSOP procedures represents a non 

compliance with 9 CFR 416.13(a) which states: "Each official establishment shall 

conduct the pre-operational procedures in the Sanitation SOP's before the start of 

operations. 

5308 M6137 BXL4905120 

314N-1 

12/14/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 12/13/2012 at approximately 2340 hours while monitoring the Establishments' 

Pre-operational Sanitation Procedures in the Packaging area, I found a 

noncompliance with the following regulatory requirements of regulations 9CFR 

416.1, 9CFR 416.4(a), 9CFR 416.4 (b) and 9CFR 416.13 (c). There were numerous 

pieces of semi-dried fat, tissue and blood approximately 1/4" to 1" sections, from 

the previous day production, on a white support bracket that is in contact with the 

blue conveyor belt that transfers product from the dumper at the end of the chiller 

#1 to the rehang belt for line . There was also a build up of fat and tissue 

approximately 3" x 3" square on the white support sprocket at the end of the same 

blue conveyor belt. I tagged the area with the U.S. Rejected/Retained Tag # B31 

406712 and informed of the noncompliance. Sanitation 

personnel re-washed the area. At approximately 2355 hours I reinspected the area 

and released it. I also informed of the noncompliance. 

(b) (6)
(b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5405123 

814N-1 

12/14/2012 06D02 Other Inspection 

Requirements 

C On 12/14/2012, at approximately 0230 hours, while monitoring the "No Viscera 

Log" for Line #1, I observed the following: Line #1 had three consecutive failures by 

Quality Control in the 4 hour period before lunch break. At 2320 hours at line speed 

of BPM, Quality Control documented 23 no viscera and only 13 or less are 

allowed. At 2352 hours at line speed of BPM, Quality Control recheck failed 

with 24 no viscera. Line Supervisor was informed and line speed was reduced to

 BPM. At 0116 hours at line speed of BPM, Quality Control documented 34 

no viscera, at this line speed only 11 no viscera are allowed, at this point the 

process is out of control. was informed. Three 

consecutive failures is a noncompliance for a failure to take proper corrective 

action. Line speed remained at BPM for the rest of the shift. At 0400 hours at 

line speed of BPM Quality Control documented 36 no viscera only 11 no viscera 

are allowed. At 0619 hours at line speed of BPM Quality Control documented 

38 no viscera only 11 no viscera are allowed. This is a noncompliance with the 

following regulatory requirements of regulations 9CFR 381.76 (a) and 9CFR 381.76 

(b). 

(b) (6)
(b) (6)

(b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6) (b) (7)(C) (b) (7)(C) (b) (7)(C) (b) (7)(C) (b) (7)(C)(b) (7)(C) (b) (7)(C) (b) (7)(C)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE520712 

1713N-1 

12/13/2012 01C02 Operational SSOP 

Review and 

Observation 

O On Wednesday December 12, 2012, during start up of the first processing at 

approximately 2230 hours, inspector hung back two carcasses 

contaminated with grease like, black colored, foreign material at station # 4 line B. 

At approximately 2300 hours, I was called to Evisceration, station # 3 line B by 

inspector , to observe two birds with the same foreign material 

located in the inner surface of the thigh. While I was still on the floor, and at 

approximately 2310 hours, inspector , at station # 2 line B hung back 

four more carcasses. Two carcasses contaminated with the same grease like, black 

colored, foreign material and the other two carcasses contaminated with rail 

dust/grease like, also black colored, foreign material, located in the inner surface of 

the left thigh and the breast. Again at approximately 2335, inspector hung 

back two more carcasses contaminated with the same grease like, black, foreign 

material, also located in the inner surface of the left thigh l. After lunch, and at 

approximately 0353, inspector , at station # 2 line B, hung back three 

more carcasses contaminated with the same black, grease like, foreign material, 

located again in the inner surface of the left thigh. In all these instances

 and , were informed and 

the affected carcasses were trimmed and reconditioned. 

stated that “ 

. At approximately 0420 

hours when I went to release inspector , from station # 2, line B, for 

USDA break, I observed that she had hung back one other carcass contaminated 

with that same black, grease like, foreign material, again located in the inner surface 

of the left thigh. While I was performing post mortem inspection I called Ms. 

to inform her of findings. While was still next to me 

listening to my notes, another two carcasses passed by us that were also 

contaminated with grease like, thick oily in consistency, black, foreign material, one 

which was approximately 1⁄4 inch in diameter the second approximately one inch by 

one inch in diameter, both located also in the inner surface of the left thigh. At 

approximately 0450 hours, and 0455 hours inspector hung back one carcass 

each time contaminated with the same black, grease like, foreign material, again 

located in the inner surface of the left thigh. Again the affected carcasses were 

trimmed and reconditioned. Ms. , was 

informed of the forthcoming noncompliance This issue was brought to the 

attention of plant personal at the weekly meeting on 12/12/2012. .The 

requirements of 9 CFR 416.3(a), 9CFR 416.4(d), 416.13(c), 416.1 and Establishment 

SSOP’s were not met. 9 CFR 416.3(a) in part which states: “... Equipment and 

utensils must be maintained in a sanitary condition so as not to adulterate 

product”. 9CFR 416.4(d) states "Product must be protected from adulteration 

during processing, handling, storage, loading, and unloading at and during 

transportation from official establishments.” 9CFR 416.13(c) states “Each official 

establishment shall monitor daily the implementation of the procedures in the 

(b) (6)
(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

Sanitation SOP’s”. 9CFR 416.1 states “Each official establishment must be operated 

and maintained in a manner sufficient to prevent the creation of insanitary 

conditions and to ensure that product is not adulterated.” Establishment SSOP’s 

procedures dated 03/13/2012 Section 1 Evisceration states “ 

.” Inspection personal documented a similar finding on 

NR # HYE4000124107N dated 12/6/2012. A response has not been received from 

the establishment regarding the previous NR. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0121122 

512N-1 

12/12/2012 06D02 Other Inspection 

Requirements 

C On 12/12/12 at approximately 1041 hours while preforming the no-viscera check in 

plant # 1 on line # 2 I observed the following . The Monitoring Log for the shift 

revealed QC personnel had failed line # 2 at 1003 hours at a line speed 0f BPM 

with a total of 16 no viscera . The line speed was then reduced to BPM and a 

recheck was preformed . At 1031 hours a recheck was preformed at a line speed of 

PBM which also failed with a total of 21 no-viscera . My no/viscera check was 

preformed at approximately 1041 hours . At a line speed of BPM there is a 

total of 11 no-visceras allowed my check revealed a total of 19 no-viscera . The next 

company recheck was at 1249 at a line speed of BPM which failed with a total 

of 12 no-visceras . The line was never brought back-into compliance and stayed at 

the rest of the afternoon . Three consecutive failures of not meeting the 

standards for the no-viscera check is a non-compliance . 

was contacted and notifyed of the non-compliance and that there would a NR 

written . My findings indicate non-compliances with thw following regulations 9CFR 

381.76(a) and 381.76(b) . 

5308 M6137 BXL1515121 

612N-1 

12/12/2012 06D02 Other Inspection 

Requirements 

C At approximately 1045 hours while performing a Presentation check on line , in 

Plant #2, I found the following noncompliance. At a line speed of birds per 

minute, Line , Station #2 had 36 weighted nonconformance points which requires 

a recheck by QC within 10 minutes. I informed and she had 

a QC come to perform the recheck. QC failed the recheck at approximately 1053 

hours with 4 viscera on the shackle at Station #1. This exceeds the limit of 3 

occurrences of one error. I then informed that a 

noncompliance record would be issued. The line speed was immediately slowed to 

birds per minute. At approximately 1101 hours QC did a recheck at the lower 

line speed of birds per minute and it passed. The line speed was then increased 

to birds per minute and QC did a recheck which passed at approximately 1107 

hours bringing the process back in control. My findings indicate a noncompliance 

with the regulatory requirements of regulation 9 CFR 381.76(b). 

5308 M6137 BXL0116124 

311N-1 

12/11/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 1303 hours while performing a Zero Tolerance Verification Task 

on Line in Plant #2 I observed the following noncompliance. After removing a 10 

bird random sample, I observed one bird with visible fecal material on the left leaf 

fat. The fecal material was a dark greenish brown color, pasty in texture and was 

approximately 1/16" by 1/8" in size. was informed of the 

noncompliance and the protocol for fecal failure was implemented. A QC recheck 

passed at 1327 hours. The leaf fat lifter was determined to be the cause of the 

failure. My findings indicate a noncompliance with 9 CFR 381.65(e) and 9 CFR 

417.2(c)(4) and the critical limit of CCP-2B 

of the Plant's HACCP Plan for Slaughter. 

(b) (6)
(b) (6)

(b) (7)(C) (b) (7)(C)

(b) (4)

(b) (4) (b) (4) (b) (4) (b) (4)

(b) (4)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE381312 

0711N-1 

12/11/2012 03J02 Slaughter HACCP C On 12/07/12 CSI and I, CSI , performed a record review 

to follow up on Zero-Tolerance failure for 12/03/12. As per the establishment's 

Corrective Deviation Report the preventive measure states: "Replaced blade arm 

and will do blade arm check once/shift for a week to verify effective." At 1312 

hours, in the Maintenance Department, I reviewed the establishment's verification 

document and noted the following: The entry for Friday the 7th at 1110 p.m. had 

no quantifiable values recorded. At the bottom of the establishment's verification 

document states, 

." Neither acceptable or unacceptable were circled. 

Upon further review I noted the times for all the completed checks, Wednesday the 

5th at and Thursday the 6th at and At 

the top of this document it states " 

." First shift 

starts at and ends at hours. Second shift starts at and 

ends at hours. According to this document, all the checks on Wednesday the 

5th and Thursday the 6th were performed on one shift only. I informed Ms. 

of my findings and of the forthcoming noncompliance for 

the failure to meet the regulatory requirements cited above. 9 CFR 417.5(a)(3) 

which states: (a) The establishment shall maintain the following records 

documenting the establishment's HACCP plan: (3) Records documenting the 

monitoring of CCP's and their critical limits, including the recording of actual times, 

temperatures, or other quantifiable values, as prescribed in the establishment 

HACCP plan; the calibration of process monitoring instruments; corrective actions, 

including all actions taken in response to a deviation; verification procedures and 

results. In addition 9 CFR 417.4(a)(2)(i)(ii)(iii) states: Ongoing verification activities 

include but are not limited to the calibration process monitoring instruments; 

direct observations of monitoring activities and corrective actions; and the review 

of records generated and maintained in accordance with 9 CFR 417.5 (a) (3) of this 

part. This is the second noncompliance for the same ongoing verification activity. 

The first occurred on 12/5/12 NR # HYE0017120905 N/1. 

(b) (6)
(b) (6) (b) (6)

(b) (6)

(b) (7)(C) (b) (7)(C) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5813120 

210N-1 

12/10/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 12/11/12 at approximately 0907 hours I observed the following while 

preforming the Pre-Op SSOP Review and Observation task after the estbalishments 

completion establishments inspection in the Room . There were two large 

pieces of fat laying on of the blue flex belt inside the Wing Midjoint Carnietech 

Loader . One piece was approximately 4" by 6" and the other approximately 3" by 4 

in size" . I mmeadietly applied US Retained/Rejected tag # B31406755 and notified

 . had both pieces of fat removed from the 

inside of the Wing Carnietech Midjoint Loader and had the entire machine rinsed 

throughly . At approximately 0916 hours the Wing Midjoint Loader was 

re-inspected and found to be in good sanitary condition, putting the establishment 

back in-compliance .My findings are indications of several regulations being violated 

9CFR 416.14 , 9CFR 416.4(a) , 9CRF 416.13(c) and 9CRF 416.13(a) . 

5309 P6137A NJN100612 

0511N-1 

12/10/2012 04C05 Poultry Good 

Commercial 

Practices 

C On night shift Sunday 9 December, 2012 at approximately 0230 hours Dr. 

identified a poultry carcass on line A as being a dead-on-arrival (DOA). Later in the 

shift around 0730 hours an inspector on line B hung back a bird for a supervisor to 

examine. I identified it as a dead-on-arrival (DOA). Both carcasses were reddish in 

color with limp necks, friable livers and had a putrid odor. 

was notified of the two separate occasions by Dr. 

and me at the time of these findings and that a non-compliance record 

would be forthcoming. The repetitive occurrence of DOAs entering into the 

eviceration department demonstrates a loss of process control and the creation of 

insanitary conditions in accordance with 9 CFR 381.71(a) and 416.4(d). 

5308 M6137 BXL1804120 

908N-1 

12/08/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 12/07/2012 at approximately 2225 hours while monitoring the establishments' 

Pre-operational sanitation Standards in Plant #1 after establishment QC personnel 

finished their inspections, I observed the following. There were numerous black 

specks and flakes of UFM(Unidentified Foreign Material) to approximately 3/8"on 

three of the four paddles checked on Chiller #1. The section of the chiller checked 

was on the inflow side nearest line #1. There was also black UFM of simular size on 

the support beams that cross the width of the chiller, and on the brackets and tray 

associated with the chain. The chiller was released by approximately 2235 hours. 

My findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.4(a) & (b) and 

9 CFR 416.13(c). 

(b) (6)
(b) (6) (b) (6)

(b) (6) (b) (6)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE390212 

1408N-1 

12/08/2012 03C02 Raw Intact HACCP C On Friday, December 7th, 2012 at approximately 2305 hours, I was performing an 

SPS task in the -degrees cooler and observed a pallet containing several tubs 

filled with salvaged drums, thighs, and leg quarters. The production card on the 

tubs indicated that the product was produced on 12/07/2012, during the day shift. 

I noticed two of the tubs did not contain ice so, I borrowed 

calibrated thermometer # 54, to check the product temperature. The thermometer 

read 42.3 degrees Fahrenheit in one tub and 42.4 in the other. I immediately took 

regulatory control action and applied U.S. retain tags # B38495487 

and # B38495488. I informed , and 

, of my findings and the forthcoming noncompliance. U.S. 

retains tags NO. B38495487 and NO. B38495488 were removed at 0008 hours and 

0009 hours, after I found the temperature to be acceptable at 35.2 and 34.2 

degrees Fahrenheit, respectively. Upon review of the thermometer calibration log, 

thermometer # 54 was found acceptable at 2155 hours. I reviewed the salvage cp 4 

monitoring log and the last two checks at 1318 hours and 1320 hours registered 

37.8, 39.7, 38.5, 37.0, 35.4 and 36.1 degrees Fahrenheit This is a failure to meet the 

regulatory requirement of 9 CFR 381.66(a) and 9CFR 381.66(c) (3). 9 CFR 381.66(a) 

states " Temperature and procedures that are necessary for chilling and freezing 

ready-to-cook poultry, including all edible portions thereof, must be in accordance 

with operating procedures that ensure the prompt removal of the animal heat, 

preserve the condition and wholesomeness of the poultry, and assure that the 

products are not adulterated." 9CFR 381.66(c) (3) states “Previously chilled poultry 

carcasses and major portions must be maintained constantly at 40 F or below until 

removed from the vats or tanks for immediate packaging ... . " This is a repetitive 

non-compliance; a similar non-compliance was documented on NR 

HYE0801111427N/1 dated 11/27/2012. A response has not been received from the 

establishment regarding the previous NR. 

5308 M6137 BXL0509120 

107N-1 

12/07/2012 03J02 Slaughter HACCP C On 12/06/2012 at approximately 0645 hours while performing a HACCP Slaughter 

Record Review Task, I found the following. The Pre-shipment Records Review for the 

End of Shift for CCP-1B ( ) Zero Tolerance for the Reprocessing 

Line # in Plant #2 dated on 12/05/2012 AM Shift was signed at 0710 hours. The 

Pre-shipment Records Review for the End the Shift for CCP-2B ), 

Zero Tolerance for Line in Plant #2 dated on 12/05/2012 AM Shift was 

signed at 0713 hours. The Pre-shipment Records Review for the End of the Shift 

CCP-2B ( ) Zero Tolerance for Line in Plant #2 dated on 

12/05/2012 AM Shift was signed at 0715 hours. The signed document certifies that 

the product is ready to be shipped. The end of the shift for the day of 12/05/2012 

AM Shift was at 0730 hours. My findings indicate a noncompliance with the 

following regulatory requirements of regulation 9CFR 417.5 (c). I notified 

of the noncompliance. 

(b) (6)
(b) (6)

(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE400012 

4107N-1 

12/07/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On Dec. 6, 2012 at approximately 2218 hours, after sanitation and QC performed 

preoperational sanitation and released area II for operations, I performed 

preoperational sanitation inspection and observed the following noncompliance: 

the Guide Bar and the Blue Chain of USDA Inspection Station 4-Line 2, had 

unidentified black material. The Blue Chain interior is a food-contact surface. I 

immediately rejected the Station by applying US Rejected Tag NO. B39757049. At 

approximately 2222 hours I observed a beaded condensation on the ceiling above 

the Lung machine for Line 2. I immediately rejected the area by applying US 

Rejected Tag NO. B38495162. , was 

notified. I showed my findings and informed him of the forthcoming NR. At 2225 

hours the Guide Bar and the Blue Chain of USDA Inspection Station 4-Line 2 were 

re-inspected, found acceptable and released. At 2227 hours the Lung machine-Line 

2 area was released once sanitary conditions were restored. Upon review of the 

SSOP-Implementation and Monitoring checklist log part 1: Pre-Operation Section 1 

Evisceration was found acceptable at 2146 hours. The requirements of 9 CFR 

416.13(c), 9 CFR 416.2(b) (2), 9 CFR 416.2(d), 9 CFR 416.4 (a), 9 CFR 416.4(b), and 

Plant’s written SSOP plan were not met. 416.13(c) states “Each official 

establishment shall monitor daily the implementation of the procedures in the 

Sanitation SOP’s”. 9 CFR 416.2 (b)(2) states: “Walls, floors, and ceilings within 

establishments must be built of durable materials impervious to moisture and be 

cleaned and sanitized as necessary to prevent adulteration of product or the 

creation of insanitary conditions.” 9 CFR 416.4(a) States: “All food-contact surfaces, 

including food-contact surface of utensils and equipment, must be cleaned and 

sanitized as frequently as necessary to prevent the creation of insanitary conditions 

and the adulteration of product’. 9 CFR 416.4(b) states, “Non-food-contact surfaces 

of facilities, equipment, and utensils used in the operation of the establishment 

must be cleaned and sanitized as frequently as necessary to prevent the creation of 

insanitary conditions and the adulteration of product”. 9 CFR 416.2(d) Ventilation 

requirement states “ Ventilation adequate to control odors, vapors, and 

condensation to the extent necessary to prevent adulteration of product, and the 

extent necessary to prevent adulteration of product and creation of insanitary 

conditions must be provided” Plant’s written SSOP procedures dated 03/13/12; 

page 1 step # 4, which states: 

. Step # 7 which states: 

. 

(b) (6)
(b) (6) (b) (6) (b) (6)

(b) (6)

(b) (6)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE100312 

2906N-1 

12/06/2012 01C02 Operational SSOP 

Review and 

Observation 

C .At approximately 0045 hours while performing the Review and Observation 

component of Operational Sanitation PHIS task, the following noncompliance was 

noted: The Liver Harvester machines on line 1 and line 2 had not been rinsed down 

at company break. Both machines had intestines, livers and gizzards on the arms of 

the Harvesters. I immediately stopped both lines and showed my findings to 

. No retain tag was applied because the plant 

implemented immediate corrective action by condemning the viscera packs until 

the machines were properly rinsed down. I reinspected and released both machine 

at 0058 hours. According to the establishments SSOP, Part II O

 Section 1, Step #1,” 

.” 9 CFR 416.1 states: "Each official establishment must be 

operated and maintained in a manner sufficient to prevent the creation of 

insanitary conditions and to ensure that product is not adulterated." 9 CFR 

416.13(c) states: (c)" Each official establishment shall monitor daily the 

implementation of the procedures in the Sanitation SOP’s." 9 CFR 416.4(a) states: 

"All food-contact surfaces, including food-contact surfaces of utensils and 

equipment, must be cleaned and sanitized as frequently as necessary to prevent the 

creation of insanitary conditions and the adulteration of product." 9 CFR 416.4(b) 

states: (b)" Non-food-contact surfaces of facilities, equipment, and utensils used in 

the operation of the establishment must be cleaned and sanitized as frequently as 

necessary to prevent the creation of insanitary conditions and the adulteration of 

product." . 

5333 P7632 HYE161112 

2306N-1 

12/06/2012 04A06 Poultry Finished 

Product Standards 

C I was performing a finished product standards verification task on the reprocessing 

line in the evisceration department at 0730 hours. I selected ten carcasses marked 

for vacuum by a split tail. One out of the ten carcass sample had lung tissue 

adhered to the rib cage of the carcass as well as one full kidney still in the cavity. I 

informed and . Then I 

performed the required recheck of ten split tail carcasses and found two carcasses 

containing airsac exudate. I informed 

and of the failure to meet the 

regulatory requirement cited above. In addition 9 CFR 381.76 table 1 #7 states: 

Lesions/conditions subject to removal following an approved cleanout process: 

Airsacculitis condition requiring removal of the kidneys. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (7)(C) (b) (7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE001712 

0905N-1 

12/05/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C On December 5, 2012 CSI and I, CSI , performed a 

record review to follow up on a Zero-Tolerance failure for 12/03/12 at 1345 hours 

in the Q.C. office. I requested the verifcation document for the preventive measures 

for the failure from . Ms. told me that 

the had the document. I then went to Mr.

 office and requested the document from him, to which he replied "I don't 

have it, it's not were it should be." I then informed Mr. that by not being able 

to produce the on going verification document represents a noncompliance with 9 

CFR 417.5(a)(3) which states: (a) The establishment shall maintain the following 

records documenting the establishment's HACCP plan: (3) Records documenting 

the monitoring of CCP's and their critcal limits, including the recording of actual 

times, temperatures, or other quantifiable values, as prescribed in the 

establishment HACCP plan; the calibration of process monitoring instruments; 

corrective actions, including all actions taken in response to to a deviation; 

verification procedures and results. was also informed of 

the noncompliance. 

5333 P7632 HYE341512 

5103N-1 

12/03/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C I was in the Evisceration department performing a Zero Tolerance verification task 

at the line one pre-Chill Evaluation Station at 1210 hours when I observed fecal 

material on one of the ten carcass sample. The fecal material was located inside the 

cavity of the carcass. It was oval shaped approximately 4mm in width and 1cm in 

length, greenish-brown in color, and had a paste like consistency. I took regultory 

control of the product with the application of U.S. Retain tag B38495480, and then 

informed and of my findings and 

the forthcoming noncompliance. was also informed 

and performed the recheck as per establishment's corrective actions, the recheck 

passed. This failure represents a noncompliance with regulation 9 CFR 381.65(e), 

which states: "Poultry carcasses contaminated with visible fecal material shall be 

prevented from entering the chilling tank". The failure also represents a deviation 

from the establishment's written HACCP plan, regulatory requirements of 9 CFR 

417.2(c)(4), which states: "List the procedures, and the frequency with which those 

procedures will be performed, that will be used to monitor each of the critical 

control points to ensure compliance with the critical limits". 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6)

(b) (6)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0609121 

201N-1 

12/01/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 12/1/12 at approximately 0340 hours I observed the following while preforming 

the operational SSOP Review and Observation Task in Plant # 1 . Stations # 1 

and # 2 on line # 1 had large beads of water on the ceiling directly above the 

evisceration line . Which appeared to be seeping from a crack in the celing and 

possibley from the rain fall from outdoors . was 

informed immediately . had the areas moped of all . My 

findings indicate that regulation 9CRF 416.2(b)(2) was violated , which states that 

walls , floors , and ceilings must be in good repair and prevent insanitary conditions 

. 

5308 M6137 BXL2607124 

201N-1 

12/01/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 12/1/12 at approximately 0005 I observed the following while preforming the 

Pre-Op Review and Observation task in the packaging area . The gray PVC pipe that 

runs the length of the Plant # 1 Halver , which is approximately 8’-10’ in length had 

a build-up of fat and old product tissue on the bottom side of the pipe . I 

immediately contacted . had the PVC pipe 

scrubbed and rinsed throughly . The PVC pipe was re-inspected at approximately 

0012 hours . The area was found to be in good sanitary condition and ready for 

production . My findings indicate non-compliances with the following regulations 

9CFR 416.13(c) , 9CFR 416.4(b) ,9CFR 416.14 , and 9CFR 416.13(a) . 

5308 M6137 BXL4803120 

401N-1 

12/01/2012 03J02 Slaughter HACCP C On 12/01/2012 at approximately 0044 hours while monitoring the establishments' 

Finished Products Standards in Plant #2 line I observed the following. After 

removing a 10 bird random sample, I observed one bird with visible fecal 

contamination. There was a cloacae attached inside the carcass at the base of the 

tail with approximately 2" of intestine. The fecal material was leaking from the 

intestine into the area of the right empty lung socket. The fecal material was a dark 

green color, pasty in texture and approximately 1/4" by 1/8" in size. 

was informed and the protocol for fecal failure was implemented. A QC 

recheck passed at 0105 hours. My findings indicated a noncompliance with 9 CFR 

381.65(e), 9 CFR 417.2(c)(4) and the critical limit of CCP 2B 

of the Plant's HACCP Plan for Slaughter. 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN321012 

5701N-1 

12/01/2012 01D01 SPS Verification C On Nobember 29, 2012, while performing the Observation component of SPS 

(Sanitary Performance Standard) following the bird flow gap, I observed the 

following non compliances: Approximately 0754 hours in the Evisceration 

Department, underneath the cabinet, water dripping from one of the corners of 

the exhaust vent onto the outside wall of the cabinet. Upon closer inspection I 

noticed the outside walls of the chute were saturated with condensation, the ceiling 

mount of the chute had heavy beaded condensation. I showed my findings to Mr. 

) and Mr.

 and of the non compliance. Mr.

 stopped the line before the birds got to that station, so no product 

was affected. Condensation was wiped dry to restore sanitary conditions and the 

line started running at approximately 0800 hours. In the South entrance to the 

Fillet Department in the Bulk Room at approximately 0813 hours, I observed three 

pallets of Styrofoam plates staged to be used. A whole package of plares that was 

partialy used, was directly on the floor, (approximately 40 to 50 plates). Regulatory 

control of that package was applied with US Reject tag #B39415868 and informed 

Mr. and of the non 

compliance. 

5308 M6137 BXL3313110 

129N-1 

11/29/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C While performing Zero Tolerance Verification Task, I observed noncompliance with 

the following regulatory requirements of regulations 9CFR 381.65 (e) and 9CFR 

417.2 (c)(4). At approximately 0904 hours, I randomly removed a 10 bird sample 

from Line #2 in Plant #1, I found one out the ten birds with visible fecal 

contamination inside the bird on the right side under the leaf fat area. The fecal 

material was a smear measuring approximately 1/4" diameter in size, dark green in 

color and pasty in texture. This exceed the limit of Zero Tolerance for the process to 

be in control. I informed and of the 

noncompliance. The protocol for fecal failure was implemented. Quality Control 

performed a recheck at approximately 0935 hours and it passed. The cause of this 

HACCP deviation was a shower head and a nozzle partial plugged up (city water). 

This is a violation of the critical limits of CCP-2B of the 

Plant's HACCP Plan for Slaughter. 

(b) (6)
(b) (6) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4404113 

929N-1 

11/29/2012 03J02 Slaughter HACCP C On 11/27/2012 at approximately 0637 hours while monitoring the Establishments' 

Finished Products Standards in Plant #2 on Line , I observed the following. After 

removing a 10 bird random sample, I observed one bird with visible fecal 

contamination. The fecal material was inside the skin near the neck in a crease 

adjacent to an intact crop. The fecal material was medium brown in color, pasty in 

texture, approximately 1/2" by 1/4" in size and gave off a pungent odor. This 

exceeded the zero tolerance for the process to be in control. was 

informed and the protocol for fecal failure was implemented. A QC recheck at 0708 

hours passed. My findings indicated a noncompliance with 9 CFR 381.65(e), 9 CFR 

417. 2(c)(4), and the critical limit of CCP 2B of 

the Plant's HACCP Plan for Slaughter. 

(b) (6)
(b) (6)

(b) (6)(b) (6) (b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE541511 

0129N-1 

11/29/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 0859 hours while performing the Review and Observation 

component of an Operational Sanitation PHIS task, the following noncompliance 

was noted: At the North Chiller Exit, I noticed two combo bins with a new liners 

which appeared to be ready to be loaded with edible product. Upon closer 

investigation, I noticed that beaded condensation formed underneath a white pipe 

that was located right above the combo bins. When I was inspecting the combo 

bins, I noticed the condensation was dripping onto the liners, which is an edible 

product contact surface. I showed the deficiency to 

, and inquired about the intended use for the combo bins, and he replied 

to me that in case of a breakdown, they would be able to load it with carcasses to 

prevent pile ups of product on the floor. For immediate corrective action, the 

establishment removed the combo bins away from the area and replaced the dirty 

liner with a clean liner. By allowing condensation dripping on direct product contact 

surface, the establishment failed to meet the regulatory requirements of 9 CFR 

416.1 which states, “Each official establishment must be operated and maintained 

in a manner sufficient to prevent the creation of insanitary conditions and to ensure 

that product is not adulterated”. 9 CFR 416.3(a) states,”... Equipment and utensils 

must be maintained in sanitary condition so as not to adulterate product”. 9 CFR 

416.4(a) states, “All food-contact surfaces, including food-contact surfaces of 

utensils and equipment, must be cleaned and sanitized as frequently as necessary 

to prevent the creation of insanitary conditions and the adulteration of product”. 9 

CFR 416.4(b) states, “Non-food-contact surfaces of facilities, equipment, and 

utensils used in the operation of the establishment must be cleaned and sanitized 

as frequently as necessary to prevent the creation of insanitary conditions and the 

adulteration of product”. 9 CFR 416.13(c) states, “Each official establishment shall 

monitor daily the implementation of the procedures in the Sanitation SOP's”. Upon 

reviewing the SSOP Daily Implementation Monitor Log from night shift, I noted that 

the last acceptable check for condensation (Step#6 

.) 

was at hours and for day shift no checks were performed previous to the 

noncompliance. and

 were informed of the forthcoming documentation for the failure to comply 

with the regulatory requirements cited above. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0312112 

728N-1 

11/28/2012 03J02 Slaughter HACCP C At approximately 0825 hours, while performing a Finish Product Standard check on 

line , Plant 2, I found one bird contaminated with feces. The bird had a cloaca 

with a 2" intestine attached to it. There was a chunk of light yellow feces inside of 

the bird's cavity near the kidney area. The feces were soft in texture, measuring 

approximately 1/4" in diameter. I notified of the failure. This 

is a violation of the critical limit of CCP2B of 

the Plant's HACCP Plan for slaughter. The fecal protocol was implemented. Venter 

machine was the cause of deviation. At approximately 0848 hours, Quality control 

performed a Passing recheck. Post chill checks were performed on the suspect lot 

from 0924 hours to 1023 hours. All product exiting the chiller was found 

acceptable. My finding represent a failure with regulatory requirement of 9 CFR 

381.65(e) and 417.2(c)(4). 

5308 M6137 BXL0920110 

828N-1 

11/28/2012 04A06 Poultry Finished 

Product Standards 

C While monitoring the Establishments' Reprocessing Procedure on Line in Plant 

#1, I observed a noncompliance with the following regulatory requirements of 

regulation 9CFR 381.84. At approximately 1342 hours, I randomly removed a 10 

bird sample for my reprocessing test, I found one out of five birds with split tails in 

the sample that contained Airsacculitis exudates. I performed a recheck at 

approximately 1345 hours, in which one of the ten birds sample contained 

Airsacculitis exudates. I immediately took regulatory control action by stopping the 

line and informed the and of my 

findings. The line was started and the product retained while corrective actions 

were being implemented. I performed a recheck at approximately 1403 hours and it 

passed bringing the process back in control. I tagged the tank were the product was 

retained with U.S. Rejected/Retained Tag # B31 406736. After the product was 

reworked, I performed a recheck and released it, at approximately 1525 hours. 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (6)

(b) (6)

(b) (6)

(b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4007112 

227N-1 

11/27/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 11/26/12 at approximately 2208 hours I observed the following while 

performing the Pre-Op SSOP Review and Observation task in Plant # 1 . In the Paw 

room the blue incline flex belt that is used to transport paws to larger bin had a 

white build-up of hardened soap film . I immediately contacted 

and applied Rejected/Retained tag # 406709 . had one of 

his workers scrub and rinse the entire flex conveyor . The Flex incline conveyor was 

re- inspected at approximately 2224 hours and found to be in good sanitary 

condition putting the establishment back in-compliance . At 2218 the Venter 

Opener on line # 2 (area #3 unit # 14) was inspected . The module area of the Vent 

Opener had areas of chicken grease ranged in size from 1" by 1" to 3" by 4" which 

appeared to be from the previous shift . was contacted once 

again . had the affected areas scrubbed and rinsed . At 

approximately 2227 hours the Vent Opener was re-inspected and found to be in 

sanitary condition . At 2230 hours the Final Trim Station/ Bird wash for lines # 1 

and # 2 was inspected . In the bird wash area the recovery tank that catches the 

excess from the shower heads had a build-up of thick white grease and fat 

approximately 1/8" around portions of the under side of the rim . 

had the underneath portion of the tank scrubbed and rinsed . At 

approximately 2236 hours the rim of the tank was re-inspected and found to be in 

good sanitary condition putting the establish back in-compliance . My findings 

indicate the violation of several regulations 9CFR 416.14 , 9CFR 416.13(c) ,9CFR 

416.4(a) and 9CFR 416.4(b) . 

5308 M6137 BXL5722115 

227N-1 

11/27/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 11/27/12 at approximately 0525 hours while preforming the Operational SSOP 

Review & Observation task I observed the following . The drip pan over lines # 1 

and # 2 in the Paw Room were covered with large beads of condensation . Plant 

personal attending the lines and the individual preforming operational sanitation 

were the only personal in the area . The condensation was pointed out ot the 

sanitation attendant , who mopped the drip pan of all condensation . Sanitary 

conditions were restored at approximately 0532 hours . My findings indicate 

noncompliances with the following regulations 9CFR 416.2(d) 9CFR 416.13(c) and 

9CFR 416.14 . 

5309 P6137A NJN451711 

0027N-1 

11/27/2012 01D01 SPS Verification O On November 27, 2012 I was in the fillet department at 1035 hrs and observed the 

following non-compliance; while I was standing by the ice machine where there was 

one combo bin under the chute being filled with ice. I saw a piece of unidentified 

foreign material approximately half inch by half an inch in size in the combo bin 

with the ice. I notified the and 

about the forthcoming non-compliance. 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE080111 

1427N-1 

11/27/2012 03C02 Raw Intact HACCP C On November 26th 2012, at approximately 0540 hours while performing an 

Operational Sanitation task in the second processing, I observed a bin filled with

 lb of young chickens thighs kill date Friday November 23d 2012. I borrowed

 calibrated thermometer # 54 to check the product temperature 

and it measured 48 degrees Fahrenheit. I immediately retained the product by 

placing retain Tag # B38494916, and informed Mr. 

, of my finding and forthcoming noncompliance. Immediately, 

Mr. started the establishment's corrective actions by adding ice on the 

product and moving it to the cooler. At approximately 0611 hours, the product was 

released after I found the temperature to be acceptable (39.7 degrees Fahrenheit). 

Upon review of the thermometer calibration log, thermometer # 54 was found 

acceptable at 2308 hours. Failure of the establishment to maintain a maximum 

internal temperature of the product at 40 degrees Fahrenheit or less is 

noncompliance in accordance with 9 CFR 381.66(a) and 9CFR 381.66(c) (3). 9 CFR 

381.66(a) states " Temperature and procedures that are necessary for chilling and 

freezing ready-to-cook poultry, including all edible portions thereof, must be in 

accordance with operating procedures that ensure the prompt removal of the 

animal heat, preserve the condition and wholesomeness of the poultry, and assure 

that the products are not adulterated." 9CFR 381.66(c) (3) states "Previously chilled 

poultry carcasses and major portions must be maintained constantly at 40 F or 

below until removed from the vats or tanks for immediate packaging ... . " 

5308 M6137 BXL0809113 

523N-1 

11/23/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 11/23/2012 at approximately 0043 hours while monitoring Operational 

Sanitation procedures in Plant #1, I observed the following. There were black UFM 

(Unidentified Foreign Material) smears on the birds exiting Chiller #1. The UFM was 

on the cut surfaces of the breast, on the fat,skin and tissue around the neck area, 

and on the tissue at the abdominal opening at the tip of the keel bone. The amount 

of UFM varied from approximately 1 inch to several square inches in size. I took 

several samples and contacted . I proceeded to the exit side of 

Chiller #2 and found the carcasses exiting Chiller #2 to have a similar black UFM. I 

again took samples for . Birds coming from the chillers were 

tanked off until approximately 0108 hours. The WOGS (With Out Giblets)being 

collected at the Sorting & Sizing line also had the same black UFM. The tanked 

product was placed under QC hold pending reconditioning. was 

informed. At approximately 0350 hours in the Rotisserie Room there were two 

tanks of WOG's with similar black UFM smears. The tanks were labeled 31328 on 

Nov. 23, item 180260 at a time of 0048 hours weighing pounds, and 31329 

on Nov. 23, also item 180260 at a time of 0052 hours weighing pounds. I 

contacted and showed her the UFM. The tanks of WOG's were 

placed under QC hold tags pending reconditioning. My findings indicated a 

noncompliance with 9 CFR 416.1 and 9 CFR 416.4(d). 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5108113 

023N-1 

11/23/2012 03J02 Slaughter HACCP C On 11/22/12 at approximately 0140 hours I observed the following while 

preforming the Finished Product Standard Task on line in Plant # 2 . After 

randomly removing 10 birds, I observed one bird with the cloaca still 

in-intact ( attached to the leaf fat ) with visible fecal material escaping from the 

opening of the cloaca . The fecal material was green in color and watery in texture . I 

immediately notified who notified

 . implemented the establishments fecal failure protocol at 

approximately 0144 hours . The recheck passed at approximately 0207 hours . The 

venter was determined to be the cause of the failure . This incident was a violation 

of the critical limits of CCP-2B of the HACCP Plan for 

slaughter including the violation of regulations 9CFR 381.65(e) and 417.2(c)4 . 

5309 P6137A NJN040911 

4623N-1 

11/23/2012 04A06 Poultry Finished 

Product Standards 

C At 0439 hrs. I was performing a FPS (Finished Product Standards) check on the 

reprocessing line in the evisceration department when I noted the following 

noncompliance: The establishment failed to remove airsacculitis exudate from 

carcass identified by USDA for air sac removal. (1) Of the (10) carcass sample 

identified for air sac removal with a split tail, contained air sac exudate. I informed 

and showed my findings to , she was given the opportunity to examine the 

airsacculitis in the carcass. I performed a recheck at 0445 hrs, at this time (1) of the 

(10) carcass sample identified for air sac removal with a split tail, contained air sac 

exudate. The retest defect requires retention and rework. The line was stopped,

 and Ms. were informed of the failure. The 

establishment did not meet the requirments of 9 CFR 381.84 which states in part: 

"less affected carcasses may be passed for food after complete removal and 

condemnation of all affected tissues including the exudate. Per the procedure of the 

establishment, , initiated immediate 

corrective action as prescribed in the establishment Vacuum Procedure. 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN080511 

5723N-1 

11/23/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 2341 hours while performing PHIS task for zero tolerance on the 

reprocessing line I observed one carcass of a ten carcass sample with visible fecal 

material on the inside cavity of the bird by the vent area. The fecal material was 

approximately 1/8 inch in diameter, dark green and tan in color and had a paste-like 

consistency. After noticing the affected carcass, I stopped the reprocessing line and 

both informed and showed the fecal matter on the affected bird to Mr. 

and Ms. The establishment did not meet 

the requirements of 9 CFR 381.65(e) which requires that the establishment prevent 

poultry carcasses contaminated with visible fecal material from entering the chilling 

system. The failure also represents a deviation from the establishment’s written 

HACCP plan, regulatory requirements of 9 CFR 417.2(c)( 4). Regulation 9 CFR 

417.2(c)( 4 )states “List the procedures, and the frequency with which those 

procedures will be performed, that will be used to monitor each of the critical 

control points to ensure compliance with the critical limits”. Per the procedure of 

the establishment, , initiated 

immediate corrective action as prescribed in the establishment HACCP plan. Upon 

reviewing the records pertaining to the failure, the establishment found all the 

mandatory pre-chill and post chill checks acceptable. 

5308 M6137 BXL1813113 

321N-1 

11/21/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1043 hours while walking through the Plant #2 Packaging area I 

observed the following noncompliance. A company employee working on Line #2 

picked up an empty pallet from the floor to move it out of the way and then came 

back to the line without washing or sanitizing his gloves and put his hands in the 

product, contaminating it. I immediately took regulatory control and had them stop 

the line and informed of the noncompliance. He 

immediately had company employees condemn the product on the line and had the 

line washed and sanitized, restoring sanitary conditions. My findings indicate a 

noncompliance with regulations 9CFR 416.1, 9CFR 416.4(a) and 9CFR 416.4(d). 

(b) (6)
(b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2017111 

721N-1 

11/21/2012 04A06 Poultry Finished 

Product Standards 

C At approximately 1025 hours, I randomly removed a 10 bird sample from line 1 in 

plant 1 for Pre-Chill finish Product Standard check. I documented 51 points of the 

processing nonconformances from the 10 bird sample. This exceeded the subgroup 

absolute limit of 30 points for the Processing nonconformances to be in control. I 

informed Quality Control and of the failure. 

At approximately 1035 hours QC performed a recheck, documenting 27 points on 

the Processing Nonconformances. This exceeded the limit of the 25 points allowed 

for the recheck. At this point the process is considered out of control. Birds size was 

inconsistent and maintenance was having problems adjusting equipment. QC. was 

failing the venter machine CP, There was mutilation on the birds and a very 

noticeable amount of birds with attached intestines. Line was slowed down to 

BPM, one back up employee was assigned to cut long shanks, two back up 

employees were assigned after the body opener and venter machine, two trimmers 

were assigned to the final trim station. was notified of the 

noncompliance. Corrective actions were implemented. Quality Control performed 

rechecks at Pre-Chill and Post-Chill. At approximately 1242 hours the process was 

back in control. My findings indicate a regulatory noncompliance with Reg. 9CFR 

381.76(b). 

5308 M6137 BXL0709111 

921N-1 

11/20/2012 06D02 Other Inspection 

Requirements 

C On 11/21/2012 at approximately 0600 hours while performing a Presentation 

check in Plant #1, I observed the following. A review of the establishments' 

Lines - No Viscera Monitoring Log for the shift revealed that QC personnel had failed 

line #1 at 0052 hours with 21 no viscera. A recheck failed at 0149 hours with 25 no 

viscera. At BPM 13 no viscera are allowed. The line was slowed to BPM. A 

check at 0351 hours failed at BPM with 14 no viscera. At BPM 11 no 

viscera are allowed. Rechecks brought the line back into compliance at 0455 hours. 

On line #2 at 0058 hours QC personnel had failed the line with 28 no viscera. A 

recheck at 0153 hours failed with 19 no viscera. The line was slowed to BPM. A 

check at 0355 hours at BPM failed with 16 no viscera. Rechecks brought the 

line back into compliance by 0504 hours. Three consecutive failures is a 

noncompliance for a failure to take proper corrective action. My findings indicated a 

noncompliance with 9 CFR 381.76(a) & (b). 

(b) (6)
(b) (6) (b) (6) (b) (6)

(b) (6)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1409114 

420N-1 

11/20/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 11/20/2012 at approximately 0545 hours while monitoring the establishments 

Operational Sanitary Procedures in Plant #1, I observed the following. The brown 

tubs being used to collect finished product from the giblet chiller had varying 

amounts of dried and semi-dried blood, and a few tubs had liver/gizzard tissue to 

1/2"on the internal and exterior surfaces. The dirtiest tubs had a semi-dried light 

brown scum in large areas approximately 1' by 6" in size on the internal surfaces. 

Most of the blood and scum residue was located on the sides of the tubs while the 

internal bottom surfaces were generally clean. The tubs gave off a strong musty 

odor. I contacted and showed him my findings. The two stacks of 

tubs staged for use were taken to the tub wash room for cleaning. There were at 

least 30 tubs in each stack. I proceeded to the Plant #2 aged breast cooler where an 

additional stack of tubs was found to be in the same insanitary condition. I next 

went to the out flow area of the Plant #2 giblet chiller where two more stacks of 

brown product tubs were also found to be insanitary. I contacted 

and showed him my findings. By approximately 0600 hours I returned to Plant #1 

where a recleaned stack of brown tubs was just being brought back from the tub 

wash room. The tubs still had the same dried and semi-dried blood, tissue and 

scum. The tubs were again returned to the tub wash room. I showed the 

insanitary condition of the rewashed tubs. My findings indicated a noncompliance 

with 9 CFR 416.1 and 9 CFR 416.4(d). 

5308 M6137 BXL3615110 

619N-1 

11/19/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C At approximately 0845 hours while performing a Pre Operational sanitation 

inspection in the room, I observed the following: The wing line conveyors 

were affected with dark gray grease. There were two chunks of pasty grease 

measuring approximately 1/4" each. There were also two areas of approximately 3 

square inches, each affected with numerous spots of grease unbidden in the 

conveyor. I also observed a wing portion inside of one of the hoppers. These are all 

product contact surfaces. I proceeded to place a U.S Rejected/Retained tag N0. B31 

407696 on the affected equipment. I showed my finding to 

. All affected areas were scrubbed and washed. 

Wing line conveyors were re inspected and found under sanitary conditions. At 

approximately 0905 hours, USDA released the equipment. My findings reflect a 

noncompliance with regulations 9 CFR 416.1; 416.4(a); 416.13(c) and 416.14 

(b) (6)
(b) (6)

(b) (6)

(b) (6)

(b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4617115 

519N-1 

11/19/2012 03J02 Slaughter HACCP C At approximately 1320 hours while performing a HACCP Slaughter Record Review 

Task, I found the following; Quality Control or designee documented on the HACCP 

Monitoring Log CCP-2B (Plant #2) dated on 11/19/2012 PM shift, 

Direct Observation on Line at 1029 hours. The time enter on verification 

activities (Direct Observation) did not corresponded with any of the monitor 

procedure entries. Records Review for that CCP-2B were already 

performed by Quality Control or designee at approximately 1258 hours. My 

findings indicate a noncompliance with the following regulatory requirements of 

regulations 9CFR 417.5 (a)(3) and 9CFR 417.5 (b). I notified 

of the noncompliance. 

5308 M6137 BXL5413110 

219N-1 

11/19/2012 06D02 Other Inspection 

Requirements 

C At approximately 0830 hours, I performed a presentation check on Line at Line 

Speed of BPM. Station #1 had (2) not uniform and (2) viscera on shackle, total of 

32 points. Station #2 had (1) not uniform and (1) viscera on shackle, total of 21 

points. Station #3 had (1) viscera not uniform and (1) not reflected, total of 10 

points. Station #1 failed with 32 points, this exceed the limit of the 25- 39 points. At 

approximately 0842 hours, Quality Control performed a recheck and Station #2 

failed with (3) not uniform, (1) viscera on shackle, (1) membrane and (1) not 

reflected, total of 36 points. This exceed the retest conformances levels of 25 points 

for the process to be in control. was informed and the Line 

speed was reduced to BPM. At approximately 0918 hours all rechecks at Line 

Speed of BPM and BPM passed, bringing the process back to control. This is a 

noncompliance with the following regulatory requirements of regulation 9CFR 

381.76(b). 

5333 P7632 HYE040311 

4419N-1 

11/19/2012 04A06 Poultry Finished 

Product Standards 

C I was performing a Poultry Finished Product Standards Verification task in the 

evisceration department on the reprocessing line at 0036 hours when I observed 

the following non compliance: I selected a ten bird sample after the final wash 

cabinet, marked with a horizontal slash across the back indicating that these 

carcasses where identified for cellulitis (inflammatory condition) removal. One out 

of ten carcasses had visible cellulitis exudate tissue under the leaf fat flap. I stopped 

the reprocessing line and showed the carcass to 

. I then performed a ten carcass recheck at 0041 hours after the line had 

restarted. I noted one carcass out of the ten with cellulitis exudate along the inside 

of the thigh. I informed of the of the 

documentation of the non compliance. initiated corrective 

actions by performing a recheck. That recheck passed. He then marked the chiller 

per the establishment's corrective actions. The failure to remove cellulitis affected 

tissue is a non compliance with 9 CFR 381.86 which states: "Any organ or other 

part of a carcass which is affected by an inflammatory process shall be condemned 

and, if there is evidence of general disturbance, the whole carcass shall be 

condemned." 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE180811 

1319N-1 

11/19/2012 01C02 Operational SSOP 

Review and 

Observation 

C At 0415 hours I was giving the on-line inspector a break on line number two (north 

line), station one when I noted the following non compliance: a carcass coming 

down the evisceration line was presented for inspection with a cockroach crawling 

down the inside of the leg towards the leaf fat flap. I immediately stopped the line 

and secured the insect into a paper towel. I rang my call button for a supervisor.

 along with 

approached the station. I showed the cockroach to and informed 

her of the non compliance. The establishment had the affected carcass condemned. 

9 CFR 416.1 states: "Each establishment must be operated and maintained in a 

manner sufficient to prevent the creation of insanitary conditions and to ensure 

product is not adulterated." 9 CFR 416.2(a) states: "The grounds about an 

establishment must be maintained to prevent conditions that could lead to 

insanitary conditions, adulteration of product, or interfere with inspection by FSIS 

program employees." 9 CFR 416.4(d) states: " Product must be protected from 

adulteration during processing, handling, storage, loading, and unloading at and 

during transportation from official establishments." 

5308 M6137 BXL0805114 

417N-1 

11/17/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 11/17/12 at approximately 0150 hours after completing a HACCP Slaughter 

Fecal check on line , I observed the following. An employee brought a brown 

product tub of birds from the Kill Line/ Evisceration Line rehang area. The carcasses 

are missed by the mechanism that removes the carcasses from the line and directs 

them into the chiller. The carcasses are contaminated when they drag on drip pans 

and over support brackets that are considered non-contact surfaces and are seldom 

cleaned. Varying numbers of carcasses are missed by the mechanism throughout 

the shift. The employee started to hang the birds on line after the final 

inside/outside wash cabinet. I removed the first bird that was hung on line and 

observed UFM consisting of black smears to approximately 2" by 1" and specks to 

approximately 1/8"on the tissue and skin around the neck area. The employee 

stopped hanging, got a scissors and started reconditioning the carcasses using the 

water at the line final inspection station. Of approximately 10-12 birds that were 

reconditioned three carcasses were still contaminated with the black UFM. I 

contacted and showed him my findings. retained 

the carcasses for retraining purposes. A review of the establishments' SSOP 

document ' ' dated 09/10/12 under ' 

. " Under ' 

" There is a 

sink near the entrance side of the chillers but the water valves are tagged "Danger 

do not operate". No QC or Production Supervisor was ensuring that reconditioning 

procedures were bring followed. My findings indicated a noncompliance with 9 CFR 

416.1, 9 CFR 416.4(d), and 9 CFR 416.12(b),(c) & (d). 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2705112 

817N-1 

11/17/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 11/16/12 at approximately 2215 hours I observed the following in Plant # 1. 

While performing the SSOP Review and Observation Task which was pre formed 

after the establishments SSOP Monitoring Procedure . The Gall Bladder and 

Intestine remover unit # 18 of area # 3 had a yellowish / brown build-up on the 

plastic blades and the rotating augers , the iron stub auger had a build-up of 

product imbedded in the groves the pan beneath the upper augers had several large 

white grease spots ranging in size from 1" by 1" to 3" by 4" . US Rejected/Retained 

tag B31406745 was immediately applied . has one of his 

workers clean the affected areas .The Intestine Gall Bladder Remover was 

re-inspected at approximately 2227 hours . The area was found to be in sanitary 

condition and released for production . At approximately 0019 the Room .The 

Wing Transfer Line had fat particles ranging in sige !/8 " to 1" . 

was informed immediately . had the Wing Transfer Line 

rinsed thought . At approximately 0025 the Wing Transfer Line was re-inspected 

and to be in sanitary condition and released for production . My find in both 

incidents are indications of several regulations being violated 9CFR 416.4(b) ,9CFR 

416.14 , 9CRF 416.13(a) .416.(c) and 416.4(a) . 

5308 M6137 BXL2713113 

816N-1 

11/16/2012 03J02 Slaughter HACCP C While performing Pre-Chill Finished Products Standards Task, I observed 

noncompliance with the following regulatory requirements of regulations 9CFR 

381.65 (e) and 9CFR 417.2 (c)(4). At approximately 0844 hours, I randomly 

removed a 10 bird sample from Line #1 in Plant #1, I found one out of the ten birds 

with visible fecal contamination inside the bird on the left side of the kidney area. 

The fecal material was a sphere approximately 1/4" diameter in size, dark green in 

color and pasty in texture. This exceed the limit of Zero Tolerance for the process to 

be in control. I informed and of the 

noncompliance. The protocol for fecal failure was implemented. Quality Control did 

a recheck at approximately 0902 hours and it passed. The cause of the deviation 

was the venter. This is a violation of the critical limits of CCP-2B 

of the Plant's HACCP Plan for Slaughter. 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6)

(b) (6)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4615114 

616N-1 

11/16/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1112 hours while walking through the Room I observed the 

following noncompliance. I turned to walk into the wing room and noticed heavy 

beaded condensation covering the entire bottom of the long white air conditioning 

unit, this unit is located right above the Hopper taking front halves to Lines #1, #2,

 the Room and the two wing lines. I immediately found

 and told him of the noncompliance. 

walked with me to look at the condensation and while doing so I observed 

condensation dripping from the bottom of the air conditioning unit onto product in 

the Hopper that was being taken up the incline belt and on to Lines #1, #2 and in 

the Room. stopped the lines and had the remaining front 

halves from the lines and hopper put into brown tubs to be reworked. There were 

29 tubs of product retained by . The air conditioning unit was cleaned and 

a company employee was put in the area to keep the unit wiped clean, the belts to 

the lines are all continuously washed with and the rest of the line 

was washed during the company break restoring sanitary conditions. All affected 

product was reconditioned by production then rechecked and released by QC under 

my supervision. My findings indicate a noncompliance with 9CFR 416.2(d), 

416.4(b),416.1 and 416.4(d). 

5308 M6137 BXL5815110 

216N-1 

11/16/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C While performing Zero Tolerance Fecal Task, I observed noncompliance with the 

following regulatory requirements of regulations 9CFR 381.65 (e) and 9CFR 

417.2(c)(4). At approximately 1244 hours, I randomly removed a 10 bird sample 

from Line #1 in Plant #1, I found one out of the ten birds with visible fecal 

contamination inside the bird on the right side under the leaf fat area. The fecal 

material was a smear measuring approximately 1/8" long and 3/16" wide, dark 

green in color and pasty in texture. This exceed the limit of Zero Tolerance for the 

process to be in control. I informed S

 of the noncompliance. The protocol for fecal failure 

was implemented. Quality Control did a recheck at approximately 1312 hours and it 

passed. The cause of the deviation was the leaf fat lifter. This is a violation of the 

critical limits of CCP-2B of the Plant's HACCP Plan for 

Slaughter. 

(b) (6)
(b) (6) (b) (6)

(b) (6) (b) (6)

(b) (6) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN310311 

1516N-1 

11/16/2012 01D01 SPS Verification C At approximately 0735 hours while monitoring the establishment’s GMP’s for hand 

washing and sanitizing at the start of shift in the Fillet Department the following 

Noncompliance was observed: A plant employee was moving a portable foot stand 

to South, after which he dipped his gloved hands in a tub of potable 

water, without sanitizing his gloves the employee began putting blue liners into 

bins used for edible product. These blue liners are considered direct product contact 

areas. I informed Mr. ) of the 

Noncompliance of the plants GMP’s. Mr. had the employee wash and 

sanitize his gloved hands . He had the blue liners removed from the bins. The 

establishment did not meet the requirements of 9 CFR 416.1 and 9 CFR 416.5(a) All 

persons must adhere to hygienic practices. 

5308 M6137 BXL1709114 

415N-1 

11/15/2012 04A06 Poultry Finished 

Product Standards 

C On 11/14/12 at approximately 0638 hours, I ramdomly removed a 10 bird sample 

from line in plant #2 for Pre-Chill Finish Product Standard Check, I documented 

35 points of the Processing Nonconformances from the 10 bird sample. This exceed 

the subgroup absolute limit of 30 points on the Processing Noncomformance to be 

in control. I informed Quality Control of the failure and at approximately 0648 

hours she performed a recheck. Quality Control documented 36 points on the 

Processing Nonconformance, this exceed the limit of the 25 points allowed for the 

recheck, at this point the process is considered out of control. I informed 

of the noncompliance. Corrective actions were implemented. Quality 

Control performed rechecks at Pre-Chill and at Post-Chill. At approximately 0725 

hours the process was back in control. This is a noncompliance with the following 

regulatory requirements of regulation 9 CFR 381.76(b). 

5308 M6137 BXL5108115 

615N-1 

11/15/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 11/13/12 at approximately 2307 hours I observed the following while 

preforming the Pre-Op SSOP Review and Observation task in the Rotisserie Room 

after the establishments SSOP daily monitoring procedure . The section of the box 

line directly above the whole bird packing line which is approximately 10’ in length 

by 3’ in width . The area had thick particles of cardboard and other debris in the pan 

directly beneath the flex belt spanning the entire length of the packing 

line . Rejected/Retained tag # B31407698 was immediately applied and 

was notified . rinsed the whole area spanning 

approximately 10’ .The area was reinspected and found to be in sanitary 

condition . At 2313 hours the Rotisserie Room was released production . My 

findings are indication of several regulations being violated 9CFR 416.13(a) , 9CFR 

416.13(c) , 9CFR 416.14 and 9CFR 416.4(b) . 

(b) (6)
(b) (6) (b) (6) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN300311 

5115N-1 

11/15/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 11-15-2012 at approximately 1217 hours I performed Pre-Operational 

Sanitation Inspection on Area # 4 Food Service. After the Establishments monitoring 

and preventative measures I observed the following noncompliance: I inspected 

unit # 20 Case Sealer and Roller belt I observed approximately 5 pieces of meat on 

the roller belt approximately 1⁄4 inches in diameter , dried fat and meat , slightly 

smaller in diameter, on the inner sides of the frame that guides the rollers for this 

belt. I also observed meat scraps of the same diameter on the floor around this 

piece of equipment. I applied U.S. Reject Tag #B39146489 rejecting this piece of 

equipment for use. Upon reinspection of the tagged equipment I observed 

identifiable pieces of wings in the drain directly under this piece of equipment. This 

in a noncompliance of 9 CFR 416.4(b), and 416.14. 

5308 M6137 BXL5408110 

214N-1 

11/14/2012 03J02 Slaughter HACCP C On 11/14/2012 at approximately 0236 hours while monitoring the Establishments' 

Post-Chill Finished Product Standards from Chiller #3, I observed the following. 

After taking a random 10 bird sample, I observed one bird with visible fecal 

contamination. There was a piece of intestine approximately 6" long attached to the 

carcass at the base of the kidneys where the sex organs would be located. The fecal 

material was inside the carcass on the right side in a crease at the end of the fat 

flap. The fecal material was a smear approximately 1/4" in size, medium brown in 

color and pasty in texture. This exceeded the Zero Tolerance for the process to be in 

control. The 10 bird sample collected were the first birds exiting the chiller after a 

scheduled company break so no carcasses were being hung going into packaging.

 was nearby so I showed her the carcass and asker her to do a 

recheck which passed at 0240 hours. Approximately 1 1/2 tanks of birds were 

placed on hold. The birds were released at approximately 0450 hours after 

reconditioning. was informed. My findings indicated a 

noncompliance with 9 CFR 381.65(e), 9 CFR 417.2(c)(4), and the critical limit of CCP 

2B of the Plant's HACCP Plan for Slaughter. 

(b) (6)
(b) (6) (b) (6)

(b) (6) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN042211 

0214N-1 

11/14/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 11-14-2012 at approximately 0120 I performed an Operational Sanitation task 

in the Packaging Department, Area 2, Section C, Segment Line & area. I 

observed grease specs in a brown tub, the grease came off to the touch, it was on a 

pallet with approximately 200 other tubs that had been cleaned and sanitized, the 

pallet of tubs was wrapped with plastic indicating they were cleaned, and sanitized 

ready for use in production. This pallet of tubs was being used to place product in 

that was being produced by the Body Halver #2 machine located on the north wall 

of the packaging room, behind the leg processers. I applied U.S. Reject 

Tag # B39146491 rejecting this tub for use. I immediately informed 

. I relinquished my U.S Reject tag after a Quality Control tag 

was applied to the pallet of bins. This is a noncompliance of 9 CFR 416.4(a), and 

416.14. 

5309 P6137A NJN581311 

0014N-1 

11/14/2012 01C02 Operational SSOP 

Review and 

Observation 

C While doing Review and Observation procedure of SSOP in the Fillet Department, I 

observed four maintenance personnel working on Wing Cutter at line . After they 

were done and QC removed her tag, a lead person splashed some sanitizer solution 

on the equipment and production started running product, I decided to inspect the 

product landing on the empty basket next to the cone lines. The product of whole 

skinless breast (four pieces) that landed in the empty basket had unidentified 

foreign material around the neck shoulder area. The foreign material ranged in size 

from approximately 1/16 of an inch to 1/8 of an inch in length plus some grease 

smears up to approximately 1⁄4 inch in length. Regulatory control of the line was 

taken at approximately 0815 hours by stopping the line and the application of U.S. 

Retained tag #B39415870 and informing Mr.

 of the non compliance. 

Regulatory Control was released at approximately 0839 hours after equipment was 

properly washed and sanitized, disposition to condemn the product and preventive 

measures were proffered by Mr. to conduct a training with leads to 

inspect product after maintenance has worked on equipment. 

(b) (6)
(b) (6) (b) (6) (b) (6)

(b) (6) (b) (4)

(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN561511 

1912N-1 

11/12/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1030 hrs while performing Operational Sanitation procedure in 

the fillet department I observed the following non-compliance. At the re-processing 

station # 2 one employee was re-conditioning the wings. She put more than 15 

pieces of wings on to the rack and wash them at the same time. I showed my 

findings to the and inform him 

about the forthcoming N R. In the Establishment SOP for the Reprocessing of 

poultry parts and carcasses step # 5 states that 

. All adulterated parts will be condemned. Wholesome parts will be 

thoroughly washed and made available for re-inspection. 

5333 P7632 HYE291711 

0512N-1 

11/12/2012 01C02 Operational SSOP 

Review and 

Observation 

C While I was observing the process at the packaging department as part of the 

review and observation of an Operational Sanitation PHIS routine task, I noticed the 

following noncompliance: At the #1 (area IV) I noticed a fly landing and 

walking on the guide bars and the clear film that is used to pack thighs. The fly 

landed right after the clear film roll is unrolling and prior to the feeder of the

 machine. killed the fly and 

the line was stopped immediately at 1405 hours. No retain tag was applied because 

the establishment implemented immediate corrective actions by cleaning the guide 

bars and removing approximately 20 feet of clear film in my presence. No edible 

product was affected. The establishment resumed production after sanitary 

conditions were restored. The finding of a fly in the production area and affecting 

product contact surfaces represents a noncompliance, in consequence, the 

establishment did not meet the regulatory requirements of 9 CFR 416.1, 9 CFR 

416.2(a) and 9 CFR 416.13(c). 9 CFR 416.1 states, “Each official establishment must 

be operated and maintained in a manner sufficient to prevent the creation of 

insanitary conditions and to ensure that product is not adulterated”. 9 CFR 416.2(a) 

states, “The grounds about an establishment must be maintained to prevent 

conditions that could lead to insanitary conditions, adulteration of product, or 

interfere with inspection by FSIS program employees. Establishments must have in 

place a pest management program to prevent the harborage and breeding of pests 

on the grounds and within establishment facilities...” 9 CFR 416.13(c) states, “Each 

official establishment shall monitor daily the implementation of the procedures in 

the Sanitation SOP's”. , and 

were informed of the forthcoming 

documentation for the failure to comply with the regulatory requirements cited 

above. 

(b) (6)
(b) (6) (b) (6) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1701111 

209N-1 

11/09/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 11/8/12 at approximately 2217 hours I observed the following while performing 

the SSOP Pre-Op Review and Observation Task in Plant #2 .The Vent Opener in 

area # 3 unit 21 had a thick layer of old dried fat and UMF ( unidentified foreign 

material ) l on top of the sprayer which is approximately 6"- 8" in length . The birds 

rotate beneath the sprayers which makes this a contact area . I immediately applied 

US Rejected/Retained tag # B31407699 and contacted 

who had one of his workers scrub and rinse the top potion of the sprayer . The 

sprayer was re inspected at approximately 2222 hours and found to be in good 

sanitary condition putting the establishment back in compliance . My findings 

indicate the violation of several regulations 9CFR 416.4 , 9CFR 416.14 and 

9CFR416.13(c) . 

5308 M6137 BXL2004114 

208N-1 

11/08/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 11/07/2012 at approximately 2355 hours while monitoring the Establishments' 

Pre-Operational Sanitation Procedures in Packaging Area #1 after SSOP monitors 

completed there inspections, I observed the following. There were numerous pieces 

of fat and tissue to approximately 2", and dried and semi dried fluids and tissue 

along large sections of both breast fillet product belts that take finished product 

from the Deboning room to Packaging. The overhead belts are approximately 

100 feet long and run parallel to the Crust Tunnel. There was a strong sour odor at 

the end of the belt near the elevator. The dried and semi dried tissue was on the 

stainless support brackets at the junction with the flexible belt. The patches of dried 

and semi-dried product were several feet long, in several places approximately 2" 

wide and 1/8" thick. Sanitary conditions were restored by approximately 0023 

hours. My findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.4(a), 

and 9 CFR 416.13(c). 

5309 P6137A NJN271611 

1608N-1 

11/08/2012 01D01 SPS Verification C At approximately 1054 hour, while performing Sanitary Performance Standard 

procedure (SPS) in the Fillet Department , Area 6; Fillet-Section E: 

Cutting & Packing, I observed four stacks of empty baskets staged to be used. I 

observed many fat particles adjacent to two of the stacks. The particles ranged in 

size from approximately 1/8 inch to over 1 1⁄2 inches in length. After closer 

inspection I observed numerous fat particles spread throughout the top side of 

baskets and some hanging from the bottoms of baskets and throughout inside and 

outside walls of equipment. Regulatory control of the baskets was taken with the 

application of USDA Reject Tags #B39415821 and #40266794 and informing Mr.

 of the forth coming non compliance. 

Regulatory Control was released at approximately 1146 hours after the baskets 

were washed, sanitized and inspected by USDA. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE360211 

3307N-1 

11/07/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 2300 hrs. I was performing a Zero Tolerance verification task of 

the reprocessing line in the evisceration department, when I noted the following 

non compliance: I observed one carcass out of a ten carcass sample with visible 

fecal material. These carcasses where visually checked after the final wash cabinet. 

This carcass contained a dark green-brown colored elongated paste-like smear 

approximately a 1/2 inch wide by 2 1/2 inches long on the inside along the right 

side of the rib cage. I took regulatory control by stopping the reprocessing line. I 

showed this finding to and and 

informed them of the documentation of the non compliance. I then relinquished 

regulatory control of the reprocessing line to production and QC to implement 

corrective actions. This failure represents a non compliance with regulation 9 CFR 

381.65(e), which states: "Poultry carcasses contaminated with visible fecal material 

shall be prevented from entering the chilling tank". The failure also represents a 

deviation from the establishment's written HACCP plan, regulatory requirements of 

9 CFR 417.2(c)(4), which states: "List the procedures, and the frequency with which 

those procedures will be performed, that will be used to monitor each of the critical 

control points to ensure compliance with the critical limits". Per the procedure of 

the establishment, initiated immediate 

corrective action as prescribed in the establishment's HACCP plan. Upon reviewing 

the records pertaining to the failure, the establishment found all mandatory 

pre-chill and post-chill checks acceptable. 

5308 M6137 BXL3816113 

406N-1 

11/06/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1010 hours, while performing a vefication check on reprocessing 

line #6 in plant 1, I observed the following. Out of a ten bird sample I found 3 birds 

contaminated with black grease. I showed the contaminated carcasses to 

. Maintenance was notified. I continued checking the birds 

after the final trimmer, finding several more birds affected with foreign material. I 

proceeded to stop the line and had production to tank off all product. I place a U.S. 

REJECTED/RETAINED tag N0 B31 407703 on a stainless steel tank 1/3 full with 

contaminated product. At approximately 1035 hours, maintenance had found the 

problem. The fingers on the Inside/Out bird washer were dirty. I performed a 

recheck, after the problem had been fixed, finding the product on line to be 

acceptable. All contaminated product was reconditioned by production. At 

approximately 1050 hours, I performed a recheck on the retained product finding it 

acceptable. U.S retained tag was removed by me. My finding represent a 

noncompliance with regulatory requirement of regulation 9 CFR 416.4(d). 

(b) (6)
(b) (6)

(b) (6)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN080311 

5407N-1 

11/06/2012 04B04 General Labeling C On 1/30/12, while reviewing products in the establishments cooler for compliance 

with product labeling requirements, I observed a noncompliance with 9CFR 

317.1(a). I observed 6 baskets of breast tenders , 5 basket of several different 

poultry parts products and 1 tub of poultry trim product, all which were not labeled 

with information to identify the lot of product or the slaughter/processing date. 

Regulation 317.1(a) states: When in an official establishment, any inspected and 

passed product is placed in any receptacle or covering constituting an immediate 

container, there shall be affixed to such container a label as described in 317.2. I 

took regulatory control of the products by applying US Retain Tags # B25206983, 

B25206989, B25206984 B39415811 and B6179507 and informed 

of the noncompliance. 

5308 M6137 BXL0418114 

805N-1 

11/05/2012 04B04 General Labeling C On 11/03/2012 at approximately 1250 hours while monitoring the weigh and price 

labeling processes, I noticed a new product being weighed and priced on line 1. 

According to the case label it was a PANKO Crusted Chicken Breast Distributed by 

. The product was individual portioned 

plastic trays with the Net Weight/Price label indicating the product was from Est. 

. I contacted a W/P Supervisor who mentioned that the product was brought 

from NCDC where it was relabeled with the Label and sent to the weigh and 

price department. The original labels with the date of pack were removed and 

destroyed, and the reason for relabeling such product was unknown. USDA at 

was not notified of this product at any time. As per regulation 381.138(b) 

which states in part: "Labeling and containers bearing any official inspection 

marks , with or without the official establishment number, may be transported 

from one official establishment to any other official establishment, only if such 

shipments are made with prior authorization of the inspector incharged at point of 

origen, who will notify the inspector in charged at the destination concerning the 

date of shipment, quantity, and type of labeling material involved." At 

approximately 1340 hours, I issued a Memorandum of Interview 

(BXL2016111503G) addressed to 

. The MOI stated that all Product code 096401 

( PANKO CRUSTED/chicken breast) relabeled with establishment No 

was on hold and was not to be shipped out of the NCDC pending further 

investigation. 3,784 cases were put on hold. The relabeling on this product was 

false and misleading. This product was not processed, packaged and labeled at

 This is a noncompliance with regulatory requirement of 9 CFR 381.1; 

381.129; 381.138(b); 381.139 and 381.140. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (7)(C) (b) (7)(C) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5316115 

805N-1 

11/05/2012 01D01 SPS Verification C At approximately 1255 hours, while performing post-mortem inspection on 

Line # , station #11, I observed a live adult cockroach on a carcass, I immediately 

stopped the line, turned the light on and grabbed some paper towels to catch the 

cockroach. I showed to SCSI what I found. The bird was condemned, I 

then went to washed and sanitized my gloves and returned back to work. SCSI

 went to talked to and 

informed her about my findings. This is a noncompliance with the following 

regulatory requirements of regulations 9CFR 416.1 and 9CFR 416.2(a). 

5308 M6137 BXL2305111 

902N-1 

11/02/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 11/01/2012 at approximately 2300 hours whole monitoring the establishments 

Operational Sanitation procedures, I observed the following. There were numerous 

black specks to approximately 1/8", black streaks to 1/2", and a piece of black 

tubing to approximately 6" on the giblets and necks coming out of Plant #2 Giblet 

chillers 3 & 4. I was told that the black tubing was gasket material . I contacted

 and showed him my findings. The product exiting the Giblet 

chillers was condemned by production until approximately 2315 hours. At 

approximately 0040 hours there were several carcasses on the exit chiller belt for 

Chiller #3 with numerous black specks of UFM (unidentified Foreign Material) to 

approximately 1/4". I took three samples to the FPS table and had a supervisor call 

. Hanging of product going into Packaging for the Organic lines was 

stopped. My findings indicated a noncompliance with 9 CFR 416.1, 416.4(d), and 9 

CFR 416.14. 

(b) (6)
(b) (6)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE380711 

5102N-1 

11/02/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On Nov. 1st and at approximately 2211 hours, after the sanitation and QC 

performed pre-operational sanitation and released the evisceration department for 

operations, I performed pre-operational sanitation task in Area II. While doing so, I 

observed the following: beaded condensation on several locations including the 

pipes above line # 1, the outer surface of the drip pan above the paws belt, and on 

the ceiling above the South Chiller at the east end. I immediately rejected area II by 

applying US rejected tag NO.B 38495148. I also notified and showed Mr. 

, of my findings and the forthcoming NR. After the 

sanitary issue was fixed, I re-inspected all affected locations, at approximately 2229, 

and were found acceptable and released. Upon review the SSOP-implementations 

and Monitoring checklist sanitation Log, the Subsection C Evisceration area and 

Subsection D Reprocessing equip, chillers & ADJ.Equip., were found acceptable at 

2200 hours. The Requirements of 9 CFR 416.1, 9 CFR 416.2(d) and Plant’s written 

SSOP were not met. 9CFR 416.1 states "Each official establishment must be 

operated and maintained in a manner sufficient to prevent the creation of 

insanitary conditions and to ensure that product is not adulterated." 9CFR 416.2(d) 

Ventilation requirement states "Ventilation adequate to control odors vapors and 

condensation to the extent necessary to prevent adulteration of product, and 

creation of insanitary conditions must be provided." Establishment's SSOP, 

Pre-operational, Subsection C Evisceration page 1 “ 

." 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0312103 

730N-1 

10/30/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 0910 hours while performing a Finish Product Standard at the 

Post Chill area in plant 2, I observed the following: It was shift change. Night shift 

employees left the line at 0910 hours and a few day shift employees took over the 

line. It was obvious that the line was not fully staffed. There was no product being 

tanked off at the end of the chillers #3 and #4 conveyors. The carcasses coming out 

of the chillers started to fall on the floor because the conveyors were too full to 

handle the load of product. There was also carcasses falling from the conveyors. I 

observed approximately 100 birds on the floor throughout the post chill/rehang 

area. I approach and notified them of the 

problem and pointed out to them all the carcasses falling on the floor. They 

mentioned that it was night shift product and proceeded to look for the night shift 

supervisor. At approximately 0915 hours, days shift started to tank some of the 

product out of the line to alleviate the problem. There was an employee picking up 

the carcasses from the floor. He was grabbing several carcasses at once and taking 

them to the chlorinated hose located at the chiller 4 exit, where he placed them on 

the catwalk and sprayed one by one. This area does not have a 200 foot candle light 

intensity. Without any further inspection, he placed the "reconditioned carcasses" 

in a stainless steel cart label "washed Product". I proceeded to inspect the 

reconditioned product, finding two carcasses contaminated with foreign material. I 

notified of my findings and showed him the affected carcasses. Both 

contaminated carcasses were rewashed and made acceptable. My finds reflect a 

lack of process control and the stablishment's failure to followed the product 

reconditioning Procedure as written in the SSOP Plan. This is a failure to comply 

with regulatory requirements of regulations 9 CFR 416.4(d); 416.14; 416.13(b); 

416.13(c) and 416.1 

5308 M6137 BXL2105104 

230N-1 

10/30/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 10/30/2012 at approximately 0035 hours while monitoring Facilities, I observed 

the following. There was heavy condensation dripping from major portions of the 

ceiling in the plant #2 cooler. There were two partial tanks of ice that were not 

covered and one tub of product labeled 'good legs' with an open lid. I contacted

 and showed him my findings. The dripping condensation was 

removed however the ceiling was still wet. The plastic protective covering on 

several tanks were replaced as in addition to the pooling condensation there were 

also several specks and flakes of black UFM (Unidentified Foreign Material) to 

approximately 1/8" on the plastics. I returned at approximately 0230 hours and 

again observed beaded condensation on the ceiling. I contacted 

who again had the condensation wiped off. My findings indicated a noncompliance 

with 9 CFR 416.1, 9 CFR 416.2(d), and 9 CFR 416.4(d). 

(b) (6)
(b) (6)

(b) (6) (b) (6)

(b) (6)

(b) (7)(C) (b) (7)(C) (b) (7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN500410 

1831N-1 

10/30/2012 04C05 Poultry Good 

Commercial 

Practices 

C On October 29, 2012 at approximately 2335 hours while performing the Poultry 

Good Commercial Practices task, I observed the following noncompliance. I 

observed chickens stacked up to 3 birds high on the conveyer that leads to the 

shacklers. Inside at the shacklers, it appeared that approximately 100 birds had very 

recently been suffocated or crushed and died and were being placed into dead piles. 

Minutes earlier, , CSI, had observed a mechanic adjust the conveyer to 

speed this belt up. He then left without visualizing what effect the adjustment had. 

We took regulatory control action and stopped dumping more cages; the remaining 

birds were allowed to be hung to reduce suffering. The establishment took 

immediate corrective action and sorted through the dead bird piles to ensure that 

no live birds were placed in the dead bins. 

, spoke with all of his personnel to notify them that they should not 

change the speed of the conveyer belt. The establishment then turned the conveyer 

belt speed down to resume dumping. They stationed a person at the conveyer 

control while the establishment came up with a temporary lock for the control. Mr.

 notified the USDA that the company would work on a permanent lock box 

later on that shift. He then spoke with the mechanic about the matter and informed 

the USDA that the incident was apparently a miscommunication due to a language 

barrier and disciplinary action will be taken against the employee. A second incident 

was observed 4 hours later by , SCSI. On October 30, 2012, at 

approximately 0337 hours while performing a good commercial practice task near 

the bird dumper, observed the following: The bird dumper was coming 

down, which was controlled by a plant employee moving a lever, directly on top of 

a live chicken roosting underneath the dumper, smashing the chicken between an 

iron bar and flat sheet of stainless steel. He immediately instructed the plant 

employee who was controlling the lever to raise the dumper. He then observed 

another live chicken trapped between a cage door and the dumper. When he 

removed the chicken from the conveyor belt and set it on the cement floor, the 

chicken appeared paralyzed and could not move but was conscious. He then 

instructed the plant employee who was controlling the dumper to remove the 

chicken that was stuck between the cage door and dumper. By this time, the 

chicken that was stuck between the cage door and the dumper was not conscious. 

He immediately informed of what happened. He also 

immediately went to the USDA office and informed me. The company was 

prevented from dumping any more cages until preventative measures were taken. 

The plant responded to the incident by having a person stationed to watch for any 

chickens that may be harmed by the unit until further modification can happen 

after slaughter ends Tuesday afternoon. Slaughter was resumed. 

was informed of the forthcoming noncompliance record. 

Both situations show a failure to comply with the regulation 9CFR 381.65(b) that 

states “Poultry must be slaughtered in accordance with good commercial practices 

in a manner that will result in thorough bleeding of the carcasses and ensure that 

(b) (6)
(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

breathing has stopped prior to scalding. Blood from the killing operation must be 

confined to a relatively small area.” 

(b) (6)
(b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1504101 

427N-1 

10/27/2012 04A06 Poultry Finished 

Product Standards 

C On 10/26/2012 at approximately 2344 hours, I randomly removed a 10 bird 

sample from Line in Plant #2 for Pre-Chill Finished Product Standard Check, I 

documented 37 points on the Processing Nonconformances from the 10 bird 

sample. This exceed the subgroup absolute limit of 30 points for the Processing 

Nonconformances to be in control. I informed Quality Control of the failure and at 

approximately 2357 hours she performed a recheck. Quality Control documented 

30 points on the Processing Nonconformances, this exceed the limit of the 25 

points allowed for the recheck, at this point the process is considered out of 

control. I informed of the noncompliance. Corrective 

actions were implemented. Quality Control performed rechecks at Pre-Chill and 

Post-Chill. At approximately 0248 hours the process was back in control. This is a 

noncompliance with the following regulatory requirements of regulation 9CFR 

381.76 (b). 

5308 M6137 BXL2604101 

026N-1 

10/26/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 10/26/2012 at approximately 0002 hours while monitoring the Establishments' 

Pre-Operational Sanitation Procedures after SSOP and HACCP monitors completed 

their inspections, I observed the following in Packaging Area #2, the Room. 

There were numerous pieces of tissue to approximately 3" on the carcass shredder 

blades. There was a thick layer of pasty white fat on the white edible product shovel 

hanging from the shredder housing. There were numerous pieces of fat and tissue 

to approximately 1/2" along the entire length of the carcass collection belt. There 

were numerous smears and specks of black UFM (Unidentified Foreign Material) on 

the large blue conveyor belt that collects skin from line . A 4' belt associated with 

line had numerous pieces of fat and tissue to approximately 1/2". There was a 

red flake approximately 1/8" on the main hanging belt for line #1 that appeared to 

be paint. There was a gray flake approximately 1/8" by 1/4" that appeared to be 

paint on the breast tender collection belt near line #1. Sanitary conditions were 

restored by approximately 0035 hours. My findings indicated a noncompliance with 

9 CFR 416.1, 9 CFR 416,2(b)(1), 9 CFR 416.4(a), 9 CFR 416.13(c) and 9 CFR 416.14. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (4)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3104102 

526N-1 

10/26/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 10/25/2012 at approximately 2140 hours while verifying the Establishments' 

SSOP Pre-Operational Sanitation monitoring procedures in plant #1, I observed the 

following. was performing her checks from a list of randomly 

selected items. In the Reprocessing Area/Line she observed the inside of a bin 

used during production to store ice for chilling finished product. The bin had several 

pieces of dried and semi-dried tissue to approximately 1/4" plus a puddle of water 

in the bottom of the tank that contained numerous specks of black UFM 

(Unidentified Foreign Material). She directed a sanitation employee to reclean the 

ice bin. He rinsed the bin with warm potable water and QC Tern released at 2154 

hours. The establishments' Pre-Operational Sanitation - SSOP under 'Corrective 

Action' states " 

." The establishments' Pre-Operational SSOP wet procedure for food contact 

surfaces states "

 The issue was discussed with

 and . My findings indicated a 

noncompliance with 9 CFR 416.1, 9 CFR 416.4(a), 9 CFR 416.13(c), and 9 CFR 

416.15(a) & (b). 

5308 M6137 BXL3113103 

526N-1 

10/26/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C On 10/25/2012, I observed a noncompliance with regulatory requirement of 

Regulation 9 CFR 417.2(c)(4) and 381.65(e) in Plant 1. At approximately 1007 hours, 

while performing a Finish Product Standard check on line 2, I observed one out of 

ten birds with visible light yellow fecal contamination. The fecal material was on the 

left wing of the carcass. There was one spot of feces approximately 1/16" on the 

wing's mid joint and another spot of feces approximately 1/8" on the drummette's 

joint close to the breast. I also observed a loose intestine approximately 5" long 

inside of the bird. This exceeded the limit of Zero Tolerance for the process to be in 

control. I contacted and showed her my findings. The 

protocol for fecal failure was implemented. A QC recheck passed at 1025 hours 

putting CCP 2B back in control. Pos Chill checks were performed from 1129 hours 

to 1204 hours finding the product acceptable for shipping. 

(b) (6)
(b) (6) (b) (6) (b) (6)

(b) (6)

(b) (6) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1009101 

425N-1 

10/25/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C On 10/25/2012 at approximately 0629 hours while performing a Finished Product 

Standards procedure in Plant #1 Line #1, I observed the following. After taking a 

random 10 bird sample, I observed one bird with visible fecal contamination. There 

was a piece of intestine approximately 2" long attached to the carcass inside at the 

tail. The fecal material was leaking from a cut in the intestine approximately 1" from 

the cut end into the left side area of the kidneys. The fecal material was medium 

brown in color, pasty in texture and measured approximately 1/2" by 1/8". This 

exceeded the limit of Zero Tolerance for the process to be in control. I contacted

 and showed him my findings. The protocol for fecal failure was 

implemented. A QC recheck passed at 0656 hours. My findings indicated a 

noncompliance with 9 CFR 417.2(c)(4), 9 CFR 381.65(e), and the Critical limit of 

CCP-2B of the Plants HACCP Plan for Slaughter. 

5308 M6137 BXL5504100 

424N-1 

10/24/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 10/24/2012 at approximately 0017 hours while monitoring Pre-Operational 

Sanitation procedures in Packaging Area #2, Room, after SSOP and HACCP 

monitors completed their inspections, I observed the following. There were 

numerous pieces of fat, tissue, and bone pieces to approximately one foot in length 

and 2" in width on the auger blade associated with the carcass shredder. The 

product exiting the shredder is collected and used for MDP. Sanitary conditions 

were restored by approximately 0035 hours. My findings indicated a 

noncompliance with 9 CFR 416.1, 9 CFR 416.4(a), and 9 CFR 416.13(c). 

5309 P6137A NJN300310 

4224N-1 

10/24/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 23:51 while performing a zero tolerance verification procedure on 

the reprocessing line, I observed one carcass of a ten carcass sample with visible 

fecal material. The fecal matter was located on the interior arch of the wing and 

measured approximately one eighth of an inch in diameter, was brown in color and 

of a paste like consistency. After noticing the affected carcass, I stopped the 

reprocessing line and both informed and showed the fecal matter on the affected 

bird to Ms. and Mr. . Mr.

 was also given the opportunity to examine the fecal matter 

on the carcass. At approximately 00:01, a recheck was conducted, completed and 

passed on the reprocessing line by Ms. . The establishment did not meet 

the requirements of 9 CFR 381.65(e) which requires that the establishment prevent 

poultry carcasses contaminated with visible fecal material from entering the chilling 

system. Similar occurrences have been documented previously on NR 

NJN3513094913N/1 dated 09/13/12 and NR NJN1414063025N/1 dated 06/25/12. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (6)(b) (6) (b) (7)(C)(b) (7)(C) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0205105 

424N-1 

10/23/2012 03J02 Slaughter HACCP C On 10/24/2012 at approximately 0040 hours while monitoring Facilities in Plant 

#1, I observed the following. The Cetylpyridinium Chloride system that is used by 

the establishment to provide the final microbial treatment was not functioning. The 

spray nozzles at the end of Chillers 1 & 2 were on dispensing at

 PPM as part of the establishments CCP-7B Corrective Action procedure. An 

establishment employee was operating the dumper adding tanks of carcasses to 

the product exiting the chillers going to the cutup line. I check the labels on the 

product being dumped and discovered that the carcasses were excess birds tanked 

by the PM shift labeled #31444 at 1718 hours on 10/23 Day Shift and #31445 at 

1688 hours on 10/23 Day Shift. The birds were being added to the product entering 

Packaging past the final microbial agent application and were not being treated. I 

contacted and , and discussed the issue. My 

findings indicated a noncompliance with 9 CFR 416.4(d), 9 CFR 417.3(b), and the 

critical limit of HACCP Plan - Slaughter Plant #1 CCP-7B . 

5309 P6137A NJN101910 

1022N-1 

10/22/2012 01C02 Operational SSOP 

Review and 

Observation 

C While performing Operational SSOP Review and Observation in the MSP Room at 

approximately 1618 hours I observed the following non compliance: Dripping 

condensation into a bin of chicken backs that was inside the east product dumper 

ready to be processed. After closer inspection, I observed the drip pans above both 

dumpers were saturated with heavy beaded condensation. I took regulatory control 

of the area and the product with the application of US Reject/Retained Tag 

#B39415822 and showing and informing Mr. and

 of the forthcoming non compliance. Mr. 

elected to condemn the bin of product and had the condensation wiped 

dry to restore sanitary conditions. 

5333 P7632 HYE070110 

1920N-1 

10/20/2012 01C02 Operational SSOP 

Review and 

Observation 

C On October 19, 2012 at approximately 540 hours Inspector 

informed me that she observed two flies, one of them flying around her and the 

second was standing on the hock of one bird. Immediately, Inspector 

condemned the affected bird and showed the other fly to the plant management. 

Mrs. , was notified of the forthcoming 

documentation of the failure to comply with the regulatory requirements of 9 CFR 

416.1, 9 CFR 416.4(d) and 416.2(a). 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4316104 

619N-1 

10/19/2012 06D02 Other Inspection 

Requirements 

C At approximately 1040 hours while performing a Presentation check on line I 

found a noncompliance with regulatory requirement of regulation 9 CFR 381.76(b). 

At line speed of birds per minute, Line , Station #2, failed with 19 

nonconformance points (3 birds with parts inside, 2 birds with viscera not uniform). 

This exceeded the limit of 3 occurrences of one error. At approximately 1049 hours 

Quality Control performed a recheck, failing station #1 with 6 birds with parts 

inside. was notified of the noncompliance. Line was slowed down to 

bird per minute. At approximately 1053 hours QC performed a recheck at line speed 

of BPM and passed it. Line speed was reduced to BPM due to increase in 

poultry pathology. At approximately 1336, due to less pathology, line speed was 

increased to BPM. QC performed a passing recheck bringing the process back in 

control. 

5308 M6137 BXL4918100 

419N-1 

10/19/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1545 hours, while monitoring the establishment's Operational 

Sanitation, I observed the following: There was a couple of employees removing 

birds from a drip pan in packaging near the Room entrance. The employee on 

the ladder grabbed (1) front half, (1) whole bird and (1) half chicken from the drip 

pan, handling one at the time to the employee holding the ladder, who was tossing 

them on the floor. The two employees proceeded to take the ladder to a nearby 

drip pan leaving the carcasses on the wet and dirty floor. I then, observed a 

sanitation employee washing the floor and splashing dirty water on these carcasses. 

I noticed the two employees coming back to grab the birds from the floor. One of 

them pick up the carcasses and took them to the reprocessing station located in the

 Room, where he rinsed the product and was about to take it back to 

production without any further inspection. These employees were further 

adulterating the product and not following the establishments procedure for 

product reconditioning as written in the SSOP plan. I requested the employee to 

leave the affected product on the reprocessing station and then contacted , 

who went to look for . As I was waiting by the reprocessing 

station, I noticed approximately 20 pound of scattered tender on the floor. This 

product had fallen from the tender line near a green combo bin. I observed a 

production employee pushing some of the tender into a pile by using his dirty boot. 

A sanitation employee working in the area grabbed a brown lid (product contact 

surface) and use it as a shovel to scrape all scattered tender into a pile. He then, 

place the lid on the floor and proceeded to grab hand fulls of tender from the floor 

into the lid. The employee was taking the lid full of tender to the reprocessing 

station, when came to the area. I share my observation 

with the Supervisor. The product was handled under insanitary practices and did 

not follow the product reconditioning procedure. All affected product 

(tenders/carcasses) was condemned by production. My findings represent a 

noncompliance with regulation 9 CFR 416.4(d); 416.1; 416.14; and 416.13(b) 

(b) (6)
(b) (6) (b) (6)

(b) (6) (b) (6) (b) (6) (b) (6)

(b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN530310 

4719N-1 

10/19/2012 01D01 SPS Verification C I was walking into packaging at 0145 hours when the following SPS noncompliance 

was observed. Paint was peeling in an area approximately 12 inches by 12 inches on 

the ceiling above the overhead incline conveyor to the dark meat deboning area of 

the Segment line. Mr. and Mr. were notified of my 

findings. The temporary corrective action was plastic sheeting placed below the 

peeling paint. I was informed that the ceiling would be scraped and repainted over 

the weekend. No USDA reject tag was applied at this time because there was no 

product involved. The peeling paint indicates that the area is not maintained in a 

sanitary condition as stipulated in 9 CFR 416.1. "And compartments must be of 

sound construction, be kept in good repair " as stipulated in 9 CFR 416.2(b) (1). Also 

9 CFR 416.2(b)(2) states “Walls, floors, ceilings, doors within establishment must be 

built of durable materials impervious to moisture and to be cleaned as necessary to 

prevent adulteration of product or the creation of insanitary conditions.” 

5333 P7632 HYE140710 

1319N-1 

10/19/2012 04C05 Poultry Good 

Commercial 

Practices 

C On October 19, 2012 at approximately 0330 hours a food inspector had hung back 

a poultry carcass suspected to be a dead-on-arrival (DOA) on the USDA rack behind 

Line 1, Station 3 for veterinary disposition. I was notified of the finding and 

confirmed the disposition to be a DOA. The carcass had a limp neck with a reddish 

coloration and a putrid odor. The liver was friable on palpation. I notified Mr. 

who also informed Mrs. 

and Mr.

 After discussing the disposition with Mr. 

, I later informed Mrs. that the occurrence will be documented on a 

non-compliance record. On October 10, 2012 another DOA poultry carcass was 

discovered at approximately 2300 hours on Line 2 at Station 4. The allowance of 

DOAs to enter the evisceration department creates an insanitary conditon and is in 

violation of 9 CFR 381.71(a). 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5617104 

118N-1 

10/18/2012 06D02 Other Inspection 

Requirements 

C At approximately 1415 hours, while monitoring the "No Viscera Log" for Line #1, I 

observed the following: Line #1 had three consecutive failures by Quality Control in 

the four hours period before lunch break. At 0803 hours at line speed of BPM, 

Quality Control documented 34 no viscera and only 13 or less are allowed. At 0828 

hours at line speed of BPM, Quality Control recheck failed with 19 no viscera. 

Line Supervisor was informed and Line Speed was reduced to BPM. At 1026 

hours at Line Speed of BPM, Quality Control documented 15 no viscera, at this 

Line Speed only 11 no viscera are allowed. at this point the process is out of control. 

At 1227 hours at line speed of BPM, Quality Control documented 10 no viscera, 

Line supervisor increased the line speed to BPM. At this time there were no 

other check documented as performed by Quality Control. At approximately 1430 

hours, I informed of the noncompliance and discussed with her 

about a missing "No Viscera" check, I explained that a check passed at BPM the 

line speed was increased to BPM and after two hours there was no recheck at 

BPM. informed me later that QC had performed the 

recheck but had failed to documented the recheck on the No Viscera Log. This is a 

noncompliance with the following regulatory requirements of regulations 9CFR 

381.76 (a) and 9CFR 381.76 (b). 

5309 P6137A NJN320210 

3318N-1 

10/18/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 2355 hours, the following noncompliance was observed in the 

fillet department. Four employees returning from break put on aprons, gloves and 

protective sleeves. Without sanitizing, the employees went to line and started 

packing product. I immediately informed Mr. of what took place. He stopped 

the line and had all the employees on the line sanitize their gloves before resuming 

work. The affected product was put in a bin, at which time production put a hold 

tag on the bin to be washed and reworked. According to the plants GMPs " 

s." The establishment's 

monitoring system was not effective in detecting the deficiency resulting in 

noncompliance with 9 CFR 416.13(c). In addition, the establishment did not meet 

the requirements of 9 CFR 416.5(a) which requires all persons to adhere to hygienic 

practices. 

(b) (6)
(b) (6) (b) (6)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0105104 

117N-1 

10/17/2012 04B04 General Labeling C On 10/16/2012 at approximately 2300 hours while monitoring Facilities, I observed 

the following. In the Plant #2 Aged Breast Cooler there were two bins of product, 

each approximately half full, that were not labeled. There was other product in the 

cooler dated from 10/12/2012. At approximately 0015 hours after Packaging 

production personnel arrived, I contacted concerning the product. 

The partial bin of wing sections and a partial bin of breast fillets was also found not 

on the establishments inventory. The wings in the bin were well iced and at 

approximately 33 degrees, intended for use as a 180094 product, the bin was 

labeled 10/15/2012 and shipped to Porterville. The bin of breast fillets which still 

had CO2 present was labeled 10/16/2012 PM shift. My findings indicated a 

noncompliance with 9 CFR 381.145(b) which states that products need to be 

identified in some manner(not full label) such that inspection program personnel 

can reinspect at any time or as often as they deem necessary to assure the products 

are not adulterated or misbranded., and 9 CFR 381.180(a) which states that the 

establishment shall furnish inspectors with accurate information including product 

composition and any changes to procedures in respect to the manufacturing of 

products such that they are not adulterated. 

5308 M6137 BXL0619104 

016N-1 

10/16/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1550 hours, while monitoring the establishment's operational 

sanitation on the Packaging area, I observed the following: There was a sanitation 

employee washing a tub full with front halves. He was using the hose located next 

to the tub wash room exit. This area does not have sufficient light intensity to 

reprocess product. According to the establishments SSOP plan under the product 

reconditioning procedure

 It took the employee 

approximately 5 minutes to finish spraying the product. He mentioned that the 

product was cleaned. I then, took the product to the reprocessing station; where, I 

inspected each front half under a 200 foot candle light intensity. I found 

approximately 75 percent of the product to be contaminated with foreign material 

that seemed to be a mix of dirt and rail dust. The employee failed to follow the 

establishment's procedure for product reconditioning as written in the SSOP plan. I 

immediately attached a US. Rejected/Retained tag No.B31 407689 on the affected 

product. I then, notified of the noncompliance. All 

affected product was reconditioned following the establishment's procedure. At 

1630 hours, I re inspected the product finding it acceptable. US tag was removed 

after sanitary conditions were restored. My finding indicate a noncompliance with 

regulations 9 CFR 416.1; 9 CFR 416.4(d); 9 CFR 416.12(a) and 9 CFR 416.14 

(b) (6)
(b) (6)

(b) (6) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5318101 

516N-1 

10/16/2012 03J02 Slaughter HACCP C While performing Post-Chill Finished Products Standards Check, I found 

noncompliance with the following regulatory requirements of regulations 9CFR 

381.65 (e) and 9CFR 417.2 (c)(4). At approximately 1515 hours, I randomly selected 

a 10 bird sample from the exit of the Chiller #1 in Plant #1, I found the last bird 

inspected with visible fecal contamination outside of the bird at the right side of the 

back, in the tail area. The bird had a cloaca attached and approximately 2" of 

intestine, from there the fecal material was oozing. The fecal material was two 

spots measuring approximately 1/4" and 1/8" diameter in size, yellow-green in 

color and watery in texture. This exceed the limit of Zero Tolerance for the process 

to be in control. Since there was no Packaging Supervisor available, I informed

 of the noncompliance. She immediately contacted the 

Lead Person of that area and he started tanking the birds coming out of the Chiller 

#1. Three tanks were placed under QC red hold tags pending for rework. At 

approximately 1521 hours, Quality Control did a recheck and passed it. This is a 

violation of the critical limits of CCP-2B of the 

Plant's HACCP Plan for Slaughter. 

5308 M6137 BXL5811100 

315N-1 

10/15/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C At approximately 0700 hours, while monitoring the establishment's Pre 

Operational Sanitation procedure, I observed the following: Plant 2 gib chillers were 

found under insanitary conditions. There was a brownish residue building up on the 

gib chiller's exit where the gibs come out. The residue coved an area of 

approximately 6 square inches on each chiller. The neck conveyor was also found 

under insanitary conditions. There was dried ingesta and several rocks that 

measured approximately 1/16". The areas affected are considered product contact 

surfaces. I proceeded to attach a Rejected/Retained U.S hold tag N0. B31 406753 to 

the affected equipment. were 

notified of the noncompliance. All insanitary areas were scrubbed and washed, 

restoring sanitary conditions. Gib chillers were released at approximately 0718 

hours. My findings indicate a noncompliance with 9 CFR 416.1, 9 CFR 416.4(a), 9 

CFR 416.13(c), and 9 CFR 416.14. 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN351610 

4215N-1 

10/15/2012 01C02 Operational SSOP 

Review and 

Observation 

C While performing PHIS task SSOP (Standard Sanitary Operational Procedure) in 

Fillet Department, I observed the following non compliance: Approximately a ten 

foot radius pool of liquid debrie of fat, skin, bone fragments, four pieces of breast 

front halves and an unidentified grayish black material on the floor underneath the 

basket catch and the first station of the wing cutter on line one. After closer 

inspection, I observed an employee trying to scoop the liquid material with 

squeegee and shovel with no avail. The liquid of debrie kept pouring out from the 

basket catch faster that the employee could collect; drainage for that wing cutter 

was plugged. More front halves kept falling on the pool of debrie, and employees 

kept trafficking through the area, thus creating an insanitary condition. Regulatory 

control of the line was taken at approximately 1249 hours with the application of 

US Retained tag #B21948350 and informing Mr. 

and of the forth coming non compliance. 

Regulatory control was released at approximately 1303 after product on floor was 

condemned, product contact surfaces were sanitized and floor washed down. 

5308 M6137 BXL2712103 

511N-1 

10/11/2012 04A06 Poultry Finished 

Product Standards 

C On 10/09/2012 a review of the Post Chill Finish Product Standards Records for 

plant 1, reflected a noncompliance with regulatory requirement of regulation 9 CFR 

381.76 (e)(1)(i) Postchill testing, establishment actions. "The establishment shall 

conduct a 10-bird subgroup test for each chiller system at a randomly selected time 

of production. In no case shall the time between tests exceed 2 hours of production 

time". Quality Control monitoring checks at the postchill were performed as follow: 

Chiller 1- first check at 0808 hours and second check at 1233 hours (4 hours, 15 

minutes). Chiller 2- first check at 0811 hours and second check at 1231 hours (4 

hours, 15 minutes). The time between tests exceeded the 2 hours of production 

time limit. was notified of the noncompliance at 

approximately 1235 hours on the same day. 

(b) (6)
(b) (6) (b) (6) (b) (6)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5022102 

011N-1 

10/11/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 10/10/2012 at approximately 1928 hours while monitoring Operational 

Sanitation Procedures in Plant #1, I observed the following. Although the 

establishment had finished hanging product going into packaging there were still 

carcasses exiting chillers 1 & 2 that were being collected in stainless steel tanks. The 

tanks being filled had numerous pieces of fat and tissue, and pink to light brown 

fluids on the sides and bottom from the previous days production. Tanks #VT260 

and # 12 were labeled with the date and time of collection, iced and placed in the 

plant #1 cooler. I checked with the QC temperature monitors for the shift who were 

monitoring 19 tanks of carcasses leftover from the PM shift. In addition, there were 

approximately 10 tanks of ice and 20 tanks of WOG's (without giblets) staged from 

the PM shift for use by the AM shift. At approximately 0030 hours when Packaging 

production functions were starting, I informed a supervisor of the issue. 

and were called and informed of the SSOP failure. A review of the 

Establishments SSOP Section #1, Pre-Operational Sanitation states that "

 The internal surfaces of a tank is a product contact surface yet 

they are not cleaned " " as part of pre-operational 

sanitation processes as the tanks were full of product leftover from the previous 

days production. My findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 

416.4(a), and 9 CFR 416.13(a),(b) & (c). 

5308 M6137 BXL3218102 

210N-1 

10/10/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1555 hours while performing a Operational Sanitation verification 

check, I observed the following. At the rotisserie and ground chicken area, while the 

line employees were on break, there was a sanitation employee washing the floor. 

He was using high pressure causing water to splash. As I got closer to the ground 

chicken line, I noticed a 2 foot tall stack of uncovered wax cardboard that was 

severely wet. This cardboard is considered a food contact surface utilized to make 

boxes to pack ground chicken. This noncompliance was brought to the attention of 

. She took immediate corrective action by disposing the 

affected cardboard. There was no product involved. A pallet with new and clean wax 

cardboard was assigned to the ground chicken area. My findings indicate a 

noncompliance with regulatory requirement of regulation 9 CFR 416.1,416.4(a), 

416.14 and 416.13(c). 

(b) (6)
(b) (6) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3220102 

810N-1 

10/10/2012 03J02 Slaughter HACCP C At approximately 1700 hours while performing a HACCP Slaughter procedure 

record keeping review, I found the following; Quality Control or designee 

documented on the HACCP monitoring Log CCP-2B (Plant #1) 

dated on 10/09/2012 AM shift, Direct Observation on Line #2 at 2319 hours. The 

first Zero Tolerance Check on Line #2 by Quality Control for that day was performed 

at 2339 hours. The time enter on verification activities (direct observation) did not 

corresponded with any of the monitor procedure entries. My findings indicate a 

noncompliance with regulations 9CFR 417.5 (a)(3) and 9CFR 417.5 (b). I notified

 of the noncompliance. 

(b) (6)
(b) (6)(b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4)

(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5822104 

510N-1 

10/10/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 10/04/2012 at approximately 0125 hours while monitoring Operational 

Sanitation procedures in Plant #2, I observed the following. An employee was 

moving a brown product tub filled with carcasses removed from Line at the 

rehang station. The carcasses are missed by the mechanism that removes the 

carcasses from the line and directs them into the chiller. The carcasses are 

contaminated when they drag on drip pans and over support brackets that are 

considered non-contact surfaces and are seldom cleaned. The employee was about 

to put the carcasses back onto line # at a location after the final IOBW's 

(inside/outside bird washers) and the final trim station. I took one carcass from the 

edible product tub and found it to be contaminated with large patches, measuring 

several inches, of black and brown UFM (unidentified foreign material). The UFM 

was on the back and breast skin, and around the neck area on the skin and tissue. I 

checked several other carcasses from the same product tub that contained 

approximately 20 carcasses and found them also to have varying amounts of black 

and brown UFM. was nearby so I showed him 

my findings. He directed the employee to wash and/or trim the carcasses to return 

them to a sanitary condition. The employee was reconditioning the carcasses at the 

line auto rehang station where carcasses are transferred from the kill line to the 

eviscerating line. After a time the same employee was again about to put the 

reconditioned carcasses back onto line . I again checked a carcass and found it to 

be still contaminated. There were 5 carcasses in the product tub that still had 

varying amounts of UFM still measuring to several inches. I watched the employee 

finish trimming and rinsing the product restoring sanitary conditions by 

approximately 0150 hours. The employee used the second final trim station and 

nearby chlorinated water hose at the end of line to recondition the last 5 birds. 

A review of the establishments' SSOP document 'Reconditioning Procedures' dated 

09/10/12 under 'Procedures for Whole carcasses - post- evisceration, pre-chill' 

states " " Under 

'Equipment' it lists 

." under 

'Responsibilities' it states that a " 

." There is no hands free sink at the rehang station where 

the birds were being reconditioned, lighting is poor, and no QC or Production 

Supervisor was ensuring that reconditioning procedures were being followed. I 

discussed the issue with and he was unsure where the 

designated reconditioning station used to recondition contaminated product in 

plant #2 is located. My findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 

416.4(d), 9 CFR 416.12(d), and 9 CFR 416.12 (b) & (c). 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6)

(b) (4)

(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0508104 

809N-1 

10/09/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 10/09/2012 at approximately 0350 hours while performing a Raw Intact HACCP 

procedure in Packaging Area #1, I observed the following. A sanitation employee 

was dumping a green container marked "Inedible" into a blue product barrel. I 

contacted who called and the issue was discussed. An 

issue with the blue barrels occurred during pre-operational sanitation and at that 

time I asked if the blue barrels were edible or inedible. 

He said the blue barrels were replacing the white edible barrels. I reviewed the 

Establishments' SSOP and found no color coding reference or any indication as to 

whether the blue barrel was intended for edible or inedible product. The blue barrel 

was not marked. The contents of the blue barrel was taken to the edible dump 

room for disposal. The edible dump room is not maintained as a product contact 

surface. After dumping the blue barrel was rinsed with potable water before being 

returned to production. Using a company calibrated thermometer the temperature 

of the water being used registered approximately 160 degrees. I checked the 

establishments SSOP about the water temperature used to restore sanitary 

conditions of the product contact surfaces. The establishments SSOP Section 

II : Operational Sanitation states 

." 

However the SSOP does not explain how that is to be accomplished. My findings 

indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.12(a), 9 CFR 416.13(b), and 

9 CFR 416.4(d). 

5308 M6137 BXL4204104 

709N-1 

10/09/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 10/09/2012 at approximately 0015 hours while monitoring Pre-Operational 

Sanitation standards in Packaging Area #1 after Quality Control and HACCP 

monitors completed their inspections, I observed the following. A blue barrel 

located at the end of packaging line had a mechanics grease and oil covered 

WYPALL in the bottom. was nearby so I 

asked if the blue barrels were for edible or inedible product. He said that the barrels 

were intended to be used as edible product containers. The WYPALL was removed 

and the barrel was rinsed with per establishment procedure. At 

approximately 0016 hours, the entire ceiling area above the Plant #1 Halving 

Machine was covered with heavy condensation. Sanitary conditions were restored 

by approximately 0030 hours. There are also four support brackets attached to the 

ceiling at the same location that are severely rusted and partially covered with 

peeling flaking paint. The brackets are directly above the product processing lines. A 

work order will be submitted. My findings indicated a noncompliance with 9 CFR 

416.1, 9 CFR 416.2(d), 9 CFR 416.4(a), 9 CFR 416.2(b)(1), and 9 CFR 416.13(c). 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5408102 

208N-1 

10/08/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 10/08/2012 at approximately 0315 hours while monitoring Operational 

Sanitation processes in Plant #1 Cooler, I observed the following. There was a partial 

pallet of brown product tubs with the product giving off a strong sour odor. There 

was a tub of breast trim, three tubs of front halves, and five tubs of 'B' grade 

carcasses on a pallet. There were no tags on any of the product tubs so it was 

impossible to establish a kill date for the product. I contacted and 

he condemned approximately 450 pounds of product. The product was disposed in 

the edible dump room by approximately 0615 hours. My findings indicated a 

noncompliance with 9 CFR 416.1, 9 CFR 416.4(d), and 9 CFR 381.145(b) which 

states that products need to be identified in some manner (not full label) such that 

inspection program personnel can re-inspect at any time or as often as they deem 

necessary to assure the products are not adulterated or misbranded, and 9 CFR 

381.180(a) which states that the establishment shall furnish inspectors with 

accurate information including product composition and any changes to procedures 

in respect to the manufacturing of products such that they are not adulterated. 

5308 M6137 BXL3815100 

906N-1 

10/06/2012 01C02 Operational SSOP 

Review and 

Observation 

C While monitoring the Operational Sanitation in plant 2, I observed a noncompliance 

with regulatory requirement of regulation 9CFR 416.1, 416.13(c), 416.14. and 

416.2(d). At approximately 1315 hours, I walked into the paw room located in plant 

2, finding it under insanitary conditions. There was feathers and paw peeling on the 

the walls, motors and floor. There was approximately 40 pounds of paws on the 

floor throughout the room. All this debri was preventing the water on the floor 

from draining freely. There was also a drip pan affected with heavy condensation. I 

notified of the noncompliance. She contacted the lead 

person, who got a sanitation employee to help him clean the area. Condensation 

was wiped up and fans on the area were turned on. All debri was picked up from 

the floor with a red shovel and place into a gray inedible barrel. Floor was washed 

restoring sanitary conditions. who is in charged of the 

area was notified of the noncompliance latter on. 

(b) (6)
(b) (6) (b) (6)(b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0204100 

905N-1 

10/05/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 10/04/12 at approximately hours while preforming the Pre-operational SSOP 

Review and Observation task after the establishments SSOP and HACCP monitoring 

inspection , I observed the following In the Packaging area . The stands the 

employees use to stand on at the chiller rehang were turned over to observe 

underneath . There was 1/8 -3/8 thick build-up (black soiled gunk ) under the 

stands on chiller rehang line was contacted 

immediately . had all the soiled stands overturned and washed 

completely .At approximately 0020 the stands were reinspected and found to be in 

sanitary condition .At 0009 Line # 1 the deboning line was inspected .There was fat 

particle ranging from 1/8 “ to 2” in length . had one of his 

workers rinse the line thoughly . The line was reinspected and found to be in 

sanitary condition at approximately 0016 hours . At 0018 the leg processors were 

inspected .There was a 3 “ by 5 “ area covered with fat and grease from the 

previous shifts production . once again had one of his employees 

remove the grease from the effected area and rinse the machine .My findings 

indicate non-compliances with several regulation 9 CFR 416.4(a) , 9 CFR 416.4(b) 

,9CFR416.13 (a) and 9CFR 416.13(c) and 9 CFR 416.14 . 

5308 M6137 BXL4405103 

505N-1 

10/05/2012 06D02 Other Inspection 

Requirements 

C On 10/04/2012 at approximately 0122 hours while monitoring Finished Product 

Standards at the reprocessing line in Plant #2, Line , I observed the following. I 

took a random 10 bird sample and found the inside of one carcass with a large 

green stain and several pierces of ingesta (corn and rice hulls). I contacted

 who was nearby and showed her my findings. I informed her 

that I would be performing a recheck. At approximately 0115 hours, I took a second 

10 bird sample and found three birds with pieces of ingesta attached to the 

connective tissue on the inside of the carcasses. I again showed 

my findings. At that point the process is judged to be out of control. Product was 

tanked until maintenance made some adjustments to the second bird washer. At 

approximately 0153 hours another 10 bird recheck passed. The tanked product was 

reworked and released by approximately 0213 hours. My findings indicated a 

noncompliance with 9 CFR 381.76(b) and 9 CFR 381.91(b). 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0401100 

404N-1 

10/04/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 10/03/12 at approximately 2223 hours while preforming the Pre-operational 

SSOP Review and Observation task after the establishments SSOP and HACCP 

monitoring inspection . I observed the following In the Plant #1 area # 3 unit 16 of 

the evisceration area . The Eviscerator on line # 1 had what appeared to be fat left 

from the pervious shifts production on the module area . US RETAINED/REJECTED 

tag # 407630 was applied and my findings were brought to the attention of

 . had an employee standing close scrub and rinse the 

affected areas . At approximately 2227 hours a recheck was preformed . The 

Eviscerator was found to be in sanitary condition and the tag was removed . At 

approximately 2231 hours the Inside /Outside Bird Washer was inspected on 

line # 1 area # 4 unit 22 . The interior guide bars along with the lower module that 

holds the bird had white grease film covering 1/3 of the Bird Washer . US 

RETAINED/REJECTED tag # 407452 was applied and was once 

again contacted . had one of his worker standing close scrub the 

guides bars and the affected parts of the module area . The Bird Washer was 

reinspected at approximately 2237 hours . Sanitary conditions were restored and 

the Inside/Outside Bird Washer was ready for production . At 2238 hours area # 5 

was inspected . The Salvage Station opposite side the vacuum station had one knife 

holder with a brownish red build-up on the inside . was notified 

again . had the inside of the knife holder scrubbed and 

rinsed . the knife holder was reinspected and found to be free of build-up . The area 

was released and ready for production . My findings indicate non-compliances with 

the following regulations 9CFR 416.4(a) , 9CFR 416.4(b) , 9CFR 416.13(a) 9 CFR 

416.13(c) and 9 CFR 416.14 . 

(b) (6)
(b) (6) (b) (6) (b) (4) (b) (4) (b) (4)

(b) (4)

(b) (4)(b) (4)

(b) (4)

(b) (4)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1709103 

703N-1 

10/03/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 09/26/2012 at approximately 2030 hours while monitoring the establishments' 

computer records, I observed the following. Packaging chlorine levels for the PM 

shift were documented at 1333 hours at ppm (part per million), at 1412 hours at 

ppm and at 1514 hours at ppm. The establishments' 'Reprocessed Products 

Log' for the shift which monitors the reconditioning of contaminated product in the

 Room showed that Quality Control personnel had monitored the 

reconditioning of product at 1300 hours, 1410 hours and 1515 hours and found 

that the procedure used and the washed product to be acceptable. The Room 

reconditioning sink uses the same chlorinated water the is monitored under 

"Packaging Chlorine'. A review of SSOP Reconditioning Procedure under #6. 

states " 

a." A review of procedures to be followed under CP-5

 under (c.) states that " 

". and under (f.) Corrective Action for 

reconditioning sink/hose concentration ppm. 

I discussed the issues with . 

The reconditioning of product was not stopped when chlorine registered at ppm 

as directed by establishment procedures. There were no entries on the Reprocessed 

Products Log that documents the number of pounds that were affected by the 

ppm chlorine application. There is no entries in the computer other then 

'Informed Refrigeration'. There are no entries on the Reprocessed Products Log that 

suggest that the QC monitoring the procedures is aware of current chlorine levels. 

My findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.4(d) , 9 CFR 

416.14, 9 CFR 416.13(c), and 9 CFR 416.15(b). 

5308 M6137 BXL2009100 

503N-1 

10/03/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C On 10/03/2012 at approximately 0522 hours while monitoring the establishments' 

Finished Products Standards on line in Plant #2, I observed the following. After 

taking a random 10 bird sample, I observed one bird with visible fecal 

contamination. Inside the carcass there was a partial stomach attached to a gizzard 

with approximately 4" of intestine attached to the gizzard. The visible fecal material 

was leaking from a hole in the intestine at a point approximately 2" from the cut 

end of the intestine onto the carcass in the area of the kidneys. The fecal material 

measured approximately 1/2" by 1/8", was medium yellow in color and pasty in 

texture. This exceeded the limit of Zero Tolerance for the process to be in control.

 was contacted and the protocol for fecal failure was 

implemented. A QC recheck passed at 0546 hours. My findings indicated a 

noncompliance with 9 CFR 417.2(c)(4), 9 CFR 381.65(e), and the Critical limit of 

CCP-2B of the Plants HACCP Plan for Slaughter. 

(b) (6)
(b) (6) (b) (6)

(b) (6)

(b) (6)

(b) (6)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4918101 

803N-1 

10/03/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C While performing Pre-Chill Finished Products Standards Check, I observed 

noncompliance with the following regulatory requirements of regulations 9CFR 

381.65(e) and 9CFR 417.2 (c)(4). At approximately 1344 hours, I randomly removed 

a 10 bird sample from Line #1 in Plant #1, I found one out of the ten birds with 

visible fecal contamination inside the bird on the right side under the leaf fat area. 

The fecal material was two spots measuring approximately 1/4" and 1/8" diameter 

in size, dark green in color and pasty in texture. This exceed the limit of Zero 

Tolerance for the process to be in control. I informed 

and of the noncompliance. The protocol for fecal failure was 

implemented. Quality Control did a recheck at approximately 1412 hours and it 

passed. The cause of the deviation was the "venter". This is a violation of the critical 

limits of CCP-2B of the Plant's HACCP Plan for Slaughter. 

5333 P7632 HYE421310 

4603N-1 

10/03/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C Due to the high incidence rate of pathology, at approximately 1045 hours, I 

performed Finish Product Standard (FPS) verification on the alternate airsacculitis 

procedure on Line A, at the quality control inspection station for FPS. I collected a 

10 carcass sample. On the seventh carcass inspected, I noticed a smear of 

gastrointestinal contents on the hock area of the left drumstick. The smear was 

approximately 5 mm in diameter. The smear had a tan/green color with a paste like 

consistency, consistent with fecal material. I showed my finding to Mr. 

. The establishment failed to prevent fecal contamination to 

reach the FPS station, prior to enter the chilling system. This failure represents a 

noncompliance with regulation 9 CFR 381.65(e). Regulation 9 CFR 381.65(e) states 

“Poultry carcasses contaminated with visible fecal material shall be prevented from 

entering the chilling tank”. The failure also represents a deviation from the 

establishment’s written HACCP plan, regulatory requirements of 9 CFR 417.2(c) 4. 

Regulation 9 CFR 417.2(c) 4 states “List the procedures, and the frequency with 

which those procedures will be performed, that will be used to monitor each of the 

critical control points to ensure compliance with the critical limits”. Per the 

procedure of the establishment, , 

initiated immediate corrective action as prescribed in the establishment HACCP 

plan. Upon reviewing the records pertaining to the failure, the establishment found 

all the mandatory pre-chill and post chill checks acceptable. Mr. 

was informed of the forthcoming documentation for the 

failure to comply with the regulatory requirements cited above. 

(b) (6)
(b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3403102 

102N-1 

10/02/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 10/1/12 at approximately 0013 hours I observed the following while preforming 

the Pre-operational SSOP Review and Observation Task in the packaging area . The 

Plant # 2 Halver had a build-up of yellow film on the frame work surrounding the 

halver , there was pieces of dried meat on and inside the large white sprocket there 

was also pieces of fat and other debris in the halver area. I immediately applied US 

Retained/Rejected tag # B 31 407687. was immediately 

contacted . He had one of his workers scrub and rinse the effected areas . At 

approximately 0018 a recheck was preformed .Sanitary conditions were restored at 

approximately 0020 and the Plant # 2 Halver was ready for production .My findings 

indicate non-compliances with the regulations 9CRF 416.13(c) , 9CFR 

41613(a) , 9CFR 416.14 , 9CFR 416.4(b) ,and 416.4(a) . 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (6) (b) (6) (b) (7)(C) (b) (7)(C) (b) (7)(C) (b) (7)(C) (b) (7)(C) (b) (7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE201110 

1702N-1 

10/02/2012 01D01 SPS Verification C At approximately 0850 hours, inspector notified me that he 

noticed approximately 6 roaches crawling up from underneath the rack that is 

attached to the wall located at the South East corner of the evisceration 

department (Area #3). The rack is used to hang aprons and frocks that are utilized in 

the slaughter process. The rack at the time of inspection was empty, did not have 

hanging aprons. Inspector immediately informed 

and . At approximately 0905 hours, 

CSI and I, CSI , inspected the area mentioned above, 

and we also noticed approximately 5 roaches crawling on the wall and on the upper 

frame of the door leading to the maintenance shop. I took regulatory control action 

by applying retain tag #B38495153 to the apron rack. We showed our finding to 

. Upon closer observation 

of the affected area, we noticed crevices in the frame of the door leading to the 

maintenance room; adjacent to where the roaches were found. The roaches were 

also observed underneath the emergency light unit located right above the door. By 

allowing a pest to enter into the evisceration department where edible product is 

being processed, the establishment has failed to meet the regulatory requirements 

of 9 CFR 416.1, 9 CFR 416.2 (a), and 9 CFR 416.2(b). 9 CFR 416.1 states, “Each 

official establishment must be operated and maintained in a manner sufficient to 

prevent the creation of insanitary conditions and to ensure that product is not 

adulterated”. 9 CFR 416.2 (a) states, “The grounds about an establishment must be 

maintained to prevent conditions that could lead to insanitary conditions, 

adulteration of product, or interfere with inspection by FSIS program employees. 

Establishments must have in place a pest management program to prevent the 

harborage and breeding of pests on the grounds and within establishment 

facilities...” 9 CFR 416.2(b) which states “Establishment buildings, including their 

structures, rooms, and compartments must be of sound construction be kept in 

good repair...”. The establishment washed and sanitized the affected areas and 

caulked the edges of the apron rack. At 1005 hours the establishment restored 

sanitary conditions and (Regulatory Control Action) RCA was relinquished by 

removing retain tag #B38495153. , was 

informed of the forthcoming documentation for the failure to comply with the 

regulatory requirements cited above. The , verbally stated 

to me, CSI and Dr. , the IIC, the establishment corrective 

action and stated that the corrective action will be provided in writing as well. 

(b) (6)
(b) (6)

(b) (6)

(b) (4) (b) (4)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0819091 

328N-1 

09/28/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1555 hours, I observed an Operational Sanitation noncompliance 

in plant 2. I observed an employee claiming on a ladder near the the end of the gib 

chillers and post chill rehang dumping area. He was using a metal hook to reach the 

carcasses on the drip pan. He grabbed a couple of carcasses and threw them on the 

floor. He then, came down from the ladder, grabbed both carcasses from the floor 

and placed them on the catwalk. He reached for the hose and picked up one bird 

from the catwalk, sprinkled a little bit of water on it and was ready to toss the bird 

back on the line with out any further inspection. I then, approach him and 

prevented him from placing the carcass back on the line. This employee was not 

following the establishments procedure for product reconditioning as stated on 

section #3 subtitle "Whole carcasses/Poultry Parts-Post-Chill". Instead, he was 

further addulterating the product. who was walking through the 

area, grabbed the birds and toss them into a gray inedible barrel.

 were notified of the 

noncompliance. The establishments SSOP plan estates under Operational Sanitation 

Daily Procedures: 

". This procedure goes into 

detail describing where, when and how product is to be reconditioned. There is only 

3 reprocessing station that meet this criteria through out the plant. These stations 

are designated reprocessing area with a 

. Product is to be reconditioned and re inspected by the 

production employee responsible for reconditioning. Product will be held at the 

designated area for a minimum of 5 minutes to give QC/USDA an opportunity to 

inspect the product before it is returned back into production. The establishment's 

reconditioning Procedure states under RESPONSIBILITIES 

." 

My findings represent a noncompliance with regulatory requirements of regulations 

9 CFR 416.1, 416.4(d) and 416.13(b). 

(b) (6)
(b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4305091 

228N-1 

09/28/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 09/27/2012 at approximately 2355 hours while monitoring the establishments' 

Pre-Operational sanitation procedures after establishment SSOP and HACCP 

monitors completed their inspections, I observed the following. In Packaging Area 

#1, there were numerous black & brown specks and flakes to approximately 1/8" 

with the consistence of rust on both overhead wing flex belts coming out of the

 Deboning room at a location in the corner near the elevator. The belts were 

partially disassembled by repair personnel. After repairs were completed a sanitizer 

was applied followed by a rinse. Sanitary conditions were restored by 

approximately 0038 hours. At approximately 0005 hours there were numerous 

pieces of fat and tissue to approximately 1/2" on the gray product belt and most of 

the associated Marel chutes utilized on Line #2 breast fillet sorting line. The area 

was rinsed with and released by approximately 0015 hours. My 

findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.4(a), and 9 CFR 

416.13(c). 

5308 M6137 BXL4805094 

328N-1 

09/28/2012 03J02 Slaughter HACCP C On 09/28/2012 at approximately 0049 hours while performing a Post-Chill Finished 

Products Standards check on line #1 in Plant #1, I observed the following. After 

taking a random 10 bird sample, I observed one bird with visible fecal 

contamination. There was a partial stomach attached to the carcass, a gizzard was 

attached to the stomach with approximately 4" on intestine attached to the 

gizzard. The visible fecal material under the cut end of the intestine, inside on the 

left side of the carcass on the kidneys. The fecal material was approximately 1/2" by 

1/4" in size, light brown in color, and creamy in texture. This exceeded the limit of 

Zero Tolerance for the process to be in control. There were no supervisors or QC 

personnel immediately available so I directed Line #1 personnel to stop hanging 

birds going into packaging. I had a lead person tank the carcasses coming from 

Chiller #1. was shown my findings. I conducted a 

recheck that passed at approximately 0058 hours. Two and one-half tanks of 

carcasses coming out of chiller #1 were placed under USDA hold pending rework. 

My findings indicated a noncompliance with 9 CFR 417.2(c)(4), 9 CFR 381.65(e), and 

the Critical limit of CCP-2B of the Plants HACCP Plan 

for Slaughter. 

(b) (6)
(b) (6) (b) (6) (b) (7)(C)

(b) (4)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE540209 

3528N-1 

09/28/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C After QC had performed the pre-operational inspection and released Area 4 as 

acceptable, I performed the hands on observation component of the Preoperational 

Sanitation Inspection procedure. I observed the following noncompliance: At 0009 

hours at unit 22, the bag line as identified by the schematics, the table that is used 

to stage the tubs of giblets had a thick, brownish- yellow residue build up around 

the bottom edge and several pieces of fat on the attached stand. I showed this 

finding to and informed him of the issuance 

of the noncompliance record. This finding represents a non compliance with 9 CFR 

416.4(b)which states: Non-food contact surfaces of facilities, equipment, and 

utensils used in the operation of the establishment must be cleaned and sanitized 

as frequently as necessary to prevent the creation of insanitary conditions and the 

adulteration of product. In addition the establishment’s Pre-Op SSOP, section 2-5, 

step 2 states: 

The establishment's failure to implement the SSOP procedures represents a 

non compliance with 9 CFR 416.13(a) which states: Each official establishment shall 

conduct the pre-operational procedures in the Sanitation SOP's before the start of 

operations. 

5308 M6137 BXL1305090 

127N-1 

09/27/2012 06D02 Other Inspection 

Requirements 

C On 09/26/2012 at approximately 0215 hours Line 1 in Plant #1 appeared to be 

having a Presentation issue with to many viscera attached to the carcasses at the 

inspection stations. I discussed the issue with Inspector who told me that 

he had already informed production at approximately 0100 hours of the problem. I 

conducted a unscheduled Presentation check on the line at approximately 0226 

hours and observed the following. The second station failed with (2) 'viscera not 

uniform', (2) 'viscera attached to the carcass', and (1) ' parts inside' for a total of 41 

nonconformance points. The third station failed with (1) 'not hung by 2 legs', (2) 

'viscera not uniform' and (3) 'attached vents' for a total of 23 nonconformances 

points. The fourth station failed with (1) 'not hung by 2 legs', (2) 'viscera not 

uniform' and (1) 'vent attached' for a total of 27 nonconformance points. I also 

performed a standard three minute 'no viscera' check as part of the procedure and 

counted (27) no viscera nonconformances. A no viscera recheck at 0338 hours again 

failed at bpm with 16 no viscera nonconformances. The line was running at 

bpm (birds per minute) which allows less than (3) occurrences of one error and (24) 

or less total nonconformance points for the process to be in control. Any station 

with over 40 nonconformance points requires an immediate line speed reduction of 

10%. No viscera at bpm is limited to 13 or less nonconformances for the 

process to be in control. At bpm 11 or less no viscera nonconformances are 

allowed. I contacted who slowed the line to bpm. My findings 

indicated a noncompliance with 9 CFR 381.76(a) & (b). 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1421093 

727N-1 

09/27/2012 06D02 Other Inspection 

Requirements 

C At approximately 1540 hours, while monitoring the "No Viscera Log" for Line #1, I 

observed noncompliance with the following regulatory requirements of regulations 

9CFR 381.76 (a) and 9CFR 381.76 (b). Line #1 had three consecutive failures by 

Quality Control in a four hours period. At approximately 1228 hours at Line speed 

of BPM, Quality Control documented 18 no viscera and only 13 or less are 

allowed. At approximately 1258 hours, Quality Control rechecked failed with 24 no 

viscera at Line speed of BPM. Line Supervisor was informed and the Line speed 

was reduced to BPM. At 1456 hours, at Line speed of BPM Quality Control 

did her regular check and failed with 15 no viscera. At this Line speed only 11 no 

viscera are allowed. Company Management elected to keep the Line speed at 

BPM the rest of the shift. I am issue a noncompliance because at this point the 

process was out of control. I informed of the noncompliance. 

5308 M6137 BXL4820091 

027N-1 

09/27/2012 04A06 Poultry Finished 

Product Standards 

C While performing Pre-Chill Finished Product Standards Check, I observed 

noncompliance with the following regulatory requirements of regulation 9CFR 

381.76 (b). At approximately 1324 hours, I randomly removed a 10 bird sample 

from Line #1 for Pre-Chill Finished Product Standard Check. I documented 32 points 

on the Processing Nonconformance's from the 10 birds sample. This exceeds the 

subgroup absolute limit of 30 points for the Processing Noncomformance's to be in 

control. I informed Quality Control of the failure and at approximately 1333 hours 

she performed a Recheck and it passed. Quality Control started performing Pre-Chill 

Finished Product Standards Checks at the exit of the Chiller because the CUSUM 

number reached (12) at the started of the shift which is above the start number 

(11) on one of the five previous company checks. The regulations states in part "If 

any of the past 5 pre-chill subgroups result in a cusum above the start number, the 

establishment shall proceed as if CUSUM reaches the action number and shall begin 

process actions as set forth in paragraph (b)(3)(iv)(d)(4)." Corrective actions were 

implemented, all rechecks at the Pre-chill and the at the exit of the Chiller passed 

bringing the process back in control. I informed and

 of the noncompliance. 

(b) (6)
(b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5108091 

627N-1 

09/27/2012 06D02 Other Inspection 

Requirements 

C On 09/27/2012 at approximately 0225 hours while monitoring the Establishments' 

slaughter functions in Plant #1 Line #2, I observed the following. There appeared to 

be an excessive number of viscera missing at the front of the slaughter line. I 

checked the establishments Lines - No Viscera Monitoring Log for the shift 

and found that a Quality Control check at 0150 hours passed. I performed a 

standard three minute 'no viscera' check on line #2 and counted 21 no viscera 

nonconformances at approximately 0232 hours at a line speed of bpm (birds 

per minute). At bpm 13 or less no viscera are allowed. A QC recheck at 0345 

hours failed with 25 no viscera nonconformances. The line was slowed to bpm. 

A recheck by Quality Control at 0611 hours failed with 25 no viscera 

nonconformances. At bpm 11 or less no viscera noncomformances are allowed. 

Attempts to fix the issue failed and the line speed remained at bpm for the rest 

on the shift. My findings indicated a noncompliance with 9 CFR 381.76 (a) & (b). 

5308 M6137 BXL5408095 

227N-1 

09/27/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C On 09/27/2012 at approximately 0513 hours while performing a Zero Tolerance 

fecal check in Plant #1 Line #2, I observed the following. After taking a 10 bird 

random sample, I observed one bird with visible fecal contamination. The fecal 

material was inside the carcass on the left side approximately 1" below the tail just 

before the start of the kidney crypt. The fecal material was approximately 1/4" in 

size, medium brown in color and pasty in texture. This exceeded the limit of Zero 

Tolerance for the process to be in control. was contacted and the 

protocol for fecal failure was implemented. A QC check passed at 0556 hours. My 

findings indicated a noncompliance with 9 CFR 381.65(e), 9 CFR 417.2(c)(4), and the 

critical limit of CCP-2B of the plants HACCP Plan for 

Slaughter. 

(b) (6)
(b) (6) (b) (6) (b) (6)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE241609 

1227N-1 

09/27/2012 03J02 Slaughter HACCP C On September 27, 2012 I was walking through the chiller rehang area of the 

Packaging department, at approximately 1319 hours, when I observed one carcass 

and two saddles (unsplit leg quarters) on the over-head drip pans. 

measured the temperature of this product with calibrated 

thermometer #37. The temperature of the carcass was 62.4 degrees F, the first leg 

quarter was 61.7 degrees F, and the last piece was 61.0 degrees F. 

was notified of the forthcoming noncompliance. The establishment chose 

to condemn all affected product. Establishment P-7632 was granted a Salmonella 

Initiative Program Letter issued on September 2, 2011. The SIP program allows 

establishment P-7632 to use alternative chilling procedures in place of 9 CFR 

381.66(b), provided the establishment: Assesses, modifies and validates as 

appropriate, the Hazard Analysis and Critical Control Points (HACCP) plan according 

to 9 CFR 381.22 and 417.4. The establishment failed to implement their SIP 

program by allowing the internal temperature of their product to rise above 

degrees F. SIP protocol states: “

 This 

noncompliance is linked to NRs # HYE4415085406N dated 

8/6/12, # HYE5617085809N dated 8/9/12 and # HYE5909080828N dated 8/28/12. 

The previous preventive measures proffered by establishment failed to prevent 

reoccurrence. 

5308 M6137 BXL4418090 

726N-1 

09/26/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 1345 hours while monitoring the establishment's Finish Product 

Standard in Plant 1, I observed the following: After randomly removing a 10 birds 

sample from line 1, I found one bird with visible fecal contamination. The fecal 

material was inside of the bird on the left side of the tail. It was light yellow in color 

and soft in texture measuring approximately 1/8" in diameter. This exceeded the 

limit of Zero Tolerance for the process to be in control.

 were notified of the noncompliance. The protocol for fecal 

failure was implemented. Venter machine was the cause of deviation. QC performed 

a passing recheck at 1413 hours. Post chill rechecks were performed on the suspect 

lot from 1511 hours to 1551 hours. My findings indicate a noncompliance with 9 

CFR 381.65(e) and 417.2(c)(4). 

(b) (6)
(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5618092 

126N-1 

09/26/2012 06D02 Other Inspection 

Requirements 

C On 09/26/2012 The LINE #1 and #2 - NO VISCERA MONITORING LOG 

reflected a non compliance with regulatory requirement 9 CFR 381.76(a) (b) There 

was 5 consecutive failures on each line. This records reflected the establishment 

lack of control in the process and furthermore the failure to keep the - NO 

VISCERA standards. Line speed was reduced in the morning by USDA due to 

presentation failures and then increased to BPM in the afternoon as 

presentation checks got better. Line speed stayed at BPM because the "No 

Viscera" checks were not meeting the standards. Line 1 - Quality Control No Viscera 

monitoring records reflected the following. At 0822 hours QC performed a check at 

line speed BPM failing the line with 21 no viscera nonconformances out of 13 

no viscera allowed. At 0840 hours QC performed a check at line speed BPM 

failing the line with 16 no viscera nonconformances out of 11 no viscera allowed. At 

1027 hours QC performed a check at line speed BPM failing the line with 14 no 

viscera nonconformances out of 9 no viscera allowed. At 1229 hours QC performed 

a check at line speed BPM failing the line with 20 no viscera nonconformances 

out of 11 viscera allowed. At 1516 hours QC performed a check at line speed 

BPM failing the line with 15 no viscera nonconformances out of 11 viscera allowed. 

Line 2 - Quality Control No Viscera monitoring records reflected the following. At 

0817 hours QC performed a check at line speed BPM failing the line with 31 no 

viscera nonconformances out of 13 no viscera allowed. At 0836 hours QC 

performed a check at line speed BPM failing the line with 30 no viscera 

nonconformances out of 13 no viscera allowed. At 1034 hours QC performed a 

check at line speed BPM failing the line with 20 no viscera nonconformances 

out of 11 no viscera allowed. At 1314 hours QC performed a check at line speed 

BPM failing the line with 19 no viscera nonconformances out of 11 viscera allowed. 

At 1511 hours QC performed a check at line speed BPM failing the line with 15 

no viscera nonconformances out of 11 viscera allowed. 

(b) (6)
(b) (6) (b) (7)(C) (b) (7)(C) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4)(b) (4) (b) (4) (b) (4)(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5618092 

126N-2 

09/26/2012 06D02 Other Inspection 

Requirements 

C On 09/26/2012 from 0745 to 0800 hours, I was working the line in plant 1 given a 

break to one of the line inspectors. The birds seem bigger than usual and it was 

really difficult to properly inspect the carcasses at line speed BPM (birds per 

minute). I decided to verify the presentation compliance on both lines. Both lines 

keep failing presentation throughout the morning and therefore line speed had to 

be slowed down several times. During the afternoon when presentation got better 

line speed was increased to BPM and stayed at the same speed due to failing 

"no viscera" checks. I notified about my plans to perform 

presentation. She was present throughout the failures and therefore aware of the 

problem. At approximately 0815 hours, while performing a presentation check at 

line speed BPM on line 2 station #6, I failed with a total of 28 nonconformaces. 

I observed (2) birds viscera not uniform and (1) bird viscera attached to carcass. At 

0840 hours, I performed a recheck at BPM, failing station #5 with 52 

nonconformances. I observed (2) birds with viscera not uniform, (3) birds with 

viscera attached to carcass. This exceeded the conformance level. Line speed was 

reduced to BPM. At 0900 hours line 2 failed at BPM with 38 

nonconformaces on station #5 and 25 nonconformaces on station #6. Line speed 

was reduced to BPM. At approximately 0922 hours, I performed a passing 

recheck at BPM increasing line speed back to BPM. At 0950 hours, I 

performed a recheck at BPM to verify compliance at such speed. Line 2 failed 

again with 28 and 38 nonconformences putting the line back to BPM. Several 

checks were performed increasing and decreasing line speed from to BPM. 

At 1230 hours USDA Supervisor performed a passing recheck at 

BPM line speed. Line stayed at that speed due to "no viscera" failures. At 

approximately 0825 hours, while performing a presentation check at line speed 

BPM on line 1 station #4, I failed with a total of 42 nonconformaces. I observed (3) 

birds with viscera attached to carcass, (2) birds opening cut and (1) bird with 

contamination inside. This exceeded the conformance level. Line speed was reduced 

to BPM. At 0845 hours line 1 failed at BPM with 26 nonconformaces on 

station #3 and three occurrences of the same error on station #1. Line speed was 

reduced to BPM. At approximately 0911 hours, line 1, failed at BPM. Line 

speed was reduced to BPM. At 1012 hours, I performed a recheck to verify 

compliance at such speed, failing the line again. From 1058 to 1115 hours, USDA 

Supervisor performed passing rechecks increasing line 1 to BPM. 

Line stayed at that speed due to "no viscera" failures. My findings reflect the 

establishment' failure to meet required standards and to keep process control. This 

represents a failure to comply with regulatory requirement of regulation 9 CFR 

381.76(a)(b). 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (7)(C) (b) (7)(C)

(b) (7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE531909 

3826N-1 

09/26/2012 01D01 SPS Verification C On September 26, 2012 Dr. , CSI and I (CSI 

) conducted a Sanitation Performance Standards verification task at 

establishment P7632, Foster Farms. We inspected the establishment’s lunchroom 

and lavatories. In the men’s lavatory we observed numerous paper towels on the 

floor around the entrance and waste receptacle. Near the toilets we saw large 

pieces of toilet tissue on the floor, one of which had human waste on it. 

, was immediately shown the condition of the 

restroom and informed of the forthcoming noncompliance. Mr. took 

immediate action by having the restroom cleaned. 

agreed that the condition of the bathroom was unacceptable. As a corrective action 

he indicated that more frequent cleaning and monitoring of the bathroom will be 

performed and tracked by a log sheet. He also indicted that management will talk 

with and further educate establishment employee about employee hygiene and the 

importance of maintaining sanitary conditions. He also indicated that the education 

will be followed by handing establishment employee a statement delineating the 

hygienic expectations.The establishment failed to comply with the following 

regulatory requirements. CRF 9 416.1 states "Each official establishment must be 

operated and maintained in a manner sufficient to prevent the creation of 

insanitary conditions and to ensure that product is not adulterated." CFR 9 416.5(a) 

states "Cleanliness. All persons working in contact with product, food-contact 

surfaces, and product-packaging materials must adhere to hygienic practices while 

on duty to prevent adulteration of product and the creation of insanitary 

conditions." CFR 9 416.2(h)(1) states "Dressing rooms, toliets rooms, and urinals 

must be sufficient in number, ample in size, conveniently located, and maintained 

in a sanitary condition and in good repair at all times to ensure cleanliness of all 

persons handling any product. They must be separate from the rooms and 

compartments in which products are processed, stored, or handled." 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4)(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1513094 

625N-1 

09/25/2012 06D02 Other Inspection 

Requirements 

C On 09/25/2012 The LINE #1 - NO VISCERA MONITORING LOG reflected a 

non compliance with regulatory requirement 9 CFR 381.76(b). At 0814 hours QC 

performed a no viscera check in line 1, failing with 44 no viscera nonconformances. 

The line was running at BPM (birds per minute) which allows 13 or less no 

viscera to be in compliance. Maintenance was notified . At 0836 hours QC 

performed a recheck at BPM, failing with 27 no viscera nonconformaces. The 

line speed was reduced to BPM. At BPM 11 or less no viscera 

nonconformaces are allowed. At 1030 hours, QC performed a recheck at line speed

 BPM failing the line with 22 no viscera nonconformances. Production 

continued running line 1 at BPM the remainder of the day. There were two 

more failures during the afternoon at BPM. At 1311 hours, 30 no viscera 

nonconformaces out of 11 no viscera allowed and at 1515 hours, 38 no viscera 

nonconformances out out 11 no viscera allowed. There was a total of 5 consecutive 

failures during the day. Maintenance was making adjustments to the equipment 

throughout the day. This adjustments were insufficient to correct the problem. Line 

did not slow down any less than BPM to corrected the noncompliance 

situation. My finding reflect the establishment's lack of process control. 

5308 M6137 BXL5908090 

025N-1 

09/25/2012 06D02 Other Inspection 

Requirements 

C On 09/25/2012 at approximately 0117 hours while monitoring the establishments' 

carcass Presentation functions in Plant #1, line #2, I observed the following. I timed 

a standard 'no viscera' check for three minutes and counted 25 no viscera 

nonconformances. The line was running at bpm (birds per minute) which allows 

13 or less 'no viscera' to be in compliance. I informed . He said the 

birds were very big and that he would slow the line down. A recheck by Quality 

Control personnel at 0157 hours failed with 20 'no viscera' nonconformances at 

bpm. At bpm 11 or less no viscera nonconformances are allowed. 

Attempts to correct the problem were unsuccessful and the line remained at 

bpm until the end of the shift. My findings indicated a noncompliance with 9 CFR 

381.76 (a) & (b). 

5333 P7632 HYE070309 

5025N-1 

09/25/2012 01D01 SPS Verification C At 0506 hours I observed a stack of nine wooden pallets staged for use with fecal 

material on the top pallet. These pallets where located next to the south chiller exit. 

I showed these findings to , 

and and informed them of the non-compliance with the 

regulation(s) sited above. I rejected the stack of pallets with the application of U.S. 

Reject Tag #B38495161. As a corrective action Mr. immediately had the 

stack of pallets removed from the production area and taken outside to be washed. 

After verification that the pallets where cleaned and acceptable sanitary conditions 

where restored, I removed the reject tag at 0657 hours. 9 CFR 416.1 states: "Each 

official establishment must be operated and maintained in a manner sufficient to 

prevent the creation of insanitary conditions and to ensure that product is not 

adulterated." 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (4)

(b) (4)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (4)(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2713090 

924N-1 

09/24/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C While monitoring the Establishments' Pre-operational Sanitation Procedures in 

Plant #2, I found the following noncompliance with regulations 9CFR 416.1, 9CFR 

416.4 (a) and 9CFR 416.13 (c). At approximately 0707 hours, I observed in Area #5, 

Unit # 20, FPS Tables of Lines # , numerous particles of black and 

white UFM ( Unidentified Foreign Material), the white UFM appeared to be paint 

chips. The drip pans that are connected to the cabinets for Line 

also had numerous pieces of black specks of UFM. I immediately tagged the area 

with U.S. Rejected/Retained Tag # B31 406447 and informed the 

and of the noncompliance. Company personnel 

rewashed the FPS tables and the drip pans. I re-inspected the area and released it. 

Sanitary conditions were restored at approximately 0714 hours. 

5308 M6137 BXL3013094 

424N-1 

09/24/2012 06D02 Other Inspection 

Requirements 

C At approximately 1019 hours, I performed a presentation check on Line . Station 

#1 had (1) viscera not uniform, (2) not reflected and 1 contamination inside the 

bird, total of 18 points. Station #2 had (1) viscera below the wing and (2) not 

reflected, total of 16 points. Station # 3 failed with (1) viscera on the shackle, (1) 

membrane and "(3) not reflected" total of 16 points, at Line speed of BPM. This 

exceed the limit of 3 occurrences of one error. At approximately 1033 hours Quality 

Control performed a recheck and station #1 failed with (2) viscera not uniform and 

(2) viscera on the shackle, total of 32 points. This exceed the limit of the 25 

nonconformances for the process to be in control. was 

informed and the Line speed was reduced to BPM. At approximately 1048 hours 

Quality Control performed a Recheck at Line speed of BPM and passed it. At 

approximately 1054 hours at Line speed of BPM, Quality Control performed a 

Recheck and passed it, bringing the process back in control. This is a noncompliance 

with regulation 9CFR 381.76 (b). 

(b) (6)
(b) (6)

(b) (7)(C)

(b) (4)

(b) (4)

(b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1109091 

022N-1 

09/22/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 09/22/2012 at approximately 0135 hours while performing a SPS Verification in 

Packaging Area #1, I observed the following. Establishment employees were 

unwrapping product labeled Boneless Skinless Thighs 

tagged Sept. 21 Night Shift with a second label stating "To Heavy". Approximately 

20 racks of product were staged awaiting re-wrap. One employee was removing the 

packaged product from a rack of product baskets. The baskets are considered a non 

product contact surface and are seldom cleaned. The baskets were covered with 

varying amounts of black & brown UFM (Unidentified Foreign Material), and pieces 

of dried and semi-dried fat and tissue. She then cut open the packages with a knife. 

There was no sanitizer being used anywhere in the process. Then she placed the 

opened package into a blue plastic lined basket. A second employee was taking the 

open packages from the blue plastic lined basket and dumping out the product into 

a brown product tub. The outer packaging surfaces that are considered by the 

establishment to be contaminated were coming into contact with the unwrapped 

product already in the brown tub. I contacted and showed him my 

findings. The process was moved to Packaging area #2, the Room, where the 

packages were rinsed with before being opened. QC hold tags 

were placed on the brown tubs of contaminated unwrapped product awaiting 

reconditioning. I went to the QC office and reviewed the Establishments' SSOP titled 

." dated May 21, 2012. The document under 

'Procedure' states 

." 

There was no sanitizer being used before the packages were opened that would 

have restored them to a sanitary condition. A review of the establishments 

SSOP - Operational Sanitation procedures reveals that there is no procedure that 

explains how product must be handled to maintain it in a sanitary condition. There 

was no sanitizer used on the knife being used to open the packages although the 

knife was clearly coming into contact with the product. My findings indicated a 

noncompliance with 9 CFR 416.1, 9 CFR 416.4(d), 9 CFR 416.13(b), and 9 CFR 

416.14. 

(b) (6)
(b) (6) (b) (6) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0113091 

021N-1 

09/21/2012 03J02 Slaughter HACCP C At approximately 0923 hours while monitoring the Establishment's Post Chill 

Finished Products Standards at Chiller #3 in Plant #2, I observed the following 

noncompliance. After taking a 10 bird sample, I observed 1 carcass with visible fecal 

contamination. The fecal material was located on the leaf fat by the tail on the left 

side, it was approximately 1/8" x 1/2", brownish green in color and pasty in texture. 

There was a piece of intestine approximately 1" in length still attached to the left 

side of the tail and a piece of intestine approximately 1/4" in length still attached to 

the right side of the tail, the bursa was also still attached. This exceeded the limit of 

Zero Tolerance for the process to be in control. There was no Supervisor 

immediately available so I directed the employees at the rehang station for birds 

going to packaging to stop hanging carcasses. I found nearby 

and he started tanking carcasses coming from the chiller. I performed a recheck at 

approximately 0929 hours which passed with no visible fecal. QC placed hold tags 

on 2 tanks of carcasses to be held for rework. My findings indicate a noncompliance 

with 9CFR381.65(e) and 9CFR 417.2(c)(4). 

5308 M6137 BXL0623090 

521N-1 

09/21/2012 01D01 SPS Verification C On 9/20/12 at approxemately 0400 hours in the plant # 1 mens lavatory there was 

a leak or over flow of water in toilet stall . Plant 1 supervisors were informed 

several times at 0500 hours ,0630 hours and 0715 hours . Water stood on the floor 

for undtermained amount of time . Upon ending my shift at 0722 hours water was 

still standing US REJECTED/US RETAINED TAG # b31 407695 was applied ,( taped to 

the door ) . This situation was a violation or regulation 416.4(h) which states that 

lavatories and toilets must be matained in a sanitary condition and in good repair 

416(e)(3) and 416.2(b)(2) 

5308 M6137 BXL5004095 

320N-1 

09/19/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C On 09/20/2012 at approximately 0040 hours while monitoring the establishments' 

Finished Products Standards in Plant #2, I observed the following. After taking a 10 

bird randan sample from line , I found one bird with visible fecal contamination. 

The fecal material was inside on the left side approximately 1" below the tail near 

the kidneys. The fecal material was approximately a 1/2" by 3/4" smear, olive 

brown in color and pasty in texture. This exceeded the limit of Zero Tolerance for 

the process to be in control. was contacted and the protocol for 

fecal failure was implemented. A QC recheck passed at 0104 hours. My findings 

indicated a noncompliance with 9 CFR 381.65(e), 9 CFR 417.2(c)(4), and the critical 

limit of CCP-2B of the Plants HACCP Plan for 

Slaughter. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5800093 

519N-1 

09/19/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 9/18/12 at approximately 2216 hours I observed the following while preforming 

the Pre-Operational SSOP Review and Observation Task in Plant # 1 .The Vent 

Opener on line # 1 in area 13 had thick grease on the module portion of the Vent 

Opener covering approximately 3⁄4 of the module area which appeared to be left 

from the previous shifts production . US RETAINED/REJECTED tag no. B 31 407686 

was applied and was standing near and my findings was brought to 

his attention . had one of his workers scrub and rinse all of the 

affected parts of the machinery . At approximately 2223 hours sanitary conditions 

were restored and the tag was removed , putting the establishment back in 

–compliance . At 2226 hours the Inside/Outside Bird Washer on line # 1 in area 22 

was inspected . My findings in area 22 was the main pipe with a brass nozzle on the 

end of it was covered with grease approximately 3 to 4 inches . RETAINED/REJECTED 

tag # B 31 407688 was applied and was contacted once 

again . had one of his workers scrub the brass nozzle and the portion of the 

connecting pipe that was affected . At approximately 2231 hours the Inside/Outside 

Bird Washer was re-inspected and found to be in clean and the tag was 

removed . At 2234 hours Sanitary conditions were restored , putting the company 

back in-compliance . At 2238 hours chillers # 1 and # 2 were inspected my findings 

on both chillers were the same having a build-up of grease on the paddles 

inspected . was once again notified . had the 

reachable affected paddles scrubbed and wiped clean . The white PVC pipe draining 

into the small red water finishing chiller had black UMF (unidentified foreign 

material) on top of the drain pipe had an employee standing 

close wiped the top of the drain pipe clean , putting the establishment back incompliance .My findings indicate non-compliances with the following regulations 

9CFR 416.4(b) ,(CFR 416.13(c) ,9CFR 416.13(a) ,9CFR 416.14 and 9CFR 416.4(a) . 

5309 P6137A NJN151609 

3219N-1 

09/19/2012 01C02 Operational SSOP 

Review and 

Observation 

C On September 17, 2012 I was in the evisceration department at 0827 hrs. When I 

observed the following noncompliance: At the end of line A after the cabinet, 

water was dripping from the shackle rail directly onto the birds as they where 

passing below. I notified Mr. He 

immediately took control and stopped the line and condemned the effected birds 

and called Mr. and maintenance. To immediately correct the situation 

Mr. wiped the liquid off the rail and started the line at 0830. I 

informed Mr. of the forthcoming noncompliance. 

(b) (6)
(b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN481309 

5119N-1 

09/19/2012 01D01 SPS Verification C While conducting Good Commercial Practices inspection on the outside premises at 

approximately 1023 hours, I observed the following non compliance: I observed 

two employees dumping product into a trailer. I asked the employees if they had 

denatured the product they had emptied in the trailer and their response was “No 

because the denature pump was empty". I counted ten hard plastic, unlabeled bins 

full of chicken backs and none of the product had any denaturant on them. I took 

regulatory control and stopped them from emptying any more product into the 

trailer, until the product was denatured. I waited for approximately 10-15 minutes 

until Ms. ) was present and I informed her 

of the non compliance and released the control to her. She assured me that she 

would stay there till the denaturant was brought in. Regulation 9 CFR 381.95(c) 

Handling and Disposal of Condemned or other Inedible Products at Official 

Establishments states: Chemical denaturing shall be accomplished by the liberal 

application to all carcasses and parts thereof. 

5333 P7632 HYE270809 

1819N-1 

09/19/2012 04A06 Poultry Finished 

Product Standards 

C At 0605 hrs. I was performing a FPS (Finished Product Standards) check on the 

reprocessing line in the eviscation department when I noted the following 

noncompliance: The establishment failed to remove airsacculitis exudate from 

carcasses identified by USDA for air sac removal. (3) of the (10) carcass sample 

identified for airsac removal with a split tail, contained air sac exudate. I informed

 who stopped the reprocessing line and initiated 

corrective actions. A recheck was performed at 0610 hrs. with no additional 

findings. 9 CFR 381.84 states in part: "less affected carcasses may be passed for 

food after complete removal and condemnation of all affected tissues including the 

exudate." 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3213093 

018N-1 

09/18/2012 06D02 Other Inspection 

Requirements 

C At approximately 1014 hours while performing a scheduled Presentation check on 

line in Plant 2, I observed a noncompliance with regulatory requirement of 9 CFR 

381.76(b). Inspection station 1, Line , line speed birds per minute. I observed: 

1 bird with no viscera = 20 points, 1 birds with viscera non uniform = 8 points 

adding up a total of 28 nonconformace points. Inspection station 3 Line , I 

observed: 3 birds with viscera not free = 8 points each, 1 birds with membrane = 2 

points and 1 bird with parts inside = 1 point adding up to 33 nonconformace points. 

I immediately notified and . 

At approximately 1028 hours QC performed a re check failing station 2 with 27 

nonconformace points (3 birds with viscera on the shackle = 8 points each, 1 bird 

not reflected = 2 points and 1 bird with parts inside =1 point). Line speed was 

immediately reduced from to BPM. At approximately 1047 hours, QC 

performed a passing recheck at BPM putting the line speed back to BPM. At 

approximately 1053 hours QC performed a re check at BPM, failing station 2 

with 32 nonconformace points (3 birds with viscera non uniform) and also failing 

station 3 with 38 nonconformace points (4 birds with viscera on a shackle= 32 

points, 2 birds with membrane= 2 points each, and 1 bird not reflected =2 points). 

Line went down to BPM until after lunch. According to , 

maintenance would work on the eviscerator machine during lunch time. At 

approximately 1224 hours QC performed a passing recheck at BPM putting the 

line speed at BPM. At approximately 1231 hours QC performed another passing 

recheck at BPM, bringing the process back in control. 

5333 P7632 HYE121409 

4818N-1 

09/18/2012 04A06 Poultry Finished 

Product Standards 

C On September 18, 2012, at 1051 hours in the cooler, I was performing a Finished 

Product Standards verification task at the salvaged parts station after the product 

went through all plant interventions and released by Quality Control personnel. 

While performing my task on one of the thigh salvage tubs I observed a thigh with 

cellulitis exudate. The exudate pieces measured approximately one inch in diameter 

at its greatest dimension. I took regulatory control of the affected tub by applying 

retain tag B38495169. I showed my findings to , 

and . As immediate corrective action the 

affected product was condemned as per the establishment decision. Upon 

reviewing Q.C. records, I noted that Quality Control personnel released and found 

the product acceptable at 1018 hours. The finding of cellulitis exudate in finished 

product represents a noncompliance as per 9 CFR 381.86 which states, "Any organ 

or other part of a carcass which is affected by an inflammatory process shall be 

condemned and, if there is evidence of general systemic disturbance, the whole 

carcass shall be condemned." Mr. was informed of the forthcoming 

noncompliance. Previous corrective actions failed to prevent reoccurrence: this 

noncompliance is linked to NR HYE1313093514N/1. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE570009 

1517N-1 

09/17/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On Sept. 16.2012 at approximately 2159 hours I was performing Pre-operation 

sanitation Review & Observation task in area II item 31 and I observed the following 

noncompliance: a fly standing on the surface of a shackle. I immediately notified 

Mr. S, my finding and informed him of the 

forthcoming noncompliance. Immediately, Mr. Killed the fly, washed 

and sanitized the shackle when I found acceptable at 2201 hours. No US Rejected 

Tag was applied this time. This represent a noncompliance with the regulatory 

requirements of 9CFR 416.13 (c), 9 CFR 416.2(a) and 9 CFR 416.4(a). 

5308 M6137 BXL0609092 

815N-1 

09/15/2012 04B03 Labeling - Net 

Weights 

C On 09/14/2012 at approximately 2030 hours while monitoring the establishments' 

Net Weight procedures, I observed the following. A review of the establishments' 

computer records for the PM shift revealed that a check at 535 PM for account 

#604201 for product 510 had failed (-.02) by . The 5 package variations 

included a +.02, +.03, +.02, -.19 and +.02. The check was for trays under 3 pounds. 

The establishments computer shows the check as acceptable, although less then 

average, as the low limit in the computer is set at -.062 which is the MAV 

(Maximum Allowable Variation) for an individual package in the class of product. 

The -.19 is a failure as the Maximum Allowable Variation was exceeded for that 

package size. I asked about the computer entry. She said that it appeared 

that a recheck should have been performed. The next check by was not 

performed until 619 PM. I checked the Quality Control - Reworked Product Log for 

the shift but found no entries for the 510 product. I reviewed Foster Farms 

dated November 27/ 2010 on file in 

Weigh & Price and found the following statement under Sample Plan: 

." 

As a recheck had not been documented as having been performed, the affected 

product may not have met Net Weight requirements when sent to NCDC for 

shipment. As the processes in Weigh & Price were completed I waited for the AM 

shift to arrive and discussed the issue with . A check of the 

Weigh & Price product computer showed the 50 cases were involved. The product 

at NCDC was placed on hold until a representative sample was taken with the 

product at which time it was found in compliance and released by approximately 

0620 hours. My findings indicated a noncompliance with 9 CFR 442.2. 

(b) (6)
(b) (6)

(b) (6)

(b) (4)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4304095 

214N-1 

09/14/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 09/13/2012 at approximately 2225 hours while monitoring the establishments' 

Pre-Operational sanitation procedures after establishment SSOP and HACCP 

monitors completed their inspections, I observed the following. In Plant #1, there 

was black UFM (Unidentified Foreign Material) that appeared to be mold in and 

nearby a seam that runs the entire length of Chiller #2. I inspected the center 

section of the chiller nearest the maintenance shop. The UFM was approximately 

1/2" to 2" wide and involves most of the section of the chiller that was inspected. 

There was a greasy film coating the paddles and support brackets associated with 

the area inspected and included several large patches of liquified fat to 

approximately 1/8" thick measuring several square feet. I showed 

of my findings. The reachable and accessible area of the paddles were 

wiped with paper towels and green scrub pads. The UFM was above the water line 

and will be addressed after the shift. The area was released by approximately 2235 

hours. My findings indicated a noncompliance with 9 CFR 416.1 , 9 CFR 416.4(a), 9 

CFR 416.13(c), and 9 CFR 416.14. 

5309 P6137A NJN240909 

5414N-1 

09/14/2012 04A06 Poultry Finished 

Product Standards 

C I was performing a FPS ( Finished Product Standards ) check at 0709 hours on the 

reprocessing line in the evisceration department when I observed the following 

noncompliance; The establishment failed to remove airsacculitis exudate from 

carcasses identified by USDA for air sac removal. (4) carcasses of the (10) carcass 

sample identified for air sac removal with a split tail contained air sac exudates. The 

establishments written procedure for air sac states " 

". The procedure also states; "

 ". I initiated regulatory control by stoping the 

reprocessing line and immediately informed Mr. 

of the forthcoming noncompliance. 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE131309 

3514N-1 

09/14/2012 04A06 Poultry Finished 

Product Standards 

C At 1040 hours I was performing the Review and Observation of a Finish Product 

Standards PHIS task at the salvaged parts station after the product went through all 

the interventions at the slaughter process and was inspected and released by 

Quality Control personnel. When I was performing my verification in one tub with 

thighs, I noted that one of thighs had cellulitis exudate between the fat tissue and 

the skin with an approximate measurement of 1 1⁄2 inches in diameter in its greatest 

dimension. I took regulatory control action by applying retain tag #B38694335 to 

the tab with the affected product. I showed my finding to 

and . As 

immediate corrective action the affected product was condemned as per the 

establishment decision. Upon reviewing the establishment records, I noted that 

Quality Control personnel released and found acceptable the affected product at 

1004 hours. The finding of cellulitis exudate in finish product represents a 

noncompliance as per 9 CFR 381.86 which states, “Any organ or other part of a 

carcass which is affected by an inflammatory process shall be condemned and, if 

there is evidence of general systemic disturbance, the whole carcass shall be 

condemned”. Mr. was informed of the forthcoming documentation 

for the failure to comply with the regulatory requirements cited above. 

5308 M6137 BXL0609094 

913N-1 

09/13/2012 06D02 Other Inspection 

Requirements 

C On 09/13/2012 at approximately 0216 hours while monitoring the establishment 

carcass Presentation functions in Plant #1 Line #1, I observed the following. I timed 

a standard 'no viscera' check for three minutes and counted 22 no viscera 

nonconformances. The line was running at bpm (birds per minute) which allows 

13 or less 'no viscera' to be in compliance. I informed . 

Adjustments were made before break and during lunch with a Quality Control 

recheck at 0354 hours failing with 18 no viscera nonconformances. The line was 

slowed to bpm with a Quality Control recheck failing at 0619 hours with 19 no 

viscera. At bpm 11 or less no viscera nonconformances are allowed. A check of 

the establishments Lines - No Viscera Monitoring Log for the PM shift for 

the same day showed that at 0810 hours at bpm a Quality Control check failed 

with 17 no viscera nonconformances. At 0836 hours a Quality Control recheck 

failed with 23 no viscera. The line was slowed to bpm at 0838 hours. At 1020 

hours at bpm a Quality Control check failed with 19 no viscera 

nonconformances. At 1304 hours at bpm a Quality Control check failed with 20 

no viscera nonconformances. At 1456 hours at bpm a quality control recheck 

failed with 17 no viscera nonconformances. The establishment made no mechanical 

adjustments to correct the failure, nor was the line slowed further to correct the 

noncompliance situation. My findings indicated a noncompliance with 9 CFR 381.76 

(a) & (b). 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1905093 

613N-1 

09/13/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 09/12/2012 at approximately 2355 hours while monitoring the establishments' 

Pre-Operational Sanitation procedures after establishment SSOP and HACCP 

monitors completed their inspections, I observed the following. In Packaging Area 

#1, there were numerous pieces of fat and tissue to approximately 1/4" on the 

inside surfaces of the cover associated with the tray dispenser on line There 

were several pieces of fat to approximately 3" on the tray flex belt on the bag fryer 

line side of line . Also along the entire length of the same Line tray flex belt, 

there were large patches of pasty fat, tissue and black UFM (Unidentified Foreign 

Material) that appeared to be mold on the stainless and white nylon portions of the 

belts support brackets. The majority of the area was scrubbed with green pads and 

rinsed with , however a detailed chemical application and cleaning will 

be accomplished for some of the non-food contact surfaces at a later time. The line 

was released by approximately 0022 hours. My findings indicated a noncompliance 

with 9 CFR 416.1, 9 CFR 416.4(a) & (b), and 9 CFR 416.13(c). 

5309 P6137A NJN221209 

3613N-1 

09/13/2012 01C01 Operational SSOP 

Record Review 

C On September 12, 2012 I was in the New Product room at 1135 hours reviewing 

SSOP records for Rotisserie Injection pick-up Verification Log when I noted that The

 recorded the checks 0926 hrs 

and the next one an 1123 hrs. The Establishment’s SSOP states 

”. The establishment had not switched lots or 

product codes at the time observation was made. I informed Ms. of the 

non compliance. 

5309 P6137A NJN351309 

4913N-1 

09/13/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 0937 hours while performing PHIS task for zero tolerance on the 

reprocessing line I observed one carcass of a ten carcass sample with visible fecal 

material on the inside cavity of the bird by the left side of the keel bone. The fecal 

material was approximately 1/8 inch in diameter, dark green in color and had a 

paste-like consistency. I immediately took regulatory control action with the 

application of US Retained Tag #B21948349, stopping the line and informing Mr.

 of the forthcoming non compliance. That 

the establishment failed to prevent fecal material from entering the chilling system 

represents noncompliance with 9 CFR 381.65(e). The retest (recheck) was 

performed at approximately 1014 hours by due to mechanical 

failure on the Offline. This document serves as written notification that your failure 

to comply with regulatory requirement's could result in additional regulatory or 

administrative action. 

(b) (6)
(b) (6)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE421809 

1113N-1 

09/13/2012 01C02 Operational SSOP 

Review and 

Observation 

C While I was performing the Review and Observation of a Poultry Zero Tolerance 

Verification PHIS task at the salvage inspection station, I observed the following 

deficiency: At 1340 hours I was inspecting a tub that contained salvaged thighs; 

when I noticed that some of the pieces of ice that are used to bring the product’s 

temperature down were contaminated with rail dust and cross-contaminating the 

product in the tub. The rail dust specks had an approximate measurement of 1 mm 

in their greatest dimension. I took regulatory control action by applying Retain 

tag # B386994336. I showed my finding to 

. At 1345 hours, the establishment decided to condemn the 

affected product. Upon reviewing the CCP-1B form, I noted that the thighs were 

released and found acceptable by Quality Control at 1302 hours. The finding of rail 

dust on ice and cross-contaminating finish product that went through all the 

interventions at the slaughter process does not meet the regulatory requirements 

of 9 CFR 416.13(c) which states, “Each official establishment shall monitor daily the 

implementation of the procedures in the Sanitation SOP's”. And 9 CFR 416.4(d) 

states, “Product must be protected from adulteration during processing, handling, 

storage, loading, and unloading at and during transportation from official 

establishments”. The employees mentioned in this document were informed of the 

forthcoming documentation for the failure to comply with the regulatory 

requirements cited above 

5308 M6137 BXL0018092 

112N-1 

09/12/2012 01C01 Operational SSOP 

Record Review 

C At approximately 1115 hours while performing Operational SSOP Record Review I 

observed the following noncompliance. On the Establishments SSOP Monitoring 

and Implimentation log for 09-11-2012 on the AM shift in Plant #1 there was a 

montoring check missing on the log. Only one monitoring check was documented at 

2324 hours, according to the Establishment's SSOP's there is to be

 The log was signed by a Supervisor as correct and 

complete. My findings indicate a noncompliance with 9CFR 416.13(b) and 9CFR 

416.16(a). 

(b) (6)
(b) (6) (b) (6)

(b) (6)

(b) (6) (b) (6)(b) (6) (b) (6) (b) (7)(C) (b) (7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1210091 

312N-1 

09/12/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 09/11/2012 at approximately 1050 hours while monitoring the packaging area, 

I noticed a lot of debri on the floor all around the bag fryer lines. I brought this to 

the attention of . He mentioned that he would take care of it. At 

approximately 1908 hours while performing a routine Operational Sanitation 

verification check, I observed a noncompliance on the bag fryer line, Packaging area. 

There were giblets, plastic bags, packaging pads on the floor and overflowing trash 

containers. There were several stainless steel container overflowing with down 

grade birds causing the birds to fall on the floor. I also noticed several bagged whole 

body birds on the floor at the end of the line. I did not notice any sanitation 

employee taking care of cleaning the area. I approach and 

brought to her attention the insanitary conditions and notified her of a 

noncompliance being issued. She immediately instructed her sanitation employee 

to clean the area. All debri was picked up from the floor and the birds were picked 

up and reconditioned. The establishment SSOP records for the packaging area 

reflected no sanitary deficiencies through out the day. My finding reflect a 

noncompliance with regulatory requierents of regulations 9 CFR 416.1, 416.13(c) 

and 416.14. 

5333 P7632 HYE341809 

5012N-1 

09/12/2012 01D01 SPS Verification C On September 12, 2012 Inspector called me to inspection station 

one on Evisceration line two at approximately 1059 hours. Inspector 

informed me that he had observed a build up of mold at his station on an electrical 

cord, and the outlet connected to it. I inspected the electrical cord that hangs under 

the station above the condemn barrel. The power cord had spots of mold on it, 3⁄4 of 

the yellow power outlet’s surface was covered in black mold. I informed 

of the noncompliance for the failure to meet 

the regulatory requirements sited above. I continued to inspect the remaining 

seven inspection stations and noted that on both evisceration lines one and two, 

stations one, two, and three, there was mold build-up on the power cords and 

outlets as well. I informed of my findings and 

Mr. purposed a corrective action of the establishment removing these 

power cords and outlets because they no longer served a purpose. In the Q.C. office 

I informed of the noncompliance and requested the 

Pre-Operational Sanitation records for September 11,2012. Upon review of this 

record I noted that perform Pre-Op inspection on unit 23 

(inspection stations) at 2148 hours and passed the unit. 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (7)(C) (b) (4)

(b) (4)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1516090 

011N-1 

09/11/2012 03J02 Slaughter HACCP C While performing Slaughter HACCP procedure record keeping review, I found the 

following noncompliance with regulation 9CFR 417.5 (c). At approximately 1100 

hours while reviewing the Establishments' HACCP Monitoring Log CCP-1B 

from 09/10/2012, I observed that Quality Control had a Fecal failure on 

Line # (reprocessing line) in Plant # 2 at approximately 1051 hours. The protocol 

for fecal failure was implemented (HACCP supplement # 26) for CCP-1B. The 

Recheck passed it at approximately 1105 hours. Quality Control completed 

corrective actions at approximately 1235 hours by performing Post-Chill checks 

every five minutes at the exit of Chiller # 3. The Pre-Shipment Records Review for 

CCP-1B Mid-Shift was signed at 1158 hours. The signed document 

certifies that all corrective actions were completed and the product is ready to be 

shipped. The Pre-shipment Records Review Mid-shift was signed before the 

corrective actions were completed. I informed 

of the noncompliance. 

5308 M6137 BXL3607092 

212N-1 

09/11/2012 01D01 SPS Verification C On 09/12/2012 at approximately 00:46 hours, Inspector brought to 

my attention an adult cockroach on the wall just above the apron rack, adjacent to 

eviseration line near the 3rd inspection station. I then killed the roach and 

showed it to and informed him of the location where the 

roach was found. Roaches are known to transport filth and disease. My findings 

indicate a noncompliance with 9 CFR 416.1 and 9 CFR 416.2. 

5308 M6137 BXL4222092 

211N-1 

09/11/2012 06D02 Other Inspection 

Requirements 

C On 09/06/2012 at approximately 0154 hours while performing a scheduled 

Presentation check on line in Plant #2, I observed the following. At the first 

inspection station with the line speed at birds per minute, I observed (1) bird 

'not hung by two legs', (1) bird with the 'viscera not uniform', (1) bird with the 

'viscera on the shackle', (3) birds "not reflected', (1) bird with 'parts inside', and (1) 

bird with 'contamination inside' for a total of 42 nonconfornmance points. This 

exceeded the limits of process control of 2 or less occurrences of one error and 24 

or less process control points. I informed of my observations and 

that as the total nonconformances exceeded 40 points an immediate 10 bird line 

speed reduction was required. Quality Control performed a recheck at 0202 hours 

at birds per minute that passed. The line was returned to birds per minute 

and the Quality Control recheck failed at 0210 hours at the first station with (3) 

'viscera on the shackle' and (2) 'membranes not broken' for a total of 28 

nonconformance points. Station #3 also failed with (3) 'viscera on the shackle' and 

(3) 'membranes not broken' for a total of 30 nonconformance points. The line was 

again reduced to birds per minute with a recheck at 0226 hours that passed and 

a recheck at 0233 hours at birds that passed bringing the process back into 

control. My findings indicated a noncompliance with 9 CFR 381.76(b). 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN510509 

1910N-1 

09/10/2012 01C02 Operational SSOP 

Review and 

Observation 

C While performing an Operational Sanitation SSOP review and observation PHIS task 

at 02:40 AM, I observed the following noncompliance: At the end of B line in the 

evisceration department there were several leaks of water dripping from the ceiling. 

The water dripping was directly above the product. I observed it dripping on the 

product and notified . He immediately took 

control of the issue by stopping the production line and alerting maintenance of the 

issue. Maintance put up plastic liners above the line to divert the dripping onto the 

floor and the production was released at 03:02 AM. I informed 

h of the forthcoming noncompliance 

record. By allowing the adulteration of product the establishment failed to follow 

the following regulatory requirements: CFR 9 416.2(b)(1) Establishment buildings, 

including their structure, rooms, and compartments must be of sound construction, 

be kept in good repair, and of sufficient size to allow for processing, handling, and 

storage of product in a manner that does not result in product adulteration or the 

creation of insanitary conditions. CFR 9 416.2(b)(2) Walls, floors, and ceiling within 

establishments must be built of durable materials impervious to moisture and be 

cleaned and sanitized as necessary to prevent adulteration of product or the 

creation of insanitary conditions. CFR 9 416.2(e)(3) Prevent adulteration of product, 

water supplies, equipment, and utensils and prevent the creation of insanitary 

conditions throughout the establishment. CFR 9 416.4(d) Product must be 

protected from adulteration during processing, handling, storage, loading and 

unloading at and during transportation from official establishment. CFR 9 416.1 

Each official establishment must be operated and maintained in a manner sufficient 

to prevent the creations of insanitary conditions and to ensure that product is not 

adulterated. 

5308 M6137 BXL3005093 

408N-1 

09/08/2012 04A06 Poultry Finished 

Product Standards 

C On 09/08/2012 at approximately 0037 hours while monitoring Finished Products 

Standards at the Post- Chill location from Chiller #3 in Plant #2, I observed the 

following. After taking a random 10 bird sample, I accumulated 11 nonconformance 

points which exceeded the subgroup absolute limit of 10 points. I informed

 of my findings. A QC recheck failed with 6 points at 0047 hours. 

The limit at the Post-Chill for a recheck is Tolerance which is 5 points. At this point 

the process is judged to be out of control. informed me of the 

recheck failure and that product was being retained. Quality Control tanked and 

identified product exiting Chiller #3 that required rework and performed additional 

rechecks that also failed at 0052 hours with 6 nonconformances, at 0100 hours 

with 7 nonconformances, at 0106 hours with 6 nonconformances, and at 0112 

hours with 7 nonconformances. The QC recheck at 0116 hours passed bringing the 

process back into control. A total of 10 tanks of product was placed on QC hold 

pending rework. My findings indicated a noncompliance with 9 CFR 

381.76(b)(3)(iv)(e)(3). 

(b) (6)
(b) (6) (b) (6)

(b) (6)

(b) (6) (b) (6) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0905091 

807N-1 

09/07/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 09/07/2012 at approximately 0130 hours while monitoring Facilities, I observed 

the following. In the storage area of the rewrap room in the Weigh & Price cooler 

there was a rack of Backs & Necks labeled 08/13/2012. The product was a light 

brown color. Some of the packages had holes in the packaging material 

apparently caused from contact with the product baskets that make up the racks. 

The product exposed to the air in these areas had changed to a light gray color. The 

product staged at this location is product that is culled from the Weigh & Price 

cooler due to age or other defects. The product is staged and is normally awaiting 

down grade and rewrapping for freezing. I contacted and 

showed her my findings. A package was opened and the product gave off a pungent 

smell. She condemned approximately 100 packages. The product was placed in a 

gray inedible barrel by approximately 0155 hours. The establishments' HACCP Plan 

for Slaughter lists the shelf life of fresh product as . The temperature of the 

Weigh & Price cooler at the products location was approximately 28 degrees. My 

findings indicated a noncompliance with 9 CFR 416.4(d). 

5309 P6137A NJN030209 

1306N-1 

09/06/2012 01C02 Operational SSOP 

Review and 

Observation 

C While performing my Operational Sanitation review and observation PHIS task at 

23:40, I observed the following noncompliance. I observed four black objects 

floating in the paw chiller. There was product in the chiller at this time. I notified 

Evis. of the noncompliance. He attempted to 

remove the objects from the chiller water. He retrieved one and identified it as a 

Paw Picker. Once all the objects were removed I informed

 of the and Mr. of the forthcoming 

noncompliance record. Mr. at this point drained all water and product from 

the paw chiller. They reworked the product and sanitized the paw chiller. At 00:15 

once sanitation was restored and they were back in compliance the paw chiller and 

product was released. By allowing the product to be adulterated they failed to 

comply with the following regulations that state: 9CFR 416.1, Each official 

establishment must be operated and maintained in a manner sufficient to prevent 

the creation of insanitary conditions and to ensure that product is not adulterated. 

9CFR 416.3(a), Equipment and utensils used for processing or otherwise handling 

edible product or ingredients must be of such material and construction to facilitate 

thorough cleaning and to ensure that their use will not cause adulteration of 

product during processing, handling, or storage. Equipment and utensils must be 

maintained in sanitary conditions so as not to adulterate product. 9CFR 416.4(a), 

All food-contact surfaces of utensils and equipment, must be cleaned and sanitized 

as frequently as necessary to prevent the creation of insanitary conditions and the 

adulteration of product. 9CFR 416.4(d), Product must be protected from 

adulteration during processing,handling, storage, loading, and unloading at and 

during transportation from official establishment. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6)

(b) (6)

(b) (6) (b) (6) (b) (4) (b) (4)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1207094 

904N-1 

09/04/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C While performing Pre-Chill Finished Products Standards Check, I observed 

noncompliance with the following regulatory requirements of regulation 9CFR 

381.65 (e) and 9CFR 417.2 (c)(4). On 09/04/2012 at approximately 0410 hours, I 

randomly removed a 10 bird sample from Line #2 in Plant #1, I found one out the 

ten birds with visible fecal contamination inside the bird at the left side under the 

leaf fat area, close to the kidneys. The fecal material was a smear measuring 

approximately 1/4 " diameter in size, brownish green in color and pasty in texture. 

This exceed the limit of Zero Tolerance for the process to be in control. I informed

 and of the noncompliance. The 

protocol for fecal failure was implemented. Quality Control performed a recheck at 

approximately 0439 hours and it passed. This is a violation of the critical limits of 

CCP-2B, of the Plant's HACCP Plan for Slaughter. 

5309 P6137A NJN391309 

1601N-1 

09/01/2012 04A06 Poultry Finished 

Product Standards 

C While performing a FPS (Finished Product Standard) check at approximately 0914 

hours on the Reprocessing Line in the Evisceration Department I observed the 

followimg non compliance: The establishment failed to remove airsacculitis exudate 

from carcasses identified by USDA for airsacculities removal. (1) carcass of the (10) 

carcass sample identified for air sac removal with a split tail contained air sac 

exudate. The establishment’s written procedure for for air sac removal states that

 During the recheck 

performed at approximately 0919 hours by , (1) carcass 

of the (10) carcass sample identified with a split tail contained air sac exudate. The 

establishment’s written procedure for air sac removal states 

. I initiated regulatory control 

by stopping the reprocessing line and informing Mr. 

) and of the non compliance. 

5333 P7632 HYE230508 

1930N-1 

08/30/2012 01D01 SPS Verification C On August 29/2012, while I was performing SSOP in the Giblet Chiller area at 0004 

hours I observed the following noncompliance: an employee picking up a glove off 

the floor, putting it on and grabbing a shovel by the handle from combo bin 

containing ice. He stirred the ice in the bin and then laid the shovel vertical inside 

the bin of ice. The ice wasn’t affected. I immediately took regulatory control action 

by placing US Rejected Tag NO. B38 495190. Mr. , 

was informed with my finding and forthcoming documentation of the failure to 

comply with the regulatory requirements cited above. At 0006 hours I released the 

shovel to , after putting a QC hold tag on it to 

restore the sanitary condition of the shovel. 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (6) (b) (4)

(b) (4)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE510208 

1329N-1 

08/29/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C At approximately 2315 hours, after sanitation and QC performed preoperational 

sanitation and released area III for operations; I performed preoperational 

sanitation and observed the following noncompliances: a piece of meat 

approximately 1 inch by 1 inch, on the transfer conveyor belt at North Chiller Exit, 

from previous shift of production. The belt is product-contact surface. The floor 

underneath that belt had several pieces of fat. I immediately took regulatory contol 

action and rejected the belt, the floor and applyied US Rejected Tag NO. B38 

494919. At approximately 2318 the belt and the floor were re-inspected found 

acceptable and released. In the same area and at 2320, I observed the following 

noncompliance: the floor underneath the Downgrade belt had numerous pieces of 

fat and meat particles from previous shift of production. I immediately took 

regulatory control action and applied rejected tag NO. B38494915. The floor was 

re-washed, re-inspected and released at 2329 hours. Mr. 

, notified of my findings and the forthcoming NR. The requirements of 9 

CFR 416.4 (a), 9 CFR 416.13(c), and Plant’s written SSOP plan were not met. 9 CFR 

416.4(a) States: “All food-contact surfaces, including food-contact surface of 

utensils and equipment, must be cleaned and sanitized as frequently as necessary 

to prevent the creation of insanitary conditions and the adulteration of product’. 9 

CFR416.13(c) states “Each official establishment shall monitor daily the 

implementation of the procedures in the Sanitation SOP’s”. 9 CFR 416.2 (b)(2) 

states: “Walls, floors, and ceilings within establishments must be built of durable 

materials impervious to moisture and be cleaned and sanitized as necessary to 

prevent adulteration of product or the creation of insanitary conditions. Plant’s 

written SSOP procedures dated 03/13/12, page 2, Section 1 Evisceration, 

Subsection D Step # 2 states: 

5308 M6137 BXL3905084 

128N-1 

08/28/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C While performing a Zero Tolerance Check, I observed noncompliance with the 

following regulatory requirements of regulation 9CFR 381.65 (e) and 9CFR 417.2 

(c)(4). On 08/28/2012 at approximately 0119 hours, 

randomly removed a 10 bird sample from Line # in Plant #2, I found one out the 

ten birds with visible fecal contamination inside of the bird at the left side of the 

ribs area. The fecal material was a smear approximately 3/4" long and 3/8" wide, 

brown-green in color and pasty in texture. This exceed the limit of Zero Tolerance 

for the process to be in control. I informed and

 of the noncompliance. The protocol for fecal failure was 

implemented. Quality Control performed a Recheck at approximately 0153 hours 

and it passed. This is a violation of the critical limits of CCP-2B, 

of the Plants' HACCP Plan for Slaughter. 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6) (b) (6) (b) (4)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE590908 

0828N-1 

08/28/2012 03J02 Slaughter HACCP C On August 27, 2012 I was performing a SPS verification task in the Packaging 

Department, at 1419 hours, when I observed a large pile up of product (leg 

quarters) had accumulated on a drip pan. The drip pan is located under Auto Loader 

#2, Leg Processor #3. I requested from to measure the 

temperature of the product to verify that the temperature requirements were being 

met. With the calibrated thermometer # 49 we observed a saddle (unsplit leg 

quarters) at the temperature of 66.5 degrees F. had 

the pile moved to a brown tub to be washed and iced down, I took regulatory 

control by applying U.S. Retain tag B38495170 to the tub. Rather than reprocessing 

and icing the product the establishment chose to condemn the affected product. I 

then informed Mr. of the forthcoming noncompliance for the failure to 

meet the requirements cited above. The product was condemned and this was 

verified by and myself. Establishment P-7632 was 

granted a Salmonella Initiative Program Letter issued on September 2, 2011. The 

SIP program allows establishment P-7632 to use alternative chilling procedures in 

place of 9 CFR 381.66(b), provided the establishment: Assesses, modifies and 

validates as appropriate, the Hazard Analysis and Critical Control Points (HACCP) 

plan according to 9 CFR 381.22 and 417.4. The establishment failed to implement 

their SIP program by allowing the internal temperature of their product to rise 

above degrees F. SIP protocol states: “

 This noncompliance is linked to NRs # HYE4415085406N dated 8/6/12 

and # HYE5617085809N dated 8/9/12. 

5309 P6137A NJN481408 

3625N-1 

08/25/2012 01C02 Operational SSOP 

Review and 

Observation 

C While conducting Sanitary Operational Procedures in the New Products Room (Area 

#5, Section C, IQF #2, by the Pack Mac #1) at approximately 1228 hours I observed 

the following non compliance: I counted seven bags of frozen product (three pound 

bags of injected thighs) on the floor. Four of those bags were not sealed properly so 

the product was scattered on the floor underneath the table and some underneath 

the product conveyor. More bags were being tossed on to a table that was already 

stacked approximately two feet high with rejected bags, so more bags kept falling 

on the floor. An employee was trying to empty the bags of product onto the return 

conveyor with no avail indicating process out of control. Also the red trash 

receptacle stationed next to the product was overflowing with trash, creating 

insanitary conditions. I took regulatory control by stopping the line and applying US 

Retained Tag #B36336883 and informing Ms.

 and of the non compliance. After corrective actions and 

proper disposition of product was implemented, Regulatory control was released at 

approximately 1237 hours. 

(b) (6)
(b) (6)

(b) (6) (b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN100408 

5524N-1 

08/24/2012 01C02 Operational SSOP 

Review and 

Observation 

C Approximately at 01:50 A.M. while conducting PHIS task Operational SSOP review 

and observation I found the following noncompliance: Two salvage parts tub, with 

product in them had foreign material on the inside of the the tub. I took regulatory 

control of the product by applying US retain tags B38495174 and B38495171. I 

informed of the 

noncompliance. He took corrective action by reworking the affected product and 

replacing the dirty tubs with clean ones. Product was released at 01:59 A.M. when 

sanitary conditions were restored. I informed Mr of the forthcoming 

noncompliance. By allowing product to come in contact with insanitary surfaces the 

establishment failed to meet the following regulatory requirements: 9CFR 

416.4(a)(d) states(a)"All food-contact surfaces, including food-contact surfaces, 

utensils and equipment, must be cleaned and sanitized as frequently as necessary 

to prevent the creation of insanitary conditions and the adulteration of product." 

(d)"Product must be protected from adulteration during processing, handling, 

storage, loading, and unloading at and during transportation from official 

establishment." 9 CFR 416.1 "Each official establishment must be operated and 

maintained in a manner sufficient to prevent the creation of insanitary conditions 

and to ensure that product is not adulterated." 

5333 P7632 HYE230208 

5523N-1 

08/23/2012 04A06 Poultry Finished 

Product Standards 

C I was performing a finished product standards (FPS) verification task on the 

reprocessing line in the evisceration department at 2248 hours. I selected ten 

carcasses marked for vacuum identified by the split tail. One of the ten carcasses 

contained a kidney, indicating an improper vacuum procedure. I informed 

and . In thier presence I 

performed the required recheck of ten split tail carcasses at 2255 hours and found 

one carcass containing airsac exudate. I informed Mr. and

 of the forthcoming documentation of the failure to comply 

with the regulatory requirements cited above. In addition 9 CFR 381.76 table 1 #7 

states: Lesion/condition subject to removal following an approved cleanout 

process: Airsacculitis condition requiring removal of the kidneys. 

(b) (6)
(b) (6)

(b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6) (b) (4)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2908081 

622N-1 

08/22/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C While monitoring the Establishments' Pre-operational Sanitation Procedures in 

Main Packaging Area, I found the following noncompliance with regulations 9CFR 

416.1, 9CFR 416.4 (a) and 9CFR 416.13 (c). On 08/21/2012 at approximately 2353 

hours, I observed on Line at the beginning of the line the white plastic line 

dividers at the point were they meet there was a red and brown thick layer of 

residue build-up and small pieces of fat from the previous day production. The 

triangle metal bracket that holds the two dividers apart had a large amount of black 

UFM (Unidentified Foreign Material) at the bottom . I immediately tagged the line 

with U.S. Retained/Rejected Tag # B31 406446 and Informed 

and of the noncompliance. Company personnel 

scrubbed and rewashed the line. I re-inspected the area and released it. Sanitary 

conditions were restored at approximately 0015 hours. 

5308 M6137 BXL4708082 

422N-1 

08/22/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C While performing Zero Tolerance Fecal Check, I observed noncompliance with the 

following regulatory requirements of regulation 9CFR 381.65 (e) and 9CFR 417.2 

(c)(4). On 08/22/2012 at approximately 0520 hours, I randomly removed a 10 bird 

sample from Line #1 in Plant #1, I found one out the ten birds with visible fecal 

contamination. There was a cloaca attached to the carcass near the base of the tail 

at the left side of the leaf fat area. The fecal contamination was located at the left 

side of the leaf fat area by the tail. The fecal material was approximately 3/8" 

diameter in size, light brown in color and watery in texture. This exceed the limit of 

Zero Tolerance for the process to be in control. I informed 

and of the noncompliance. The protocol for 

fecal failure was implemented. Quality Control performed a recheck at 

approximately 0551 hours and it passed. The cause of the deviation was "body 

opener failed". This is a violation of the critical limits of CCP-2B, 

of the Plant's HACCP Plan for Slaughter. 

5308 M6137 BXL3104080 

721N-1 

08/21/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C While performing Pre-Chill Finished Products Standards Check, I observed 

noncompliance with the following regulatory requirements of regulation 9CFR 

381.65 (e) and 9CFR 417.2 (c)(4). On 08/21/2012 at approximately 0112 hours, I 

randomly removed a 10 bird sample from Line #1 in Plant #1, I found one out the 

ten birds with visible fecal contamination inside the bird at the right side by the 

kidneys area. The fecal material was a smear measuring approximately 1/4" by 3/4" 

in size, dark green in color and pasty in texture. This exceed the limit of Zero 

Tolerance for the process to be in control. I informed and

 of the noncompliance. The protocol for fecal failure 

was implemented. Quality Control performed a recheck at approximately 0141 

hours and it passed. The cause of the deviation was "venter". This is a violation of 

the critical limits of CCP-2B, of the Plant's HACCP Plan for 

Slaughter. 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE250708 

1821N-1 

08/21/2012 01C02 Operational SSOP 

Review and 

Observation 

O At approximately 3:28 A.M. while performing PHIS task Operational SSOP review 

and observation, I observed the following noncompliance while walking through 1st 

processing: A pipe directly above the giblet staging area had condensation and it 

was dripping directly over exposed product . I informed 

who in turn called . I informed 

her of the noncompliance and she called 

. I informed him of the noncompliance. He then told me that 

they had already received an NR the night before and I confirmed that yes they had. 

I then asked him about what was going to be done with the affected product today. 

Mr said that they would be condemning the product and wiping down the 

pipe. and Mr were both informed of the forthcoming 

noncompliance. By allowing condensation to adulterate product the establishment 

failed to meet regulatory requirements of 9 CFR 416.1 which states "Each official 

establishment must be operated and maintained in a manner sufficient to prevent 

the creation of insanitary conditions and to insure that product is not adulterated." 

9 CFR 416.2(d) "Ventilation adequate to control odors, vapors, and condensation to 

the extent necessary to prevent adulteration of product and the creation of 

insanitary conditions must be provided." 

5308 M6137 BXL0213081 

320N-1 

08/20/2012 01B02 Pre-Op SSOP 

Review and 

C On 8/20/12 at approximately 0655 hours I observed the following while preforming 

the Pre-oreratiolal SSOP Review and Observation Task in Plant # 1 . In the Paw room 

Observation on line # 1 , the round shaft on the inter portion of the picker had a build-up of 

yellow grease .The area was approximately 2” by 4” , US Retained /Rejected tag # B 

31 407672 was applied . I immediately notified . 

had one of his workers scrub the shaft and rinse it throughly . At 0702 

sanitary conditions were restored and the area was ready for production . At 

approximately 0704 hours the Transfer Machine on line # 1 was inspected . The Drip 

pan that runs off onto the Transfer table , which is a food contact surface had a 

build-up of grease on the outer walls and there were several pieces of black fiber 

like material also pieces of fat inside the drip pan . was once 

again notified . had one of his men remove the grease from the 

walls of the drip pan and rinse the drip pan and transfer table also . The area was 

re-inspected and found to be in sanitary condition .My findings indicate 

non-compliances with the following regulations , 9 CFR 416.13(c) ,9 CFR 

416.14 , 9CFR 416.4(a) and 9CFR 416.4(b) . 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE210908 

0420N-1 

08/20/2012 01C02 Operational SSOP 

Review and 

Observation 

C I was in the Packaging Department prior to start up on August 18, 2012 when I 

noted the following deficiencies: Two white mobile product conveyors had meat 

and fat particles from the previous day’s production, one conveyor also had black 

water like foreign material in some spots. Both conveyors where tagged with the 

application of U.S. retain tags B39757024 and B38495131 at approximately 0840 

hours. I continued my inspection of the area and observed that the product belts 

for Segment Lines one and two were both contaminated with meat and fat 

particles. Segment Line one also had the same black, water like, foreign material on 

the product contact surface of the belt. Segment Line One was retained with U.S. 

retain tag B38494925, Segment Line two was retained with U.S. retain tag 

B38494924. I informed and 

of the forthcoming noncompliance. After I reinspected the affected 

belts and confirmed sanitary conditions were restored I released the product 

conveyor at 0905 hours. I reviewed the establishment’s Pre-Operational Sanitation 

Records in the Q.C. office. I noted that conducted 

Pre-Op inspection on both Segment Lines one and two and found them acceptable 

at 0224 hours on August 18,2012. 

5333 P7632 HYE330508 

3020N-1 

08/20/2012 01D01 SPS Verification C At approximately 02:00 A.M. on 08/20/12 I was performing the review and 

observation component of SPS task when I observed the following noncompliances: 

There was condensation on the bottom of the drip pans above the rehang area by 

the north chiller. There was exposed product directly underneath the condensation. 

There was also condensation on the pipes above the staging area for the giblets. I 

informed of the noncompliance. Mr 

then instructed an employee to clean the area while he covered the product. 

Although no condensation was observed dripping on the product, the 

establishment chose to rework some of the product. I verified that sanitary 

conditions were restored immediately after they wiped down the areas . By 

allowing condensation to accumulate, the establishment failed to meet the 

regulatory requirements of 9 CFR 416.2(d) which states, "Ventilation adequate to 

control odors, vapors, and condensation to the extent necessary to prevent 

adulteration of product and the creation of insanitary conditions must be 

provided". Mr. was informed of the 

forthcoming documentation for the failure to comply with the regulatory 

requirements cited above. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4)(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE400608 

0220N-1 

08/20/2012 01C02 Operational SSOP 

Review and 

Observation 

C At 0002 hours on August 19th and after I performed Post-Chill checks on Noth 

Chiller I observed the following noncompliance at Segment 1 & 2 Re-hang Belt: an 

establishment employee grabbed a metal stand, adjusted underneath him, and 

then he proceeded and touched the carcasses on the Re-belt without washing and 

sanitizing his gloves. The products were transferred to combo bins. I immediately 

took regulatory control action by applying rejected tag No B38495146 on the 

Segment 1&2 Re-hang Belt and two Retained tag No B38495147 and No 

B38495145 on two combo bins filled with the affected product. The Segment 1&2 

Re-hang Belt was washed, sanitized reinspectd and released at 0010 hours. After 

the establishment took appropriate disposition of the affected product, the two 

combo bins were released to the company at 0045 hours and 135 hours 

respectively. Mr. , was notified of the 

forthcoming documentation of the failure to comply with the regulatory cited 

above. As a proposed preventive measure, Mr. stated that he will train the 

employee. 

5308 M6137 BXL0205081 

318N-1 

08/18/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 08/18/2012 at approximately 0020 hours while monitoring the establishments' 

Pre-Operational Sanitation Procedures in Packaging Area #2 after SSOP and HACCP 

monitors completed their inspections, I observed the following. There was a red 

flake that appeared to be paint on the large trim table adjacent to Deboning 

Line #1. The chip measured approximately 1/4" by 1/8". There were three red flakes 

that appeared to be paint chips on the main belt at the loading end of 

Deboning Line #1. The largest flake was approximately 3/8" by 1/4". There were two 

large white flakes that appeared to be paint on the belt that collects the carcasses 

adjacent to Line . The flakes measured approximately 1/4" by 1/4". A large 

support pilar painted white nearby has similar flaking paint chips as the post 

appears to have been repainted with non-compatible paints. A shiny piece of metal 

was on the main belt at the loading end of Line . The metal piece was 

approximately 1mm by 6mm's. It was partially imbedded in the belt surface. The 

reverse side was irregularly shaped and appeared to be a piece of welding slag. I 

discussed my findings with . He was given most of the paint 

flakes. was shown the piece of metal. My findings 

indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.2(b)(1), 9 CFR 416.4(a), and 

9 CFR 416.13(c). 

(b) (6)
(b) (6) (b) (6)

(b) (6) (b) (4)

(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1800084 

517N-1 

08/17/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 08/16/2012 at approximately 1927 hours while monitoring Processing 

functions in the Packaging Department, I observed the following. A sanitation 

employee was washing stainless steel tanks in the area between the sorting & sizing 

lines and cooler #2. The washing was taking approximately 1-2 minutes per tank 

and no soap or sanitizer was being used. I looked inside the tanks which had up to 

approximately 50 pierces of giblets, necks, soaker pads plus pink to brown fluids 

from the previous days production. The tanks were then covered with blue plastic 

in preparation to being placed in the Plant #2 cooler. The blue plastic cover is used 

by the establishment as a marking system that identifies the tank as clean and 

ready for use. The tanks are used during production to store WOG's for rotisserie 

and to store excess birds exiting the chilling system. I placed USDA rejected tags on 

tanks 33-L,56, 83-L, L28, and on one tank without a number. I contacted 

and discussed him my findings. A review of the establishments' SSOP for 

pre-Operational Sanitation Wet Clean-Up (food contact surfaces) under Clean: 

states 

The employee was only using a 

high pressure rinse at approximately degrees, no soap and was 

doing no scrubbing. Soap was applied and the tanks were recleaned by 

approximately 0740 hours. When asked if the bottoms and wheels of the tanks 

would be cleaned only has the wheels & tank bottoms cleaned 

on the weekends. My findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 

416.4(a), 9 CFR 416.13(c), and 9 CFR 416.14. 

5333 P7632 HYE590208 

1616N-1 

08/16/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C While performing my pre operational sanitation inspection at 23:56 in second 

processing I observed the the following non compliances: Auto loader #1 manual 

feeder had 1/2 to 1 inch pieces of fat along the entire length of the belt. Three tub 

stands in between the stand and the production line had 1 inch pieces of fat and 

along the floor under the production line also had several pieces of fat . At the 

rotisserie packing belt and packing station I observed 1/2 to 1 inch pieces of fat in 

the chutes and the belts. Regulatory control of the area was taken with application 

of US Retain tag # B38495193 I informed of 

the non compliance. Regulatory control of the area was released at 00:13 once 

sanitary conditions were restored. 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6)

(b) (7)(C)

(b) (4) (b) (4) (b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0409085 

215N-1 

08/15/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C On 08/15/2012 at approximately 0345 hours while performing a Zero Tolerance 

check in Plant #1 on Line #2, I observed the following. After taking a random 10 bird 

sample, I observed one bird with visible fecal contamination. The fecal material was 

inside on the left side of the carcass in the area where the leaf fat is located. The leaf 

fat had been removed. The fecal material was approximately 1/4" by 1/8" in size, 

olive green in color and pasty in texture. This exceeded the limit of Zero Tolerance 

for the process to be in control. I contacted who 

implemented the establishments' Protocol for Fecal Failure. A QC recheck passed at 

0412 hours. My findings indicated a noncompliance with 9 CFR 381.65(e), 9 CFR 

417.2(c)(4), and the critical limit of CCP-2B of the 

Plants HACCP Plan for Slaughter . 

5308 M6137 BXL3316080 

015N-1 

08/15/2012 01D01 SPS Verification C At approximately 1110 hours while walking through the Plant #1 Packaging Rehang 

area I observed the following noncompliance. The drip pan directly over the end of 

the sizing lines where the carcasses are tanked was covered in heavy condensation 

that was dripping and running down the length of the drip pan. The long drip pan 

on the opposite side that is over the end of the sizing lines where the samples are 

taken and extends to the cabinet had condensation running then entire 

length. The drip pan that runs from the end of Chiller #1 and extends to the 

cabinet was covered in heavy dripping condensation, tanked product is passed 

under this drip pan to be dumped for rehang. I immediately informed

 the noncompliance. had a sanitation 

employee wipe down the drip pans restoring sanitary conditions by 1125 hours. My 

findings indicate a noncompliance with 9CFR 416.1, 9CFR 416.2(d) and 9CFR 

416.4(b). 

5333 P7632 HYE180108 

5315N-1 

08/15/2012 01D01 SPS Verification C On the morning of 8/14/2012 at approximately 605 hours, food inspector 

, who was on station #4, line one, informed me about her observation of the 

trimmers' knife sharpener. She noticed that the knife sharpener was rusty and had 

brown foreign material. I immediately rejected the knife sharpener and continued 

on to check all of the knife sharpeners at all of the stations. At station #1, line one, I 

found that the knife sharpener was also rusted. I showed the rusty sharpeners to 

Mr. , and informed him of the forthcoming 

NR. Mr. stated that he will discard the rusty sharpeners and replaces them 

with new ones. Upon review of the establishment operational sanitation log 

records, the last check for step #3 before my finding was 0558 hours: All relevant 

SSOP’s performed? The answer was: Yes. All Sanitation Requerment’s met? The 

answer was: Yes. The Requirements of 9 CFR 416.1, 416.4(b) and Plant’s written 

SSOP were not met. Plant’s written SSOP part II Operational page1 step #3 states: 

(b) (6)
(b) (6)

(b) (6)

(b) (6)

(b) (6)

(b) (6)

(b) (4)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE491508 

4715N-1 

08/15/2012 04A06 Poultry Finished 

Product Standards 

C After observing a high percentage of birds presented for post-mortem inspection 

were being hung back on the Reprocessing line for pathology the establishment 

initiated their alternative On-Line Vacuuming/Air-Sac Removal Procedure. I elected 

to verify the effectiveness of the alternative procedure by selecting a ten bird 

sample from Evisceration Line One. I observed airsacculitis exudate adhering to the 

leaf fat, renal areas and thoracic cavities to two of the ten bird sample. I notified

 of my findings and at 1107 hours I performed the 

required recheck. I observed one of the ten bird sample to have airsacculitis 

exudates adhering to the thoracic cavity of the bird and notified 

of the forthcoming documentation of the failure to comply with the 

regulatory requirements cited above. 

5309 P6137A NJN440708 

4114N-1 

08/14/2012 04A06 Poultry Finished 

Product Standards 

C I was performing a FPS ( Finished Products Standards ) check at 0515 hours on the 

reprocessing line in the evisceration department when I observed the following 

noncompliance; The establishment failed to remove airsacculitis exudate from 

carcasses identified by USDA for air sac removal. (4) carcasses of the (10) carcass 

sample identified for air sac removal with a split tail contained air sac exudates. The 

establishments written procedure for air sac states " 

l ". The procedure also states; "

 ". I initiated regulatory control by stopping the reprocessing line 

and immediately informed Mr. and Ms. 

of the forthcoming noncompliance. 

5308 M6137 BXL5117082 

613N-1 

08/13/2012 01D01 SPS Verification C At approximately 1115 hours while walking through the Packaging Paw Room 

located next to the loading dock I observed the following noncompliance. I observed 

several flies on walls and pipes in the room, I proceeded further to the small 

adjacent room where waxed boxes are put together and blue plastic liners are 

inserted and stored for use in the Paw Room to package product. There I observed 

approximately 13 more flies on the ceiling, walls and pipes throughout the room. I 

immediately informed the lead person and of the 

noncompliance. My findings indicate a noncompliance with 9CFR 416.1 and 9CFR 

416.2(a). 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1809081 

111N-1 

08/11/2012 04A06 Poultry Finished 

Product Standards 

C On 08/11/2012 at approximately 0553 hours while performing a HACCP Slaughter 

check on Line in Plant #2, I observed the following. After taking a random 10 bird 

sample, I observed two birds with split tails and visible Airsacculitis exudates. The 

establishments' marking system has the tails split on carcasses identified as 

needing vacuuming for whatever reason. I contacted who 

was nearby and showed him my findings. I informed him that I would be doing a 

recheck. A recheck at approximately 0559 had 2 of 10 carcasses with split tails and 

visible Airsacculitis exudates. immediately started tanking 

Line product. A recheck at 0613 hours brought the process back into control. The 

tanked product was reworked and released by approximately 0625 hours. My 

findings indicated a noncompliance with 9 CFR 381.84. 

5308 M6137 BXL3008083 

611N-1 

08/11/2012 03J02 Slaughter HACCP C On 8/11/12 approximately 0547 hours I observed the following while preforming 

the Finished Product Standards Post-Chill Task in Plant # 1 on the # 2 Chiller .Taking 

a ten bird sample I observed one bird with a attached cloaca and a dangling 

intestine Approximately 1’ in length .There was a 1/8 “ by 1/8” light brown spot of 

feces . The affected area was approximately 2” below the opening cut and was 

watery in texture . was notified at once . Once the spot 

was confirmed to be fecal the establishments Post Chill Fecal Failure protocol was 

implemented by the QC . Two tanks of birds were retained for re-work while a 

recheck was preformed .The recheck passed at approximately 0558 . Chiller # 2 was 

monitored for approximately the next 60 minutes .My findings indicate 

non-compliances with the following regulations 9CFR 416.2(c)(4) and 9CFR 

318.65(e) also the critical limits of CCP-2B and the of 

the Establishments’ Haccp Plan for Slaughter . 

(b) (6)
(b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0804082 

409N-1 

08/09/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 08/08/2012 at approximately 2220 hours while monitoring the Establishments' 

Pre-Operational Sanitation procedures in Plant #2 after SSOP and HACCP monitors 

completed their inspections, I observed the following. There were numerous specks 

and flakes of black UFM (Unidentified Foreign Material ) to approximately 1/8", and 

a thick coating of pasty fat and tissue on the kick out and support brackets that 

drop birds onto a belt at the end of line . Line is used to recondition 

contaminated and diseased birds. There were also numerous specks and flakes of 

black UFM of a similar size on the flex belt and stainless supporting brackets at that 

location. The flex belt transports reconditioned birds to chiller #3 or #4. There was a 

large amount of black UFM on the top and sides of the white sprocket that holds 

the line shackles while the bird is removed. There were numerous specks and flakes 

of black UFM to approximately 1/4" also on the associated drip pans at the same 

location. There was a thin layer of dried and semi-dried fat, tissue, black UFM and 

feathers on the guide bars associated with the unit. The area was cleaned with 

green pads, brown paper towels and rinsed with then released by 

approximately 2240 hours. My findings indicated a noncompliance with 9 CFR 

416.1, 9 CFR 416.4(a) & (b), 9 CFR 416.13(c), and 9 CFR 416.14. 

(b) (6)
(b) (6)

(b) (6)

(b) (7)(C) (b) (7)(C)

(b) (6)

(b) (4)

(b) (4)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE561708 

5809N-1 

08/09/2012 03C02 Raw Intact HACCP C While performing the Review and observation component of a SPS PHIS task; CSI,

 and I, CSI, , observed approximately 7 carcasses that 

were over the Segment Line Rehang Belts located at the Rehang area and the North 

Chiller Exit. As part of the SIP Waiver that was granted to the establishment, we 

decided to take the temperature on the carcasses. We requested to 

, to take the temperature with her calibrated 

thermometer #51. Two carcasses registered their internal temperature at 62.8 F 

and 61.4 F. The finding of temperatures above degrees F does not comply with 

the SIP waiver granted to the establishment by USDA/FSIS. The SIP protocol using 

the alternative chilling procedures in place of 9 CFR 381.66(b), states, 

Mr. informed us that according to a training 

document, the employees responsible for this task are to condemn any left over 

carcasses during the lunch time clean up. We requested to see the training 

document, and we noticed that it states, “ 

”. We also reviewed a 

deviation report generated in response to NR#HYE4415085406N / 1(carcass found 

with temperature over F at the rehang area). The preventive measures proffered 

by the establishment were: “Training will be conducted for employees that stay 

over at lunch time for wash down to remove all birds or iced product left on the 

processing floor”. The establishment failed to implement the preventive measures 

that were set to prevent product to be neglected and the internal temperature to 

rise over the parameters set in the SIP waiver. By not implementing its preventive 

measures, the establishment failed to meet the regulatory requirements of 9 CFR 

417.3(a)(3). The establishment elected to condemn the affected product. Mr. 

, was informed of the forthcoming 

documentation for the failure to comply with the establishment’s SIP program and 

the regulatory requirements cited above. 

(b) (6)
(b) (6)

(b) (6)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2603082 

808N-1 

08/08/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 08/07/2012 at approximately 2205 hours while monitoring the establishments' 

Pre-Operational Sanitation procedures in Plant #2 after SSOP and HACCP monitors 

completed their inspections, I observed the following. There is a light gray paint like 

material peeling and flaking from the ceiling above the Scalder for line . The flakes 

are up to approximately 2" by 1`" and cover an area approximately 15 feet by 20 

feet on the kill line side of the Scalder. The prewash cabinet for the bird 

washer on line was still coated with fat and feathers from the previous days 

production. The hang back racks at the final trim station for line had numerous 

pieces of fat and tissue to approximately 1/4" on the product contact surfaces. The 

guide bar at the final trim station for line 4B had a heavy coating of black UFM 

(Unidentified Foreign Material). Sanitary conditions were restored by approximately 

2230 hours. The ceiling above the Scalder will be addressed later. My findings 

indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.4(a) & (b), and 9 CFR 

416.13(c). 

5308 M6137 BXL3103081 

008N-1 

08/08/2012 01D01 SPS Verification C On 07/20/2012 at approximately 1935 hours while monitoring corrective actions 

for a Pre-Operational Sanitation issue in Plant #1, I observed the following. In the 

Plant #1 Cooler there was condensation spraying from the center refrigeration unit. 

The spray was condensing on the ceiling, pipes adjacent to the ceiling, and being 

blown out approximately 30 feet onto tanks of covered product. Production was in 

progress so bins of finished product passing through the area from the scale to the 

Staging Cooler for shipping could be contaminated by the spraying condensates. 

The bins of product were wrapped in plastic but any condensation that gets into the 

bin will be added to the product during dumping. Additionally, the defrosting 

condensation was leaking from the front of the unit and dripping onto two pallets 

of salvaged parts in brown product tubs located under the unit. The parts in the 

tubs and bins have already received their final microbial intervention. Again any 

moisture that collects on the product tubs can be added to the product during 

handling and dumping. I showed my findings. I stopped the flow 

of bins through the area until the refrigeration unit was turned off. I got a ladder 

and inspected the refrigeration unit. There was a layer of black UFM (Unidentified 

Foreign Material) on the fan blades. The defrosting condensation was not collecting 

in the units collection tray but was instead dripping from the stainless steel flashing 

under the fan. Nine plastics were replaced on the tanks in front of the unit. Two 

pallets of salvaged parts were moved and the 12 lids on the tubs were replaced. My 

findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.2(b)(1), and 9 CFR 

416.2(d). 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6)

(b) (6)

(b) (6)(b) (6) (b) (4) (b) (4) (b) (4) (b) (4)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4712080 

206N-1 

08/06/2012 06D02 Other Inspection 

Requirements 

C While performing a Finish Product Standard verification check on line plant 2, I 

found a noncompliance wit regulatory requirement of regulations 9 CFR 381.91(b) 

and 381.76(b). At approximately 0840 hours, I randomly removed a 10 bird sample 

from the reprocessing line in plant 2. I found one out of ten birds contaminated 

with a piece of visible ingesta measuring approximately 1/8" and also one our of 

ten birds affected with cellulitis. The cellulitis was located by the leaf fat area 

measuring approximately 1/4". I notified of my findings. 

The line was full of birds with one final trimmer at the end of the line at BPM line 

speed. At approximately 0845 hours, I proceeded to perform a recheck finding 1/10 

birds affected with several small pieces of ingesta on the breast by the neck area, 

each measuring approximately 1/16". At this point the process was deemed to be 

out of control. I gave the contaminated carcass to and notified 

her of the noncompliance. took corrective action by 

stopping the line, reducing line speed to BPM and tanking off product. At 

approximately 0857QC performed a passing recheck putting the process back in 

control. Retained product was put on hold by Quality Control, reworked by 

production, rechecked and released by Quality Control. 

5333 P7632 HYE441508 

5406N-1 

08/06/2012 03C02 Raw Intact HACCP C While performing a post-chill Finish Product Standards check at the south chiller 

exit, at 1328 hours, I observed a whole body bird lodged between a wog line chute 

and the rail of the stand. I requested to take the 

temperature of the bird, with the calibrated and Q.C. verified thermometer #20. The 

temperature was 61.2 degrees F, I then retained the bird with the application of 

U.S. retain tag B38494923 and informed 

and of the forthcoming noncompliance. The bird 

was condemned by . Establishment P- 7632 

was granted a Salmonella Initiative Program Letter issued on September 2, 2011. 

The SIP program allows establishment P-7632 to use alternative chilling procedures 

in place of 9 CFR 381.66(b), provided the establishment: Assesses, modifies and 

validates as appropriate, the Hazard Analysis and Critical Control Point (Haccp) plan 

according to 9 CFR 381.22 and 417.4. The establishment failed to implement their 

SIP program by allowing their product internal temperature to rise above 

degrees. SIP protocol states: '' 

'' 

(b) (6)
(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3504081 

004N-1 

08/04/2012 04B04 General Labeling C On 08/03/2012 at approximately 2200 hours while monitoring the establishments' 

HACCP plans, prerequisite programs and supporting documents, I observed the 

following. The Retained Moisture Evaluation document dated 08/03/12 Plant #2 

from Chiller #3 PM shift at 0836 hours indicated a moisture gain of 10.16 %. The 

establishments procedure for Chiller Moisture Gain Monitoring dated February 3, 

2012 states under #2 Corrective Action ( a.) " 

" The 10.16% exceeded the acceptable percentage. There are no 

corrective action logs or recheck documents on file. The Dwell Time was not entered 

on the 0836 hour log so it is impossible to determine if the carcasses were held in 

the chiller for an extended period. However, other moisture evaluations 

documented on 08/03/12 documented dwell times from 85 to 99 minutes. I 

reviewed the Retained Moisture Evaluation logs for 1-4 August 2012 and found the 

following issues. On 08/02/2012 in Plant #2 from Chiller #4 on the AM shift at 0115 

hours the Retained Moisture Evaluation log indicated a moisture gain of 12.73%. On 

08/02/2012 AM shift at 0152 hours from chiller #4 the moisture gain was 

documented as 12.64%. On 08/02/2012 on the AM shift from Chiller #3 at 0613 

hours the moisture gain was documented as 11.24%. On 08/02/2012 in Plant #2 

AM shift from Chiller #4 at 0620 hours the moisture gain was documented as 

10.37%. On 08/03/2012 in Plant #2 from Chiller #3 PM shift at 1001 hours the 

moisture gain was documented as 10.16%. On 08/04/2012 AM shift at 0330 hours 

from Chiller #3 the moisture gain was documented as10.31%. On 08/04/2012 AM 

shift from Chiller #3 at 0543 hours the moisture gain was documented as 10.38%. 

On 08/04/2012 in Plant #1 from Chiller #1 on the AM shift at 0034 hours the 

moisture gain was documented as 10.39%. Again there were no corrective action 

logs or recheck documents on file. My findings indicated a noncompliance with 9 

CFR 381.1(b)(viii) and 9 CFR 441.10. 

(b) (6)
(b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2704082 

603N-1 

08/03/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 08/02/12 at approximately 2225 hours while monitoring the Establishments' 

Pre-Operational Sanitation Procedures in Plant #1 after SSOP and HACCP monitors 

completed their inspections, I observed the following. The paper towel dispenser at 

the end station (4) on line #1 and the lead station (5) on line #2 have large patches 

of black UFM (Unidentified Foreign Material) inside that appeared to be mold. An 

attempt to clean the dispensers was made, however a detailed cleaning will be 

conducted Saturday. The reuse water tank associated with Line #1 Inside/Outside 

bird washer had numerous pieces of fat and tissue to approximately 1/4" and a thin 

layer of white product grease measuring approximately 6" by 15 " on two sides 

near the bottom of the tank. There were numerous pieces of fat and tissue to 

approximately 1/4" inside the reuse water tank at the bird washer for line . The 

tanks were wiped with brown pater towels then rinsed with . There 

was also a thick layer of pasty fat and tissue on the guide bar also associated with 

the line bird washer. The bar was cleaned with a green scrub pad and rinsed. 

There were numerous pieces of black UFM to approximately 1/2" on the first 

paddle at the inflow side of chiller #1. There were also several large areas of dried 

and semi-dried fat and froth on the first six paddles of Chiller #1 at the same 

location on the side adjacent to Line #1. The accessible and reachable areas of the 

chiller paddles were cleaned with green pads and brown paper towels. The area was 

released at approximately 2245 hours. At approximately 2305 hours in Packaging 

Area #1, the Rotisserie Room, there were several pieces of fat to approximately 1" 

on the center gray product belt on the main line. There was also greasy white fat 

pooled in several locations on the incline belt. The belts were rinsed with potable 

water and released by approximately 2318 hours. At approximately 2345 hours 

there was a thick layer of black UFM on two flex belts in Plant #1 associated with 

the sorting & sizing line. The UFM was on the white nylon support brackets, on the 

internal belt surfaces and on the sprocket at one end of the each belt. A tank of 

disinfectant was brought from the main packaging area and the belts were 

recleaned. There were 5 stainless tanks staged in the area. The tanks were brought 

out of Plant #1 cooler by production personnel. The tanks were covered with blue 

plastic. The blue plastic is used by the establishment to identify tanks that are clean 

and ready for use. The tanks had numerous pieces of tissue to approximately 1/4", 

feathers to approximately 1", pieces of coagulated blood to approximately 1/4", 

and large areas of white greasy product fat from previous days use. The area was 

released by approximately 0015 hours. At approximately 0016 hours there was a 

layer of a medium brown slimy substance at least 1/8" thick on the base of the 

vertical door going from the Plant #1 cooler to the Packaging area. This is the main 

avenue that is used to transport product into and out of the cooler. The base of the 

door was cleaned and released by approximately 0030 hours. My findings indicated 

a noncompliance with 9 CFR 416.1, 9 CFR 416.4 (a) & (b), 9 CFR 416.13(c), and 9 

CFR 416.14. 

(b) (6)
(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0505080 

101N-1 

08/01/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 07/31/2012 at approximately 2230 hours while monitoring the Establishments' 

Preoperational Sanitation Procedures in Plant #1 and after Establishment SSOP and 

HACCP personnel completed their inspections, I observed the following. There were 

patches of dried and semi-dried pasty fat and tissue measuring up to approximately 

6" by 3" on the chute that guides the birds into chiller #1. There was also black UFM 

(Unidentified Foreign Material) that appeared to be mold ,and patches of 

dried/semi-dried fat and tissue measuring up to approximately 12" by 2" on the 

kickout and supporting brackets at that location. There were also large patches of 

dried and semi-dried fat and tissue on the first three paddles of chiller #1 at the 

carcass inflow side adjacent to line #1. The patches were up to several square feet in 

size. The first paddle also had several pieces of black UFM as well as pieces of 

coagulated blood to approximately 1/2" . Reachable and accessible areas were 

cleaned with green pads and brown paper towels. The area was released by 

approximately 2245 hours. At approximately 2355 hours in Packaging Area #1 there 

was a coating made of feathers fragments, fat and tissue on the stainless product 

contact surfaces of a pallet jack located near the edible dump room. There was 

dried/semi-dried pasty fat and tissue on the stainless brackets associated with the 

overhead belt adjacent to the crust tunnel. Approximately a 10 foot section of both 

lines were rinsed with per establishment policy. In Packaging Area #2, 

the Deboning Room, there were numerous pieces of fat and tissue to 

approximately 2" on a belt adjacent to line that collects skin from all lines. 

The belt has a white nylon divider that runs the length of the belt making it very 

difficult to clean. There were numerous pieces of fat and tissue to approximately 3" 

on the white product cones associated with lines There are numerous cones 

along lines that had dried and semi-dried pierces of fat and tissue to 1/2" 

imbedded in the cracks and scrapes, and adhering to the rough deteriorated 

surfaces . The condition of the cones makes the cleaning process very inefficient. 

My findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.2(b)(1), 9 CFR 

416.4(a), and 9 CFR 416.13(c). 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1816080 

801N-1 

08/01/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C While performing a zero tolerance fecal verification on line 1 Plant 1, I found a 

noncompliance with regulatory requirement of regulations 9CFR 381.65(e) and 

417.2(c)(4) At approximately 1400 hours, I randomly removed 10 birds from line 1 

plant 1 and performed a scheduled zero tolerance verification check. I found one 

out of ten birds contaminated with feces. The fecal material was inside of the bird 

cavity near the tail and kidney area. It was dark brown in color and pasty in texture 

measuring approximately 1/4" in diameter. I immediately notified 

and of the noncompliance. The establishment 

proceeded to implement the zero tolerance protocol as part of their immediate 

corrective action. Venter was established to be the cause of deviation. Maintenance 

adjusted the settings on the venter machine. Quality control performed a passing re 

check at 1432 hours, putting CCP 2B under control. Extra fecal checks were 

performed at the end of the line by . Post chill checks 

were performed at the chiller 1 exit from 1512 hours to 1612 hours. All product 

coming out of the chiller was found acceptable. Pre shipment review was sign and 

dated after all corrective actions had taken place. 

5308 M6137 BXL1308075 

031N-1 

07/31/2012 03J02 Slaughter HACCP C On 07/31/2012 at approximately 0539 hours while monitoring the Establishments' 

Post-Chill Finished Products Standards in Plant #1 from Chiller #1, I observed the 

following. After taking a random 10 bird sample, I observed one bird with visible 

fecal contamination. There was a cloacae with approximately 6" of intestine 

attached. The intestine was attached to the carcass near the base of the left side 

leaf fat. The fecal material was located inside the carcass on the left side leaf fat. The 

fecal material was a smear approximately 3/4" by 3/8", medium brown in color and 

pasty in texture. This exceeded the limit of Zero Tolerance for the process to be in 

control. There were no supervisors immediately available so I directed the 

employees at the rehang station for birds going into Packaging to stop hanging 

carcasses. I had a lead person nearby tank the carcasses coming from Chiller #1.

 and arrived and I showed 

them my findings. A QC recheck passed at 0545 hours. Two and one-half tanks of 

carcasses coming out of chiller were placed under USDA hold. My findings indicated 

a noncompliance with 9 CFR 417.2(c)(4), 9 CFR 381.65(e), and the critical limit of 

CCP-2B of the Plants HACCP Plan for Slaughter. 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5820072 

730N-1 

07/30/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C While performing Pre Operational Sanitation in plant 1, I observed two 

noncompliances. At approximately 700 hours while inspecting plant 1, area 3, unit 

15 (Eviscerator and viscera shackle washer), I noticed a layer of thick white and gray 

recidue building up on the white plastic brackets suround the unit. I notified 

the non compliance and proceeded to place a US. tag N0 B31 

407656 on the affected equipment. Sanitation employees cleaned the equipment 

and made it acceptable. Unit 15 was released to production at approximatelly 0720 

hours. This is a noncompliance with regulatory requirement of regulation 9 CFR 

416.4(b). On Monday, at approximatelly 0710 hours, while inspecting area 5, unit 

21 (giblet chiller), I noticed half of a liver left from the previous production day on 

the bottom of the giblet chiller. It was light bown in color meassuring 

approximatelly a square inch. was notified of the 

noncompliance. Liver was immediately taken out by sanitation. Water in the giblet 

chiller was treated with as production started 

running. This is a noncompliance with regulatory requirement of regulation 9CFR 

416.4(a). 

5309 P6137A NJN301907 

2030N-1 

07/30/2012 01D01 SPS Verification C At approximately 1542 hours while conducting a verification procedure Sanitary 

Performance Standard (SPS) in the Packaging Department, by the Line I 

observed the following non compliance: Three flies on top of a liner covering a hard 

plastic bin that was half full of chicken thighs of product that was staged to be used. 

Two of the flies were dead and one was moving around. Regulatory Control of the 

bin was taken with the application of US Reject Tag #B39415805 and informed Mr. 

) and of the forthcoming non 

compliance. Regulatory control was released at approximately 1547 hours. Sanitary 

conditions were restored after the liner with the flies was removed carefully and 

was discarded. A clean liner was applied to cover the product. No product was 

affected. 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1009071 

228N-1 

07/28/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 7/27/12 at approximately 2354 hours I observed the following in the Packaging 

Area .The rehang area in Plant # 2 was inspected first .Upon inspecting the rehang 

area at end of Chiller # 4 I observed pieces of fat floating in the water in the drip 

pans behind the rehang table . Inspecting the chiller #3 area I found pieces of fat on 

the lower portoin of the flex conveyor that tranfers product to the sizing lines . 

was notified immediately had the drip pans and the 

flex conveyor belt rinsed thourghly . At approximately 0006 the the area was re 

-inspected .Sanitary conditions were restored and the area was released for 

production . At approximately 0009 hours the Leg Processors were inspected . The 

large white sprocket that is used to sperate the drum from the leg had a large piece 

of fat lodged in the center grove . The piece of fat was approximately 2” by 3” in size 

. was notified immediately . had the piece of fat removed by 

one of his employees .At approximately 0014 sanitary conditions were restored and 

the leg processor was ready for production . At appropriately 0016 Line was 

inspected .Line is a flex conveyor that transfers trays to be packed with 

product . The flex conveyor had pieces of fat on the top side of the belt ,the guide 

bars and under the conveyor belt , the outer casing of the conveyor also had debris 

and pieces of fat on it . was once again contacted . He had two of 

his men re-rinse the entire line thourghly . At 0029 Line was re-inspected and 

found to be in sanitary condition and Line was ready for production . At 0031 

the Room was inspected .The Tender Transfer Line had pieces of fat on it and 

also in the drip pan underneath the flex conveyor . was notified of 

my findings immediately . had one of his workers rinse the flex conveyor and 

the drip pan underneath . At 0037 the Tender Transfer conveyor line was 

re-inspected and found to be in sanitary condition . My findings indicate 

noncompliances with the following regulations 9CFR 416.13(a) ,9CFR 416.13(c) 

,9CFR 416.16(a) ,9CFR 416.1 , 416.4(a) and 416.4(b) . 

5333 P7632 HYE051407 

5628N-1 

07/28/2012 04A06 Poultry Finished 

Product Standards 

C I was performing a Finished Product Standards verification task in the cooler, at 

1122 hours, on the staged salvaged parts after all plant interventions were 

implemented when I observed the following noncompliance. In one of the salvage 

tubs I observed cellulitis exudate in between the skin of a chicken leg and the 

muscle. I then took regulatory control of the salvage tub with the application of U.S. 

retain tag B38495157 and informed of my 

findings. were also 

shown the affected product and notified of the noncompliance. Mr. 

proffered corrective actions that the product would be reconditioned at the product 

wash station and for a preventive measure a training would be conducted with the 

employees involved. I released the product at approximately 1200 after I 

reinspected it to confirm sanitary conditions were restored and the wholesomness 

of the product. 

(b) (6)
(b) (6) (b) (6) (b) (6)

(b) (6) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE531107 

0628N-1 

07/28/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 0900 hours while performing the Review and Observation 

component of an Operational Sanitation PHIS task, the following noncompliance 

was noted: At the North Chiller Exit, I noticed a combo bin with a new liner which 

appeared to be ready to be loaded with edible product. Upon closer investigation, I 

noticed that beaded condensation was formed underneath a white pipe that was 

located right above the combo bin. When I was inspecting the combo bin, I noticed 

that condensation was dripping on the liner, which is edible product contact 

surface. I showed the deficiency to 

and , and inquired in what was the 

intended use for the combo bin, and they replied to me that in case of a 

breakdown, they would be able to load it with carcasses to prevent pile ups of 

product on the floor. For immediate corrective action, the establishment removed 

the combo bin away from the area and replaced the dirty liner with a clean liner. By 

allowing condensation on direct product contact surface, the establishment failed 

to meet the regulatory requirements of 9 CFR 416.1 which states, “Each official 

establishment must be operated and maintained in a manner sufficient to prevent 

the creation of insanitary conditions and to ensure that product is not adulterated”. 

9 CFR 416.3(a) states,”... Equipment and utensils must be maintained in sanitary 

condition so as not to adulterate product”. 9 CFR 416.4(a) states, “All food-contact 

surfaces, including food-contact surfaces of utensils and equipment, must be 

cleaned and sanitized as frequently as necessary to prevent the creation of 

insanitary conditions and the adulteration of product”. 9 CFR 416.4(b) states, 

“Non-food-contact surfaces of facilities, equipment, and utensils used in the 

operation of the establishment must be cleaned and sanitized as frequently as 

necessary to prevent the creation of insanitary conditions and the adulteration of 

product”. 9 CFR 416.13(c) states, “Each official establishment shall monitor daily 

the implementation of the procedures in the Sanitation SOP's”. Upon reviewing the 

SSOP Daily Implementation Monitor Log from night shift, I noted that the last 

acceptable check for condensation (Step#6: 

) was at 

0832 hours and for day shift no checks were performed previous to the 

noncompliance. and 

, were informed of the forthcoming documentation for the 

failure to comply with the regulatory requirements cited above. 

(b) (6)
(b) (6) (b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6) (b) (7)(C) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0909072 

527N-1 

07/27/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C On 07/27/2012 at approximately 0553 hours while monitoring Finished Products 

Standards in Plant #2, I observed the following. After removing a 10 bird random 

sample from line , I observed one bird with visible fecal contamination. There was 

a gizzard with approximately 5" of intestine attached. The fecal material was leaking 

from the end of the intestine into the area of the kidneys. The fecal material was 

medium yellow in color, pasty in texture and approximately 1/4" in size. This 

exceeded the Zero Tolerance limit for the process to be in control. I contacted

 who implemented the protocol for fecal failure. A recheck at 0521 

passed. My findings indicated a noncompliance with 9 CFR 417.2(c)(4), and 9 CFR 

381.65(e), and the critical limit of CCP-2B of the 

Plants HACCP Plan for Slaughter. 

5308 M6137 BXL4604071 

327N-1 

07/27/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 7/26/12 at approximately 2216 hours I observed the following while preforming 

the Pre-Operational Review and Observation Task in Plant #1 . Inspecting the breast 

plates on the Vent Opener on line # 1 after the Quality Control inspection I found 

approximately 1⁄2 dozen breast plates with white grease from the previous shifts 

production . US Retained/Rejected tag B31 407675 was applied the the area . My 

findings were brought to the attention of and 

who were both standing near . Both and began scouring 

the affected areas . Once the breast plates were cleaned and rinsed they were 

reinspected . At approximately 2223 hours sanitary conditions were restored and 

the Vent Opener was ready for production . These noncompliances were a violation 

of the following regulations 9CFR 416.13(a) , 9CFR 416.1 ,9CFR 416.13 (c) and 9CFR 

416.14 . 

5309 P6137A NJN230307 

2327N-1 

07/27/2012 04C05 Poultry Good 

Commercial 

Practices 

C At 0015 hrs on 7/27/12 Inspector called me to station 3 on B line 

to examine a bird he had hung back on the USDA rack. I diagnosed it as a DOA based 

on the following signs: 1. Carcass purple in color on dorsal surface, pale on ventral 

surface. 2. Decomposition of back muscle tissue. 3. Congestion and degeneration of 

kidneys and liver; remaining viscera had not been presented for inspection. 4 Foul 

odor. This is a violation of regulation 9CFR 381.71(a). I immediately informed

 of the forthcoming NR. 

(b) (6)
(b) (6) (b) (6)

(b) (6)

(b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2105074 

726N-1 

07/26/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 07/26/2012 at approximately 0125 hours while monitoring Packaging 

Department processes, I observed the following. There were several gizzards on the 

rehang belt for line with varying amounts of ingesta on the internal and external 

surfaces, and several had partial stomachs attached. One of the gizzards had a piece 

of intestine attached with light brown pasty fecal material inside. The belt had 

Organic carcasses on it at the time. Organic carcasses at this point in the processes 

have already received final microbial intervention. I contacted and 

showed him my findings. Hanging was stopped. The carcasses on the belt were 

tanked. The line was rinsed with and returned to production by 

approximately 0135 hours. There were approximately 35 gizzards on the belt. The 

tanked birds were reconditioned and released by approximately 0220 hours. Two 

additional carcasses were found during reconditioning with intestines attached. A 

check of the establishments computer records revealed that a chlorine check at 

0119 hours in Packaging was at PPM total chlorine. The establishment does not 

monitor Free Available Chlorine at this location so it is unclear if the belt rinse and 

product reconditioning had any desirable affect. 

were informed. My findings indicated a noncompliance with 9 CFR 

416.1, 9 CFR 416.4(d), and 9 CFR 416.14. 

5308 M6137 BXL5016074 

926N-1 

07/26/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 0959 hours, while performing a Finished Product Standards 

procedure at Post Chill for Chiller #3 in Plant #2, I observered the following 

noncompliance. I observered multiple gizzards on the belt with the carcasses when I 

noticed some of them had pieces of intestine to 3" long still attached. One of the 

gizzards had approximaetly a 3" long piece of intestine attached was leaking fecal 

material on the belt with carcasses sliding around the belt. I immediately informed

 and of the noncomliance, they 

immediately took corrective actions by tanking off two tanks of carcasses to be 

reworked. I attached USDA retain tags #B31406758 and #B31406759 to the tanks 

of product. As the belt is continuously washed with after a few 

passes around the washer the belt was clean and sanititary with no fecal material 

visible. The carcasses were reprocessed and on reinspection I released the carcasses 

back to production. My findings indicate a noncompliance with 9CFR 416.4(a) and 

9CFR 416.4(d). 

(b) (6)
(b) (6)

(b) (6)

(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2909074 

425N-1 

07/25/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 07/25/2012 at approximately 0255 hours while monitoring Packaging 

Department processes, I observed the following. The exit conveyor belt from chiller 

#4 was emptying for the scheduled company break, I observed at least 25 gizzards 

going around on the belt. The gizzards had varying amounts of ingesta on the 

internal and external surfaces, and the inside of several gizzards also contained 

what appeared to be yellow digestive fluids. The gizzards were removed as part of 

cleanup. I proceeded to Line rehang belt where the retail grade birds from Chiller 

#4 are hung going into packaging for cutup. There were an additional 15 gizzards at 

that location. Several of the gizzards had partial stomachs attached and one gizzard 

had a piece of intestine attached. There was also a separate piece of intestine 

including the pancreas. The separate intestine was approximately 6" long and had 

light brown pasty fecal material leaking from two places. Concerned about fecal 

cross contamination, I had approximately 10 birds removed from the belt that were 

near the intestine. As there were no supervisors nearby, I contacted 

and showed him my findings. The line has a continuous chlorine rinse which 

upon checking the establishments computer showed a level of PPM total 

chlorine at 0114 hours. The establishment does not monitor Free Available Chlorine 

so it is unclear if the chlorine rinse has any desirable affects.

 were informed. My findings indicated a noncompliance with 9 CFR 416.1, 9 

CFR 416.4(d), and 9 CFR 416.14. 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE172007 

5125N-1 

07/25/2012 01D01 SPS Verification C At approximately 1735 hours while performing the Review and Observation 

component of an Operational Sanitation PHIS task, I observed a sanitation 

employee washing down hearts, livers and gizzards that were piled up on the floor 

underneath the giblet chiller exit. While he was washing the floor, a combo bin filled 

up with whole carcasses that was staged approximately 6 feet away from the chiller 

exit was getting overspray on the outside of the plastic liner, I also noticed a pile of 

hearts and livers underneath the combo bin in between the pallet’s frame. I took 

regulatory control action by applying Retain Tag# B38495154 to the combo bin. 

Although, the product in the combo bin was not affected, an insanitary condition 

was created by over spraying with dirty water a container with edible product. The 

establishment failed to meet the regulatory requirements of 9 CFR 416.1 which 

states, “Each official establishment must be operated and maintained in a manner 

sufficient to prevent the creation of insanitary conditions and to ensure that 

product is not adulterated”. 9 CFR 416.4(b) states,“Non-food-contact surfaces of 

facilities, equipment, and utensils used in the operation of the establishment must 

be cleaned and sanitized as frequently as necessary to prevent the creation of 

insanitary conditions and the adulteration of product”. 9 CFR 416.4(d) states, 

“Product must be protected from adulteration during processing, handling, storage, 

loading, and unloading at and during transportation from official establishments”. 

The establishment switched the product to a clean combo bin as immediate 

corrective action to prevent the adulteration of product. After verifying that the 

carcasses were not cross-contaminated, the regulatory control was withdrawn at 

1750 hours. , and 

, were informed of the forthcoming documentation for the 

failure to comply with the regulatory requirements cited above. 

5308 M6137 BXL0218072 

324N-1 

07/24/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1510 hours while walking through the Packaging area I observed 

the following noncompliance. The drip pan at the end of the Breast Fillet Pack Out 

Line had a large area of heavy beaded condensation that was dripping on the blue 

transfer belt that takes the breast fillets to the line. The breast fillets were falling on 

one side of the blue transfer belt and the condensation was dripping on the 

oppostie side so no product was contaminated at the time. The blue transfer belt is 

continuously washed with chlorintaed water as it goes around maintaining sanitary 

conditions after one time around. I immediately notified and

 of the noncompiance.They immediately took corrective action 

by covering the line with blue plastic to protect the product from being 

contaminated. The condensation was cleaned restoring sanitary conditions by 

approximately 1525 hours. My findings indicate a noncompliance with 9CFR 

416.2(d) and 9CFR 416.4(a). 

(b) (6)
(b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4)

(b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4604073 

524N-1 

07/24/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 07/24/2012 at approximately 0055 hours while monitoring the Establishments' 

processing procedures in Packaging, I observed the following. There were dark gray 

specks and flakes to approximately 1/4" on the carcasses on the Organic bag fryer 

line I removed 5 affected birds from the line and showed them to 

The UFM (Unidentified Foreign Material) was on the birds saddle area, 

backs, and hock. There was also numerous pieces on the tray between the giblet 

storage areas where unacceptable giblets are discarded. The neck area of the 

carcasses in the packaging process drag through this discarded material. There were 

also numerous pieces on the carousel at the end of the line where the packaged 

product collects. The line was stopped. Birds were removed from the front of the 

line. The line was washed. Three racks of finished wrapped product were retained 

for inspection and reconditioning as necessary. The line was restarted at 

approximately 0105 hours. As specks of UFM were still showing up on the 

carcasses, an employee was places at the front of the line to remove affected birds. 

Birds should be processed in a sanitary manner using good commercial practices. 

My findings indicated a noncompliance with 9 CFR 416.1 and 9 CFR 416.4(d). 

5309 P6137A NJN571307 

3724N-1 

07/24/2012 01C02 Operational SSOP 

Review and 

Observation 

C While conducting an Operational Sanitation Procedure in the Fillet Department at 

approximately 0924 hours, I observed the following non compliance: A pile of rib 

cages on the floor (approximately 30 to 40 pieces) underneath Cone Lines and 

. Upon closer observation I observed another pile of rib cages on the floor half 

way down line That pile was so high that it was coming in contact with the 

return cones as they passed by and nobody was taking action. Another pile of the 

same kind of product was observed at the end of the line. Regulatory control of the 

line was taken with the application of US Reject Tag #B38495138 and informed Ms.

 and of the non 

compliance of the failure to protect product from adulteration during processing as 

stated in regulation 9 CFR 416.4(d). Regulatory control of the line was released at 

approximately 0935 after sanitary conditions were restored, product on the floor 

was condemned (one and a half barrels of product) and maintenance adjusted the 

rubber fingers at the end of line as preventive measures. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0521075 

023N-1 

07/23/2012 01C02 Operational SSOP 

Review and 

Observation 

C While monitoring the Establishments' Operational Sanitation Procedures, I 

observed the following noncompliance with regulation 9 CFR 416.4 (d). At 

approximately 1834 hours, I observed along the west wall of the Plant #1 cooler, 

two brown tubs full of drums. These tubs had the lids only covering part of the tub. 

There were numerous black specks of UFM (unidentifiable foreign material) on the 

top of the lids. I inspected the product and I found UFM on the drums also. I 

immediately attached a U.S. Retained/Rejected Tag # B31 406258 to the tubs and 

Informed of the noncompliance. elected 

to condemn the product in the tubs. I removed my tag at approximately 1840 

hours and observed the product being condemned and the tubs were sent to the 

tub wash room. 

5308 M6137 BXL4508074 

421N-1 

07/21/2012 03J02 Slaughter HACCP C On 07/21/2012 at approximately 0540 hours while monitoring the Establishments' 

Post-Chill Finished Products Standards from Chiller #1 in Plant #1, I observed the 

following. After taking a random 10 bird sample, I observed one bird with visible 

fecal contamination. There was a cloacae attached just inside the carcass at the tail 

with approximately 3" of intestine. The fecal material was located inside the carcass 

on the left side kidney area and on the left side adjacent to the keel bone. The fecal 

material at both locations was approximately 1/2" by 1/8", dark green in color and 

pasty in texture. This exceeded the limit of Zero Tolerance for the process to be in 

control. There were no supervisors immediately available so I directed the 

employees at the rehang station for birds going into packaging to stop hanging 

carcasses. A lead person nearby started to tank the carcasses coming from the 

chiller. I performed a recheck that passed at approximately 0551 hours. Two tanks 

of carcasses were placed under US Retained tags which were replaced by 

Establishment QC hold tags for rework. and

 arrived and I showed them my findings. My findings indicated a 

noncompliance with 9 CFR 417.2(c)(4), 9 CFR 318.65(e), and the critical limit of 

CCP-2B of the Plants HACCP Plan for Slaughter. 

(b) (6)
(b) (6) (b) (4)

(b) (4)

(b) (4)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5522074 

620N-1 

07/20/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 07/20/2012 at approximately 1915 hours while monitoring production 

processes in Plant #1, I observed the following. A sanitation employee was washing 

stainless steel tanks in the reprocessing room (Line . The washing was taking less 

than a minute per tank and no soap or sanitizer was being used. I looked inside the 

tanks which had varying amounts of fat, tissue, giblets, necks and pink fluids from 

previous days of production. The tanks were being covered with blue plastic and 

placed into the Plant #1 cooler. The blue plastic cover is used by the establishment 

as a marking system that identifies the tank as clean and ready for use. The tanks 

are used during production to store ice and WOGS for rotisserie, for parts collected 

and shipped for MDP, and for parts that are disposed of in the edible dump room. I 

placed U.S. Rejected tags on the tanks labeled N-20,58-l, #112, and #11. A review of 

the establishments' SSOP for Pre-Operational Sanitation Wet Clean-Up (food 

contact surfaces) under Clean: states " 

. The employee was only using a high pressure rinse. I 

contacted and showed him my findings. An available portable 

dispenser of sanitizer was brought from the main packaging area to used on the 

tanks. I tipped the first tank over after cleaning. The wheels on the tank were still 

coated with fat and tissue, and the bottom of the tank was covered with black UFM 

(Unidentified Foreign Material) that appeared to be mold. Sanitary conditions were 

restored by approximately 2000 hours. The tanks are in continuous use so they are 

seldom empty and available for cleaning using the SSOP Pre-Operational procedure 

as ice and WOG's are refilled throughout the shifts and filled at the end of the 

second shift for the next days use. A review of the Establishments SSOP shows that 

there is no reference made to Less Than Daily cleaning procedures Per FSIS Dir 

5000.5 Verification of Less than Daily (Ltd) Sanitation Procedures in Processing 

Operations. The Establishments' SSOP under Operational Sanitation states 

" 

." During the shift I observed the tanks in 

use in Plant #1. The tanks when emptied are only rinsed with by 

the ice house employee before being refilled with ice. The tanks used for WOG's in 

Rotisserie are refilled repeatedly without a rinse. The tanks in the Edible Dump 

Room are again simple rinsed for less than a minute with water that registered on a 

company calibrated thermometer at approximately 140'F. The Edible Dump Room 

is not maintained as a product contact surface. My findings indicated a 

noncompliance with 9 CFR 416.1, 9 CFR 416.4a, 9 CFR 416.12(a), 9 CFR 

416.13(a) & (c), and 9 CFR 416.14. 

(b) (6)
(b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0209073 

319N-1 

07/19/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 7/18/12 at approximately 2219 hours while preforming the Preoperational 

Sanitation Procedure task in Plant # 2 I observed the following . In area # 3 

section # 1 there was a black build -up which appeared to be mold on the insulation 

surrounding the edges of the over head drip pan against the wall . The wash sink 

below the over head drip pan had a build-up of black scum in the right hand corner 

which appeared to have been there for awhile . The bottom and back portion of the 

soap dispenser had a build-up of grease . USDA Retained/Rejected tag B 31 407604 

was applied to the area . I immediately informed who had 

one of his workers hose the build-up off the insulation and clean the bottom and 

back of the soap dispenser . The area was reinspected and found to be in sanitary 

condition . At approximately 2232 the area was released for production . My 

findings indicate noncompliances with the following regulations 9CFR 416.1 , 9CFR 

416.4(b) ,9CFR 416.13(a) , 9CFR 416.13(c) and 9CFR 416.14 . 

(b) (6)
(b) (6)(b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1009074 

719N-1 

07/19/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 07/18/2012 at approximately 2225 hours while monitoring the Establishments' 

Preoperational Sanitation Procedures after QC and SSOP inspections were 

completed, I observed the following. In Plant #1 there was pasty fat and tissue, and 

black UFM (Unidentified Foreign Material) that appeared to be mold on the 

bottoms of two support brackets on the inside half at the out flow end of Chiller #1. 

There were several pieces of black UFM (Unidentified Foreign Material) with the 

consistency of blackened dust on the top of the chiller paddle at the same location. 

I proceeded to the opposite side of chiller #1 to the out flow end. Near the ceiling 

there is a large fan. The screen on the front of the fan is coated with a similar 

looking black dust like substance. The issue was discussed with . 

The fan screen will be cleaned after production. The reachable areas of the chiller 

were cleaned by approximately 2240 hours using green scouring pads and brown 

paper towels. At approximately 2330 hours in Packaging Area #1 at the rehang area 

from Plant #1 there was pasty fat on the inside surfaces along the entire length 

approximately 35 feet of the return belt that collects birds from the sorting & sizing 

line and delivers then back to the rehang belt. There were numerous pieces of fat 

and tissue to approximately 1/4" on a tray that guides carcasses from the sorting 

and sizing line to the cutup line belt. Soap was applied followed by a 

rinse to breakup the fat on the conveyor belt and sanitary conditions were restored 

by approximately 0000 hours. At approximately 2355 hours there were a few 

specks to approximately 1/8" of black UFM (Unidentified Foreign Material) along a 

small area on the product collection belts for leg processor #8. I proceeded to leg 

processor #8 where there were also several black specks of (UFM) on the white 

cutting wheels. Two black rubber hydraulic lines associated with the unit are 

severely deteriorated and when touched give off a similar black grease like 

substance. The hoses will be addressed by the mechanics. Sanitary conditions were 

restored by approximately 0008 hours. At approximately 0009 hours in Packaging 

Area #2 the Deboning Room along Line #1 there was fat and tissue to 

approximately 3" on the light blue belt and stainless/white nylon support brackets 

that collect the skin. Adjacent to Line #1 there were numerous pieces of fat and 

tissue to approximately 1/4" with a strong sour smell on a section of the belt that 

collects breast tenders for lines 1 . Also in the area of Line #1 there were 

numerous pieces of fat and tissue to approximately 1/4" on the belt used to 

remove the wing tips from all four lines. The areas were rinsed with 

per establishment procedure and released by approximately 0025 hours. 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (6) (b) (6)

(b) (6) (b) (6) (b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE221807 

3019N-1 

07/19/2012 01C02 Operational SSOP 

Review and 

Observation 

C On Wednesday July 11, 2012, at approximately 1435 hours, while I was performing 

Operational SSOP Review and observation in 2nd processing, I observed regulatory 

noncompliance with CFR 416.4 (a), and CFR 416.13 (d). I observed establishment 

employee handling non-sanitary surface, opening and handling boxes, then 

immediately handling product, necks, in a pan. I immediately notified the 

, of the operational SSOP violation. 

inquired about the potentially contaminated product. When I identified the pan 

containing the potentially contaminated product, immediately 

disposed the product in the pan in a clearly labeled inedible can. 

also removed the pan that contained the potentially contaminated product out of 

the processing area. The establishment personnel implicated in the incident was 

halted from handling any food contact surface or product. In conclusion, sanitary 

conditions were restored and potentially contaminated product was properly 

disposed. CFR 416.4 (a) states “All food-contact surface, including food-contact 

surfaces of utensils and equipment, must be cleaned and sanitized as frequently as 

necessary to prevent the creation of insanitary conditions and the adulteration of 

product.” CFR 416.13 (d) states “Product must be protected from adulteration 

during processing, handling, storage, loading and unloading at and during 

transportation from official establishments.” The establishment SSOP for Packaging, 

Section 2C, Step # 3 states “ 

” and 

, were informed of the forthcoming documentation for the failure to 

comply with CFR 416.4 (a) and CFR 416.13 (d). 

5308 M6137 BXL0505070 

218N-1 

07/18/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 07/17/2012 at approximately 2355 hours while monitoring the establishments' 

Preoperational Sanitation Procedures after establishment SSOP and HACCP 

inspections, I observed the following. In Packaging Area #1 there was black UFM 

(Unidentified Foreign Material), and dried and semi-dried pasty tissue on the 

shackles above the rehang belt from chiller #4 that directs carcasses to 

sorting & sizing. There were numerous pieces of fat and tissue to approximately 

1/2" on the blue wheel that supports the chain/shackles at the chiller outflow side 

above the rehang belt for chiller #4. I showed my findings to 

. The Lockout/Tagout for the line was released so that the line could be 

started for cleaning. The area was released by approximately 0025 hours. At 

approximately 0015 hours there was an accumulation of a yellowish pasty 

substance on the overhead conveyor that runs parallel to the Crust Tunnel. The 

substance was on the entire length of the line which is approximately 60' long. The 

line transports breast fillets from the Deboning Room to X-Ray machine #2. 

Sanitary conditions were restored by approximately 0030 hours. My findings 

indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.4(a) & (a), 9 CFR 416.13(c), 

and 9 CFR 416.14. 

(b) (6)
(b) (6) (b) (6) (b) (6)

(b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1218074 

318N-1 

07/18/2012 01D01 SPS Verification C At approximately 1400 hours, while performing a Post chill check in plant 1, I 

noticed a noncompliance with regulatory requirement of regulation 9 CFR 416.1 

and 416.2(a). I observed an adult fly which was barely alive inside of a gray combo 

bin located near chiller #2 exit. This combo bins are utilized to store edible product. 

Even though, a plastic liner is placed in this combo bins, they still need to be kept in 

sanitary conditions free of any contaminants and pests. I immediately placed a US 

Rejected/Retained tag N0. B31 406858 on the affected container. I then, notified

 of the noncompliance. He took immediate corrective action 

by washing and sanitizing the combo bin. I removed the US tag after rechecking the 

container and finding it clean. At approximately 1500 hours, while walking through 

the Packaging Paw Room located next to the loading dock, I also found a non 

compliance with regulatory requirement of regulations 9 CFR 416.1 and 416.2(a). 

There was approximately 10 adult flies inside of the Paw room. This flies were 

standing on the sealing, walls and pipes throughout the production area. I notified 

the lead person and of the noncompliance. Flies were 

carefully killed to avoid product contamination. mentioned 

that he would have the whole area fogged during the weekend and that more fly 

traps would be put in place in the surrounding areas of the paw room. He also 

mentioned that the air curtain at the door entrance was properly working. 

5308 M6137 BXL3123072 

218N-1 

07/18/2012 01D01 SPS Verification C On 07/18/2012 at approximately 2000 hours while monitoring Facilities, I observed 

the following. In the Plant #1 Cooler there was condensation spraying from the 

overhead refrigeration unit located over the Plant #1 door. Up to approximately 1 

cup of condensation and several pieces of black UFM(Unidentified Foreign Material) 

with the consistency of blackened dust to approximately 1/2" was collecting on 

cover tanks up to approximately 20 feet from the unit. I contacted 

and showed him my findings. A mechanic was called and said that the unit 

was in normal defrost mode. I got a ladder and inspected the unit. There are 

numerous pieces of blue plastic stuck to the front screen which is also coated with 

black UFM. The drip tray that collects the defrosted condensates includes a drain 

pipe. The drain hole for the drip tray is at least a foot away from the end of the 

pooling fluids in the tray so no drainage was occurring. The units fan was still 

picking up the fluids at approximately 2020 hours and spraying it on the ceiling, 

pipes and tanks of product. The plastic on approximately 12 tanks were replaced, 

several tanks were moved out of the area, and the condensation was dried from the 

ceiling and pipes. My findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 

416.2(d) and 9 CFR 416.2(b)(1) 

(b) (6)
(b) (6)

(b) (6) (b) (6)

(b) (6)

(b) (6) (b) (6)(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0818073 

117N-1 

07/17/2012 06D02 Other Inspection 

Requirements 

C On 7/17/2012, while performing “No viscera” presentation check on the Nu-Tech 

system in Plant 1. I observed noncompliance with the regulatory requirements of 

regulations 9CFR 381.76(a) and 9CFR 381.76(b). Inspection Personnel informed me 

that on Line 2 there was an excessive amount of birds coming to their inspection 

stations with no viscera to inspect. At approximately 1510 hours I performed a “No 

viscera” presentation check on Line 2. I found 18 “no viscera” during the 3 minute 

allotment of time for the check. I immediately informed 

that my check had surpassed the 13 “No viscera” allowed for the process to be in 

control. At approximately 1524 hours Quality Control personnel performed a 

recheck of the system. Quality Control personnel recorded 21 ”No viscera” during 

the allotted time period, the process was deemed to be out of control and the line 

speed was slowed down to birds per minute. I informed 

that I was documenting a noncompliance. The establishment elected to 

leave the line speed at birds per minute for the rest of the day. 

5308 M6137 BXL1621073 

717N-1 

07/17/2012 04B04 General Labeling C While monitoring the Establishments' Operational Sanitation Procedures in Main 

Packaging Area, at approximately 1709 hours, I observed the following: In the old 

breast aged cooler next to the Halvers Machine #2 there was a stainless steel tank 

covered with a blue plastic. I looked inside and it was half full of parts and whole 

birds, pieces of fat and skin with a lot water mixed with blood. The product was 

emitting a strong rancid or putrefy like odor. The tank did not have any tag or label 

to identify product name, date and time. I attached a U.S. Rejected/Retained 

Tag # B31 406257 to the tank and informed and 

of the noncompliance. informed me that this 

cooler is used only by condemn the product in the 

edible condemn room at approximately 1718 hours. My findings indicate a 

noncompliance with 9 CFR 381.145(b). 

(b) (6)
(b) (6)

(b) (6) (b) (6)

(b) (6) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2903075 

817N-1 

07/17/2012 01D01 SPS Verification C On 07/16/2012 at approximately 2030 hours while monitoring Facilities, I observed 

the following. There was a large puddle of fluid on the floor of the Plant #2 Cooler. 

As sanitation had started the between shift cleanup, I contacted 

and showed him my findings. There was approximately 12 

pallets of giblets, 25 pallets of salvaged parts, and 25 tanks of birds in the cooler. 

The puddle extended from the giblets palletized near the cooler wall adjacent to the 

door on the Plant #2 side of the cooler to approximately 6 feet from the Packaging 

side Cooler door. The puddle was to approximately 2" deep near the drain and 

several feet wide. The fluid was pinkish in color and probably a collection of blood 

and melted ice from the PM shift. came by and said he had 

been in the cooler 30 minutes earlier but saw nothing. I informed him that the 

pallets and tank wheels should be treated as contaminated. Several pallets were 

moved to gain access to the drain. A mechanic pumped several gallons of gray 

colored sour smelling fluid from the drain trap. was 

sprayed on the floor inside and outside the Plant #2 side cooler door to reduce the 

spread of putrid contaminants. The drain was still clogged at approximately 2200 

hours when I had to go to Plant #1 as production was starting. I returned at 

approximately 2300 hours and found some residue still on the floor. I had more 

antimicrobial soap applied and the cooler rinsed before releasing it back to 

production. My findings indicated a noncompliance with 9 CFR 416.1 and 9 CFR 

416.2(e)(4). 

5308 M6137 BXL2700074 

614N-1 

07/14/2012 01D01 SPS Verification C On 07/13/2012 at approximately 0730 hours while monitoring Facilities at the end 

of the shift in Plant #2, I observed the following. There was a juvenile cockroach on 

the wall just above the apron wash soap container adjacent to Evisceration line 4B 

near the Inside/Outside washers. The roach was killed and shown to 

who said he was busy and to show the roach to in the office, 

which I did. Roaches are known to transport filth and disease. My findings indicated 

a noncompliance with 9 CFR 416.1 and 9 CFR 416.2(a). 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5619070 

913N-1 

07/13/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1250 hours while performing a Finish Product Standard check at 

the Pos-Chill area, I observed a non compliance with regulation 9 CFR 416.4(d) at 

the exit of chiller 4 in plant 2. I observed a bird on the drip pan located above the 

sorting blue conveyor belt at the chiller 4 exit. The bird was blocking the drip pan’s 

draining pipe, causing the water to pour out on to the rail, moving chain, shackles 

and finally on the blue conveyor full of product. As mentioned previously, this 

water was touching several non food contact surfaces prior showering the product 

underneath, which at this point was deemed to be contaminated. I took immediate 

control action by instructing the employees working at the area to stop hanging 

birds. I then, notified Quality Control who was also at the chiller exit collecting the 

moisture birds. was also notified of the noncompliance. He 

immediately removed the bird from the drip pan allowing the water to run freely 

through the drain pipe. A stainless steel tank full of product was placed on hold by 

Quality Control. Conveyor was allowed to run and be sprayed by the line prayers, 

making it acceptable. Production was resumed. All contaminated product was 

reconditioned and made acceptable. 

5309 P6137A NJN161007 

4013N-1 

07/13/2012 01D01 SPS Verification C At approximately 1840 hours while conducting a verifycation procedure Sanitary 

Performance Standard (SPS) in the Weigh and Price department, I observed the 

following non compliance: Numerous flies on the stack of pallets that were stagged 

for use, numerous flies on production line . More flies were observed on the 

southeast door jam of that department. I took regulatory control of the area with 

the application of US Reject Tag #B39415806 and informed Mr. 

and QC Tec in charge of the area of the forthcoming non 

compliance. 

5308 M6137 BXL3014070 

612N-1 

07/12/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1425 hours, while performing a Operational Sanitation 

verification task in Plant 2, I found a non compliance with regulatory requirement of 

regulation 9 CFR 416.4(a). I observed a couple of dirty gray salvage tubs located at 

the end of line in plant 2. These tubs are a product contact surface utilized for 

salvage parts at the final trimer station. They were contaminated with multiple 

shiny silver specks of foreign material. I took regulatory control action by placing 

two U.S Rejected/Retained tags No. B31 407544 and B31 407545 on the affected 

containers. I then, notified of the noncompliance. She took 

immediate corrective action by washing the gray tubs. I re-inspected the containers, 

finding their condition to be sanitary. US tags were removed at approximately 1433 

hours. 

(b) (6)
(b) (6) (b) (6) (b) (7)(C) (b) (4)

(b) (4)

(b) (7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3704073 

612N-1 

07/12/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 07/11/2012 at approximately 2215 hours while monitoring the establishments' 

Preoperational Sanitation Procedures after establishment SSOP and HACCP QC 

checks, CSI observed the following. The transfer belt for line where birds 

are transferred from the kill line to the eviscerating line is frayed to approximately 

2" and the top surfaces has numerous blackened spots which appear to be have 

been melted caused by welding sparks or other hot maintenance procedure. The 

belt is severely deteriorated making it extremely difficult to clean and inspect. There 

were numerous large patches of dried and semi-dried fat and froth on the four 

chiller paddles associated with the center inside section ( near the center walkway) 

of chiller #3. The fat and froth residue was near the water line on the main 

structural brace that attaches the paddle to the chiller. There was also dried fat and 

froth on the tines on the dry paddles that are above the chiller. It is obvious which 

way the high pressure water was applied as the dried fat and froth is on the back 

side of the structures. Accessible and reachable sections were cleaned with scouring 

pads and wiped off with paper towels. The chiller was released by approximately 

2242 hours. The establishments' Preoperational Sanitation Daily Procedures under 

'before start of operations ...' and 'wet clean-up(food contact surfaces)' states in 

part 

." After finding considerable dried and semi dried product 

from the previous days production the effectiveness of the procedure as it is 

currently being performed is questionable. The chiller was checked by SSOP 

personnel with in plant #2 and was found acceptable at 917 hours (2117). The 

second shift worked overtime so the chillers would not have been empty of product 

until approximately 1930 hours. SSOP forms were verified by the establishments' 

Sanitation Superintendent. My findings indicated a noncompliance with 9 CFR 

416.2(b)(1), 9 CFR 416.1, 9 CFR 416.4(a), 9 CFR 416.13(c) and 9 CFR 416.14. On 

07/11/2012 while monitoring the Establishments' Preoperational Sanitation 

Procedures in Plant #1, CSI found the following noncompliance with 

regulations 9 CFR 416.1, 416.4(a), 416.13(c) and 416.14. At approximately 2234 

hours, I observed pasty dried and semi-dried fat on a large section of the two 

support brackets for the paddles on the center of the right side of the Chiller #1, 

also on one of the paddles there was white slimy residue. I immediately attached a 

U.S. Rejected/Retained Tag # B31 405256 to that area. On Chiller #2 at the end of 

left side on one of the paddles was also with white slimy residue. I informed

 and of the noncompliance. The 

reachable areas of the brackets and the paddles were cleaned with a green pads and 

brown paper towels. The area was released at approximately 2244 hours. 

(b) (6)
(b) (6) (b) (6)(b) (6) (b) (6) (b) (7)(C) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5518070 

712N-1 

07/12/2012 01D01 SPS Verification C At approximately 1050 hours, while performing a Operational Sanitation 

verification task, I found a non compliance with regulatory requirement of 

regulation 9 CFR 416.4(a) and 416.1 On the hallway leading into the receiving 

loading dock located next to the supply room and packaging, I observed a couple of 

medium size cardboard boxes. These boxes were opened, exposing the white 

soaking pads inside of them. These pads are a product contact surface utilized to 

absorb excessive product moisture on the tray pack. As I got closer, I noticed that 

the top layer of soaking pads was contaminated with black foreign material. I took 

immediate regulatory control action by placing a U.S Rejected/Retained tag N0. B31 

407543 on the affected product contact surface packaging materials. I then notified

 of the noncompliance. He took immediate corrective 

action by disposing of the contaminated pads. U.S tag was removed after sanitary 

conditions had been restored. 

5308 M6137 BXL2214073 

411N-1 

07/11/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1021 hours while walking through the packaging area I observed 

the following noncompliance. On the drip pan over the Breast Halver that is across 

from the Bag Fryer line there was heavy beaded condensation. A company 

employee started to mop the condensation and while doing so he dripped dirty 

mop water all over the ice inside of a cardboard bin that they were using to put on 

product in the brown tubs to cool the product. I immediately took regulatory 

control action by applying USDA Reject tag #B31406757 to the bin of ice. I then 

notified of the noncompliance. The bin of ice was 

condemned and dumped at approximately 1032 hours restoring sanitary 

conditions. My findings indicate a noncompliance with 9CFR 416.2(d) and 416.4(a). 

5309 P6137A NJN571207 

1410N-1 

07/10/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 0925 hours while performing PHIS task for zero tolerance on the 

reprocessing line, I observed the third carcass of the sample with visible fecal 

material. The fecal material were two small smears on the right side of the tail next 

to the oil gland approximately 1/16 inch in diameter individually and was dark 

green in color and had a paste-like consistency. I immediately took regulatory 

control of the line with the application of US Retained Tag #B38495112 and 

informed Mr. of the forthcoming non 

compliance. Mr. asked for a second opinion 

and SCSI Mr. confirmed my finding in front of Mr. . That the 

establishment failed to prevent fecal material from entering the chilling system 

represents noncompliance with 9 CFR381.65(e). Noncompliance 

NJN1414063025N/1 recorded on 6/25/2012 is with symilar cause, fecal on 

reprocessing line. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3802072 

609N-1 

07/09/2012 04B03 Labeling - Net 

Weights 

C On 07/07/2012 at approximately 0615 hours while monitoring Establishment Net 

Weight procedures in Weigh & Price, I observed the following. A review of 

establishment computer records for the shift revealed that a check at 2330 hours 

for account #604201 for product 509 had failed (-.01). A check at 2352 hours for 

account #603803 for product 508 had failed (-.01). A check at 0456 hours for 

account #703802 for product 528 had failed (-.02). The three checks were for trays 

under 3 pounds. I asked at the first station if procedures had 

changed. He said that the failures were not at his station but from the entries made 

it appeared that a recheck should have been performed. I reviewed the Foster 

Farms Net Weight Content Compliance Testing Program dated November 27, 2010 

on file in Weight & Price and found the following statement under Sample Plan: 

" I asked the making the checks and she said she had no 

failures for the shift and had retained no product. The computer shows the checks 

as acceptable, although less then average, as the low limit in the computer is set at 

-.062. As a recheck had not been performed it was clear that the affected product 

had not met Net Weight requirements when sent to NCDC for shipping. I contacted

 and showed him my findings. Eleven pallets totaling 

approximately 600 cases were placed on hold at NCDC. The product was released by 

approximately 0905 hours after a representative sample per established procedures 

revealed that the product was in fact in compliance. My findings indicated a 

noncompliance with 9 CFR 442.2. 

5308 M6137 BXL0213074 

005N-1 

07/05/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1530 hours while walking through the Packaging rehang area in 

Plant #1 I observed the following noncompliance. There was heavy condensation 

running the entire length of the drip pan that connects to the cabinet near 

the chiller exit and is directly over the short sizing belts. There were approximately 

6 whole carcasses on belts #2 and #4 with condensation dripping heavily on the 

belts and carcasses, I immediately informed of the 

noncompliance. A company employee was instructed to rinse the carcasses with 

chlorinated water and wipe down the condensation on the drip pan. The area was 

cleaned and the carcasses reworked by 1545 hours, restoring sanitary conditions. 

My findings indicate a noncompliance with 9CFR 416.1, 9CFR 416.4(a) and 9CFR 

416.4(d). 

(b) (6)
(b) (6) (b) (6) (b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (7)(C) (b) (4) (b) (4) (b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5104073 

905N-1 

07/05/2012 03C02 Raw Intact HACCP C On 07/05/2012 at approximately 0050 hours while monitoring the Establishments' 

Operational Sanitation Procedures in Packaging Area #1, I observed the following. 

There were approximately 35 birds from chiller #3 on the rehang belt for line . 

The line was not being used at the time. I checked the birds and found seven with 

one to several metal flakes on the carcass exterior surfaces and on the neck skin 

area of the carcass. Most of the metal flakes were in the range of 2-4mm, however, 

three carcasses had shiny metal flakes that measured to approximately 8-9 mm by 

from 1 to 3mm. I contacted and showed him my findings. I proceeded 

to line where the whole carcasses from chiller #3 are wrapped. At 

approximately 0110 hours I randomly checked approximately 5 birds finding one 

with a shiny metal flake measuring approximately 8mm by 3mm. I showed

 then again contacted . 

and USDA DVM were also informed. According to FDA 

guidance metal in a food product in excess of 7mm is considered to be a health 

hazard. The 8-9mm metal pieces that I observed exceeded that limit. I reviewed the 

Establishments' Hazard Analysis-Raw Not Ground-Packaging at step #8 'Packaging' 

under 'Potential Hazard Introduced, Controlled or Reduced at this step' the plan 

lists . Under "Justification for Decision" 

there are no supplemental supporting documents provided. My findings indicated a 

noncompliance with 9 CFR 417.2(a)(1). 

5308 M6137 BXL5511071 

305N-1 

07/05/2012 01D01 SPS Verification C On 7/5/15 at approximately 0734 hours while preforming the SPS task I observed 

the following in the packaging area . Underneath the Plant # 2 Halver the entire drip 

pan was saturated with thick beaded condensation . I immediately brought my 

findings to the attention of . had one of 

his workers mop the condensation . Sanitary conditions were restored at 

approximately 0750 hours .My findings indicate noncompliances with the following 

regulations 9CFR 416.2(d) 9CFR 416.4(d) and section two of SSOP PLan which states 

5308 M6137 BXL5412065 

330N-1 

06/30/2012 01D01 SPS Verification C At approximately 0915 hours while walking from Plant #2 to the packaging area I 

observed the following noncompliance. The overhead drip pan above the sizing 

lines was covered in heavy condensation and dripping all around the lines. There 

was also condensation on the end of the drip pans in the walkway where the double 

drip pans end by the Gib Chiller. I immediately informed and

 of the noncompliance. immediately 

told sanitation to wipe down the drips and sanitary conditions were restored by 

0925. My findings indicate a noncompliance with 9CFR 416.1, 9CFR 416.2(d) and 

416.4(b). 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (6) (b) (6)

(b) (6)

(b) (6) (b) (4) (b) (4) (b) (4)

(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5516061 

530N-1 

06/30/2012 04A06 Poultry Finished 

Product Standards 

C At approximately 1325 hours, while monitoring the establishment's Pre-Chill Finish 

Product Standard in Plant #2, I found the following noncompliance. After randomly 

removing a 10 bird sample from line , I documented a total of 38 weighted 

nonconformance points under processing category. This exceeded the subgroup 

absolute limit (30) for the process to be under control. I immediately informed

 who did a recheck at approximately 1335 hours to verify sample validity. She 

failed the recheck with a total of 31 weighted noncomformance points. This 

exceeded the tolerance (25) allowed for the recheck. At that point the process is 

considered out of control. I informed of the 

noncompliance so that corrective action could be taken. By approximately 1412 

hours QC had performed two consecutive passing Pre-chill checks on line 

bringing the process back in control at the pre chill area. QC performed Post Chill 

rechecks starting at 1429 hours to 1512 hours. The Pre-Chill criteria 

for the processing category was applied to the Post-Chill rechecks. all Post- Chill 

checks passed. Product was deemed to be acceptable for shipping. My findings 

indicate a noncompliance with regulatory requirement of regulation 9CFR 

381.76(b). 

5308 M6137 BXL2109065 

729N-1 

06/29/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C While performing Pre-Chill Finished Products Standards Check, I observed 

noncompliance with the following regulatory requirements of regulation 9CFR 

381.65 (e) and 417.2 (c)(4). At approximately 0416 hours, I randomly removed a 10 

bird sample from Line #2 in Plant #1, I found one out the ten birds with visible fecal 

contamination located at the right side of the abdominal cavity of the bird. The 

fecal material was a smear, approximately 1/4" diameter in size, dark green in color 

and pasty in texture. This exceed the limit of Zero Tolerance for the process to be in 

control. I informed , and

 of the noncompliance, the protocol for Fecal Failure was 

implemented. Quality Control performed a Recheck at approximately 0444 hours 

and it passed. This is a violation of the critical limits of CCP-2B, 

of the Plants' HACCP Plan for Slaughter. 

5308 M6137 BXL2813065 

629N-1 

06/29/2012 01D01 SPS Verification C On 6/29/12 at approximately 0811 hours I observed the following in 

plant # 1 . Directly above the sizing lines there was beads of condensation on the 

drip pan directly above the sizing conveyors . I immediately contacted the 

. had the 

condensation monitor mop the affected areas . At approximately 0826 hours 

sanitary conditions were restored . My observation indicates a noncompliance with 

the following regulation 416.2(d) and 416.1 and Section # 2 of the SSOP 

Plan , which states

 “ . 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6)

(b) (6)

(b) (6) (b) (6) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2512064 

128N-1 

06/28/2012 01D01 SPS Verification C On 6/28/12 at approximately 0919 hours I observed the following in 

plant # 1 . Directly above the sizing lines there were beads of condensation on the 

drip pan directly above the sizing conveyors . I immediately contacted the closest

 which happen to be who contacted 

by radio . had the condensation monitor mop the affected 

areas . At approximately 0936 hours sanitary conditions were restored . My 

observation indicates a noncompliance with the following regulation 416.2(d) 

5308 M6137 BXL5514060 

628N-1 

06/28/2012 06D02 Other Inspection 

Requirements 

C While performing a Finish Product Standard verification check on line 5 Plant 2, I 

found a noncompliance with regulatory requirement of regulation 9CFR 381.91(b) 

and 381.76(b). At approximately 0916 hours, I randomly removed a 10 bird sample 

from the reprocessing line in plant 2. I found one out of ten birds contaminated 

with a piece of visible ingesta meassuring approximately 1/16". I notified 

of my findings. The line was full of birds with one final trimmer at the 

end of the line. As I was pulling birds of the line to perform my recheck, the 

supervisor started helping the employee at the end of the line. Both of them were 

pulling birds off the shackles and on to the table which was filled with birds 

immediately. Even though this check did not reflect line true process, I still found 

another bird with several visible ingesta contaminants. At this point the line had 

already failed even when the Supervisor was interfering with my inspection check 

by making temporary changes on the process. I gave the contaminated carcass to 

the Supervisor whom immediately stopped the line and went to talk to all 

employees working on the line. After a while she came back and turned the line 

back on and continues helping the employee at the end of the line. She failed to 

start tanking off the birds. I asked the Supervisor if she was to keep only one 

employee at the end of the line. She mentioned that at BPM line speed there is 

no need to have 2 employees at the end of the line. I requested her to stop helping 

the final trimer so that I could perform a recheck that would actually reflect the true 

process of the reprocessing line. At approximately 0920 hours, I perform a valid 

recheck finding one out of ten birds contaminated with ingesta. I then, notified

 of the noncompliance and the need to start tanking off 

product. stoped the line and went to talk to the 

employees again. She added and extra employee at the end of the line and then she 

started the line. I place a US. Rejected/Retained tag N0. B31 406264 on the affected 

product. At approximately 0926 hours I perform a passing recheck putting the 

process back in control. Production stoped tanking off product. At approximately 

1010 hours, I perform a recheck on the reworked product. US tag was removed 

after the product was found acceptable. 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3207065 

327N-1 

06/27/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 06/26/2012 while monitoring the Establishments' Pre-operational Sanitation 

Procedures in Packaging Area at the exit of the Chiller #1 and Chiller #2, I found the 

following noncompliance with regulations 9CFR 416.1, 416.4 (a) and 416.13 (c). At 

approximately 2358 hours, I observed numerous particles of black 

UFM ( Unidentified Foreign Material) on the blue sorting conveyors belts at the exit 

of Chiller #1 and Chiller #2. The black UFM was covering approximately almost the 

entire length area of the blue sorting conveyors belts. I immediately attached a U.S. 

Rejected/Retained Tag # B31 404653 to both conveyors belts and informed 

of the noncompliance. He immediately washed and rinsed the 

sorting blue conveyors belts. I reinspected and released the area at approximately 

0007 hours. 

5308 M6137 BXL3014062 

325N-1 

06/25/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 6 /25/12 at approximately 0705 hours while preforming the Preoperational 

SSOP Review and Observation task I observed the following In Plant #1. The Liver 

Harvester on line #2 in area #4 had a large piece of liver laying on the connecting 

drip pan which was approximately 2” by 3” in size and gave out a very foul 

odor , which appeared to be left from last weeks production .I immediately 

informed . had the piece of liver 

removed and the drip pan rinsed . Sanitary conditions were restored ay 

approximately 0710 hours . At 0713 hours the Inside Out Side washer in area # 5 

was inspected ,the bottom of the washer had a build- up of grease which appeared 

to have been there for a while . had the affected guide bars 

underneath scrubbed and rinsed . The packaging Area was inspected at 

approximately 0825 .At approximately 0855 the Leg processors were inspected the 

three conveyor belts that transport product to the packaging area had pieces of fat 

on them ranging in size from 1/8 “ to 3/4 “ was informed 

immediately . She had the three conveyors rinsed of all fat particles . The conveyors 

were rechecked and found to be in sanitary condition at approximately 0906 hours 

.My findings indicate noncompliance with the following regulations 

416.13(a) , 416.13(c) , 416.4(a) and 416.4(b) . 

(b) (6)
(b) (6) (b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN141406 

3025N-1 

06/25/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 0910 hours while performing PHIS task for zero tolerance on the 

reprocessing line I observed one carcass of a ten carcass sample with visible fecal 

material on the inside of a carcass at the rib area. The fecal material was 

approximately 1/4 inch in diameter, dark green in color and had a thick paste-like 

consistency. I immediately took a regulatory control action to the reprocessing line 

and notified Mr. , and the QC 

technician assigned to the area, showed them my findings and informed them of 

the forthcoming noncompliance. That the establishment failed to prevent fecal 

material from entering the chilling system represents noncompliance with 9 CFR 

381.65(e). This document serves as written notification that your failure to comply 

with regulatory requirement's could result in additional regulatory or 

administrative action. 

5333 P7632 HYE020806 

1725N-1 

06/25/2012 03J04 Poultry Zero 

Tolerance 

C I was in the evisceration department performing a Zero Tolerance verification task 

at the line one Pre-Chill Evaluaution Station at 0023 hours when I observed fecal 

Verification material on one of the ten carcass sample. The fecal material was located on the 

leaf fat inside the carcass. It was approximately 1/8 inch in diameter, dark green in 

color, and had a paste like consistency. I took regultory control of the product with 

the application of U.S.Retain tag B38495142, I then had to find and informed Ms. 

, of my finding. Mr.

 and were also 

informed of the noncompliance. 

5308 M6137 BXL1505060 

622N-1 

06/22/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 06/22/2012 at approximately 0035 hours while monitoring Packaging 

Department processes, I observed the following. At Line #1 immediately after the 

X-Ray machine there were several boneless skinless breast fillets from the 

Deboning Room that had smears of black UFM (Unidentified Foreign Material). The 

contaminated breasts were those rejected by the X-Ray machines and sent to a trim 

station before returning to line #1. I collected the fillets into a gray product tub and 

contacted who was setting up the boneless breast packaging line. I 

explained the monitoring steps I followed. She had a line sanitation employee wash 

the two small belts that collect breast meat from the X-Ray machine. The UFM was 

smears and specks to 3" by 1". Approximately 15 fillets were collected before a 

washing of the line stopped the contamination. I contacted and 

showed him my findings. The affected product went to the rewash station for 

reconditioning. My findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 

416.4(d), and 9 CFR 416.15(b). 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2016064 

822N-1 

06/22/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C The Noncompliances listed below were observations made by EIAO's while 

conducting a Food Safety Assessment (FSA). On 5/31/2012 during preoperational 

sanitation inspection, the EIAO's observed the plastic divider on the conveyor table 

in the paw room heavily worn including chunks of white plastic hanging off the belt 

with the potential to contaminate product. The divider was replaced prior to 

production. In the room, the EIAO's observed a small piece of loose plastic on 

a cutting board. The immediatley inspected 

all cutting boards and removed three from production.This describes 

noncompliance with 416.1,and 416.4(a) Additionally, EIAO's observed 

preoperational sanitation inspection on 5/31/2012. The establishment employees 

observed multiple equipment with product residue from previous day’s production 

including a product belt in the room, product belt in the packaging room, and 

a giblet table in plant 2. Product residue from the previous days production was 

found in multiple non food contact locations including the floors and drains in both 

plant 1 and 2, Cropper 1 in plant 1, on hand railings at the inspection stations and 

around the giblet chiller in plant 2, on the sides of the giblet chiller in plant 2, and 

on the floor in the corner of the Rotisserie Room near the lock out tag out area. The 

EIAO's observed cutting boards being stored in inedible barrels after being cleaned. 

The establishment had released the room for USDA inspection prior to these 

observations being made. The EIAO's discussed this with the 

. Ms. and the EIAO's observed product residue on the 

cutting boards. Ms. had all cutting boards re-cleaned and inspected for 

product residue. The EIAO's reviewed preoperational records for 5/31/2012 and 

found that no deficiencies or corrective actions taken were documented on the 

records. The establishment did not maintain daily records associated with the 

corrective actions taken. This is a noncompliance with Title 9 CFR 416.16(a). The 

establishment has failed to evaluate the effectiveness of their SSOP's to keep them 

effective in preventing insanitary conditions that may result in direct contamination 

and adulteration of products. The establishment conducts sanitation procedures 

daily and conducts preoperational monitoring daily by randomly selecting 

equipment in each area to be inspected. In reviewing establishment SSOP records, 

the establishment is not always documenting and identifying deficiencies. However, 

FSIS In plant inspection personnel have documented 30 Noncompliance Records 

(NRs) from 11/17/2011-5/17/2012 for findings of insanitary conditions on food 

contact surfaces identified during preoperational inspection. FSIS has identified 

multiple instances in which the establishment’s implementation and monitoring of 

the SSOP has been insufficient in preventing insanitary conditions. The 

establishment has not demonstrated that they are evaluating the SSOP's to 

determine the effectiveness of their sanitation procedures is being maintained. 

Based on the noncompliances issued and the observations during preoperational 

inspection during the FSA, the establishment is not routinely evaluating the 

effectiveness of the Sanitation SOP’s and the procedures therein in preventing 

(b) (6)
(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

direct contamination or adulteration of products. This is a noncompliance with Title 

9 CFR 416.14 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3715064 

022N-1 

06/22/2012 01D01 SPS Verification C The Noncompliances listed below were observations made by EIAOs while 

conducting a Food Safety Assessment (FSA). On 5/30/2012, the EIAO's observed 

operational sanitation. On the thigh deboning machine in the processing room 

beaded condensation was observed over product being placed in an edible 

container. There was also beaded condensation over the belt carrying the boneless 

thighs to packaging. An employee was observed wiping the beaded condensation 

with a mop reserved for wiping condensation. The EIAO's observed water dripping 

from the mop as the employee wiped condensation over product. The dripping 

water did not touch exposed product or direct product contact surfaces at this 

time. The was notified of the condensation. 

Ms. informed us that the product being placed into an edible container was 

sent directly to inedible rendering and the employees were trained to wipe all 

condensation with clean paper towels instead of the mop to prevent dripping water 

onto exposed products. On 5/31/2012, the EIAO's observed beaded condensation 

under the newly installed chillers in plant 2. The condensation was above the exit of 

the chiller and above the B grade belt. On 6/8/2012, the EIAO's observed 

condensation on the pipes and light cover above the giblet chiller in Plant #2. The 

establishment immediately removed all condensation. These instances of 

condensation above product demonstrates the establishment is not maintaining 

adequate ventilation to control condensation to prevent the creation of insanitary 

conditions. This describes a noncompliance with Title 9 CFR 416.2(d). On 

5/31/2012, EIAO's observed live and dead flies in the condemn room leading into 

the Paw Room. Upwards of 60 live flies were observed crawling on the 

un-operational UV Fly light and upwards of 30 dead flies observed in the 

un-operational UV Fly Light and on the floor surrounding the light. This describes a 

noncompliance with title 9 CFR 416.2(a) and 416.4(b). The un-operational UV fly 

light demonstrates that the establishment’s pest management procedures are not 

being fully implemented. The EIAO's observed no other pest activity during the FSA. 

5308 M6137 BXL4316060 

622N-1 

06/22/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C While performing Pre-Chill Finished Products Standards Check, I observed 

noncompliance with the following regulatory requirements of regulation 9CFR 

381.65 (e) and 417.2 (c)(4). At approximately 1008 hours, I randomly removed a 10 

bird sample from Line #2 in Plant #1, I found one out the ten birds with visible fecal 

contamination inside the bird on the back right side area, between the kidneys and 

the tail. The fecal material was a smear measuring approximately 1/4" diameter in 

size, dark green in color and pasty in texture. This exceed the limit of Zero Tolerance 

for the process to be in control. I informed and

 of the noncompliance, the protocol for fecal failure was 

implemented. Quality Control performed a recheck at approximately 1033 hours 

and it passed. The cause of the deviation was " bird washer plug up module". 

This is a violation of the critical limits of CCP-2B, of the 

Plant's HACCP Plan for Slaughter. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5623063 

322N-1 

06/22/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 06/21/2012 at approximately 0015 hours in Packaging Area #2, the 

Deboning Room, while performing Preoperational Sanitation Procedures after 

establishment SSOP and HACCP QC checks, I observed the following. The conveyor 

belt that collects breast fillets from Line #1 had a large amount of fat and tissue 

debris to approximately 2" on the inside of the belt near the sprocket. I checked 

several white product cones associated with lines 1,2 & and found numerous 

pieces of fat and tissue on the inside and outside surfaces to approximately 1" on 

most of the cones inspected. Sanitary conditions were restored on the items 

checked by approximately 0035 hours. Line in the Room was being 

repaired by maintenance and was not ready for preop inspection U.S. Rejected tag 

#B31407642 was applied to the line until approximately 0845 hours. My findings 

indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.4(a) & (b), and 9 CFR 

416.13(c). 

5309 P6137A NJN570506 

4921N-1 

06/21/2012 01D01 SPS Verification C I was verifying operational sanitation in the evisceration department at 0248 hours 

when I noted the following non compliance: There were several gray inedible barrels 

at various locations in the department in disrepair, containing cracks and holes. 

These cracks and holes ranged in size from approximately two square inches to 

twelve inches in length. I informed of the non compliance. 

Inedible receptacles must be maintained in good repair to prevent the creation of 

insanitary conditions per 9 CFR 416.3(c). 

5308 M6137 BXL1318063 

519N-1 

06/19/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 6/19/12 at approximately 1535 hours while preforming the Operational SSOP 

Review & Observation task I observed the following . The drip pan over the sizeing 

line in plant # 2 was dripping large drops of condensation into a full bin of product. I 

immediately brought my findings to the attention of . tagged 

the bin so the product would be reworked by a plant employee, which was 

completed at approximately 1640 hours . She also contacted , 

who had the drip pan moped of all condensation . Sanitary conditions were 

restored at approximately 1547 hours . My findings indicate noncompliances with 

the following regulations 9CFR 416.2(d) 9CFR 416.4(d)) . 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3508061 

319N-1 

06/19/2012 04A06 Poultry Finished 

Product Standards 

C At approximately 0522 hours, while monitoring the establishments' Pre-Chill 

Finished Products Standards in Plant #2, I observed the following noncompliance. 

After randomly selecting a ten bird sample from line , I documented a total of 31 

weighted nonconformance points under Processing Nonconformance. This exceeds 

the subgroup absolute limit (30) for the process to be in control. I immediately 

informed QC, who performed a recheck at approximately 0526 hours to verify 

sample validity and documented 28 weighted nonconformance points. This exceeds 

the tolerance (25) allowed for recheck and at that point the process is considered to 

be out of control. I informed of the noncompliance. 

Corrective actions were implemented. All rechecks at Pre-Chill and Post-Chill passed 

bringing the process back in control. My findings indicate a noncompliance with 9 

CFR 381.76 (b). 

5333 P7632 HYE120806 

1519N-1 

06/19/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C I was performing the Pre-Operational Sanitation Review and Observation task when 

I noted the following failures that generated this noncompliance. In Area III, 

cabinet one had fat residue from the previous day production on the outside 

surfaces of the cabinet above the segment line rehang belts and inside the 

cabinet. The drain in the cabinet was clogged with a white clump of fat and yellow 

skin pieces from leg hocks. I then, at 2327 hours, retained the cabinet with the 

application of U.S. Retain tag B40193569 and informed 

of my findings and the noncompliance. Mr. implemented 

corrective actions; with sanitary conditions restored I released the area at 2345 

hours. In Area IV, I observed an insanitary state, around the floor of ossids five and 

six. The surrounding floor had fat and meat pieces from the day before’s 

production. Fat and meat pieces were on the platform for Segment Line two, back 

conveyer belt and thigh belt. The overhead light was contaminated with dried blood 

and fat particles on it as well. This area was also retained with the application of 

U.S. Retain tag B38495133 at 0004 hours. 

and were informed of the noncompliance and began corrective 

actions. I verified that sanitary conditions were restored in this area and then 

released it at 0018 hours. During my inspection there was no Q.C. representive 

present but I did inform at a later time of the 

situation. 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (4) (b) (4)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4316060 

518N-1 

06/18/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C While monitoring the Establishments' Pre-operational Sanitation Procedures in 

Main Packaging Area, I found the following noncompliance with regulations 9 CFR 

416.1, 416.4 (a) and 416.13 (c). At approximately 0854 hours, I observed numerous 

pieces of black UFM ( Unidentified Foreign Material) and reddish brown dust on 

Line . The UFM material were on both sides of the line were the livers, hearts, 

necks and gizzards are staged to be placed into whole body birds (Gib Tables) and 

also between the Gib tables. The reddish brown rail dust was on the end of the 

section between the Gib Tables, before the red Conveyor Belt and Tipper Tie 

Machines. I immediately tagged the line with U.S. Rejected Tag # B31 406361 and 

informed

 of the noncompliance. Company personnel washed the Gib 

Tables and the section between the Gib Tables with potable water. I reinspected the 

area and released it at approximately 0909 hours. 

5308 M6137 BXL4920065 

818N-1 

06/18/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 06/18/2012 at approximately 1712 hours while monitoring processes in Main 

Packaging Area, I observed the following. There were numerous pieces of black UFM 

(Unidentified Foreign Material) on a white cutting board and on the stainless steel 

portion between the Gib Tables on Line The UFM had the consistency of rail 

dust. The birds going down the line were being dragged through the UFM with the 

wings and the skin around the neck area coming into direct contact with this area 

just prior to being packaged. I immediately tagged the Line with U.S. 

Rejected/Retained Tag # B 31 407652 and contacted and

 and showed them my findings. The line was stopped. The 

affected area was cleaned with a bottle labeled Surface Sanitizer D2 and paper 

towels. I inspected the product and released to production. The Establishments 

SSOP under Operational Sanitation states that 

". The area was released at 

approximately 1718 hours. My findings indicated a noncompliance with regulation 

9CFR 416.4(a). 

(b) (6)
(b) (6)(b) (6) (b) (6) (b) (6)

(b) (4)

(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN451006 

3216N-1 

06/16/2012 03J02 Slaughter HACCP C At approximately 1545 hours while performing the recordkeeping component of 

the slaughter HACCP task for PHIS I elected to review the plant records for the 

morning lot of production on June 14, 2012. The establishment states in their 

program that the HACCP monitor will verify the “ 

. The plant HACCP monitor recorded a check at 10:21 hours and 

then again at 12:11 hours for a total of one hour fifty minutes. The total time 

between checks exceeded the as required by the plants 

HACCP plan. The pre-shipment review question that states “Were all critical limits 

in compliance?” was answered “Yes” and was signed by Mr. at 1157 

hours. That the establishment failed to record a check every hour represents 

noncompliance with 9CFR 417.5(b) and 417.5(a)(3). I informed Mr. , 

Evis/Pkg Dept. Supervisor Days, of the forthcoming noncompliance. 

5308 M6137 BXL1704060 

015N-1 

06/15/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 06/15/2012 at approximately 0045 hours while monitoring Packaging 

Department processes, I observed the following. At line #1 immediately after the 

X-Ray machine there were several boneless skinless breast fillets from the 

Deboning Room that had smears of black UFM. I collected the fillets on a brown 

product tub lid and contacted . One fillet on the breast fillet 

packaging line was also found with a gray flaky substance measuring approximately 

1/2" by 1/2" that had the consistency of dried paint. Two partial tubs of breast 

fillets were collected/retained by production and placed under a Q.C. hold tag for 

reconditioning. My findings indicated a noncompliance with 9 CFR 416.1 and 9 CFR 

416.4(d). 

5308 M6137 BXL2104063 

015N-1 

06/15/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 06/15/2012 at approximately 0125 hours while monitoring Facilities in Plant 

#2, I observed the following. An Establishment employee was about to place 

chickens from a brown product tub into Chiller #4. The birds are missed at the front 

of the Chiller where birds are automatically dropped into the chiller. The birds are 

collected at the rehang station and placed in the brown product tub. There were 

approximately 20 birds in the tub. After sorting through the birds approximately 10 

of the birds had varying size patches of black and brown UFM (Unidentified Foreign 

Material). Smears and specks were located on varied parts of the carcasses and 

measured up to approximately 3" by 5". The UFM collects on the carcass when in 

contact with the drip trays and support brackets associated with the return line 

prior to the auto-rehang station. The drip trays are not treated as product contact 

surfaces and are seldom cleaned. I showed my findings. My 

findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.4(d). 

(b) (6)
(b) (6) (b) (6)

(b) (6)

(b) (6)

(b) (6)

(b) (4) (b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2404060 

815N-1 

06/15/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 06/14/2012 at approximately 2225 hours while monitoring the Establishments' 

Preoperational Sanitation Procedures in Plant #2, I observed the following. There 

were numerous areas of rust and corrosion on the top visible paddle of the Chiller 

#3 Finishing Chiller. I showed my findings. A work order was 

placed with maintenance. During production the Finishing Chiller contains a 

which is used as a backup 

antimicrobial step. The rust areas measure up to 1/2" and some are raised to over 

1/8". My findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.13(c), 

and 9 CFR 416.2(b)(1). 

5308 M6137 BXL5416060 

615N-1 

06/15/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1059 hours, while walking through the packaging area to Plant #2 

I observed the following noncompliance. The 2 overhead drip pans running down 

the walkway in front of the sizing lines in Plant #2, by the machine were 

covered with condensation at the end of the sizing lines, sanitation started to clean 

the drip pans and as I was walking by I observed a large amount of dirty mop water 

flying off of the mop and onto a tank of whole birds, contaminating them. I 

immediately took regulatory control action and tagged the tank with USDA Retain 

tag #B31406760 and told of the noncompliance.

 had a company employee rework the tank of birds restoring sanitary 

conditions by approximately 1125 hours at which time I removed my tag. My 

findings indicate a noncompliance with 9CFR 416.2(d), 416.4(d) and 416.4(b). 

5333 P7632 HYE080106 

4315N-1 

06/15/2012 01D01 SPS Verification C At approximately 2049 hours while conducting a verification procedure Sanitary 

Performance Standard (SPS) in the Wet Dock area, I observed the following non 

compliance: I saw flies on the door frame and the wall inside the buiding next to the 

elevator. Some flies were observed on the wall by the Dry Ice machine (13 flies were 

counted). Regulatory Control of the area was taken with the application of US Reject 

Tag #B38495113 and informed Mr. and showed 

a the non compliance. Regulatory control was released at 

approximately 2214 after employee killed and disposed of flies and washed and 

sanitized the area. 9CFR 416.2(b)(3) states: Walls, floors, ceilings, doors, windows, 

and other outside openings must be constructed and maintained to prevent the 

entrance of vermin such as flies, rats, and mice. 

(b) (6)
(b) (6) (b) (6)

(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (7)(C) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE280906 

2115N-1 

06/15/2012 04C05 Poultry Good 

Commercial 

Practices 

C On the morning of June 14, 2012 at approximately 0340 hours, I was informed by 

SCSI of a poultry carcass suspected to be dead-on-arrival (DOA) that 

had been hung back by a food inspector on the USDA rack behind station 2 on line 2 

for veterinary disposition. After being notified I confirmed the disposition of the 

carcass to be a DOA. The carcass was slightly reddish in color with a limp neck, 

friable liver, dark purple lungs, and a slight putrid odor. I notified 

of the finding who then summoned 

and I 

discussed the disposition of the carcass with Mr. and Mr. and later 

informed them that I would be documenting the incident on a non-compliance 

record. A memorandum of interview (MOI) was issued to Mr. on June 12, 

2012 documenting similar ocurrences. The repetitive occurrence of DOAs entering 

into the evisceration department demonstrates a of loss of process control and the 

creation of insanitary conditions in accordance with 9 CFR 381.71(a) and 416.4(d). 

5308 M6137 BXL0619062 

714N-1 

06/14/2012 03J02 Slaughter HACCP C While performing a Post-Chill Finished Products Standards Check at the exit of the 

Chiller #2 in Plant #1, I observed the following noncompliance with regulations 9CFR 

417.2 (c)(4) and 381.65 (e). At approximately 1233 hours, I randomly select a 10 

bird sample, I found one of the ten birds with visible fecal contamination inside the 

bird on the right leaf fat area by the tail. The fecal material was a smear measuring 

approximately 3/16" diameter in size, dark green in color and pasty in texture. Since 

there was no Packaging Supervisor available, I informed the Lead Person. The Lead 

Person started tanking the birds coming from Chiller #2, then he informed 

. I showed my findings. I also informed

 and of the noncompliance. Three 

tanks of product were placed under QC red hold tags pending for rework. At 

approximately 1239 hours Quality Control performed a recheck and it passed. 

5308 M6137 BXL2513062 

114N-1 

06/14/2012 06D02 Other Inspection 

Requirements 

C At approximately 1028 hours, I performed a presentation check on line I failed 

the line with 41 nonconforming points. station #11, I observed one bird with 

viscera not uniform (8 noncomforming points); one bird not hung by two legs (9 

nonconforming points) and three birds with viscera on the shackle (24 

nonconforming points). On the same line, station 12 also failed with three birds 

swinging (18 nonconforming points). This exceeded the limit of 3 occurrences of 

one error. I notified . Line speed was reduced down to 

BPM. At approximately 1043 hours QC performed a passing check at BPM, Line 

speed went back to BPM. At 1049 hours QC performed another passing recheck 

at BPM, bringing the process back in control. This is a noncompliance with 

regulation 9CFR 381.76(b). 

(b) (6)
(b) (6) (b) (6)

(b) (6)

(b) (7)(C) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4403062 

314N-1 

06/14/2012 06D02 Other Inspection 

Requirements 

C At approximately 2300 hours, I was in Plant 2 evaluating the evisceration lines. I 

noticed that on all three inspection stations on Line , that all the “Hang High” 

hang back racks were full. Inspector was working on the second 

station. He informed me that a lot of birds were being presented to him with the 

heart and liver still inside the bird. I could see that there was an issue with the 

presentation and performed a presentation check to evaluate the performance of 

the system. At approximately 2333 hours, I performed a presentation check on Line 

The first inspection station failed with 3 “not reflected” errors and 5 “parts 

inside’ errors at birds per minute. At this time I noticed that Line had slowed 

down in speed. I checked and the line speed had been slowed to birds per 

minute. The second station failed at birds per minute with 1 “viscera not 

uniform” error, 1 ”viscera on shackle” error, 3 “not reflected” errors and 4 “parts 

inside” errors, for a total of 26 points. The third station failed at birds per 

minute with 1 “viscera on shackle” and 5 “parts inside”. This exceeds the limits of 

process control of 2 or less occurrences of one error and 24 or less process control 

points. I informed of the failure and he informed Quality Control 

personnel that a recheck would need to be performed. Quality Control personnel 

performed a recheck at approximately 2346 hours. The first inspection station 

failed with 2 “viscera on shackle” error, 1 “no viscera” error and 4 “not reflected” 

errors, for a total of 44 process control points. This exceeds the retest limits of 

process control of 2 or less occurrences of one error and 24 or less process control 

points and Line was slowed to birds per minute. Quality Control personnel 

performed a recheck at approximately 2353 hours and the first station failed at 

birds per minute with 3 “not reflected” errors and 6 “parts inside” errors. The 

establishment elected to leave the line at birds per minute, until maintenance 

could be performed. I informed and

 of the noncompliance with regulatory requirements of regulation 

9CFR 381.76(b). At approximately 0034 hours Quality Control personnel performed 

a recheck at birds per minute and it passed. Quality Control personnel 

performed rechecks at approximately 0041 hours, 0047 hours and 0053 hours. All 

rechecks passed bringing the process back into control and the line speed was 

increased to birds per minute. 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (6)

(b) (6)

(b) (6) (b) (4)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE450406 

2913N-1 

06/13/2012 04A06 Poultry Finished 

Product Standards 

C I was performing a Poultry Finished Product Standards check in the degree 

cooler on the salvage products from the Evisceration department production line at 

0216 hours, after all plant interventions and Quality control checks had been 

performed. I observed the following noncompliance: In a salvage tub of thighs I 

found one thigh with cellulites exudate attached to the muscle and fat tissue. In a 

second salvage tub of chicken legs, drums, I found cellulitis exudate covering half 

the leg on the muscle tissue under the skin. I then notified 

and , of my findings and the 

noncompliance. Both tubs of salvage parts were retained with the application of 

U.S. retain tag B38495135, and B38495136. The product was reworked and I 

reinspected it to confirm wholesomeness then released it at 0515 hours. Preventive 

measures were proffered that employees involved would be retrained. 

5309 P6137A NJN350306 

4212N-1 

06/12/2012 04A06 Poultry Finished 

Product Standards 

C I was performing a Finished Products Standards check (FPS) at 0508 hours on the 

reprocessing line in the evisceration department when I noted the following 

noncompliance; The establishment failed to remove airsacculitis exudate from 

carcasses identified by USDA for air sac removal. (3) carcasses of the (10) carcass 

sample identified for air sac removal contained air sac exudate. The establishment's 

written procedure for air sac removal states

 I initiated regulatory control by stopping the 

reprocessing line and informing Mr. , and Ms.

 of the noncompliance. Regulatory control was 

relinquished to Quality Control so that corrective actions could be implemented to 

regain process control and perform rechecks in order to identify all affected product 

associated with the failure. 

5309 P6137A NJN210806 

1311N-1 

06/11/2012 01D01 SPS Verification C I chose to verify the conditions of the outside premises (SPS Check) at 0416 hours 

when I noted the following non compliance: There where three cardboard combo 

bins left over from Saturdays production that contained inedible product. The bins 

had a putrid offensive odor. One of the bins was torn on the bottom leaking fat and 

liquid onto the ground creating an unsanitary condition. I informed

 and . 

Grounds and outside premises of an establishment need to be maintained in a 

manner to prevent the creation of insanitary conditions to prevent attracting pests, 

rodents and vermin as per 9 CFR 416.2(a). 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (7)(C) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1205062 

207N-1 

06/07/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 06/06/2012 at approximately 2222 hours while monitoring the establishments' 

Preoperational Sanitation Procedures in Plant #1, I observed the following. On the 

center section of Chiller #1 on the side adjacent to Chiller #2, there was pasty and 

semi-dried fat and debris on two support brackets for the paddles. On the outflow 

section of Chiller #1 also on the side adjacent to Chiller #2 there was semi-dried 

yellowish fat and chiller froth on large sections of two paddles. The heaviest 

reachable areas of the chiller paddles were cleaned with a green scouring pad and 

paper towels by approximately 2230 hours. There is a drip pan at the inflow side of 

chiller #2 that slopes towards the chiller and appears to drain into the tray that 

guides birds into the chiller #2. The drip tray is considered a non-food contact 

surface and should drain to a floor drain. I showed my findings. 

My findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.4(a), 9 CFR 

416.2(b)(1), and 9 CFR 416.13(c). 

5309 P6137A NJN160206 

4407N-1 

06/07/2012 04C05 Poultry Good 

Commercial 

Practices 

C On the morning of Tuesday June 5, 2012 at approximately 0715 hours I was notified 

by SCSI of two poultry carcasses suspected to be dead-on-arrival (DOA) 

that had been hung back by two line inspectors for veterinary disposition. At 

approximately 0735 hours I confirmned the disposition of the two carcasses that 

were hanging on the USDA rack behind station #2 on line “A” to be DOAs. Both 

carcasses were reddish in color with limp necks, friable livers and had a putrid odor. 

One carcass also had a friable spleen with a purplish discoloration in the intestines. 

, was notified on two separate occasions 

by the line inspectors at the time of their findings. I informed the establishment 

during the weekly Establishment Awareness Meeting that I would be documenting 

the incidences on a non-compliance record. The repetitive occurrence of DOAs 

entering into the evisceration department demonstrates a loss of process control 

and the creation of insanitary conditions in accordance with 9 CFR 381.71(a) and 

416.4(d). 

5308 M6137 BXL4416063 

706N-1 

06/06/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 0918 hours while performing my Post Chill procedure for Chiller 

#3 in Plant #2, I observed the following noncompliance. A company employee was 

wiping down condensation with a mop, off of the drip pan above the transfer belt 

that carries the carcasses to be hung for line ( the cut up line) in Packaging, as he 

did so he splashed dirty mop water on the belt and the product on the belt. I 

immediately notified and of the 

situation. They had employees on the belt stop hanging the carcasses and started 

tanking them until all affected product was removed. As the belt is continuosly 

washed with from beneath sanitary conditions were restored after 

1 pass over the washer. The tank of birds was reworked and sanitary conditions 

were restored by approximately 0946 hours. My findings indicate a noncompliance 

with regulations 9CFR 416.2(d) and 9CFR 416.4(d). 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5316061 

706N-1 

06/06/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 1034 hours, I randomly removed 10 carcasses from line 2 in Plant 

1 to perform a Zero tolerance Fecal Inspection. I found one of the ten carcasses 

contaminated with feces. The fecal matter was located inside of the birds cavity 

near the tail area. It was light yellow in color and pasty in texture measuring 

approximately 1/8" in diameter. I immediately notified of 

the noncompliance. The establishment began implementing the Zero Tolerance 

Protocol. At approximately 1103 hours, QC performed a passing recheck. From 

1125 hours to 1240 hours Post Chill checks were performed on the suspect lot 

coming out of chiller #2. All product was found acceptable. Pre shipment Review 

Record was sign at 1247 hours, releasing the product. My findings indicate a 

noncompliance with regulation 9CFR 361.65(e) and 417.2(c)(4) 

5333 P7632 HYE211606 

1406N-1 

06/06/2012 01C02 Operational SSOP 

Review and 

Observation 

C On June 5, 2012 at approximately 0709 hours, while performing an unscheduled 

Operational Sanitation in 2nd processing I noticed the following non-compliance, 

fatty residual build-up on the product-contact surfaces of the blue rotisserie incline 

conveyor. Pre-Operational sanitation had been preformed at 2315 and released at 

2342. The said the line had not been 

used by the previous shift. No Regulatory control action was necessitated because 

Quality Control took control of the line upon notification. Mr. was 

informed of my findings and of the forthcoming non-compliance. At 0740 the 

conveyor was washed and sanitized prior to the start of production. The same 

non-compliance was observed on May 31, 2012. This was documented on Non 

Compliance record #HYE3816051531N/1. Regulation 416.4(a) states; sanitary 

operations. All food-contact surfaces, including food-contact surfaces of utensils 

and equipment, must be cleaned and sanitized as frequently as necessary to 

prevent the creation of insanitary conditions and the adulteration of product. 

5308 M6137 BXL4704060 

305N-1 

06/05/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 06/04/2012 at approximately 0055 hours while monitoring the establishments' 

Preoperational Sanitation Procedures in Packaging Area #1, I observed the 

following. There was a white product shovel laying on the floor grating at the Plant 

#1 Halving Machine. A white cutting wheel at the same location was also on the 

floor grating. While using a wrench to remove the wheel currently attached to the 

unit, an establishment employee stepped on the wheel that was on the floor 

grating. The white shovel and white cutting wheel are considered product contact 

surfaces and should be stored in a sanitary manner in their designated location.

 was informed of my findings. The items were returned to sanitary 

condition by approximately 0005 hours. My findings indicated a noncompliance 

with 9 CFR 416.1, 9 CFR 416.4(a), and 9 CFR 416.13(c). 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN090206 

0205N-1 

06/05/2012 01C02 Operational SSOP 

Review and 

Observation 

C I was walking thru the "new" loading dock at 2330 hours when I noted the following 

non compliance: At door 2, trailer # 2479 had pallets of brown tubs containing 

carcass front halves. One of the tubs on the top layer did not have a lid on it 

exposing the product in the tub. The regulatory requirements of 9 CFR 416.4(d) 

where not being met by allowing product to be exposed during loading, unloading 

or transportation. I informed , who then applied a QC hold tag 

to the tub. I also informed of the non compliance. 

5308 M6137 BXL2712061 

904N-1 

06/04/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C While monitoring the Establishments' Pre-operational Sanitation Procedures in 

Plant #2, I found the following noncompliance with regulations 9 CFR 416.1, 416.4 

(a) and 416.3 (c). At approximately 0712 hours, I observed in Area #4, Unit #46 the 

Inside/Outside Bird washer recycle water tank had in it UFM (unidentified foreign 

material). I notified about the noncompliance. The tank 

was washed. At approximately 0714 hours sanitary conditions were restored. At 

approximately 0715 hours, I observed in Area #5, Unit #1 the blue conveyor belt 

that catches the birds from Line it had numerous black specks of UFM 

(unidentified foreign material) and also the conveyor belt that connects the 

conveyor belt that catches birds for line to the chiller had four strips of metal 

measuring approximately 6" long by 1/8" wide. I attached a U.S. Rejected/ Retained 

Tag # B31 406363 to that area and informed about the 

noncompliance. Sanitation personnel washed the belts and removed the metal 

strips. Sanitary conditions were restored at approximately 0722 hours, then I 

removed the tag. 

5308 M6137 BXL5202065 

802N-1 

06/02/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C ON 06/01/12 at apprximately 2255 hours while preforming the Preoperational 

Sanitation Procedure in the Packaging area #1 I observed the following . The 

Plant # 1 Halver had pieces of fat from the pervious days production on the flex belt 

that carries product from the room to the packaging area the pieces ranged 

from 1/8 “ to 1” in Diameter, the drip pan also pieces of fat floating on the water in 

the drip pan which also ranged from 1/8 “ to 1”. There were also large beads of 

condensation on the entire ceiling above the area . I immediately brought my 

findings to the attention of . U.S. Rejected /U.S. Retained tag 

#B31 407605 was immediately applied to the area . had one 

of his workers thoroughly rinse the flex belt and drip the condensation was also 

removed .The area was rechecked and found to be in sanitary conditon . The tag 

was removed at approximately 0008 and the area was ready for production . My 

findings indicate noncompliances with the following regulations 9CFR 416.13(c), 

9CFR 416.14 , 9CFR 416.13(a) ,9CFR 416.4(b) ,9CRF 416.4(a) . 

(b) (6)
(b) (6)

(b) (6)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE370506 

2502N-1 

06/02/2012 01C02 Operational SSOP 

Review and 

Observation 

C While walking through the chiller rehang area performing an Operational Sanitation 

inspection task on June 1, 2012 at 0350 hours I observed the following 

noncompliance: a pile of whole birds product had accumulated on the belt and floor 

below the incline belt for the North chiller exit. During this time the north chiller 

paddle was continuing to push more whole body birds out onto the belt piling on 

the floor. The product pile-up was too heavy for the belt to operate and plant 

employees were picking up product off the floor and placing them into a large gray 

combo bin that was tagged by establishment Q.C. for rework . Clean product that 

was on top of the pile was also placed in this bin, thus contaminating the clean 

product. I then observed a lead mechanic shout “The belt is to heavy to move,” 

after which the establishment employees began removing clean product from the 

belt putting it on to the floor. This product was placed in the bin after the product 

belt began to move. The affected product was retained by Q.C. in two large gray 

combo bins to be reworked. and 

were informed of the noncompliance. The preventive measures proffered 

was to have a meeting with supervisors and employees to train them in proper 

product handling procedures. 

5308 M6137 BXL3503064 

501N-1 

06/01/2012 06D02 Other Inspection 

Requirements 

C On 05/30/2012 at approximately 0206 hours while monitoring Presentation at the 

third station on line in Plant #2, I observed the following. A standard sample 

revealed the following nonconformances and corresponding valves : one bird with 

viscera Front or Side (11), one bird with Viscera on Shackle(8), one bird with No 

Viscera(20), three birds with intact Membranes (6), two birds with the fat flap Not 

Reflected (4), one bird with Parts Inside (1) for a total on 50 nonconformance 

points. Total nonconformances over 40 points indicates that the process is out of 

control. A line Supervisor was contacted. The line was slowed down to birds per 

minute and a retraining was conducted. Quality Control conducted a recheck at 

and birds per minute bring the line back into compliance by 0224 hours. My 

findings indicated a noncompliance with 9 CFR 381.76(b). 

(b) (6)
(b) (6) (b) (6) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3403053 

631N-1 

05/31/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 05/30/2012 at approximately 2220 hours while monitoring the establishments' 

Preoperational Sanitation Procedures in Plant #2, I observed the following. There 

was dried greasy black UFM(Unidentified Foreign Material) along the entire length 

of the guide bars inside the the last bird washer on line The area was cleaned 

with a green scouring pad, paper towels and rinsed with by 

approximately 2225 hours. The guide bars are not considered a product contact 

surface but are directly above the open product at the last wash point before 

entering the chilling system. There were large patches of dried and semi-dried 

yellowish UFM(Unidentified Foreign Material) on the paddles located on the 

midsection on the Sorting & Sizing Line side of Chiller #3. Inspection of the chiller at 

that location is difficult as air hoses and other design issues limit access and 

visibility. The heaviest reachable areas were wiped with paper towels by 

approximately 2245 hours. My findings indicated a noncompliance with 9 CFR 

416.1, 9 CFR 416.4(a) & (b), 9 CFR 416.13(c), and 9 CFR 416.3(b). 

5333 P7632 HYE381605 

1531N-1 

05/31/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 0748 hours, while performing an unscheduled Operational 

Sanitation in 2nd processing I noticed fatty residual build-up on the product-contact 

surfaces of the blue rotisserie incline conveyor. Pre-Operational sanitation had been 

preformed at 2315 and released at 2325. No product had been introduced to the 

area prior to my findings. The said the line had not been used by 

the previous shift. No Regulatory control action of the noncompliance was 

necessitated because Quality Control took control of the line upon notification. Mr.

 was informed of my findings and of the forthcoming non-compliance. 

At 0812 the conveyor was washed and sanitized prior to the start of production. A 

similar non-compliance was observed on May 19, 2012. The blue conveyor belt 

located on the south wall in the packaging department used to move backs into 

bins had a build up of residue from the previous shifts production. This was 

documented on Non Compliance record # HYE1410050019N/1. Regulation 416.4(a) 

states; sanitary operations. All food-contact surfaces, including food-contact 

surfaces of utensils and equipment, must be cleaned and sanitized as frequently as 

necessary to prevent the creation of insanitary conditions and the adulteration of 

product. 

(b) (6)
(b) (6) (b) (6) (b) (6)

(b) (6)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0813050 

629N-1 

05/29/2012 06D02 Other Inspection 

Requirements 

C At approximately 0900 hours, I performed a presentation check on line I failed 

the line with 36 nonconforming points. station #8, I observed one bird with 

viscera not uniform (8 noncomforming points); one bird with viscera below wing 

(12 nonconforming points) and two birds with viscera on the shackle (16 

nonconforming points). I notified and . 

At approximately 0914 hours, QC performed a recheck, failing with 44 

nonconforming points. station #7, She observed three birds with viscera non 

uniform (24 nonconforming points); one bird with viscera below wing (12 

nonconforming points) and four birds not reflected (8 nonconforming points). This 

exceeded the limit of 3 occurrences of one error and the 25 nonconforming for the 

process to be in control. Line speed was reduced down to BPM. At 

approximately 0958 hours QC performed a passing check at BPM, Line speed 

went back to BPM. At 1014 hours QC performed another passing recheck at 

BPM, bringing the process back in control. This is a noncompliance with regulation 

9CFR 381.76(b). 

5308 M6137 BXL1109052 

729N-1 

05/29/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 0650 hours, I observed noncompliance with the regulatory 

requirements of 9CFR 416 (d). At the end of the Plant 1 chiller grading belts, I 

observed a stainless steel tank. The tank was staged at the end of the grading belts 

and under returning empty lines from packaging, numbers 8, 9 and 11. The tank 

was half full of birds. There were numerous birds in the tank with numerous black 

specks (unidentifiable foreign material) on them. The black specks ranged in size 

from 1/32 to 1/16 inches in diameter and smeared when touched. The black specks 

appeared to be rail dust. I attached USDA Retain Tag # B1406374 to the tank. I 

informed of the noncompliance. The birds were 

reworked and the tank was rinsed. I removed the USDA Tag and released the 

product back to production at approximately 0715 hours. 

5308 M6137 BXL3903053 

929N-1 

05/29/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C On 05/29/2012 at approximately 0038 hours while monitoring the Establishments' 

Finish Product Standards on Line in Plant #2, I observed the following. After 

selecting a random 10 bird sample, I observed one bird with visible fecal 

contamination. There was a partial stomach connected to a complete gizzard that 

had approximately 5" of intestine attached. There was fecal contamination leaking 

from the cut end of the intestine into the area of the kidneys. The fecal material was 

approximately 1/2" by 1/8" in size and was yellowish brown in color. This exceeded 

the limit of Zero tolerance for the process to be in control. I showed 

my findings. He implemented the protocol for fecal failure. The recheck 

passed at 0107 hours. My findings indicated a noncompliance with 9 CFR 

417.2(c)(4), 9 CFR 381.65(e), and the critical limit of CCP-2B 

of the Plants HACCP Plan for slaughter. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4514050 

229N-1 

05/29/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C While performing a Zero Tolerance Check, I observed a noncompliance with the 

following regulatory requirements of regulation 9 CFR 381.65 (e) and 417.2 (c)(4). 

At approximately 1018 hours, I randomly removed a 10 bird sample from Line #2 in 

Plant #1, I found one out the ten birds with visible fecal contamination inside the 

bird on the right side under the leaf fat area by the kidneys. The fecal material was a 

smear approximately 3/16" diameter in size, green and white in color and pasty in 

texture. This exceeds the limit of Zero Tolerance for the process to be in control. I 

informed of the noncompliance, the protocol for fecal 

failure was implemented. Quality Control performed a Recheck at approximately 

1053 hours and it passed. The cause of the deviation was that the water sprayers 

were plugged. This is a violation of the critical limits of CCP-2B, 

of the Plants' HACCP Plan for Slaughter 

5309 P6137A NJN260205 

5229N-1 

05/29/2012 01D01 SPS Verification C I was on the east side of the building at 2339 hours, returning from performing a 

good commercial practice task when I made the following observation: Next to the 

dumpster was an excessive amount of trash piled on the ground. I counted 14 red 

trash cans, one gondola, 4 combo bins and 14 large blue trash bags. I came inside 

and had contacted by radio to meet me outside at this area. 

I showed this area to Mr. and informed him of the non compliance. I also 

informed of the non compliance. The trash and debris on the 

ground indicates an area that is not maintained in a sanitary condition as stipulated 

in 9 CFR 416.2 

(b) (6)
(b) (6) (b) (4)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0405050 

326N-1 

05/26/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 05/26/2012 at approximately 0150 hours while monitoring Facilities, I observed 

the following. In the Rewrap Room there were two establishment employees 

rewrapping bag fryers. One employee was removing bag fryers from gray product 

baskets. The internal surfaces of the product basket was covered with numerous 

pieces of dried and semi-dried fat and tissue to approximately 1/4", and a layer of 

brown and black UFM(Unidentified Foreign Material) specks. The employee then 

used a brown paper towel to wipe off the brown colored UFM (Unidentified Foreign 

Material) from the outside of the bag fryer packaging. The UFM typically adheres to 

packaged product when they come in contact with the Weigh & Price Cooler floor. 

The cooler floor was last cleaned on the weekend of 5/12/2012 . The employee 

then took a knife from a gray plastic pan that contained an unknown sanitizing 

solution that was approximately 3/4" deep. The sanitizing solution used and its 

concentration is not part of the establishments CP or SSOP monitoring. The gray 

pan that the solution was in had a large brown ring around its entire interior 

surface approximately 1" wide. The brown ring started approximately 1" above the 

sanitizing solution in use. The knife was used to cut open the packaged carcasses. 

The chicken carcass was removed, the absorbent pad was removed from the 

bottom of the carcass and the chicken was placed on a stainless table. At no time 

was the employees gloves sanitized after touching the soiled bag prior to handling 

the carcasses. A second employee was handling the gray product baskets that the 

rewrapped birds were being stacked into. The surfaces of the gray product baskets 

are considered a non-product contact surface and are seldom cleaned. The gray 

basket again had numerous pieces of dried and semi-dried fat and tissue to 

approximately 1/8", and numerous brown and black specks. The second employee 

was taking the unwrapped carcasses and placing them into fresh packages and 

placing them onto the contaminated gray product basket. Again more 

contaminants were added to the carcass as no glove sanitizer was used by the 

second employee although there is a sanitizing unit immediately adjacent to the 

bagging process. After making observations for several minutes, I proceeded to the 

rack storage area and found over 25 racks of bag fryers waiting to be rewrapped. 

Visible labels indicating that the kill dates ranged from 5/17 thru 5/24. 25 racks is 

approximately 3500 carcasses. At this time I contacted , showed 

her the SSOP procedure which she apparently had not seen before. I discussed the 

cross contamination issues that I observed, tagged the affected the product, and 

shut down the process by approximately 0205 hours. A review of the SSOP 

procedure dated May 21, 2012 for 'Handing of Rework' under procedure states that 

(a) " . " The 

procedure does not state how this will be accomplished. Then (b) "

 However, the establishment SSOP last updated May 22, 2012 does not 

list any requirements for product handling. Then (c) 

(b) (6)
(b) (6) (b) (6) (b) (4)

(b) (4)

(b) (4)

(b) (4)

(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

." Again the SSOP does not say how this is to be accomplished. The 

only reference to Reworked product in the SSOP states that 

" A review of the establishments 'SSOP 

" for the shift documented that a check was 

made at 0123 hours by SSOP and indicates that the following items 

were found to be acceptable. " 

" was contacted and a temporary 

procedure was implemented and the rewrap room was reopened. The affected 

product was rinsed with per establishment SSOP procedure in the 

Rotisserie Room product wash sink and was sent back to rewrapped by 

approximately 0430 hours. A check of establishment computer records indicates 

that the used to 'recondition the product per 

company procedure' in the Rotisserie room rewash sink is not routinely monitored 

so it is unclear if the wash used had any beneficial affect. My findings indicated a 

noncompliance with 9 CFR 416.1, 9 CFR 416.4(d), 9 CFR 416.5(a), and 9 CFR 

416.12(a). 

(b) (6)
(b) (6)

(b) (6)(b) (6)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN560505 

3426N-1 

05/26/2012 03J02 Slaughter HACCP C I was in the evisceration department at 0235 hours when I noted the following 

noncompliance; the HACCP monitor was not monitoring CCP 1-B parts from “A” 

and “B” evisceration lines at the designated inspection area as stated in the 

establishment’s written HACCP plan. The establishment’s written HACCP plan 

states the 

. I observed the HACCP monitor conducting the HACCP monitoring check 

CCP 1-B, at the salvage station for the evisceration “B” line and not at the deignated 

reinspection station. After conducting the check I noted the HACCP monitor 

documenting the HACCP monitoring CCP 1-B for salvaged product from evisceration 

lines “A” & “B” as acceptable at 0236 hours. At the time the HACCP monitor was 

conducting the CCP monitoring check there was no salvaged product staged at the 

designated CCP 1-B monitoring reinspection station. I informed Mr. 

, and Ms. of the noncompliance. 

In response to the monitoring noncompliance that occurred on 5-26-12, 

as stated in the establishment’s 

written HACCP plan. I reviewed the corrective actions, preventive measures and the 

preshipment review to verify compliance with the recordkeeping requirements as 

per 9 CFR 417.3 and 9 CFR 417.5. While reviewing the HACCP records and the 

preshipment review associated with the product involved I noted the following 

recordkeeping noncompliance; the establishment did not document corrective 

actions associated with the affected product, and the establishment failed to 

document the monitoring failure for CCP 1-B at 0236 for the “A” and “B” 

evisceration lines when completing the preshipment review. The establishment 

documented that performing the CCP monitoring check while the product is still in 

process is acceptable because the check was performed under the proper lighting. 

Additionally by performing the CCP monitoring checks at the salvage stations the 

establishment is not following the CCP monitoring procedures as written in the 

establishment’s written HACCP plan, therefore monitoring the CCP at the salvage 

stations is not acceptable as written the establishment’s HACCP plan. The section of 

the preshipment review step #3 were all entries made at the required frequency 

and step #4 the results of the Pre-shipment are acceptable were documented and 

signed as acceptable. I informed Mr. of the 

noncompliance 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6)

(b) (6)

(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2904054 

625N-1 

05/25/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C On 05/25/2012 at approximately 0122 hours ,while performing Pre- Chill Finished 

Product Standards check, I observed noncompliance with the following regulatory 

requiments of regulation 9CFR 381.65 (e) and 417.2 (c)(4). and the critical limits of 

CCP-2B, of the Plant's HACCP Plan for Sluaghter. I 

randomly removed 10 bird sample from line # 1 in Plant # 1, the first bird of the 10 

bird sample had visible fecal contamination on the leaf fat , and approximately 3 

inches intestine inside the cavity with visible fecal on the cloaca side. The fecal 

materlial measured approximately 1/4 inch in diameter , brownish green in color 

and pasty in texture. This exceeds the limit of Fecal Zero Tolerance for the process 

control. I informed and of the 

noncompliance. The protocol for fecal failure was implemented. Quality Control 

performed a recheck at approximately 0145 hours and it passed . 

5308 M6137 BXL0216053 

924N-1 

05/24/2012 04A06 Poultry Finished 

Product Standards 

C While monitoring the establishments' reprocessing procedure on Line in Plant 

#2, I observed a noncompliance with the following regulatory requirements of 

regulation 9CFR 381.84 (airsacculitis). At approximately 0958 hours, I randomly 

removed a 10 bird sample for my reprocessing test, I found one out the ten birds 

with split tail in the sample that contained Airsacculitis exudates. I then performed 

a recheck at approximately 1004 hours, in which two out the ten birds with splits 

tails contained Airsacculitis exudates. As was close, she 

immediately stopped the line. I showed her my findings and then she began to 

retain the product in a tank. Quality Control did a recheck at approximately 1024 

hours and it passed bringing the process back in control. Quality Control placed a 

hold tag on the tank. The retained product was reworked and released at 

approximately 1050 hours. I informed and

 of the noncompliance. 

(b) (6)
(b) (6)

(b) (7)(C)

(b) (7)(C) (b) (7)(C) (b) (7)(C)

(b) (4)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE521705 

5124N-1 

05/24/2012 04A06 Poultry Finished 

Product Standards 

C At 1234 hours I was called out to Evisceration Line 1 by Food Inspector 

who was performing bird-by-bird post-mortem inspection at Station 4. 

Inspector explained to me that she called four birds for airsacculitis-salvage 

and that her trimmer marked them per the establishment’s Air-Sac Salvage 

Procedure with 

The carcasses were collected by the salvage employee 

who took them to the offline salvage station. Because there were numerous gaps in 

the line where the shackles were empty, Inspector was able to observe the 

salvage employee wash out the carcasses and cut the skin away from the back of 

the carcasses. The employee then brought the carcasses back and hung them on the 

reprocessing line. Inspector managed to retrieve two of the carcasses and 

observed that they were two of the carcasses she had previously identified as 

having interclavicular air sac lesions and had hung back for Air Sac Salvage. I 

inspected the birds and confirmed the presence of airsacculitis exudate inside the 

thoracic cavity and also evidence of interclavicular involvement. The skin was 

removed from the entire backs of both carcasses from the posterior opening to the 

neck annd wings. The establishment’s Airsacculitis Salvage procedure states 

. That the 

establishment failed to follow the written procedures of their Air Sac Salvage 

program and circumvented the marking sytem designated in the program 

represents noncompliance with the protocols of the program. The failure to remove 

all air sac exudate and affected tissue represents noncompliance with 9 CFR 381.84.

 was notified of the forthcoming 

documentation of the failure to comply with the regulatory requirements cited 

above. 

(b) (6)
(b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1223054 

623N-1 

05/23/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 05/23/2012 at approximately 0335 hours while monitoring Establishment 

Facilities in Plant #1, I observed the following. There was black UFM (Unidentified 

Foreign Material) on ice flakes being collected at the location adjacent to Chiller #2. 

The ice is manufactured at a location on the roof and is collected from a dispenser 

into stainless steel tanks. I contacted and showed him my 

findings. The ice was condemned and dumped in the edible dump room. A 

mechanic was called, the machine and dispenser were cleaned. A quantity of brown 

and black coated ice flakes came from the dispenser chute during the cleaning 

process included a piece of black UFM approximately 1" by 3/8" that contained 

shiny flakes that appeared to be metal shavings. I checked the ice in use at several 

locations but found nothing. When the ice was clear it was again collected. I 

returned again at approximately 0410 hours and found ice flakes being collected 

that contained brown UFM. I again contacted who condemned 

the ice. A mechanic was called and at this time the process was shifted to a second 

ice machine. My findings indicated a noncompliance with 9 CFR 416.2(g)(1). 

(b) (6)
(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN250605 

1623N-1 

05/23/2012 01C01 Operational SSOP 

Record Review 

C I elected to perform a SSOP records review task to verify the establishment had met 

the regulatory requirements set forth in 9 CFR 416.16 for product adulteration that 

occurred on the morning of 5-22-12 when a hydraulic hose broke during production 

in the Food Service department. The establishment initiated corrective actions, 

identified all affected product, segregated product that had not been affected, took 

measures to restore sanitary conditions, and documented measures to prevent 

recurrence. I noted several recordkeeping noncompliances while performing the 

SSOP records review in regards to identity of the affected product. 1. The tags used 

to identify the affected product were filled out incorrectly. The QC technician filled 

out 4, 3 part QC tags, numbers 43671, 43672, 43673, and 43674. Documented on 

each tag was “one bin" & "pending.” The establishment stated the tags should have 

been filled out 3 tags with “one bin" & "pending” and one tag stating “one 

tub" & "pending”. 2. The QC tags placed on the affected product did not match the 

amount of affected product documented on the SSOP implementation and 

monitoring log. The QC technician documented on the SSOP implementation and 

monitoring log that 3 combo bins and 1 tub of product were affected while the QC 

3 part retain tags placed on the product were all documented as 4 tags each 

identifing the affected product as "one bin". 3. The amount of affected product 

documented on the SSOP implementation and monitoring log did not match the 

amount of affected product documented on the establishment’s non routine SSOP 

observation form. The SSOP implementation and monitoring log has 3 combo bins 

and 1 tub documented on it, while the non routine SSOP observation form has 3 

combo bins documented as the amount of affected product. The non routine SSOP 

observation form is used by the establishment to document “cause of the 

deviation, affected product, corrective actions, and preventive measures” to meet 

the regulatory requirements outlined in 9 CFR 416.15 and 9 CFR 416.16. 4. One of 

the combo bins of affected product had 2 different types of QC tags on it. It had 2 

QC 3 part tags plus an orange QC tag. Documented on the non routine SSOP 

observation form "3 combo bins to be condemned" were retained with QC 3 part 

tags and labeled "disposition pending" on the tag. Documented on the non routine 

SSOP observation form "product not affected by the hydraulic oil was segregated (5 

combo bins) and retained". The 5 combo bins were retained with orange QC tags 

which stated "needs cecure and pending." The combo bin had QC tags with 

conflicting product dispositions. Documented on the non routine SSOP observation 

form is that after sanitary conditions were restored the 5 combo bins of unaffected 

product were to be run through the treatment and placed back 

into production. Based on my review of the establishment’s documented SSOP 

records and inspecting the affected product and QC tags applied to the affected 

product in cooler #5 I elected to apply USDA retain tags B39415973, 74, 75 & 76 to 

4 combo bins of product. The 4 combo bins are listed in the order they were 

arranged and the type of QC tag, or tags each bin contained. Bin #1, one combo bin 

of wogs with one QC 3 part tag. Documented on the QC 3 part tag was “one 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6)

(b) (6)

(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

bin" & "pending”. Bin #2, one combo bin of wogs with a brown tub of cut up 

product placed in the corner of the combo bin on top of the wogs. Bin #2 had 3 QC 

tags applied to it, one orange QC tag and two QC 3 part tags. Both QC 3 part tags 

had “one bin" & "pending” documented on them. The orange QC tag was glued to 

the top of the liner and had “needs and pending” documented on it. There 

was no tag placed on the brown tub of cut up product inside the combo bin. Bin #3 

was partially filled and contained boneless skinless breast fillet. There was no QC 

tag, production tag, or any other type of product identification on the bin of breast 

fillets. Bin #4 contained wogs. Documented on the QC 3 part tag was “one 

bin" & "pending”. After reviewing the records and inspecting the product I notified 

Mr. and Ms. on the 

noncompliance. 

5308 M6137 BXL4812052 

722N-1 

05/22/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1552 hours, while walking through the packaging area to Plant #2 

I observed the following noncompliance. The 2 overhead drip pans running down 

the walkway in front of the sizing lines in Plant #2, by the machine were 

covered with heavy condensation that was actually dripping heavily around the 

tanks at the end of the sizing lines. I immediately informed 

and of the noncompliance. They had sanitation start to 

clean the drip pans and as and I were standing there we 

observed a large amount of dirty mop water flying off of the mop and onto a tank 

of whole birds, adulterating them. I immediately took regulatory control action and 

tagged the tank with USDA Retain tag #B31406119. and a 

company employee reworked the tank of birds restoring sanitary conditions and I 

removed my tag at approximately 1605 hours. My findings indicate a 

noncompliance with 9CFR 416.2(d), 416.4(d) and 416.4(b). 

5308 M6137 BXL5604051 

422N-1 

05/22/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 05/22/2012 at approximately 0030 hours while monitoring the Establishments' 

processing procedures in Packaging area #1, I observed the following. There was 

black UFM (unidentified foreign material) on several breast fillets on a conveyor 

belt just prior to a final trim station. I also found two breast fillets with similar UFM 

on the conveyor belt immediately after the xray machine. The UFM specks 

measured up to 1/8" and the smears to approximately 2". I contacted 

and showed him my findings. A few breast fillets with the UFM continued to 

come down the conveyor belt just before the final trim station until approximately 

0105 hours. The affected product approximately 35 fillets were reconditioned per 

establishment SSOP procedure with chlorinated water by approximately 0130 

hours. My findings indicated a noncompliance with 9 CFR 416.4(d). 

(b) (6)
(b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN020205 

1522N-1 

05/22/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 05/21/2012 at 0700 hrs. in the evisceration department I had completed the 

on-line inspector breaks and I was walking towards the auto rehang area when I 

noticed the following non compliance: I observed that birds moving down 

evisceration line A were coming into contact with condemned carcasses in a gray 

condemn barrel. The two gray condemn barrels located on either side of the carcass 

conveyor belt were full of condemned carcasses. The barrels were placed next to the 

line and coming into contact with the carcasses on the evisceration line. Regulatory 

control was not initiated because only the necks were coming into contact with the 

condemned carcases. The necks are not harvested for edible purposes however this 

represents an unsanitary practice because the necks are not deemed inedible until 

removal from the carcass at a later point in the process. I noted another non 

compliance while in the re-hang area. I observed approximatley 15 carcasses on the 

floor under the auto rehangers covered with blood and feces. The carcasses had 

been on the floor for several minutes. That the carcasses were not being picked up 

in a timely manner represents an unsanitary operational condition. The birds were 

falling on the floor because the chutes underneath the auto rehang machines were 

backed up with carcasses. I informed and 

(b) (6)
(b) (6)

(b) (6)

(b) (6)

(b) (6)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN500805 

1722N-1 

05/22/2012 04A06 Poultry Finished 

Product Standards 

C I was performing a Finished Products Standards check at 0538 hours on the 

reprocessing line in the evisceration department when I noted the following 

noncompliance; The establishment failed to remove airsacculitits exudate from 

carcass identified by USDA for air sac removal. (5) carcasses of the (10) carcass 

sample identified for air sac removal contained air sac exudate, and (1) carcass of 

the (10) carcass sample contained cellulitis lesions. The establishment's written 

procedure for air sac removal states if 

. I initiated regulatory control by stopping the reprocessing line 

and informing Mr. and Mr. 

of the noncompliance. Regulatory control was relinquished to 

Quality Control so that corrective actions could be implemented to regain process 

control and perform rechecks in order to identify all affected product associated 

with the failure. 

5308 M6137 BXL5011051 

921N-1 

05/21/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C While performing Pre Operational Sanitation Inspection in the second processing 

area I found two noncompliances: At approximately 0845 hour, while inspecting the

 Room area, I found a noncompliance with regulatory requirement of 

regulation 9 CFR 416.4(a). On the wing line, there was pieces of fat and also a 

substantial accumulation of fat residue on the bars located under the blue 

conveyors. I immediately placed a retained/Rejected U.S. Tag N0. B31 406251 on 

the affected equipment. I then notified . All 

affected areas were scrubbed and rinsed by sanitation employees. Area was 

released at approximately 0910 hours, after sanitary conditions were restored. At 

approximately 0850 hours, while inspecting the Packaging area, I found a 

noncompliance with regulatory requirements of regulations 9 CFR 416.4(a) and 

416.2(a). On the Deboning Line, there were several 1/2" pieces of dried meat on the 

thigh deboning equipment. There were also several mosquitos on the cutting white 

boards of the deboning table. I immediately notified

 of my findings. All affected areas were immediately rinsed restoring 

sanitary conditions. Area was released to production at approximately 0905 hours. 

(b) (6)
(b) (6)

(b) (6)

(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE141005 

0019N-1 

05/19/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 0745 hours. I performed an unscheduled Operational Sanitation. 

The following non compliance was observed in 2nd Processing on equipment not in 

use; the blue incline conveyor located on the south wall in packaging department 

used to move backs into bins had a build up of fat and residue from the previous 

shifts production. Mr. was informed of my findings and of the 

forthcoming non-compliance. At 0758 Quality Control hold Tags were placed on 

conveyor until such time that conveyor can be properly cleaned. On April 21, 2012 

the same non-compliance was observed and documented on Non Compliance 

record # HYE2310041N/1. Regulation 416.4(a) states; sanitary operations. All 

food-contact surfaces, including food-contact surfaces of utensils and equipment, 

must be cleaned and sanitized as frequently as necessary to prevent the creation of 

insanitary conditions and the adulteration of product. 

5308 M6137 BXL3104052 

619N-1 

05/18/2012 04A06 Poultry Finished 

Product Standards 

C On 05/19/2012 while performing Pre-Chill Finished Product Standards, I observed 

noncompliance with the following regulatory requirements of regulation 9CFR 

381.76 (b). At approximately 0013 hours, I randomly removed a 10 bird sample 

from Line #2 in Plant #1 for Pre-Chill Finished Product Standards Check. I 

documented 35 points on the Processing Noncomformance's from the 10 bird 

sample. This exceeds the subgroup absolute limit of 30 points for the Processing 

Noncomformance's to be in control. I informed Quality Control of the failure and at 

approximately 0024 hours she performed a Recheck. Quality Control documented 

34 points, this exceeds the tolerance of 25 points allowed for the recheck, at this 

point the process is considered out of control. I informed

 of the noncompliance. Corrective actions were implemented. All 

rechecks at Pre-chill and Pos-chill passed bringing the process back in control. 

5308 M6137 BXL4204052 

518N-1 

05/17/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 05/17/2012 at approximately 2210 hours while monitoring the Establishments' 

Preoperational Sanitation Procedures in Plant #2 after Establishment SSOP and 

HACCP monitors completed their checks and before the start of production, I 

observed the following. There was a buildup of black UFM (unidentified foreign 

material) to approximately 1/8" on the guide bars inside the final wash cabinet for 

Line . The UFM on the top bar was up to approximately 1/8" thick along its entire 

length. There were several pieces of fat and tissue to approximately 2" on one spray 

head and the associated support bracket associated with the first wash cabinet on 

Line . There were numerous black specks and a piece of bone to approximately 

1/2" on top of the lower sprocket assembly where birds are dropped for Chiller #3. 

Sanitary conditions were restored by approximately 2230 hours. My findings 

indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.4(a) & (b), and 9 CFR 

416.13(c). 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6) (b) (6)

(b) (4)

(b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4205053 

918N-1 

05/17/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C While performing Pre-Chill Finished Products Standards Check, I observed 

noncompliance with the following regulatory requirements of regulation 9 CFR 

381.65 (e) and 417.2 (c)(4). On 05/18/2012 at approximately 0131 hours, I 

randomly removed a 10 bird sample from Line #1 in Plant #1, I found one out the 

ten birds with visible fecal contamination inside the bird on the left side of the ribs. 

The fecal material was a piece measuring approximately 1/2" long and 3/8" wide, 

dark green in color and pasty in texture. This exceed the limit of Zero Tolerance for 

the process to be in control. I informed 

and of the noncompliance, the 

protocol for fecal failure was implemented. Quality Control performed a Recheck at 

approximately 0153 hours and it passed. The cause of the deviation was the ball 

valve, (valve and metal shower heads targeting saddle cavity area partially closed. 

valve was weighted down). This is a violation of the critical limits of CCP-2B, 

of the Plant's HACCP Plan for Slaughter. 

5308 M6137 BXL0318053 

816N-1 

05/16/2012 01D01 SPS Verification C At approximately 1512 hours, while walking through the packaging area I 

observered the following noncompliance. The 2 drip pans that run the length of the 

Cut Up line were covered in heavy condensation that was running to the center 

seam and dripping off of the drip pan. At both ends of the line there are drip pans 

that go across the line, one end having product on it and the other end crossing 

over the package sealing machine also had heavy condensation. I immediately 

informed and of the 

noncompliance and had sanitation come to wipe down the drip 

pans, restoring sanitary conditions. My findings indicate a noncompliance with 9 

CFR 416.1 and 9 CFR 416.2(d). 

5308 M6137 BXL0708050 

216N-1 

05/16/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 05/16/2012 while monitoring the Establishments' Pre-operational Sanitation 

Procedures in Main Packaging Area, I found the following noncompliance with 

regulations 9CFR 416.1, 416.4 (a) and 416.13 (c). At approximately 0020 hours, I 

observed the following: Line , four removable metal trays had numerous pieces 

of fat, one metal tray had numerous pieces of ingesta and the drum dropper had 

pieces of fat measuring approximately 1" long and 1/2" wide from the previous day 

production. I immediately attached a U.S. Rejected Tag # B31 406364 to the Line. I 

notified of the noncompliance. He had Sanitation 

Personnel wash the entire area. I reinspected Line and found it acceptable. 

Sanitary conditions were restored at approximately 0030 hours, I then removed the 

tag from the line. Establishments Pre-operational Sanitation Records showed that 

Line # was inspected and found acceptable by Quality Control Personnel before 

USDA inspection. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6)

(b) (6)

(b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4808052 

015N-1 

05/15/2012 03J02 Slaughter HACCP C On 05/15/2012 while performing a Post-Chill Finished Products Standards Check at 

the exit of the Chiller #2 in Plant #1, I observed the following noncompliance with 

regulations 9 CFR 417. 2 (c)(4) and 381.65 (e). At approximately 0344 hours, I 

randomly select a 10 bird sample, I found one of the ten birds with visible fecal 

contamination inside the bird on the right leaf fat area by the tail. The fecal material 

was a piece measuring approximately 1/4 inch diameter in size, dark green in color 

and pasty in texture. I immediately asked the establishment personnel hanging 

birds from Chiller # 2 to stop hanging. Since there was no Packaging Supervisor 

available, I asked a Lead Person to tank the birds coming from Chiller #2. The Lead 

Person informed , I then showed him my findings. I also 

informed and of the noncompliance. 

Eight tanks of birds were on hold for rework. Quality Control did a recheck at 

approximately 0400 hours and it passed. 

5308 M6137 BXL4408054 

415N-1 

05/11/2012 03J02 Slaughter HACCP C On 05/12/2012 at approximately 0043 hours while monitoring the Establishments' 

Post-Chill Finished Products Standards, I observed the following. After taking a 

random 10 bird sample at the exit from Chiller #2 in Plant #1, I observed one bird 

with visible fecal contamination. There was a piece of intestine approximately 3" 

long outside the carcass. The intestine was attached to the carcass inside near the 

tail. There was fecal material leaking from the cut end of the intestine onto the 

exterior front side of the breast. The fecal material was medium brown in color, 

past in texture, and measured approximately 1/4". I contacted 

who was nearby. Hanging of birds going into packaging was stopped and four tanks 

of product were placed under QC hold tags pending rework. A recheck passed at 

0048 hours. My findings indicated a noncompliance with 9 CFR 381.65(e) and 9 CFR 

416.2(c)(4). 

5309 P6137A NJN340505 

1211N-1 

05/11/2012 01D01 SPS Verification C I was in the rack cooler at 2322 hours when I observed the following SPS 

noncompliance; There is an area of the concrete floor in the rack cooler, 

approximately 15 feet by 15 feet, in disrepair. There are loose rocks, dirt and 

"patches" of concrete missing from the floor creating an insanitary condition. This 

area is located just west of the entrance to the blast tunnel. No USDA reject tag was 

applied because the condition of the floor represents an SPS noncompliance and no 

product was involved. It is an SPS noncompliance because the floor is not being 

maintained in good repair as outlined in Regulation 9 CFR 416.2(b)(1). I notified

 and . 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (6)

(b) (4) (b) (4)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5706055 

411N-1 

05/10/2012 04A06 Poultry Finished 

Product Standards 

C While performing directed PHIS procedure Poultry Finished Product Standards, I 

observed noncompliance with the regulatory requirements of regulation 381.76(b). 

At approximately 2325 hours, I randomly removed a 10 bird sample from Line in 

Plant 2 for my Pre-Chill Finished Product Standards test. I accumulated 33 points on 

the Processing Nonconformance's from the 10 bird sample. This exceeds the limit of 

30 points for the Processing Nonconformance's to be in control. I informed 

of the Processing Nonconformance failure and she 

immediately performed a recheck. At approximately 2332 hours

 performed a recheck of the Processing Nonconformance's 

and it failed with 33 points. I informed of the 

noncompliance. Quality Control Personnel performed rechecks of the Processing 

Nonconformance's at the Pre-Chill and Post-Chill. All subsequent rechecks passed 

bringing the Processing Nonconformance's for Line back into control. 

5333 P7632 HYE181105 

2009N-1 

05/09/2012 01C02 Operational SSOP 

Review and 

Observation 

C At 0840 hours on May 09, 2012, while performing an operational sanitation 

inspection procedure I observed an establishment employee gather up five birds 

from the floor in front of the chiller exit tables and between the rehang table and 

the sorting tables. He carried two in one hand and three in the other to the 

reprocessing station where he put the birds on the "To Be Reprocessed" table which 

also had other product from the department. Regulatory control of the product was 

taken with the application of US Retain Tag #B38495104 and 

was notified of the forthcoming documentation of the failure to 

comply with the regulatory requirements cited above, including 9 CFR 416.4 which 

states, "Product must be protected from adulteration during processing, handling, 

storage, loading and unloading at and during transportation from official 

establishments." This also represents noncompliance with Step #7 of Part II, Section 

Two of the Establishment's SSOP Plan which states, " 

." The 

Product Reconditioning Procedure states in Line 5 under Post-Chilling - Whole Birds, 

Parts and Paws, " ." At 

0858 hours regulatory control of the product was relinquished with the acceptance 

of effective corrective actions to restore sanitary conditions, make appropriate 

disposition of product and the proposed preventive measure that a department 

retraining would be performed so that all associates understood the importance of 

proper sanitary handling of product. 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6)

(b) (6)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE550605 

4009N-1 

05/09/2012 01C02 Operational SSOP 

Review and 

Observation 

C While conducting Operational SSOP Review & Observation procedure, I observed 

the following non compliance: In 2nd Processing Department Segment Line #2, 

approximately 0334 hours, I observed a plant associate dumping an inedible yellow 

tub container half way filled with product that was staged on the floor underneath 

the Breast Processors onto an edible brown tote on a cart. I followed him to see 

what he was going to do with the product, he came to a stop in front of the Chicken 

Backs bone conveyor and dumped the contents of the brown tote onto moving 

conveyor. After closer inspection I observed many black specks of (UFM) 

unidentified foreign material and two wood splinters up to 1/4 inch in length on the 

product on the conveyor. I took Regulatory Control of the moving conveyor with 

the application of US Reject tag #B38495114 and the full bin of product with US 

Retained tag #B38494968. Another empty cardboard bin was set to catch the rest 

of the contaminated product and I tagged that bin with US Retained tag 

#B38494999. and Mr.

 were informed of the non compliance. Regulatory 

control was released at approximately 0343 after the belt was washed and sanitized 

to restore sanitary conditions. The product was released to QC for proper 

disposition to condemn the product and preventive measures were proffered by 

Mr. to retrain the employee. 

5308 M6137 BXL1904050 

308N-1 

05/08/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C While performing a Zero Tolerance Check, I observed noncompliance with the 

following regulatory requirements of regulation 9 CFR 381.65 (e) and 417.2 (c)(4). 

On 05/08/2012 at approximately 0123 hours, randomly 

removed a 10 bird sample from Line # in Plant #2, I found one out the ten birds 

with visible fecal contamination inside of the bird on the left side of the ribs area. 

The fecal material was two pieces, one approximately 3/16" and the other one 

1/16" diameter in size, dark green in color and pasty in texture. This exceed the 

limit of Zero Tolerance for the process to be in control. I informed 

of the noncompliance. The protocol for 

fecal failure was implemented. Quality Control performed a Recheck at 

approximately 0150 hours and it passed. The cause of the deviation was the bird 

turner not working properly. This is a violation of the critical limits of CCP-2B, 

of the Plants' HACCP Plan for Slaughter. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (4) (b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2305051 

009N-1 

05/08/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 05/08/2012 at approximately 2355 hours while monitoring the Establishments' 

Preoperational Sanitation Procedures in Packaging Area #1 after Establishment 

SSOP and HACCP monitors completed there checks and before the start of 

production, I observed the following. There was a thick layer of white fatty paste 

along the entire length on the white nylon support brackets associated with the 

short conveyor belt nearest the dumper in the Plant #2 sorting and sizing line. 

There were numerous pieces of fat and tissue to 1/4" on two of the stainless chutes 

that direct birds to a rehang line at the same location. Sanitary conditions were 

restored by rinsing with potable water per establishment policy by approximately 

0005 hours. At approximately 0010 hours I observed numerous pieces of fat and 

tissue to approximately 3" on two chutes associated with Breast Processor #10. The 

chutes direct cut product to the collection belts below the machine that deliver the 

product to the packaging area. The chutes were rinsed with potable water restoring 

sanitary conditions by approximately 0015 hours. My findings indicated a 

noncompliance with 9 CFR 416.1, 9 CFR 416.4(a) , and 9 CFR 416.13(c). 

5308 M6137 BXL0813051 

207N-1 

05/07/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On Monday May 7th 2012, while performing Pre-Operational Sanitation Inspection 

in Plant 1, I found the following noncompliance: At approximately 0650 hours, 

while inspecting the Gizzard Harvester Deffater located on line 2, I noticed 

numerous pieces of ingesta and small pebbles inside of the gizzard Harvester 

Deffater's cover. According to the establishment's Pre-Operational records, this 

equipment was inspected and found acceptable by prior to 

USDA inspection. I placed a U.S.Rejected/Retained tag No. B31 407639 on the 

affected equipment and then notified . At 

approximately 0655 hours, while inspecting the Liver tumbler located on line 2, I 

noticed 1/2" piece of liver inside of the tumbler. This is a product contact surface. 

According to the establishment's Pre Operational records, this equipment was 

inspected and found acceptable by prior to USDA inspection. I 

placed a U.S. Rejected /Retained tag No. B31 407640 on the affected equipment 

and then notified . My findings indicate a noncompliance 

with regulatory requirement of regulation 9CFR 416.14 and 9CFR 416.4(a) At 

approximately 0708 hours, while inspecting the 

located at the chiller's exit plant 1, I found all the piping system full with pasty fat 

residue. There was also decaying fat residue inside of the filter located next to the 

system's pump. I placed a U.S Rejected/Retained tag No. B31 406266 on the 

affected system. was notified of the noncompliance. My 

findings indicated a noncompliance with regulatory requirement 9CFR 416.4(a). All 

affected equipment was properly scrubbed and washed by sanitation. U.S. tags 

were removed by USDA. Area was released by 0745 after sanitary conditions were 

restored. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6)

(b) (6)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4409051 

107N-1 

05/07/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 5/7/12 at approximately 0655 hours while preforming the establishments 

Preoperational Sanitation Procedure in Plant # 2 , I observed the following in 

area # 3 . The Rehang Transfer Table on line # had a build up of white chicken fat 

and grease underneath the top side of the belt . The area was approximately 18 " in 

length and about 3 " wide . I immediately placed RETAINED/REJECTED Tag # B31 

406231 on the belt and informed , he had two of his workers 

scrub and rinse the area . Once the area was clean it was reinspected . At 0703 the 

table was found to be in sanitary condition and the tag was removed . My findings 

indicate non compliances with the following regulations CFR 416.1,CFR 416.13(a), 

416.13(c), 416.14 and 416.4(a) 

5308 M6137 BXL0808052 

504N-1 

05/04/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 05/03/2012 while monitoring the Establishments' Preoperational Sanitation 

Procedures in Main Packaging, I found the following noncompliance with 

regulations 9CFR 416.1, 416.4(a) and 416.13 (c). At approximately 2358 hours, I 

observed the following: Line #1 all the chutes that are associated with the white 

removable cutting tables that lead to the white conveyor belt, had slimy residue 

and numerous pieces of fat and meat from the previous day production. These 

chutes are consider to be product contact surface. I immediately attached a U.S. 

Rejected Tag # B31 406365 to the Line. I notified and

 of the noncompliance. They had Sanitation Personel scrub 

and rinse the chutes. Sanitary conditions were restored at approximately 0012 

hours, I then removed my tag. 

5309 P6137A NJN110805 

3504N-1 

05/04/2012 01C02 Operational SSOP 

Review and 

Observation 

C I was performing operational sanitation in the packaging department at 0705 hours 

when I noted the following noncompliance; I observed a plant employee overspray 

a stack of product trays, approxiamtely 300 trays, while washing down the hopper 

for the polar massager. The plant employee was washing down the polar massager 

to remove the spice mixture and product residue when he oversprayed the stack of 

uncovered trays. I applied USDA Reject tag B13468938 to the stack of trays at 0707 

hours and notified and 

of the noncompliance. The trays were released at 0750 hours after 

corrective actions were implemented. No product was involved. 

(b) (6)
(b) (6) (b) (6)

(b) (6)

(b) (6)

(b) (6) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3209053 

104N-1 

05/03/2012 04A06 Poultry Finished 

Product Standards 

C On 05/04/2012 at approximately 0515 hours while monitoring the Reprocessing 

Line procedures in plant #2, I observed the following. After selecting a random 

10 bird sample from the location after the final house inspectors, I found three of 

the ten birds with visible airsacculitis exudates. One bird had visible airsacculitis 

exudates measuring approximately 1/2" by 1/2" on the left fat flap. The fat flaps are 

normally removed as part of the Reprocessing Line process. The other two birds had 

extensive visible exudates on the left side from the abdominal air sac to the thoracic 

air sac region. At that point the process is judged to be out of control. As a foreman 

was not available, I proceeded to the rehang station and found 

. I showed him my findings. Line was stopped and birds were tanked 

until a retraining was conducted. A recheck passed at approximately 0527 hours. A 

partial tank of product was reworked and released by approximately 0557 hours. 

My findings indicated a noncompliance with 9 CFR 381.76(2) and 9 CFR 381.84. 

5308 M6137 BXL1918052 

101N-1 

05/01/2012 01D01 SPS Verification C At approximately 1552 hours, while walking through the Packaging area I observed 

the following noncompliance. At the Breast Halver machine across from the Bag 

Fryer line there was a large area of heavy beaded condensation on the drip pan 

directly above the tank of ice used to ice product as it is put into brown tubs and 

put on pallets. I immediately had a company employee move the almost full tank of 

ice and clean the area before the condensation dripped into the ice and 

contaminated it, restoring sanitary conditions. I then contacted 

and told him about the condensation and we walked to the area, the 

employee was still cleaning the area and the tank of ice was returned to it's original 

position for use. said that he had instructed the employees to 

keep the area wiped down and that he had turned a fan toward the area to keep the 

condensation problem down. This is a repetitive noncompliance with 9 CFR 416.1 

and 9 CFR 416.2(d). 

5309 P6137A NJN280605 

3201N-1 

05/01/2012 01C02 Operational SSOP 

Review and 

Observation 

C I was verifying operational sanitation conditions in the new product room at the I Q 

F line # 2 at the start up of operations when I observed the following 

noncompliance: there were several pieces of fat on the sorting belt from the 

previous day's productions. The belt is a direct food contact surface. I retained the 

belt by applying the US reject tag #B39415971 at 2334. I notified the 

and the . The US Reject tag 

was removed after the sanitary condition was restored at 2339. There was no 

product involved. 

(b) (6)
(b) (6) (b) (6)

(b) (6)

(b) (6) (b) (6)

(b) (4)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN410505 

2001N-1 

05/01/2012 04A06 Poultry Finished 

Product Standards 

C I was performing a FPS (Finished Product Standards) check at 0241 hours on the 

reprocessing line in the evisceration department when I noted the following 

noncompliance; The establishment failed to remove airsacculitis exudate from 

carcasses identified by USDA for air sac removal. (1) carcass of the (10) carcass 

sample identified for air sac removal with a split tail contained air sac exudate. The 

establishment's written procedure for air sac removal also states that 

. During the recheck performed at 

0248 hours I noted (1) carcass of the (10) carcass sample identified with a split tail 

contained air sac exudate. The establishment's written procedure for air sac 

removal states 

. I 

initiated regulatory control by stopping the reprocessing line and immediatly 

informing , and 

of the noncompliance. 

5309 P6137A NJN370304 

3027N-1 

04/27/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 04/27/2012 I was performing an operational sanitation verification task in the 

packaging department at 0056 hrs. On the product belt of line #1 there where 

boneless/skinless thigh fillets in the process of being bulk packed. I found two 

boneless/skinless thighs on the product belt that contained black specks, one thigh 

had a black grease smear on the outer surface. I immediately informed 

and as well 

as . The immediate corrective actions by the establishment 

was to stop the production line and wash and sanitize the product belt. The product 

on the belt, including the product already bulk bagged was put on hold for 

reprocessing. I applied U.S. Retained Tag #B13468958 to the four stacked tubs of 

product. The belt was washed sanitized, reinspected and released. After the 

involved product was reprocessed, I inspected and found it to be acceptable. I then 

removed the retain tag and gave control of the product back to the establishment. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6)

(b) (4)

(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN381404 

3027N-1 

04/27/2012 04A06 Poultry Finished 

Product Standards 

C At approximately 0834 hours while performing PHIS task for Finished Product 

Standards on the reprocessing line I observed five carcasses of a ten carcass sample 

with ingesta both in the cavity and in the crop area. I removed the carcasses from 

the line and showed my findings to , and had 

him notify the QC technician on the floor to as per the plant 

reprocessing procedure which states " 

. The subsequent retest performed at 0845 hours by the QC technician found 

two carcasses with ingesta. All product was diverted from the line and was sent for 

further processing by the establishment. At 0855 hours another recheck was 

performed and at which time the check passed. Production was then allowed to 

continue as normal. I informed Mr. , of the 

forthcoming non-compliance. 9 CFR 381.91(b)(1) states "Any carcass of poultry 

accidentally contaminated during slaughter with digestive tract contents shall not 

be condemned if promptly reprocessed under the supervision of an inspector and 

thereafter found not to be adulterated. Contaminated surfaces that are cut shall be 

removed only by trimming. Contaminated surfaces that are not cut may cleaned by 

trimming alone, or at an approved reprocessing station away from the main 

processing line, by any method that will remove the contamination, such as 

vacuuming, washing, and trimming, singly or in combination. All visible specks of 

contamination must be removed, and if the inner surfaces are reprocessed other 

than soley by trimming, all surfaces of the carcass shall be treated with chlorinated 

water containing . 

5333 P7632 HYE021604 

2327N-1 

04/27/2012 04A06 Poultry Finished 

Product Standards 

C At 1316 hours after observing that a high percentage of birds presented for 

post-mortem inspection were being hung back on the Reprocessing Line for 

pathology and that the plant had initiated their alternative On-Line Vaccuuming/Air 

Sac Removal procedure, I elected to verify the effectiveness of the alternative 

procedure. I went to the FPS Pre-Chill Station on Evisceration Line I and collected a 

ten-bird sample which had been vaccuumed in the alternative procedure. I observed 

airsacculitis exudate adhering to the leaf fat, renal areas and thoracic cavities of the 

six of the ten birds in the sample. I notified of my findings and at 1321 

hours I performed the required retest and observed airsacculitis exudate adhering 

to the leaf fat, renal areas and thoracic cavities of the two of the ten birds in the 

sample. I notified of the forthcoming 

documentation of the failure to comply with the regulatory requirements cited 

above. 

(b) (6)
(b) (6)(b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2809045 

626N-1 

04/26/2012 06D02 Other Inspection 

Requirements 

C On 04/26/2012 at approximately 0523 hours, I performed a presentation check on 

Line , station #3 failed with 3 not reflected at line speed BPM. At 

approximately 0603 hours QC performed a recheck at line speed BPM and 

station #1 failed with 3 membrane , 3 not reflected, 1 viscera on shackle, 2 viscera 

not free, total of 40 points. Station #2 failed with 3 viscera on shackle, total of 24 

points and station #3 failed with 3 viscera on shackle, 1 not reflected, total of 26 

points. This exceeded the limit of 3 occurrences of one error and the 25 

nonconformances for the process to be in control. was 

informed and the Line speed was reduce to 81 BPM. At approximately 0617 hours 

QC performed a recheck and failed. The Line speed was reduced to 70 BPM. At 

approximately 0633 hours the rechecks passed bringing the process back in control. 

At approximately 0611 hours, I performed a presentation check on Line , station 

#1 failed with 3 viscera on shackle, 2 not reflected, total of 28 points. Station #2 

failed with 2 viscera not uniformed, 2 viscera on shackle, 3 not reflected, total of 38 

points. At approximately 0628 hours QC performed a recheck at Line speed of 

BPM and station # 2 failed with 2 viscera not uniform, 3 viscera on shackle, total 40 

points. Station #3 with 3 viscera on shackle, total of 24 points. This exceed the limit 

of 3 occurrences of one error and the 25 nonconformances for the process to be in 

control. was informed and the Line speed was reduced 

to 81 BPM. informed me at approximately 0635 hours 

that for the rest of the shift the Line speed will stay at 81 BPM. This is a 

noncompliance with regulation 9CFR 381.76 (b). 

5308 M6137 BXL3905043 

127N-1 

04/26/2012 01D01 SPS Verification C On 04/26/2012 at approximately 2200 hours while monitoring Facilities, I observed 

the following. I entered the Plant #2 Dressing Room/Lavatories and on the stainless 

partitions used by both Packaging and Slaughter employees to hang their aprons 

while on break there were numerous pieces of dried and semi-dried fat and tissue, 

and a layer of greasy fat covering must of the surface of the partitions. The bottom 

lip of the partition acts as a catch tray for filth and had a layer of black/brown 

(UFM), and dried and decaying tissue at least 1/8" thick. There were raisins on a 

bench located near the wall indicating that food might be consumed at this 

location. The floor in the hand wash sink area was covered with large patches of 

liquified and semi-dried brown greasy filth. The toilet/urinal area floor was covered 

with the same greasy brown (UFM) as well as a layer of black (UFM) that appeared 

to be coming from the toilets. Several of the toilets were covered with the same 

black (UFM). I contacted after Preoperational Sanitation was 

completed and showed him my findings. He said that the restrooms are cleaned 

with soap only on Mondays. Two sanitation workers cleaned the restroom for 

approximately 30 minutes until was satisfied. He said a more 

though cleaning would be performed on 04/27. My findings indicated a 

noncompliance with 9 CFR 416.1 and 9 CFR 416.2(h)(1). 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN200704 

5526N-1 

04/26/2012 01C01 Operational SSOP 

Record Review 

C I was verifying operational sanitary conditions in the evisceration department at the 

start up of operations when I noted the following noncompliance; two of the brown 

salvage tubs used to chill and store the salvaged product had fat and meat particles 

on them from the previous days production. I noted one tub on "B" line at 2318 

hours and one tub on "A" line 2320 hours. The tubs were staged for use at the 

salvage stations and had ice in them. The brown tubs are a direct product contact 

surface area. I notified and 

of the noncompliance. No USDA tag was applied because the 

establishment implemented immediate corrective actions and no product was 

involved. 

5333 P7632 HYE001604 

3126N-1 

04/26/2012 04A06 Poultry Finished 

Product Standards 

C At 0948 hours after observing that a high percentage of birds presented for 

post-mortem inspection were being hung back on the Reprocessing Line for 

pathology and that the plant had initiated their alternative On-Line Vaccuuming/Air 

Sac Removal procedure, I elected to verify the effectiveness of the alternative 

procedure. I went to the FPS Pre-Chill Station on Evisceration Line I and collected a 

ten-bird sample of birds which had been vaccuumed in the alternative procedure. In 

the thoracic cavities of the third and eighth birds I observed affected lung tissue 

with hemorrhagic lesions adhering to the ribcage. At 0956 hours, I performed the 

required retest and observed affected lung tissue adhering to the ribcage in the 

thoracic cavity of the sixth bird. I notified 

of the forthcoming documentation of the failure to comply with the regulatory 

requirements cited above. 

(b) (6)
(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0605040 

826N-1 

04/25/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 04/26/2012 at approximately 0005 hours while monitoring the establishments' 

Preoperational Sanitation Procedures, I observed the following. In Packaging area 

#1, there were several pieces of fat and tissue to approximately 2" on a sprocket 

associated with the overhead belt that transfers product from the Deboning 

Room to Packaging Area #1. The sprocket was at a location at the beginning of a 

belt located near the elevator. The tissue gave off a strong sour odor. There were 

numerous black specks of (UFM) dried on a white cutting wheel associated with 

Line at a point on the Plant #1 Halving Machine where the front halves 

(Breast & Wings) are dropped. There were numerous pieces of fat and tissue to 

approximately 1/4" on the stainless and white support brackets associated with the 

collection belt for line also at the plant #1 Halving Machine. There was a layer of 

yellowed product dried in an area measuring approximately 2' by 6" on the line 

top catch tray associated with the plant #1 Halving Machine. There were numerous 

pieces of fat and tissue to approximately 2" on the white cutting wheel, stainless 

cutting blade and other parts associated with Line at the plant #1 Halving 

Machine. The area of Line adjacent to the Plant #1 Halving Machine, 

approximately 40', had numerous pieces of fat and tissue to approximately 4" on 

the rail and rail supports, chain, shackles, and drip pan. Sanitary conditions were 

restored by approximately 0020 hours by rinsing the area with potable water per 

establishment policy. In Packaging Area #2, there were approximately 10 pieces of 

white paint to approximately 1/4" on a product belt near line #1. The belt collects 

carcasses from all four lines. The carcasses are ground (MDP) and used for further 

processed products. Sanitary conditions were restored by approximately 0030 

hours. My findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 

416.4(a) & (b) and 9 CFR 416.13(c). 

(b) (6)
(b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2213041 

824N-1 

04/24/2012 04A06 Poultry Finished 

Product Standards 

C On 04/23/2012 at approximately 0905 hours in Plant #2, I found the following 

noncompliance, while performing a Finished Product Standards check at Gib Chiller 

#3. After randomly selecting a sample of 10 necks exiting the Gib Chiller I found a 

total of 6 major nonconformance points which exceeds the absolute limit of 5 

major nonconformance points for necks. I immediately notified QC of the 

noncompliance, QC then put a hold tag on the tank of necks while she proceeded to 

do a recheck of the necks. QC failed her recheck of the necks with 6 major 

nonconformance points at 0925 hours, which exceeds the tightened criteria for 

necks of 3 major nonconformance points. At that point the process is considered to 

be out of control. QC proceeded to have the tank of necks that had been placed on 

hold condemned and they were dumped at approximately 0930 hours. QC did a 

recheck on the new tank at approximately 1011 hours which passed with 2 major 

nonconformance points and another recheck at approximately 1101 hours, which 

also passed with 2 major nonconformance points. A new second tank was then put 

in place and QC did a third recheck on the second tank at approximately 1120 

hours, which also passed with 2 major nonconformance points, bringing the 

process back in control. The hold tags were removed from the tanks at that point, 

allowing product to proceed back into production. My findings indicate a 

noncompliance with 9 CFR 381.76(b). 

5308 M6137 BXL0416042 

323N-1 

04/23/2012 04A06 Poultry Finished 

Product Standards 

C At approximately 0930 hours, while monitoring the establishment's Pre-Chill Finish 

Product Standard in Plant #1, I found the following noncompliance. After randomly 

removing a 10 bird sample from line 2, I documented a total of 36 weighted 

nonconformance points under processing category. This exceeded the subgroup 

absolute limit (30) for the process to be under control. I immediately informed QC, 

who did a recheck at approximately 0937 hours to verify sample validity. She failed 

the recheck with with a total of 29 weighted nonconformance points. This exceeded 

the tolerance (25) allowed for the recheck. At that point the process is considered 

out of control. I informed of the noncompliance so that 

corrective action could be taken. By approximately 1020 hours, QC had performed 

two consecutive passing Pre-Chill checks on line 2 bringing the process back in 

control at the pre chill area. QC performed Post-Chill rechecks every half hour 

starting at 1035 hours to 1145 hours. The Pre-Chill criteria for the processing 

category was applied to the Post-Chill rechecks. All Post-Chill checks passed. 

Product was deemed to be acceptable for shipping. 

(b) (6)
(b) (6) (b) (6) (b) (6)

(b) (6) (b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1519040 

723N-1 

04/23/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 1558 hours, while performing a Pre-Chill Finish Product Standard 

check on line 2 plant 1, I found one out of the 10 birds contaminated with feces. 

The Fecal matter was inside of the bird cavity on the right side of the rail area. The 

feces were light yellow in color and pasty in texture measuring approximately 1/8" 

in diameter. I immediately notified of the noncompliance. 

She took immediate corrective action by ensuring proper implementation of the 

establishmen's zero tolerance fecal protocol. Venter was found to be the cause of 

deviation. Quality control performed a passing recheck at approximately 1622 

hours bringing CCP2B back into control. Post-Chill checks were performed from 

1641 hours to 1742 hours. All product was found acceptable for shipping. 

5308 M6137 BXL2512045 

223N-1 

04/23/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 4/21 while monitoring the Establishments Operational Sanitation Procedure at 

approximately 0523 in Plant # 1 I observed the following . The tray underneath the 

chiller rehang belt was full of birds which caused birds to fall on the floor there were 

also birds laying on the metal stands , there were approximately 15-20 birds on the 

floor . workers were stepping on some birds while trying to maneuver their way 

around others . I immediately contacted a supervisor . was 

close , so the situation was brought to his attention . The foreman was 

notified . had the birds cleared off the stands and the tray beneath the 

rehang table cleared also . Putting the establishment back in compliance at 

approximately 0546 . The SSOP plan states that 

. My findings indicate non 

compliances with the following regulations CFR 416.13(b) CFR 416.14 and CFR 

416.1 . 

5309 P6137A NJN170204 

2923N-1 

04/23/2012 01C01 Operational SSOP 

Record Review 

C On April 21, 2012 I was in the New Products Room at 1737 hours reviewing SSOP 

records for production when I noted that the SSOP records (The General 

Sanitation Log and the Daily Implementation and Monitoring Log for the Daily 

Production) had both been verified, pre-signed and dated by the supervisor prior to 

the end of production. Production did not finish until 1921 hours. I informed 

of the non compliance. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (4)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN261604 

5123N-1 

04/23/2012 04A06 Poultry Finished 

Product Standards 

C While performing PHIS task Finish Product standards I performed a verification 

inspection procedure of the establishment's " " 

program in the evisceration department at 1126 hours when I observed a rack of 

birds staged for inspection prior to being put back on the line.The rack did not have 

the "Production Hold" tag applied, thus indicating the carcasses were ready to be 

introduced back into production. I examined the carcasses and noted one carcass 

with cellulitis affected tissue. I applied US Retained Tag # B4019355 to the rack. I 

informed and QC technician on the floor of my 

findings and the Forthcoming noncompliance .At 1130 hours I removed the tag so 

the establishment could initiate corrective actions.The requirements of 9 CFR 

381.86 and the establishment's cellulitis SOP program were not met. 9 CFR 381.86 

states; "Any organ or other part of a carcass which is affected by an inflammatory 

process shall be condemned and, if there is evidence of general systemic 

disturbance, the whole carcass shall be condemned.The establishment's cellulitis 

SOP program Part 2(h), sub section (b) states;" t 

" 

5333 P7632 HYE320704 

3323N-1 

04/23/2012 04A06 Poultry Finished 

Product Standards 

C I was in the First Processing department conducting a Poultry Finished Product 

verification task on the reprocessing line at approximately 0447 hours when I 

observed the following non compliance: I selected ten birds marked with a split tail 

for air sac reprocessing, two of the ten carcass sample had large amounts of yellow 

air sac exudate inside the cavity along the rib cage of the carcasses. I took regultory 

control of the reprocessing line with th appilcation of U.S. retain tag B 38495130 

and informed , of my 

findings and the forthcoming noncompliance. 

performed the recheck and passed. Regultory control was relinquished at 0453 

hours. 

5333 P7632 HYE231004 

1221N-1 

04/21/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 0725 hours. I performed an unscheduled Operational Sanitation. 

The following non compliance was observed in 2nd processing, on equipment not in 

use; the blue incline conveyor located on the south wall in packaging department 

used to move backs into bins, had a build up of fat and residue from the previous 

shifts production. U.S. rejected tag #B38494992 was applied. Mr. 

was informed of my findings and of the forth coming non-compliance. At 0820 

regulatory control was released to Quality Control. QC hold tags were placed on 

conveyor until such time that conveyor can be properly cleaned. Regulation 

416.4(a)states; Sanitary operations. All food-contact surfaces, including 

food-contact surfaces of utensils and equipment, must be cleaned and sanitized as 

frequently as necessary to prevent the creation of insanitary conditions and the 

adulteration of product. 

(b) (6)
(b) (6) (b) (6) (b) (6)

(b) (6) (b) (6)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5704040 

221N-1 

04/20/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 04/21/2012 at approximately 0140 hours while monitoring Facilities, I observed 

the following. There is rust developing on the exterior surfaces of chiller #4 at the 

outflow end, on the underside of the catch tray that directs product from the 

Finishing Chiller for Chiller #4 to the rehang belt, on the exterior support brackets of 

the rehang belt from Chiller #4, on the exterior surfaces of the Finishing Chillers for 

Chiller #4 & #3, and on the support brackets of the outflow conveyor from Chiller 

#3. There was a small puddle of light yellow fluid on a bracket associated with the 

outflow conveyor for Chiller #3. The fluid was pooling and dripping onto the 

conveyor belt directly below which moves product from the rehang belt for Chiller 

#4 to a cutup line in Packaging. I contacted and showed him my 

findings. A plastic sheet was placed directing the light yellow fluids on Exit Chiller #3 

conveyor belt to the floor. My findings indicated a noncompliance with 9 CFR 

416.4(d) and 9 CFR 416.3(a). 

5333 P7632 HYE010404 

5020N-1 

04/20/2012 01C02 Operational SSOP 

Review and 

Observation 

O While in the Rack cooler at 2102 hours, I was performing the PHIS task review and 

observation of Operational SSOP when I observed the following noncompliance: 

there was one pallet of Rotisserie Chicken Marinade mix not in the spice cage and 

without a Q.C. hold tag. I inspected the pallet and found one bag opened and half 

used with an unknown liquid pooled in the creases of the crumpled up package. 

, was informed of the noncompliance 

and proffered that the product would be retained in the spice cage. I reviewed the 

establishment s SSOP plan and it states Part 2 Operational Sanitation Section 4 Dry 

Storage Step # 4 :

 I went to the Weigh and Price department s office and informed 

, of the noncompliance. 

was also notified and he retained the open bag. The establishment s 

corrective action was discarding the open bag of Chicken Marinade. In response to 

the SSOP operational sanitation noncompliance, dated 4-20-12, in the Rack cooler I 

reviewed the establishment s SSOP records to verify compliance with the regulatory 

requirements for record keeping. I noted that upon USDA request the 

establishment did not have records of documenting corrective actions or preventive 

measures for the noncompliance dated 4-20-12. I notified Mr. 

of the record keeping noncompliance. In response to 

the establishment s appeal dated 4/25/12 I have agreed with the establishment 

that the applicable requirement in the SSOP Section 4 Step #3 which states 

" ." The SSOP was implemented but it 

did not prevent the unknown liquid from being present on the opened spice bag. 

This represents noncompliance with 9CFR 416.4 (d). 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (4)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3816040 

319N-1 

04/19/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 04/17/2012 at approximately 1458 hours while monitoring the Establishments' 

Operational Sanitation Procedures in Packaging, I observed the following. There 

were numerous black specks of foreign material to approximately 1/8" in size on 

several birds on the top layer of a partially filled bin with blue plastic liner at the 

#258 Drop for whole birds. Most of the black specks were on the skin of the breast, 

back and legs. I attached USDA Retain Tag #B31406218 to the bin and contacted

 to inform him of my findings. He immediately took corrective 

action and had the bin of birds reworked, which restored sanitary conditions. I 

released the bin back to production at approximately 1545 hours after rechecking 

the birds and finding them acceptable. My findings indicate a noncompliance with 9 

CFR 416.4(d). 

5308 M6137 BXL0805044 

618N-1 

04/18/2012 03C02 Raw Intact HACCP C On 04/17/2012 at approximately 0040 hours while monitoring the Establishments' 

Operational Sanitation Procedures in Packaging Area #1, I observed the following. 

After checking a few of the birds coming out of the Chillers from Plant #2 and 

finding nothing, I proceeded to the end of Packaging Line where Organic birds 

were beginning to be wrapped. I checked approximately 15 birds at random and 

found one of the birds with a piece of shiny metal. Using a ruler from the 

establishments' nearby office the metal shard measured approximately 8mm by 

1mm. The metal shard was located on the breast near the right wing. I contacted

 and showed him my findings. was 

called. According to FDA guidance metal in a food product in excess of 7mm is 

considered to be a health hazard. The 8mm metal shard that I observed exceeded 

that limit. I reviewed the Establishments' Hazard Analysis-Raw Not GroundPackaging at Step 8 'Packaging' under 'Potential Hazard Introduced, Controlled or 

Reduced at this step' the plan list 

. My findings indicated a noncompliance with 9 CFR 417.2(a)(1). 

5308 M6137 BXL0904043 

119N-1 

04/18/2012 01D01 SPS Verification C On 04/18/12 at approximately 2325 hours while monitoring the Establishments' 

Facilities, I observed the following. There were numerous specks of black and brown 

(UFM) to approximately 1/4" with the consistency of rust on the tops of several 

pallets of brown product tubs in the Plant #2 aged breast cooler. The product with 

the heaviest concentration of UFM was under the first overhead compressor by the 

door. I contacted and showed him my findings. The lids 

on approximately 20 tubs were replaced. Two gray containers used for salvaged 

parts were covered with the UFM. The containers were taken to the tub wash room. 

The plastic bags covering bulk wrapped wing sections in a gray product basket was 

rinsed. Sanitary conditions were restored by approximately 2335 hours. 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (6)

(b) (6)

(b) (6)

(b) (6)

(b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5202041 

718N-1 

04/18/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 4/17 at approximately 2336 hours I observed the following while preforming 

the Preoperational Sanitation Procedure task in Plant # 1 . In the Paw Room the 

bottom side of the flex belt that carries product to the Condemn Room had a thick 

layer of fat and grease covering a 4'- 5' span of the middle section of the belt . I 

immediately placed US Retained/Rejected tag # B-31406342 and contacted

 . had two of his workers rewash and rinse the belt . The 

belt was then reinspected. Once sanitary conditions were restored the tag was 

removed . At approximately 2243 the establishment was back in compliance . At 

2245 hours the Auto transfer Tables on line 1 and 2 were inspected. The table one 

line 1 was unacceptable . The Belly Pan on the bottom side of the table had a thin 

layer of grease from the previous days production , my findings were the same on 

the conveyor on line # 2 . I once again contacted . had 

one of his workers clean the inside of the Belly Pan , the lines were reinspected after 

they were cleaned , restoring sanitary conditions at approximately 2249 . At 2254 

Chiller # 1 was inspected , it was also dirty there was a yellowish film on the outer 

edge of one of the paddles which was approximately 3 " by 5" in size . 

was notified at once . had the outer edge of the paddle scrubbed and 

wiped clean sanitary conditions were restored at approximately at 2306 and the 

establishment was ready for production . PACKAGING PLANT # 1 At approximately 

0010 hours the leg processors were inspected . The yellow wiring on the processors 

had a build-up of mold and black scum . I immediately informed 

of my findings . had the wires scrubbed and rinsed. At approximately 

0015 sanitary conditions were restored . The Room was inspected at 

approximately 0020 . In the Room there were pieces of meat from the 

previous shifts production on the Wing Transfer Conveyor on line #

 was notified of the noncompliance . had the conveyors rewashed 

and rinsed , putting the company back in compliance . At 0027 the Wing 

Conveyors were inspected . There were pieces of fat and bone between the plastic 

guide bars under the belt . I immediately placed US RETAINED/REJECTED 

tag # B-34106341 on the conveyor and contacted . had the 

belt rewashed and rinsed . At approximately 0035 sanitary conditions were 

restored and the area was ready for production .My findings indicate non 

compliances with the following regulations 9CFR 416.14,9 CFR 416.4(b), 9 CFR 

416.4(a), 9CFR 416 , and 9CFR 416.13(c) . 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN140804 

3418N-1 

04/18/2012 01C01 Operational SSOP 

Record Review 

C I was in the evisceration department verifying operational sanitation at 0415 hours 

when I observed the following noncompliance: I noted the north end of the 

evisceration department was full of steam and there was an offensive odor. I also 

noted there was an excessive amount of condensation on the overhead pipes. The 

pipes above the paw chiller had beaded condensation that was dripping into the 

paw chiller. The fan located above the south end of the paw chiller was covered 

with beaded condensation and was spitting droplets of condensation into the 

chiller, and onto the product conveyor located beneath it. The overhead pipes 

above the auto rehanger had beaded dripping condensation located directly above 

the product conveyors and evisceration lines. I applied USDA retain tag to the 

evisceration department at 0416 hours and notified

 and of the noncompliance. After 

corrective actions the auto rehang area was released at 0440 hours. The paw chiller 

and product conveyors were released at 0600 hours. The affected product was 

released the following day after corrective actions were implemented by the 

establishment. In response to the SSOP operational sanitation noncompliance, 

dated 4-18-12, in the evisceration department I reviewed the establishment's SSOP 

records the following day to verify compliance with the regulatory requirements for 

record keeping. As part of my SSOP records review I noted the establishment had 

identified a record keeping error for the SSOP failure which occurred on 4/18/2012, 

and that the records had been signed off as acceptable at the end of the shift by the 

authorized establishment employee. The establishment did not have records 

documenting corrective actions or preventive measures for the two record keeping 

errors as required by 9 CFR 416.16. I notified Ms. 

of the record keeping noncompliance. 

(b) (6)
(b) (6) (b) (6) (b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE201604 

3017N-1 

04/17/2012 01C02 Operational SSOP 

Review and 

Observation 

C At 1218 hours on April 17, 2012, while performing a Finished Products Standards 

Post Chill procedure at the South CHciller exit, I observed that the chiller rehand 

table was backed up with birds. I observed that the catch-basket designed to 

prevent product overflow beneath the incline belt feeding the rehang table was full 

and overflowing. I went to the north side of the rehang table and observed 28 birds 

on the floor around the catch-basket. In less than ten seconds I observed 8 more 

birds fall from the table to the floor before I observed a plant employees pick up 

two birds from the floor. I observed no one taking any effective measures to regain 

control of the process to stop birds from falling to the floor. Regulatory conrol of 

the rehang table was taken with the application of US Reject Tag B38 494936 and

 was noified of the forthcoming documentation 

of the failure to comply with the regulatory requirements cited above. While 

observing production pick up the birds around the catch-basket, I observed a plant 

associate use a long wire hook to drag birds across the the floor and the water 

flowing across it and place them into a pile on the floor next to the reprocessing 

cart. Regulatory control of this product was taken and Ms. was notified of 

the forthcoming documentation of the failure to comply with the regualtory 

requirements cited above including Line of the establishment's Reprocessing 

Procedures, which state that 

. The affected product was released to QC and taken to 

reprocessing for reconditioning. Regulatory control was relinquished at 1226 hours 

with the acceptance of effective corrective actions to restore sanitary conditions, 

appropriate disposition of product and the following proposed preventive 

measures: The product overflow reaching the floor was attributed to staffing issues 

and in the future when there are such staffing issues, additional combo bins will be 

staged in the department to better enable effective product flow management. The 

employee dragging product across the floor will received additional training on the 

importance of handling product to be reconditioned in a more sanitary manner. NR 

HYE02316045403N documents a similar noncompliance on 04/03/2012 where 

product backing up on the rehang belt led to product pile-up on the floor and no 

effective measures being taken to stop more product from falling. The preventive 

measure of training of a supervisor monitoring the area during surges until other 

modifications could be made did not prevent product pile-ups at the rehang table 

from recurring. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (7)(C) (b) (7)(C) (b) (7)(C) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3819040 

016N-1 

04/16/2012 04A06 Poultry Finished 

Product Standards 

C At approximately 1603 hours, while monitoring the establishment's Pre-Chill 

Finished Products Standards in Plant #2, I found the following noncompliance. After 

randomly selecting a 10 bird sample from Line # , I documented a total of 55 

weighted nonconformance points under processing. This exceeds the subgroup 

absolute limit (30) for the process to be in control. I immediately informed QC, who 

did a recheck at approximately 1611 hours to verify sample validity and 

documented a total of 31 weighted nonconformance points. This exceeds the 

tolerance (25) allowed for the recheck and at that point the process is considered 

out of control. I informed and of the 

noncompliance so that corrective actions could be taken. QC then did a Post Chill 

recheck at 1623 hours which passed with 14 nonconformance points and 

proceeded to do another Pre-Chill recheck at 1629 hours which passed with 15 

nonconformance points and again at 1638 which passed with 8 nonconformance 

points. QC performed subsequent Post Chill rechecks every half hour starting at 

1713 hours to 1823 hours, which all passed. The Pre-Chill criteria for the processing 

category was applied to the Post Chill rechecks, bringing the process back into 

control. 

5308 M6137 BXL4120042 

516N-1 

04/16/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 0936 hours while performing Post-Chill Finished Product 

Standards, I observed the following noncompliance with regulations 9CFR 416.4 (d). 

I found numerous birds with UFM (unidentified foreign material) which was a black 

grease like substance on the membrane and on the skin of the carcasses at the end 

of Chiller #1. At approximately 0940 hours, I took regulatory control action by 

retaining all the product that were coming out of the chiller. I placed a U.S. 

Rejected/Retained Tag # B31 405423, B31 406255, B37 946300, B39 505562, B39 

505563, B39 505564, B39 505580, B39 506275, B39 506276, B39 506277 on the 

tanks, 10 in total. At approximately 0950 hours SCSI inspected the 

birds coming out of the Chiller #2 and he found UFM on the birds also, he then 

began retaining all the product. QC personnel placed Red Hold Tags on the tanks, 9 

in total. At approximately 1020 hours SCSI inspected the birds on 

Chiller # 2 and it passed. At approximately 1025, I inspected the birds on Chiller #1 

and it passed. I informed about the 

noncompliance. At approximately 1100 hours discussed 

with SCSI about what reprocessing methods they going to use for the 

adulterated product. At approximately 1230 hours 

contacted me and I went to the tank cooler in Plant #1 and released the product to 

QC. QC placed a Red Hold Tags on the 10 tanks that were tagged with U.S. 

Rejected/Retained Tags. 

(b) (6)
(b) (6)

(b) (6) (b) (6)(b) (6) (b) (6) (b) (7)(C) (b) (7)(C) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5005045 

117N-1 

04/16/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 04/17/2012 at approximately 0040 hours while monitoring the Establishments' 

Operational Sanitation Procedures in Packaging Area #1, I observed the following. 

After checking a few of the first birds coming out of the Chillers from Plant #2 and 

finding nothing, I proceeded to the end of Packaging Line where Organic birds 

were beginning to be wrapped. I checked approximately 15 birds at random and 

found 6 with numerous specks of black (UFM) to approximately 1/8" on the skin 

and tissue in the area of the neck. Several of the other birds had only a few specks 

which I removed. On one of the birds there was also a flat piece of gray material 

measuring approximately 3/4" by 1/2" that crumbled like paint. The gray material 

was located between the skin and tissue in the neck area. I contacted 

and showed him my findings. was called. As 

the blacks specks were no longer present only the first rack of product was retained 

under a QC hold tag pending rework. My findings indicated on noncompliance with 

9 CFR 416.4(d). 

5308 M6137 BXL5918045 

916N-1 

04/16/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1045 hours, I observed the following noncompliance at the gib 

chiller exits in plant 2. There was foreign material inside of the brown tubs and lids 

being utilized for hearts, livers and gizzards. These utensils are a product contact 

surface that at this point was adulterating the gibs coming out of the chillers. The 

foreign material looked like black, silver and gray specks measuring approximately 

1/16" to 1/8" in diameter. I immediately placed the affected product on hold by 

issuing a Reject/Retained tag NO: B31 406377 on 16 tubs full of gibs. I then, 

proceeded to inspect the rest of the tubs and lids located near by, finding them 

contaminated with the same type of foreign material. I immediately place a U.S. 

rejected/Retained tag NO: B31 406378 and B31 406376 on the affected containers. 

I then notified of the nocompliance. At approximately 1105 

hours, Inspector and I decided to go to the Second Processing area to 

monitor the brown tubs/lids being utilized throughout the area. At approximately 

1110 hours, at the halver machine located near the bag fryer line, I found a dolly 

holding a stack of lids that were also affected with black, silver and gray specks. I 

immediately placed U.S. Rejected/Retained tag NO: B31 406270 on the affected 

lids. I then, notified of the noncompliance. At 

approximately 1115 hours, at the wing line, Inspector found a stack of 

brown tubs also affected with the same type of foreign material. She place the 

edible containers on hold by issuing a U.S. Rejected/Retained tag No: B31 406214. 

She notified of the noncompliance. All contaminated 

tubs and lids were taken to the tub wash room, where they were washed and 

released by USDA. 16 tubs full with gibs contaminated with foreign material, were 

condemned in my presence. USDA tag was removed by me after sanitary condition 

were restored. Cleaned tubs were assigned at the gib chillers exit. My findings 

indicate a noncompliance with regulation 9CFR 416.4(a) and 9CFR 416.4(d). 

(b) (6)
(b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1005040 

814N-1 

04/13/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 04/14/2012 at approximately 0010 hours while monitoring the Establishments' 

Preoperational Sanitation Procedures in Packaging Area #1, I observed the 

following. There was a thick layer of dried fat and tissue approximately 1/8" thick 

and several inches high on approximately a 40 foot section of the stainless steel 

portion of an overhead conveyor belt that transfers breast fillets from the deboning 

room to the packaging room at a location adjacent to the Crust Tunnel door. The 

dried tissue was at a point where product on the belt contacts the stainless steel. 

There was also a large amount of tissue directly on the product contact surface of 

the belt and in the sprocket area associated with the same overhead product belt at 

a location near the elevator. At approximately 0030 hours after releasing the 

majority of Packaging Area #1, a supervisor started removing the stainless carts and 

gray product baskets stored in the bulk side of the Crust Tunnel. The carts and 

baskets are used in packaging to hold finished wrapped product. The stainless carts 

(18) were covered with a thick layer of fat and tissue to approximately 3". A rack of 

empty baskets also had numerous pieces of fat to 3". Sanitary conditions were 

restored by approximately 0040 hours. My findings indicated a noncompliance with 

9 CFR 416.1, 9 CFR 416.4(a) & (b), 9 CFR 416.13(c), and 9 CFR 416.14. 

5308 M6137 BXL3220045 

013N-1 

04/13/2012 01C02 Operational SSOP 

Review and 

Observation 

C While performing a routine Operational Sanitation verification check in the 

Packaging area, I observed a noncompliance with regulatory requirement of 

regulation 9CFR 416.4 (d). Product falling on drip pans is considered to be 

adulterated and have to be recondition according to the establishments SSOP 

program. Drip pans are a non food contact surface. At approximately 1800 hours, 

while standing at the bag fryer's line and looking at the halvers equipment located 

near by, I observed a sanitation employee walking on top of the halver's drip pan. 

He was picking up front halves from the drip pan and tossing them into the shoot 

that leads the product into brown edible tubs. There was a couple of employees 

underneath the drip pan, one of them was shoveling ice on the tubs full product 

and the other employee was stacking them on a wood pallet. The sanitation 

employee came down from the drip pan after he was done picking up all the 

product. When they were ready to take the product into the cooler. I stopped the 

employee and placed a U.S. Rejected/Retained tag N0. B31 406118 on the 

contaminated product. There was a total of 10 tubs. I then notified 

of the noncompliance. All the affected product was washed with 

chlorinated water. USDA tag was removed by me, after sanitary conditions were 

restored. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6)

(b) (6)

(b) (6)(b) (6)

(b) (7)(C) (b) (7)(C) (b) (7)(C)

(b) (7)(C)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN150704 

4013N-1 

04/13/2012 04C05 Poultry Good 

Commercial 

Practices 

C At 0305 hrs on 04/13/12 Inspector Jesse Ruiz called me to station 3 on B line to 

examine a bird he had hung back on the USDA rack. I diagnosed it as a DOA based 

on the following signs: 1. Carcass purple in color. 2. Lungs completely congested, 

blackish color, friable. 3. General congestion in viscera, decomposition of kidneys. 4. 

Decomposition of breast muscle tissue. 5. Foul odor. This is a violation of regulation 

9CFR 381.71(a). I immediately informed of 

the forthcoming NR. 

5308 M6137 BXL1218043 

812N-1 

04/12/2012 04A06 Poultry Finished 

Product Standards 

C While performing procedure 04C04 (On-line Reprocessing Procedures), I observed 

noncompliance with the following regulatory requirements of regulation 381.84 

"Airsacculitis" which states in part "Less affected carcasses may be passed for food 

after complete removal and condemnation of all affected tissue including exudate". 

At approximately 1325hrs I removed a 10 bird sample of split-tail birds (marking for 

vacuum of airsacculitis) from Line in Plant 2. I found three of ten birds with 

airsacculitis exudates inside the birds. I informed of the 

noncompliance. She immediately suspended the on-line reprocessing and counseled 

plant personnel. I performed a recheck at approximately 1343hrs and found two of 

ten birds with airsacculitis exudates inside the birds. informed me 

that she would retain all split-tail birds after the final trim station. At approximately 

1408hrs I performed a recheck and found the process back in control. The retained 

birds were reworked and at approximately 1415hrs I rechecked them and released 

them. All birds affected with exudates were reworked on the reprocessing line. 

5308 M6137 BXL5714040 

912N-1 

04/12/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 04/12/2012 at approximately 1105 hours Dr. observed a 

noncompliance. I was walking from evisceration in Plant #2 through Packaging at 

approximately 1107 hours when Dr. informed me about the 

noncompliance. We observed numerous beads of condensation formed on the 

bottom of the drip pans which are directly over the conveyors belts at the end of 

the Chiller #3 and Chiller #4. The conveyors belts are used to transfer product from 

the Chillers to the grading tables and line , line to packaging for cut up. The 

condensation was dripping directly onto the product on line . We immediately 

took regulatory control action by informing 

immediately stopped the line. He had company personnel wipe the 

condensation from the drip pans, he washed the conveyor belts and tanked the 

adulterated product. I attached a U.S. Retained/Rejected Tag # B31 407548 to the 

tank. Dr. informed and I informed 

about the noncompliance. The adulterated product was reworked. SCSI

 at approximately 1230 hours when company personnel finished the 

rework of the product removed the tag. This is a noncompliance with regulations 

9CFR 416.2 (d) and 416.4(d). 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6) (b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN080804 

5612N-1 

04/12/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C I was performing the hands on observation component of a pre-operational 

sanitation inspection procedure in the evisceration department at 2230 hrs after 

the QC technicians had performed their preoperational sanitation inspection and 

released the area for production when I observed the following noncompliance; I 

observed a build-up of fat and feathers from the previous days production's on the 

fingers of the paw scalder. I applied U.S. Retain Tag # B39415972 to the Paws 

scalder at2240 hrs and notified the of the 

noncompliance. After sanitary condition was restored the area was released at 

2255 hrs. 

5309 P6137A NJN390504 

5212N-1 

04/12/2012 04A06 Poultry Finished 

Product Standards 

C On April 12, 2012, I performed a verification inspection procedure of the 

establishment's " program in the eviseration 

department at 0150 hours when I observed a rack of 10 birds staged at the viscera 

removal station just prior to the cropper machine. The rack did not have the 

"Production Hold" tag applied, thus indicating the carcasses were ready to be 

introduced back into production. I examined the ten carcasses and noted one 

carcass with cellulitis affected tissue. Part 2(h), sub section (b) of the cellulitis 

program states: 

. I notified

 and of the non 

compliance. 

5308 M6137 BXL1501044 

811N-1 

04/11/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 4/10/12 at approximately 2248 hours I observed the following While 

performing the establishments Preoperational Sanitation Procedure in Plant 

#2 . while inspecting the middle portion of Chiller # 3 . The paddles along the outer 

edge of the cat walk had a thick layer of chicken grease which appeared to be from 

the previous shift. I immediately notified of my findings 

. had the paddles cleaned , putting the establishment back in 

compliance .My findings indicate noncompliances with several regulations 9CFR 

416.16(a),9CFR 416.13(c),9CFR 416.13(a),9CFR 416.4(a) and 9CRF 416.14 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2017041 

211N-1 

04/11/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 04/11/12 at approximately 0805 hrs I was walking through the packaging area I 

observed the following noncompliance. At the bird halver machine for Plant #1 

across from the bag fryer line there was heavily beaded condensation falling from 

the drip pan located directly above the tank of ice used for icing the product in tubs. 

This is a noncompliance with the following regulations. 9CFR 416.2(d) Ventilation 

adequate to control odors, vapors, and condensation to the extent nessecary to 

prevent adulteration of product and the creation of insanitary conditions must be 

provided. 9CFR 416.4(d) Product must be protected from adulteration during 

processing, handling storage, loading, unloading, and during transportation from 

official establishments. I immediately notified who 

removed the tank of ice and had it codemned. At approximately 0810 hrs the 

condensation was removed, restoring sanitary conditions. He instructed the 

employees to keep the area wiped down throughout the day as it seems to be a 

problem area. 

5308 M6137 BXL2105042 

111N-1 

04/10/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 04/11/2012 at approximately 0300 hours while monitoring the Establishments' 

Operational Sanitation Procedures in Packaging, I observed the following. There 

were numerous black specks (UFM) to approximately 1/8" on several birds on the 

top of a partially filled tank at the first collection station near the dumper on the 

Plant #2 sorting and sizing line. I contacted and showed 

him my findings. Most of the black specks were located on the skin and fatty tissue 

around the neck area. I checked several other tanks in the area but found nothing.

 arrived and took charge of the corrective action 

placing a QC hold tag on the tank of product pending rework. My findings indicated 

a noncompliance with 9 CFR 416.4(d). 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3105045 

511N-1 

04/10/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 04/10/2012 at approximately 2240 hours while monitoring the Establishments' 

Preoperational Sanitation Procedures, I observed the following. In Plant #1, there 

was a light coating of white fat on approximately a 4' section of a chute associated 

with the Line #2 auto rehang machine. The chute directs birds from the machine to 

the manual rehang station. There was white greasy fat on the interior surfaces of 

the reuse water tank associated with the Line #2 Cropper. There was black (UFM), 

fat and tissue to 1/8" on a portable cart located at the Line #2 final trim station.

 was informed of my findings. Sanitary conditions were 

restored by approximately 2302 hours. At approximately 2325 hours when 

Packaging Preoperational Sanitation was to begin I informed

 that I would check the Rewrap room. I proceed to the area and found 

the room would not be ready for approximately 5-10 minutes. I proceeded to 

Packaging Area #1 to check the outflow area for Chillers 3 & 4 from Plant #2. I again 

was told that the area was not ready. I returned to the Rewrap Room and observed 

5 people cleaning the room. They were using a spray bottle marked 'Glass Cleaner' 

and paper towels. At approximately 2348 hours when the space was ready I asked

 why SSOP procedures were not being used to clean the 

product contact surfaces in the room. The spray bottle apparently had no cleaner 

but contained only water. I asked if soap or sanitizer was available to treat the 

product contacted surfaces. The Establishments' SSOP under Preoperational 

Sanitation - Daily Procedures (food contact surfaces) lists the following process. 

" 

." Sanitizer was applied to the stainless counter and portable table. The 

room was released by approximately 2352 hours. In Packaging area #1 at 

approximately 2355 hours there were numerous pieces of fat and tissue to 

approximately 2" on the sprocket and approximately 6' of white support bracket 

associated with the product belt that takes birds from chiller #4 outflow to the 

cutup line. There was a portable stainless tray with a layer of dried on fat and tissue 

on the post-chill finished product standards table. There were numerous pieces of 

fat and tissue to 1/8" on the middle chute associated with the outflow conveyor for 

chiller #4. There was a layer of pasty fat and tissue on approximately a 6' section of 

the white support bracket associated with the outflow conveyor belt for Chiller #4. 

There was a thick layer of pasty yellow fat and tissue on a sprocket associated with 

the outflow conveyor belt for Chiller #3. was informed of my 

findings. Sanitary conditions were restored by approximately 0010 hours. My 

findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.4(a) , 9 CFR 

416.13(b) & (c), and 9 CFR 416.14. 

(b) (6)
(b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4216041 

910N-1 

04/10/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1100 hours, while performing Operational Sanitation verification 

procedure, I noticed the following noncompliance by the ice machine located in 

plant 1. There were two stainless steel tanks each 1/3 full of ice. The ice in these 

two tanks had numerous black (UFM) specks measuring approximately 1/16" to 

1/4". I immediately placed U.S Rejected/Retained tags N0. B31 407577 and N0. B31 

407576 on the affected tanks. I then, notified . He took 

immediate corrective action by condemning the contaminated ice. The affected 

tanks were also washed by the employee working at the area. Ice comming out of 

the ice dispenser shoot was acceptable. I observed the ice in use at several station 

and found no visible UFM. USDA tags were removed by USDA inspector after 

sanitary conditions were restored. 

5333 P7632 HYE360404 

3910N-1 

04/10/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C After the department was inspected and released as acceptable by QC, I performed 

the hands-on observation component of Preoperational Sanitation Inspection 

procedure in Second Processing Department, I observed the following 

noncompliance: At approximately 2358 hours, at Area IV, unit number 10, (Main 

Dark Meat Belts and Chutes), I observed numerous meat and fat particles from 

previous days production on top of the belt and in between the roller and bottom 

of belt, ranging from approximately 1/8 of an inch to two inches in length. The right 

side of the chute wall had a large smear of meat and fat on the inside wall, 

approximately 6 inches in length. Both deficiencies are direct product contact 

surfaces. Regulatory control was taken with the application of US Reject Tag 

#B38494969 and Mr. was notified of 

the forthcoming NR. At 0007 hours after the unit was washed and sanitized and 

after re-inspection, regulatory control was released to production. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (7)(C) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1517042 

809N-1 

04/09/2012 01C02 Operational SSOP 

Review and 

Observation 

C On April 9, 2012 at approximately 1330hrs Dr. asked me to investigate a 

possible adulteration of product in Plant 1. She informed me that she had 

witnessed water spraying from the first inside/outside bird washer on Line 1 into a 

bin of front halves staged for packaging near the grading belts. At approximately 

1335hrs I contacted to get information about what type of 

water is being used by the first inside/outside bird washer. 

informed me that the first inside/outside bird washer was using recycled water to 

rinse the birds. and I went to the end of Line 1 to observe the 

situation. We could see that water form the first bird washer was indeed squirting 

into the combo bin of front halves. Some of the water was splattering off the drip 

pans, guide bars and metal braces into the combo bin as well. At this time

 informed us that the shroud around the inside/outside 

bird washer was broken and that maintenance was unable to fix it until swing shift. 

At this point I informed that the recycled water was causing an 

adulteration of product. instructed maintenance to hang plastic 

around the bird washer to contain the spray. I then placed USDA Retain tag # B31 

407593 on the combo bin of front halves that water was spraying into. I asked

 to call someone from packaging. At approximately 1350hrs

 arrived. I informed him that the combo bin of product that had 

been staged next to the bird washer had been cross contaminated with recycled 

water that had also contacted non-food contact surfaces. informed 

me that the front halves would be reworked. The product was reworked and the 

USDA retain tag was removed at approximately 1400hrs. My findings indicate a 

non-compliance with the regulatory requirements of 9CFR 416.4(d). 

5308 M6137 BXL3714041 

109N-1 

04/09/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C While monitoring the Establishments' Pre-operational Sanitation Procedures in 

Plant #2, I found the following noncompliance with regulations 9CFR 416.1, 416.4 

(a), 416.4 (b) and 416.13 (c). At approximately 0738 hours, I observed in Area #5 

section #1 the catch tray and the blue conveyor belt for Line # and it had 

numerous pieces of fat and meat from the previous day production. The blue 

conveyor belt that catches the birds from Line also had numerous pieces of fat. I 

found a grease black permanent marker on the conveyor belt, these conveyors belts 

transfers the birds to the chiller. The end of a drain pipe that is located next to the 

catch tray and drains into the drip pan under the blue conveyor belt had fat and 

yellow residue on it. I immediately attached a U.S. Rejected/Retained Tag # B31 

407556 to that area. I informed about the noncompliance. 

The marker was removed from the conveyor belt and the catch tray, conveyors 

belts and the end of the pipe were washed. Sanitary conditions were restored at 

approximately 0745 hours, then I removed the tag. 

(b) (6)
(b) (6) (b) (6) (b) (7)(C) (b) (4) (b) (4) (b) (4)

(b) (4)

(b) (4) (b) (4)

(b) (4)

(b) (4) (b) (4) (b) (4)(b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1110040 

106N-1 

04/06/2012 04A06 Poultry Finished 

Product Standards 

C On 04/05/12 while monitoring the establishments reprocessing procedure on line

 in Plant#2 I observed a noncompliance the following regulatory requirements of 

regulation 9 CFR 381.76 and 9 CFR 381.84. At approximately 1515 hours, I 

randomly removed a 10 bird sample for my reprocessing test. I found 1 out of four 

birds with split tails in the sample that contained Airsacculites exudates. I notified 

Q.C. and performed a recheck at 1525 hours, I removed another 10 bird sample and 

found two of five birds with split tails to contain airsacculites exudate. Q.C. 

immediately took action by retaining the product into a tank and placed a hold tag 

on the tank. I informed of the noncompliance. At 

approximatley 1529 hours Q.C. performed a retest and it passed. The retained 

product was reworked and released at approximately 1530 hours. This is a 

repetitive noncompliance. 

5308 M6137 BXL2523044 

009N-1 

04/06/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 04/07/2012 at approximately 0220 hours while monitoring Facilities in Plant 

#2, I observed the following. Line had stopped. However, the 

cabinet for line did not shut off. I started a stop watch to record 

the time that the birds were left in the cabinet. At approximately 7 minutes 10 

seconds the machine operator manually shut the valve to the cabinet on line 

. I waited to see what would be done with the birds in the cabinet but when the 

line started, I removed the 5 affected birds placing U.S. Retained tag #B31407587 

on the carcasses. The Establishments' HACCP Plan for Slaughter in Plant 2 Step 22 

'Carcass Wash' identifies 

The birds that were 

removed from the cabinet were a pale white color with several blackened patches 

on the wings and backs of the carcasses. There were also numerous blackish specks 

to 1/8" that crumbled to the touch and were probably from cooked blood building 

up in the pipes of the machine. I showed the birds to and he 

condemned the birds disposing of the carcasses in a gray inedible barrel. 

concentration as documented at 0202 hours was 11.7%. The cabinets were 

recently reinstalled as part of a construction project. The cabinet has been 

staying on all week whenever line stops. My findings indicated a noncompliance 

with 9 CFR 416.4(d). 

(b) (6)
(b) (6)

(b) (6)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN550704 

0406N-1 

04/06/2012 01C02 Operational SSOP 

Review and 

Observation 

C I was verifying operational sanitation in the fillet department at 2226 hours when I 

observed the following non compliance; the plant employee reprocessing product 

that falls onto the floor failed to follow the establishment's SOP procedures for 

reprocessing product that falls onto the floor. I observed the employee washing 

multiple pieces of breast fillets at the same time. The establishment's written 

procedure "Reprocessing product that falls" onto the floor states step 5: " 

". 

Regulation 9 CFR 416.12(a) states: "The establishment shall describe all procedures 

an official establishment will conduct daily, before and during operations, sufficient 

to prevent direct contamination or adulteration of product(s). Regulation 9 CFR 

416.13(c) states: "Each official establishment shall monitor daily the 

implementation of the procedures in the Sanitation SOP's". I informed Mr. 

, and of the 

noncompliance. 

(b) (6)
(b) (6) (b) (6)(b) (7)(C) (b) (7)(C) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4)

(b) (4)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1912042 

705N-1 

04/05/2012 03J02 Slaughter HACCP C is an approved antimicrobial agent used in On Line 

Reprocessing(OLR) of Raw Poultry Carcasses. acts as a surfactant and prevents 

bacteria from attaching to the carcass. On April 04, 2012, at approximately 1340 

hours, I found the following noncompliance: While performing a Finish Product 

Standard check on line plant 2, I noticed the sprayers on lines 

were turning off and on. Carcasses going through the cavinets were dried. I 

immediately stop all the lines. I then proceeded to notify of the 

noncompliance. He mentioned that there was electrical problems. Production was 

aware of the problem but failed to take corrective action. The establishment failed 

to go back to Off-Line Reprocessing. I notified IIC Dr of the noncompliance. He 

immediately instructed each one of the USDA on line inspectors to mark all the 

contaminated birds and place them on the Off-Line reprocessing line. Maintenance 

was notified of the problem and production was resumed. At approximately 1420 

hours after the problem had been fixed, Dr. instructed all the on line inspector 

to go back to On Line Reprocessing. was properly working under maintenance 

supervision. Under The establishment's biological hazard analysis, Process step 

#22/Carcass Wash / Pathogen, i.e. Salmonella is NOT significant. The 

establishment's address as a justification for this decision: 

" Establishment P6137 was granted a waiver 

for regulation 9CFR 381.91(b) (Off-Line reprocessing) on September 2011. Under 

the establishment's alternative procedures for waved regulation 381.91(b) states: 

" 

". Location in Food Safety system, Pre-requisite Program. My 

findings indicate a noncompliance with regulation 417.5(a) and 381.3(b). The 

establishment is failing to follow alterantive procedure, Pre-requite Program and 

supporting decisions made in the hazard analysis. 

5308 M6137 BXL3613041 

905N-1 

04/05/2012 01B01 Pre-Op SSOP 

Record Review 

C While Monitoring the Establishments' Pre-operational Sanitation Records Review, I 

found a noncompliance with 9CFR 416.16 (a). At approximately 1140 hours while 

reviewing the Pre-operational Sanitation Records for 04/02/2012 and 04/03/2012 

AM shift and PM shift, I noticed that the SSOP Pre-op Daily Implementation and 

Monitoring Log for Plant #2 AM shift for 04/02/2012 was missing. I found the SSOP 

Pre-op Daily Implementation and Monitoring Log for Plant #2 but dated with the 

wrong date of 04/01/2012. I informed about the 

noncompliance. 

(b) (6)
(b) (6) (b) (7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3715040 

205N-1 

04/05/2012 01C01 Operational SSOP 

Record Review 

C On 04/03/2012 and 04/04/2012 at approximately 1030 and 1340 hours SCSI

 went to review the Establishments' prior days activity reports for the 

Pre-operational and Operational daily monitoring logs and reports. All findings and 

reports dated 04/02/2012 and 04/03/2012 for Pre-operational and Operational in 

Plant 2's Rehang/Weigh/Sort Areas, corrective actions of the adulterated product 

from the affected chillers, reworking of product, monitoring the adulterated 

product and any further planned actions were not obtainable and not in the 

establishment filing system for reviewing. Due to the severity of the 

noncompliances for the past 2 days, accessibility to these recorded documentations 

was essential and crucial to the USDA's food safety mission. On 04/04/2012 at 

approximately 1150 hours while reviewing the Operational Sanitation Records for 

04/02/2012 PM Shift, I observed the following. The SSOP Preliminary Corrective 

Action Log for that day was missing. I talked to 

approximately 1400 hours and she was not able to provide the records at that time. 

This is a noncompliance with 9CFR 416.16 (a) that states " Each official 

establishment shall maintain daily records sufficient to document the 

implementation and monitoring of the Sanitation SOP's and any corrective actions 

taken". 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6) (b) (7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4802042 

505N-1 

04/05/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 4/4/12 at approximately 2234 hours while preforming a Preoperational 

Sanitation Procedure in Plant # 1, I observed the following. Picker # 1 had grease on 

and between the black fingers. There was also a thin build-up of grease on the lid of 

the picker. I placed US Rejected tag # B31406236 on the picker. 

had two of his workers clean and rinse the entire inside of the picker restoring 

sanitary conditions. At approximately 2249 hours at inspection station # 7 there 

was thick grease and debris from the previous days production on approximately a 

3 ' length of the over head guide bar to the right of the inspector station. 

had the guide bar cleaned and rinsed restoring sanitary 

conditions. At approximately 2252 hours at the last Salvage Station there was a 

thick build-up on UFM on the knife sanitizer. had the inside of the knife 

sanitizer scrubbed and rinsed restoring sanitary conditions. PLANT- # 2 At 

approximately 2255 hours in plant # 2 CSI observed the following. The 

Finishing Chiller # 4 had numerous pieces of tissue and fat to approximately 1/4" on 

the paddle and internal surfaces above and below the surface the water . The unit 

was emptied and recleaned. There was pasty fat and tissue to approximately 1/8" 

above the water line in patches 4"-8" high and several feet long at more than one 

location on the exit end of Chiller # 4 on the side adjacent to the wall. There were 

also numerous pieces of fat and feathers floating in the water. Sanitary conditions 

were restored to a satisfactory condition by approximately 2305 hours. PACKAGING 

AREA: At approximately 2350 in Packaging Area # 1 there was grease and pieces of 

fat floating in a puddle of water on a tray under the flex belts at the rehang tables at 

the end of the Chiller 3 and 4. was contacted. 

The area was recleaned restoring sanitary conditions. At approximately 2357 hours 

the entire platform and floor area under the Breast Processors was covered with 

small pieces of fat and debris. was contacted and had the 

platform rewashed bringing the area back into compliance. My findings indicated a 

noncompliance with 9 CFR 416.13(c), 9 CFR 416.4(a) &(b), 9 CFR 416.1, and 9CFR 

416.14. 

(b) (6)
(b) (6) (b) (6)

(b) (6)

(b) (6)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5513042 

405N-1 

04/05/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 4/5/12 at approximately 0945 hours while observing operational sanitation 

procedures, I observed a plant employee take a metal hook and drag multiple 

chickens across the floor and then pick them up and throw them back onto the 

floor underneath the conveyor belt at the chiller exit to two other plant employees 

who were then taking them and placing them into a brown tub. I immediately 

informed , who was standing close to 

me, of my observations. He then went over and spoke with the guys. I asked him 

what he planned to do with the adulterated product that was drug and thrown back 

onto the floor. He said he was planning to recondition the product and asked what I 

would suggest be done. I informed him that it states in their SSOPs that 

. I suggested it be condemned. He then decided to condemn the 

product. I also informed him of this noncompliance. This is a violation of 9 CFR 

416.4(d) and 416.13(b). 

5309 P6137A NJN470304 

4605N-1 

04/05/2012 01C02 Operational SSOP 

Review and 

Observation 

C I was performing an Operational Sanitation verification activity in the Packaging 

Department at 0059 hours when I noted the following noncompliance: I observed 

water dripping from a seam of an overhead drip pan onto a roll of blue plastic liners 

below. This drip pan was located below the chick weigh line as it exited the body 

halfer. I informed and 

as well as of the noncompliance. The 

establishment implemented immediate corrective actions by installing a temporary 

sheet of plastic to redirect the dripping water onto an adjacent drip pan until the 

completion of production when mantainence can perform a more permanent 

solution. On 04/04/2012 the establishment documented a non routine incident for 

this same occurrence, which included corrective actions of maintenance repairing 

the seam in the drip pan. That corrective action was either not implemented or 

ineffective in preventing the same occurrence. 

(b) (6)
(b) (6) (b) (6) (b) (7)(C) (b) (7)(C) (b) (7)(C) (b) (7)(C)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1119044 

304N-1 

04/04/2012 03J02 Slaughter HACCP C On April 2, 2012, a deviation or unforeseen hazard of metal was identified on 

product at the end of the first cycle of the newly installed chillers. Metal continued 

to be identified on product throughout the days production following product 

chilling. These hard and some sharp metal fragments, shavings, and pieces were 

found adhering to the skin and muscle of over 45 tanks of product that were placed 

on hold by the establishment. This was visible to the USDA IPP: Dr. SPHV, 

SCSIs , and all CSIs during the inspection of the product as the 

product was dumped from the chillers on to the receiving rehang conveyors. On 

4/4/12, when asked about the HACCP reassessment due to chiller installation,

 informed Dr. , SPHV that a reassessment 

would take place on Friday, 4/6/12. No reassessment had been performed at this 

time. This is a violation of 417.3(b)(4). Due to this deviation or unforeseen hazard of 

metal found adulterating product and the increase in monitoring steps throughout 

the process on 4/2/12, reassessment was essential and necessary prior to the 

usage of this equipment and following the deviation or unforseen hazard to 

determine and evaluate for any potential food safety hazards. On 4/4/12 after 

reviewing the HACCP Plan, SCSI noted the lack of this 

documentation. This is a violation of 9 CFR 417.3(c). 

5308 M6137 BXL4512040 

904N-1 

04/04/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 4/2/12 at approximately 1400 hours while observing operational sanitation 

procedures, I observed a plant employee pick up multiple whole chickens from the 

processing floor underneath the conveyor belt leading to the B grade cut up line, 

and throw them onto that same conveyor belt without properly reconditioning the 

product. I immediately went over to observe up closer what the employee was 

doing and observed him continuing to separate out some bird to be condemned 

and throw some birds from the floor onto the conveyor belt to continue to 

processing. I immediately informed Mr. of my observations 

and this noncompliance. He immediately went over to speak with the employee 

and he said he would make sure that the birds got condemned right away. Your 

SSOPs state that 

. Therefore, you have failed to implement your reprocessing 

procedures. Your failure to do so is a noncompliance with 9 CFR 416.4(d) and 

416.13(b). 

(b) (6)
(b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN470304 

2804N-1 

04/04/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C I performed pre-operational sanitation inspection in the New Products Room at 

2230 hrs. after QC had performed pre-operational sanitation inspection and 

released the room for production when I noted the following non compliance: There 

were several pieces of fat and product particles on the walkway and a chicken piece 

(wing segment) inside the drip pan. These findings where located at unit #14 of IQF 

line #1. I informed , of these findings at 2240 hrs. 

A U.S. Reject tag was not applied since sanitary conditions where immediatly 

restored. Once sanitary conditions where restored to the unit I reinspected and 

released the area for production at 2249 hrs. 

5333 P7632 HYE231604 

5403N-1 

04/03/2012 01C02 Operational SSOP 

Review and 

Observation 

C At 0937 hours on April 03, 2012, while performing an Operational Sanitation 

inspection procedure in the chiller exit rehang area, I observed that the rehang table 

was backed up with birds. I went to the north side of the rehang table and observed 

20+ birds on the floor around the catch pan designed to catch product overflow 

beneath the incline belt feeding the rehang table. I observed plant employees 

picking up the product but no one was taking any effective measures to regain 

control of the process so that birds would stop falling to the floor. In less than ten 

seconds I observed 14 more birds fall from the table to the floor. Regulatory control 

of the rehang table was taken with the application of US Reject Tag B38 494935 and

 were notified of the 

forthcoming documentation of the failure to comply with the regulatory 

requirements cited above. The affected product was released to QC and taken to 

reprocessing for reconditioning. Regulatory control was relinquished at 0942 hours 

with the acceptance of effective corrective actions to restore sanitary conditions, 

appropriate disposition of product and the proposed preventive measure that a 

supervisor would be assigned to monitor the area until the maintenance issue 

which caused the back-up of product could be addressed and a better response plan 

could be put into place. NR HYE0617034409N documents a similar noncompliance 

on 03/09/2012 where product backing up on the rehang belt led to product pile-up 

on the floor and no effective measures being taken to stop more product from 

falling. The preventive measure of training the Day Shift Chiller Rehang Lead person 

to adjust their schedule to provide coverage during breaks and lunches to better 

address product flow surges at those times did not prevent product pile-ups at the 

rehang table from recurring. 

(b) (6)
(b) (6) (b) (7)(C) (b) (7)(C) (b) (7)(C) (b) (7)(C) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1510042 

402N-1 

04/02/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C At approximately 0600 hours, while performing Pre operational inspection 

verification in the Condemned Room and Live Hang Welfare areas located in plant 2 

slaughter area, SCSI found the following noncompliance: There 

was a putrid and rancid odor coming from the inside of the condemn room. The 

auger and 1/4 of the dump bin in the condemn room were found decaying with 

chicken body parts, feathers and fat debri. All these poultry remaining were left in 

there since March 23rd 2012 at 1530 hours. was 

notified of the noncompliance. He took immediate corrective action by having the 

dumpbin and the auger unlocked and washed. Condemned Room was released to 

production after sanitary conditions were restored. 

5308 M6137 BXL1510042 

402N-2 

04/02/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C While performing Pre Operational inspection in plant 2 slaughter area, Dr. 

and I found the following non compliances: 1- At approximately 0720 hours while 

inspecting area 2, we observed a white feather approximately 1" in size outside of 

picker #1 line and also several feathers approximately 1" in size inside of picker 

#1 line 2- At approximately 0725 hours while inspecting area 3, we noticed 

multiple particles of black foreign material ranging from 1/16" to 1/8" in size 

affecting the Automatic Transfer Machine Line and and Transfer Table line 

which are consider product contact surfaces. There were also 3 stainless steel tanks 

affected with back and sandy foreign material. 3- At approximately 0735 hours 

while inspecting area 4, Dr. and I noticed a brownish build up on the 

liver/heart machine line . There was also a couple of white edible barrels affected 

with foreign material. These equipment and utensils are product contact surfaces. 

4- At approximately 0745 hours while inspecting the gizzard puller on line area 

4, Dr. noticed a brownish build up. Each of these non compliances was 

pointed out to the sanitation lead person at the times specified previously. All 

insanitary conditions were corrected immediately by sanitation as pre operational 

inspection was taking place. Slaughter area was released at approximately 0751 

hours. 

(b) (6)
(b) (6)

(b) (6)

(b) (6)(b) (7)(C) (b) (7)(C) (b) (7)(C) (b) (7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4813044 

702N-1 

04/02/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C While monitoring the Establishments' Pre-operational Sanitation Procedures in 

Main Packaging Area, Dr. SCSI and I observed the following 

noncompliance with regulations 9CFR 416.1, 416.4 (a), 416.4 (b) and 416.13 (c). At 

approximately 0830 hours, we observed in the entire rehang area and weigh/sort 

lines in Plant #2 a noncompliance. The belts, conveyors, drip pans, dividers and 

conveyors sides were covered with fine dust of metal flakes, small and large metal 

flakes, pieces of metal and welding material. All created from welding and 

installation friction movement of tools and metal of the new Chillers. The entire 

location had U.S. Rejected/ Retained Tags # B31 407557, # B31 407594 and # B31 

407595. We informed about the 

noncompliance. Sanitation Personnel scrubbed, washed and rinsed all food contact 

and non- food contact surfaces of the entire rehang and weigh/sort area. The 

rehang area was released after sanitary conditions were restored at approximately 

0906 hours by SCSI and the weigh/sort was released after sanitary 

conditions were restored at approximately 0920 hours by Dr. and I. 

5333 P7632 HYE010704 

3702N-1 

04/02/2012 03J04 Poultry Zero 

Tolerance 

C I was in the evisceration department performing a Zero Tolerance verification task 

on evisceration line # 2 at 0443 hours when I observed fecal material on one carcass 

Verification of the ten carcass sample. The fecal material was located on the left wing of the 

carcass. It was approximately 1/16 of an inch in diameter, dark green in color, and 

had a paste like consistency. I immediately notified Ms. 

, and Mr. of the noncompliance. 

(b) (6)
(b) (6) (b) (4)

(b) (4)

(b) (4)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2003031 

031N-1 

03/31/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 03/30/2012 at approximately 2005 hours while monitoring the establishments' 

Weigh & Price and Rewrap Room procedures, I observed the following. There were 

establishment employees unwrapping packages of Foster Farms half breasts (506) 

and placing the product on to different size trays Foster Farms half breasts (951). I 

observed the process for approximately 5 minutes. The packaged product was being 

removed from gray product baskets that are assembled into racks in Packaging and 

sent to Weigh & Price. I examined several of the baskets being emptied and found 

that the baskets all had a thick coating on the interior surfaces of the baskets of 

black & brown (UFM), and pieces of dried and partially dried fat and tissue to 

approximately 1". The baskets are treated as a nonproduct contact surface and are 

seldom cleaned. An establishment employee wearing gloves was removing the 

product (506) from the contaminated baskets, unwrapping the product with the 

gloves touching the exterior top and potentially contaminated bottom of the 

wrapper around the package then dumping the product and arranging the 

breast pieces onto a larger size tray with the same contaminated gloves. At this 

point the contamination from the gray basket was tranfered to the breast halves. 

The exterior of the wrapped product and the knife being used were not being 

sanitized in any manner. A hand wash sink and glove sanitating unit is available but 

was not being used. Other employees were selecting breast halves from a pile and 

filling up the rest of the larger tray before passing the repacked product through the 

wrapping machine. I went to the QC office to reviewed the SSOP and Hazard 

Analysis. The establishment SSOP Section II: Operational sanitation 'Daily 

Procedures' states that " 

." but does not state how this will be accomplished. 

The Establishments Flow Chart for Packaging Step 15 noted 

." The Establishments HACCP 

Plan-Raw Not Ground(Packaging) Step 15(rework) identifies under 

." Supplements 6,21 and 33 are listed as supporting documents. The 

supplements reference temperature and bacterial growth concerns. There were no 

QC personnel present to monitor the process. Hundreds of packages are rewrapped 

daily. After the rewrap process the items are returned to the Weigh & Price cooler 

for shipping. I took a basket to and showed him my concerns 

with the process in the rewrap room. He stopped the process and said he would 

discuss the matter with management. I attached B31407586 and B31407578 to 

two racks, approximately 192 packages, being worked in my presence. My findings 

indicated a noncompliance with 9 CFR 416.4(d). 

(b) (6)
(b) (6) (b) (6) (b) (6)

(b) (6)

(b) (6)

(b) (6)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2019030 

631N-1 

03/31/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 0940 hours while performing a Zero Tolerance fecal check on line 

#2 plant 1, I found feces in one of the 10 randomly selected birds. There were two 

particles of feces located inside of the bird's cavity by the tail area, each measuring 

approximately 1/8" in diameter. These particles were light yellow in color and soft 

in texture. I immediately notified of the noncompliance. 

She started the establishment's zero tolerance protocol. Quality control performed 

a passing recheck at approximately 1025 hours. The cause of deviation was the 

Venter Machine. Post chill checks were performed from 1031 hours to 1135 hours. 

This is a violation of the critical limit CCP2B, of the Plant's 

HACCP Plan for slaughter. 

5333 P7632 HYE391503 

1931N-1 

03/31/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 0709 hr while performing PHIS task for review and observation of 

Operational SSOP in 2nd processing, a stack of tub lids were in the east sink behind 

the Breast Processors. I observed a plant employee pick the stack of lids up and 

place them on a cart with clean tubs and lids. The employee then took one of the 

lids from the stack of contaminated lids and placed it on a tub of whole chicken 

breasts. I placed U.S. Retained tag # B38494957 on the tub. Mr. 

was informed of the situation and of the forth coming Noncompliance record. 

Control of product was returned to plant at 0715 affected product was tagged by 

plant to be washed and reworked; lids were removed from the cart to be properly 

washed. Mr informed me that the employees would be trained on not 

using the hand wash station as a holding area for the tubs and lids. 

5333 P7632 HYE260803 

3930N-1 

03/30/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 0545 hours while performing the hands-on observation 

component of a Poultry Zero Tolerance Verification inspection procedure on the 

reprocessing line, in the presence of Ms. 

I observed the following non-compliance: On the fourth bird of my inspection, 

a smear of fecal material, approximately one quarter of an inch in length by one 

eight of an inch wide on the inside cavity by the Keel bone of the right breast. It was 

dark green in color, paste like consistency. Regulatory control of the line was taken 

with the application of US Retained tag #B38495000. Ms. 

and Mr. was 

shown the fecal material and notified of the forthcoming NR. QC, Production and 

Maintenance went into immediate actions per the corrective action procedures 

prescribed in the Establishment s HACCP Plan. Regulatory Control of the line was 

released at 0558 hours after a recheck on the reprocessing line was performed and 

was acceptable. That the establishment would have failed to prevent fecal material 

from entering the chilling system represents a non-compliance with 9 CFR 381.65(e) 

which states, Poultry carcasses contaminated with visible fecal material shall be 

prevented from entering the chilling tank. 

(b) (6)
(b) (6) (b) (6) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0205031 

430N-1 

03/29/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 03/29/2012 at approximately 2241 hours while monitoring the establishments' 

Preoperational Sanitation Procedures in Plant #1, I observed the following. There 

were several large patches of white fat on the internal surfaces of the tank at the 

auto rehang station for line #2. The tank is used during production to collect birds 

when the line is stopped. Sanitary conditions were restored by approximately 2250 

hours. At approximately 2355 hours in Packaging Area #1, there was a pallet jack 

located adjacent to line #1. The pallet jack had several large pieces of fat and tissue 

on the front of the unit. There was also a layer of fatty tissue on the stainless arms 

of the pallet jack. The arms extend into the product when the tank is grasped prior 

to moving. Sanitary conditions were restored by approximately 0015 hours. In 

Packaging area #2 the red piping for the fire fighting system directly above the lines 

has patches of rusting, chipping, and peeling paint. The piping directly above line 

is the worst with large pieces of paint to approximately 1" missing in numerous 

locations. My findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 

416.4(a) & (b), 9 CFR 416.13(c), and 9 CFR 416.2(b)(1). 

5308 M6137 BXL1806034 

430N-1 

03/29/2012 01C02 Operational SSOP 

Review and 

Observation 

C While monitoring the Establishments' Operational Sanitation Procedures in Main 

Packaging, I observed the following noncompliance with regulations 9CFR 416.4 (a), 

416.12 (a), 416.13(c). At approximately 1107 hours, I observed maintenance 

personnel working on the Dumper Conveyor in Main Packaging, after maintenance 

personnel completed their work at 1124 hours, I waited to observed if Supervisor 

Production, SSOP, HACCP or QC personnel would check the conveyors for sanitary 

conditions because company personnel were on break. At approximately 1137 

hours company personnel came back from break and I checked the conveyors. The 

conveyors had black residue that looks like grease. Company personnel started the 

conveyor and I told them to stop. I took regulatory control action by attaching a 

U.S. Rejected/Retained Tag # B31 407472 on the conveyors and called the 

Supervisor. At approximately 1139 hours and

 came and I informed them about the noncompliance. Both 

Supervisors took corrective action by washing the conveyors and condeming the 

product involved. At approximately 1147 hours, after sanitary conditions were 

restored, I released the area. 

(b) (6)
(b) (6) (b) (6) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5315032 

729N-1 

03/29/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 03-29-2012 at approximately 1120 while performing a SSOP review and 

observation procedure in the wing sizing room I observed the following, (1) 

Condensation on the ceiling, the air supply ducting, the flashing at the wall to 

ceiling joint, the structural metal beams and the overhead piping. (2) A sprayer on 

the system was spraying up through the line onto the overhead pipes and 

falling back onto the conveyor which is a food contact surface. The room was at 

break so no product was involved. (3) A drip pan was leaking water through the 

silicone at the edge and onto the floor. The silicone sealant was growing mold in a 

yellowish and brown color at three spots along the bead approximately one to two 

inchs in length each. I notified , (1) He had 

the condensation removed from the effected areas, (2) The sprayer was adjusted 

and the conveyor was then washed and resanitized before production resumed. (3) 

Maintenance removed the silicone, the mold was cleaned and fresh silicone was 

applied to the drip pan. This a noncompliance with regulations CFR 416.2(d) 

Ventilation, CFR 416.13(c) Plant monitors implementation of SSOP procedures, CFR 

416.4(a) Food contact surfaces, CFR 416.4(b) Non-food contact surfaces. 

5308 M6137 BXL3611031 

228N-1 

03/28/2012 04A06 Poultry Finished 

Product Standards 

C At approx 1036 hours on March 27, 2012 while preforming an AQL check on the 

giblets in Plant #1 I found the following noncompliance. I took a sample of 10 livers 

coming out of the gib chiller and found 5 of the 10 livers with whole spleens and 

gallbladders still attached. I immediately notified QC and S of 

the noncompliance. QC did a recheck at 1043 hours which also failed and another 

recheck at 1049 hours which also failed. These findings show that the process was 

out of control. QC put a hold tag on 2 tubs of livers for rework before a recheck 

finally passed. QC did a recheck at 1052 which passed and another at 1054 which 

also passed showing the process was back in control. The 2 tubs of livers that were 

held were reworked and released by QC at 1156 hours and 1158 hours respectively. 

(b) (6)
(b) (6)

(b) (6)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4112032 

528N-1 

03/28/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1118 hours while walking through the Room I observed the 

following noncompliance. There was an establishment employee washing breast 

fillets at the product reprocessing sink and I stopped to observe the process to 

verify the proper reprocessing procedure was performed as she was almost finished 

reworking the product. During the process no ice was added to the product at any 

time. As soon as she was finished another employee walked up and loaded 3 tubs 

of product onto a dolly and started to take the tubs to the line to be put back into 

production without waiting 5 minutes for Quality Control reinspection. As this is 

not the protocol to be followed, as stated in the SSOP Plan, I immediately took 

Regulatory Control action and stopped him and attached USDA Retain Tag 

#B31406210 to the stack of tubs. I then notified of the 

noncompliance. He said he would talk to the employee and QC. As stated in the 

establishments SSOP Plan the protocol to be followed states under PROCEDURES: 

. As this did not happen it is a failure of 

the establishment to properly implement it's reprocessing procedure. 

5309 P6137A NJN411403 

2828N-1 

03/28/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1124 hours while performing PHIS task for Operational Sanitation 

in the packaging area I observed a plant employee washing the floor during a 

company break. Water from the floor was allowed to spray into one bin 

(approximately 1000 lbs.) of whole chickens at the end of the chiller exit conveyor 

thus cross-contaminating the product within the bin. I applied US Retain Tag # B39 

415888 to the affected product and informed Mr. 

and the QC technician assigned to the area. All of the product 

was moved to reprocessing area to be washed in accordance with the plant's 

reprocessing procedure. After reprocessing the affected product and after 

re-inspection I released the product back to production at 1225 hours. That the 

establishment failed to protect the product during processing represents a 

non-compliance with 9CFR 416.4(d). 

(b) (6)
(b) (6)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE150303 

4229N-1 

03/28/2012 01D01 SPS Verification C While conducting SPS (Sanitary Performance Standards) at the start of the shift at 

the Weigh and Price department after employees started running transfer lines and 

computer scales were being set, I observed the following non compliance: The floor 

by the scales had all kinds of trash and debris from previous day s production. Dirty 

paper towels, pieces of crumbled paper and cardboard, wood splinters, crumbled 

plastic wrap, styrofoam, pieces of meat and fat, metal screws and plastic shavings 

along the transfer belt from robot cages. Some of the transfer belts by the scales 

had dirty paper towels caught between the belts. The computer scales on line two 

had an accumulation of dust and dirty paper towels on top. The stainless steel box 

carts tables had dirty paper towels and used priced stickers on top of plastic bag 

liners used to bag product. Regulatory control of the area was taken at 

approximately 2140 hours with the application of US Reject tag # B40193561 and 

Ms. was notified of the non compliance. 

After sanitary conditions were restored, the area was released for production at 

2153 hours. Plants SSOP s step #2 states: 

5308 M6137 BXL1805031 

027N-1 

03/26/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 03/26/2012 at approximately 2355 hours while monitoring the Establishments' 

Preoperational Sanitation Procedures in Packaging Area #1, I observed the 

following. There was a line approximately 1/4" wide of pasty fat and tissue to 1/8" 

along the entire width, approximately 24", of a wing line product belt. There were 

numerous pieces of dried on fat and tissue to 1/4" on the removable tray 

associated with the automatic tray drop mechanism. There was a coating of black 

(UFM) with the appearance of grinding dust on two small tables located adjacent to 

the wing line. There was a layer of black (UFM) with the consistency of grinding dust 

on the bottom tray of leg processors 1, 2 & 3. Miscut leg quarters collect on the 

tray. There was also numerous pieces of back (UFM) to 1/8" on the white cutting 

wheel of the leg processors. Sanitary conditions were restored by approximately 

0015 hours. My findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 416.4 

(a) & (b), and 9 CFR 416.13(c). 

(b) (6)
(b) (6) (b) (6)

(b) (4)

(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1514033 

923N-1 

03/23/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C While performing a Finish Product Standard check in plant 1 line 2, I found a Zero 

tolerance fecal failure. At approximately 0920 hours, I randomly removed 10 birds 

from line #2 for my FPS check. I found one out of the ten bird contaminated with 

feces. The bird had an attached cloaca with a 1" long piece of intestine. There was 

fecal matter on the base of the tail area affecting part of the right leaf fat of the 

carcass. The fecal matter was light yellow in color and liquid in texture. There was 

two fecal smears each measuring approximately 1/8" in diameter. I immediately 

notified of the noncompliance. This is a failure to keep CCP 2B 

under control. The establishment implemented the zero tolerance protocol. Quality 

control performed a passing recheck at approximately 0946 hours. Maintenance 

worked on the venter machine during break time (1000 hours to 1015 hours). 

Suspect lo was from 1013 hours to 1036 hours. Quality control perfomed post chill 

checks at the end of chiller #2. All suspected product was deemed acceptable. 

5308 M6137 BXL4009033 

623N-1 

03/23/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 03/22/2012 at approximately 0612 hours while monitoring Facilities after a 

scheduled establishment break, I observed the following. Line was stopped as 

the courtesy washdown was not completed. There were no supervisors present. I 

went to the automatic rehang station where birds are moved from the kill line to 

the eviscerating line. The conveyor belt for line was full and to that point 

approximately 50 birds were on the floor. I proceeded to the office and contacted 

. Establishments' response to a similar 

noncompliance dated 02/23/2012 under Management Response (Further Planned 

Action) stated that " A modified tank has been fabricated for the underneath the 

rehang line. The tank is designed to allow production to operate the line in reverse 

when the line experiences down time. This will prevent carcasses from falling on the 

floor. The tank was installed on 3/15/12. In addition production employees were 

verbally counseled regarding reconditioning procedures." The modified tank was 

present however the tank and the reverse feature on the conveyor belt was not 

being used. The floor at this location is covered with varying amounts of debris 

from the kill line. At approximately 0635 hours supervisors arrived to start 

corrective action by starting the conveyor in reverse to fill the modified tank that 

kept the birds on the conveyor belt. Birds on the floor were reconditioned and 

rehung by approximately 0640 hours. Rehanging was completed by approximately 

0645 hours. The establishments' SSOP Reconditioning Procedures under #1 states 

" 

." Birds should be slaughtered in a sanitary manner using 

Good Commercial Practices. My findings indicated a noncompliance with 9 CFR 

416.15(b) and 9 CFR 416.4(d). 

(b) (6)
(b) (6) (b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4317031 

122N-1 

03/22/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C While performing a Finish Product Standard inspection check, I found a zero 

tolerance fecal failure. At approximately 1035 hours, I randomly selected 10 birds 

from line #1 in plant #1. I found one out of the ten birds contaminated with feces. 

The fecal matter was dark brown in color and pasty in texture. There were two fecal 

spots measuring approximately 1/8" each. One of the fecal spots was located by the 

kidney area and the other fecal spot was located on the left leaf fat area. I 

immediately notified of the 

noncompliance. The establishment implemented the zero tolerance protocol. 

Quality control performed a passing recheck at 0958 after a temporary corrective 

action was put in place (showers prior the cabinet were turned on). According 

to the cause of deviation was broken leaf fat lifters. The 

deficiency was fixed during break time (1000 to 1015 hours). Quality control 

performed a passing CCP2B check at 1029 hours. Suspect lot was from 1011 hours 

to 1139 hours. All post chill checks performed by quality control were found 

acceptable. 

5309 P6137A NJN390703 

3722N-1 

03/22/2012 01C02 Operational SSOP 

Review and 

Observation 

C I was performing an Operation Sanitation verification activity in the Packaging 

Department at 0230 hours when I noted the following noncompliance; I observed a 

plant employee overspray water from the floor and drain onto the product 

conveyor located under the polar massager exit, while he was washing down the 

floor. The conveyor belt was not running however, the hopper was full of marinated 

product. The product conveyor is a direct product contact surface. I initiated 

regulatory control at 0235 hours and retained the product and the 

hopper/conveyor with USDA retain tag B39415954. I notified Mr. 

and Mr. of the 

noncompliance. After corrective actions to restore sanitary conditions were 

implemented and measures to prevent recurrence were proffered the product and 

unit were released at 0430 hours. 

5308 M6137 BXL3306032 

021N-1 

03/21/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 03/20/2012 while monitoring the Establishments' Preoperational Sanitation 

procedures in Plant #1, I found the following noncompliance with regulations 9 CFR 

416.1, 416 4 (a) and 416.13 (c). At approximately 2251 hours, I observed in Area #4 

the recycle water tank that captures the Inside/Outside Bird Washer water, had 

slimy residue, fat and feathers in it. This tank is a Food contact surface. I 

immediately attached a U.S. Rejeted Tag # B31 407496 to the tank. I notified the

 and the of the noncompliance. 

The tank was scrubbed and rinsed. Sanitary conditions were restored at 

approximately 2300 hours then I removed the tag. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2415033 

720N-1 

03/20/2012 03J02 Slaughter HACCP C At approximately 915 hours while performing a Post-Chill Finish Product Standard 

check in Plant #1 on line #1, I found one out of the 10 birds contaminated with 

feces. The fecal matter was inside the bird cavity by the kidney area. There were 

three fecal spots each measuring approximately 1/8" in diameter and there was 

also a piece of feces measuring approximately 1/4" in diameter. The fecal matter 

was light yellow in color and soft in texture. I took immediate regulatory control 

action by having the establishment personnel working at re hang area to stop 

hanging birds. I then, notified of the noncompliance. From 

915 hours to 925 hours, 4 tanks full of carcasses were put on hold by Quality 

Control as part of their immediate corrective action. Suspect lot was from 915 

hours to 1025 hours. Post chill checks were performed by Quality control from 925 

hours to 1035 hours. All product on hold was reworked by the establishment, 

reinspected and released by quality control. My findings indicate a failure to keep 

CCP 2B under control. The establishment's monitoring frequencies were not 

effective in preventing feces from entering the chiller. 

5308 M6137 BXL0915035 

419N-1 

03/19/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 3/19 at approximately 0937 while preforming a Finished Product Standard 

check I observed the following non compliances. After pulling a ten bird random 

sample I noticed two out of the ten birdshad grease smears, one bird had a smear 

on it's breast approximately 2-3 sq inches the other bird had a smear on it's back 

about 2" wide and about 3" long I notified of my findings. The QC notified

 who had preform a recheck .The QC's Findings were 

consistent with mine finding several more birds with grease smears. At 0955

 had his people stop hanging, and began to tank off birds . The 

product was tagged by QC and held to be reworked .At 1006 QC preformed another 

recheck which was found to acceptable butting the company back incompliance.My 

findings indicate noncompliance with regulations with 416.14(d) 416.4(d) and 

416.13(c) . 

(b) (6)
(b) (6)(b) (6) (b) (6) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2420035 

619N-1 

03/19/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C While performing Pre Operational Sanitation Inspection on the ground chicken area, 

I found a noncompliance with regulatory requirement of regulation 9CFR 416.4(b). 

At approximately 0838 hours, I noticed a rotten smell coming from the stack of 

black plastic divider. These egg shell shaped dividers are utilizedfor palletized 

ground chicken cases. The first 5 dividers on top of the stack were clean, 

howevermost of the dividers underneath were dirty. There was stagnant cloudy and 

smelly water mixed with blood from the previous production day. I immediately 

placed US Rejected/Retained tag N0 B31 407553 on the insanitary stack of dividers. 

I notified of the noncompliance. The pallet 

holding these dividers was taken to the loading dock area to be washed by 

sanitation in the afternoon shift. After sanitary conditions were restored, US tag 

was released by USDAon night shift. While performing Pre Operational Sanitation 

inspection on the packaging rehang area plant 1, I found a noncompliance with 

regulatory requirement of regulation 9CFR 416.4(a). At approximately 0848 hours, I 

noticed a stainless steel tank with several chunks of fat measuring approximately 

1/8". This tank is a product contact surface utilized to hold carcasses coming out of 

the chiller. This tank was washed immediately by sanitation as I pointed out the 

noncompliance. was notified as well. I reinspected the 

tank and found it to be acceptable. Area was released after sanitary conditions were 

restored. 

5308 M6137 BXL1605033 

916N-1 

03/16/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 03/16/2012 at approximately 0000 hours while monitoring the Establishments' 

Preoperational Sanitation Procedures in Packaging #1, I observed the following. 

There was a layer of dried brown (UFM) on most of the accessible shackles along 

approximately 100 ft of line at the plant #2 halving machine. The line conveys 

birds to the halving and other processing machines for cutup. 

decided to use the shackle washers so Lockout/Tagout was released and no US 

Reject tag was applied. Sanitary conditions were restored by approximately 0035 

hours. At approximately 0005 hours the following items were found along the thigh 

deboning line. There were several pieces of fat to approximately 1/2" on the 

product contact surfaces of the catch tray at the tub dumper. There were numerous 

pieces of fat and tissue to approximately 2" on the short conveyor belt associated 

with the dumper catch tray. There were numerous pieces of fat and tissue to 

approximately 1/2" on the two white conveyor belts associated with the skin 

removers. There were numerous pieces of fat and tissue to approximately 2" on the 

white nylon and stainless belt assembly that feeds product into the #1 . 

There were numerous pieces of fat and tissue to approximately 1/2" along the 

entire length of the collection belt that removes the trim from the line. Sanitary 

conditions were restored by rinsing with potable water per establishment policy by 

approximately 0020 hours. My finding indicated a noncompliance with 9 CFR 416.1, 

9 CFR 416.4(a), and 9 CFR 416.13(c). 

(b) (6)
(b) (6)

(b) (6) (b) (6)

(b) (6)(b) (6)

(b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5218034 

816N-1 

03/16/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 1534 hours, I found a zero tolerance fecal failure. I randomly 

selected 10 birds from line 2 plant 1. I found one out of the ten birds contaminated 

with feces. The fecal matter was light yellow in color and pasty in texture measuring 

approximately 1/4" in diameter. It was located inside of the bird cavity near the tail 

area close to the right leaf fat. I immediately notified 

of the noncompliance. My findings reflect the 

establishment's failure to maintain CCP 2B under control even after the established 

monitoring frequencies are followed.The establishment's zero tolerance protocol 

was implemented. According to and 

the cause of deviation was the Inside/outside Bird Washer. Quality Control 

recheck passed at approximately 1608 hours after the cause of deviation had been 

established and deficiency had been fixed by maintenance. Suspect lot was 

determined to be from 1626 hours to 1718 hours. Quality Control performed 

rechecks at the post chill for chiller 2. All of the rechecks were found acceptable. 

Product coming out of the chiller was deemed to be acceptable. 

5308 M6137 BXL2811032 

315N-1 

03/15/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1455 hours while walking through the packaging area I found the 

following noncompliance. At the end of the breast fillet line I observed 

condensation on the drip pan directly above the transfer belts. These belts bring 

product to Line for tray pack. There was also a leak in a welded seam on the pan 

dripping onto the metal sides of the lower transfer belt splashing water onto the 

belt and product. I immediately notified of the problem. He 

immediately called maintenance about the leak and got a piece of blue plastic to 

use to divert the welded seam leak away from the belt. I had notified and 

when he came he took over handling the leak problem and talked to mechanics and 

told to get the condensation cleaned up. got a 

mop and while he was wiping condensation off of the drip pan the mop splashed 

dirty mop water onto the belts and product going to Line . I immediately took 

regulatory control action and had stop the line. 

stopped the line and took corrective action by having all of the product on the 

line taken off and put in tubs to be reprocessed. I applied USDA Retain tag 

#B31406209 to the pallet of 13 brown tubs. QC was notified to monitor the 

reprocessing of the pallet of product. The product was reprocessed and sanitary 

conditions were restored. The USDA retain tag was removed and product was 

released back to production by USDA at 1705 hours. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3515030 

915N-1 

03/15/2012 01D01 SPS Verification C At approximately 1145 hours while walking through the packaging area I found the 

following noncompliance. At the breast halver machine across from the bag fryer 

line there was condensation on the drip pan directly above the tank of ice used for 

icing the product in tubs and directly above the roller belt the tubs of product are 

filled on.I immediately contacted I informed him of the 

problem and he had the condensation removed, restoring sanitary conditions. He 

also had the tank of ice moved from the area condensation seems to form and had 

a fan turned to that area to help with the condensation problem. He told the 

employees and to have the area wiped down every 5 to 10 

minutes throughout the day as it seemed to be a problem area. 

5308 M6137 BXL0510031 

014N-1 

03/14/2012 01D01 SPS Verification C On 03/14/2012 at approximately 0720 hours while monitoring Facilities, I observed 

the following. On the loading dock there was rain water dripping between the truck 

trailer and door seal attached to the building. The area is not treated as a product 

contact surface. There were pallets of product being certified for temperature which 

would have been loaded onto the affected trailers. As the bins are not covered any 

fluids that gets in the bins or on the liner could be transferred to the product when 

dumped. Or the fluids could contaminate the boxed product during unwrapping by 

the receiver. I contacted and showed him my concerns on doors 

10,14 and 15. There was product loaded on the three trailers but as I did not 

observe them being loaded I do not know if the bins, pallets of brown tubs and bulk 

boxed product were loaded before or after it started to rain. Doors 14 & 15 had the 

most leakage with a continuous flow of water across the entire door way.

 had the product ready for loading put temporarily back into the 

staging cooler while the truck driver moved the trailers to a door that was not 

leaking. By approximately 0755 hours, decided that if the doors 

could not be repaired in a timely manner that pallets being loaded would be 

covered with plastic during the loading process. With this understanding the area 

was released to production. My findings indicated a noncompliance with 9 CFR 

416.1 and 9 CFR 416.2(b)(2). 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6)

(b) (6)

(b) (6) (b) (7)(C)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN250503 

4614N-1 

03/14/2012 01C02 Operational SSOP 

Review and 

Observation 

C At 0251 hrs. I observed a stack of nine wooden pallets staged for use, with 

numerous particles of visible fecal material (bird feces) on the top pallet. These 

pallets where located in the new products room at the end of the rotisserie line. I 

informed and showed these findings to and 

and informed them of the non-compliance with the regulation sited 

above. Mr immediatly put a QC tag on the stack of pallets. The pallets where 

then removed from the production area under QC control. 9 CFR 416.4(b) states 

that "non food contact surfaces of facilities, equipment, and utensils used in 

operation of establishment must be cleaned and sanitized as frequently as 

necessary to prevent the creation of insanitary conditions and adulteration of 

product". This document serves as written notification that your failure to comply 

with regulatory requirement(s) could result in additional regulatory or 

administrative action. 

5333 P7632 HYE530603 

4314N-1 

03/14/2012 04C05 Poultry Good 

Commercial 

Practices 

C While performing the observation component and following intructions of District 

Veterinarian Medical Specialist Dr. on Good Commercial Practices, at 

approximately 0340 hours, just prior to birds entering the scalder for line #2, I 

observed a live bird with the eyes wide open, the neck was not hanging and no 

blood was observed. I grabed the bird and it responded with a twitching and 

squaking sound. Ms. was notified of 

the occurence. The bird was idetified as a cadaver approximately 6 minutes after it 

exited the pickers in the presence of Mr. 

and he was notified of the non compliance. NR number HYE4311022528N was 

recorded on 02/28/2012 with same ocurrence of live birds going into scalders. 9 

CFR 381.65 (b) states in part; Poultry must be slaughtered in accordance with good 

commercial practices in a manner that will result in thorough bleeding of the 

carcasses and ensure that breathing has stopped prior to scalding. 

5309 P6137A NJN210803 

4113N-1 

03/13/2012 01B01 Pre-Op SSOP 

Record Review 

C While performing a Pre-Operational sanitation record review in the Q.C. office at 

0145 hrs, for the production date 3/10/2012, I noticed the following 

noncompliance. The SSOP Daily Implementation and Monitoring Log for the break 

room was not signed and dated by the sanitation supervisory personnel and/or 

designee. I informed of the forthcoming documentation 

of the noncompliance. The establishment's SSOPs state: 

. 9CFR 416.16(a) states: The 

establishment employee (s) specified in the sanitation SOP as being responsible for 

the implementation and monitoring of the procedure(s) specified in the sanitation 

SOPs shall authenticate these records with his or her initials and the date. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (6) (b) (7)(C) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL0615033 

512N-1 

03/12/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 3/12 at approximately 0955 , while preforming a Finished Product Standard 

check at the post chill area in plant 2 on line I observed the following 

noncompliances. After pulling a ten bird random sample I noticed 4 out of the ten 

birds had numerous tiny black specks on the breast, thigh, and the back area. I 

immediately notified . had his workers stop 

hanging birds and started tanking off birds (three tanks), the tanks were held by QC, 

who had them reworked and also placed a hold tag on the product .At 

approximately 1012 after preforming a recheck the birds were free of foreign 

material, and the company was allowed to return to production. My finding 

indicate noncompliances with the following regulations416.1 416.4(d) and 

416.13(c) . 

5308 M6137 BXL2701032 

410N-1 

03/10/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 03/08/2012 while performing Pre-operational Sanitation Procedures in the 

Rotisserie Room, I observed noncompliance with regulations 9CFR 416.1, 416.2 (d) 

and 416.4(a). At approximately 2332 hours, I observed heavy beads of 

condensation formed on the ceiling above the Injector Machine, Metal Detector and 

the Conveyor belt. I informed and 

of the noncompliance. The Lead Person immediately took corrective action by 

sending Sanitation Personnel to wipe off the condensation. When Sanitation Person 

was wiping the condensation from the ceiling, the condensation was dripping on 

the conveyor belt between the InjectorMachine and the Metal Detector. I informed 

. Sanitation Person after finished wiping off the 

condensation, washed the conveyor belt. At approximately 0043 hours sanitary 

conditions were restored and I released the area. 

5309 P6137A NJN430303 

1010N-1 

03/10/2012 01C02 Operational SSOP 

Review and 

Observation 

C I was in the Evisceration department at start up of operations when line inspector, 

Ms. , called me to her station on "B" line station #1. The inspector 

had informed me that there was foreign material that looks like gray dust 

coveringthe entire station. Upon further investigation I noted that both lines "A" 

and "B"from the oil gland machine to the neck popper machcine, including the drip 

pans and over head lights of the six USDA stations, where covered in this gray dust 

like foreign material. I took regulatory action by stopping and applying my USDA 

Reject/Retain tag # B38494981 to "A" line, "B" line, at 2310 hours. I informed Mr.

 of the noncompliance. After corrective actions 

the evisceration lines where reinspected and released at 2339 hours. No product 

was effected because both lines where stopped prier to the product reaching the 

effected area. 

(b) (6)
(b) (6) (b) (6)

(b) (6)

(b) (7)(C) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4409033 

909N-1 

03/09/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C While performing Pre-Chill Finished Product Standard Check, I found a 

noncompliance with the following regulatory requirements of regulation 9CFR 

381.65 (e) and 417.2 (c)(4). On 03/09/2012 at approximately 0057 hours, I 

randomly removed a 10 bird sample from Line in Plant #2, I found one out the 

ten birds with visible fecal contamination on the right side of the abdominal flap on 

the bird. The fecal material was a smear approximately 3/8" long and 1/4" wide and 

a chunk approximately 1/8" diameter, brownish green in color and pasty texture. 

This exceed the limit of Zero Tolerance for the process to be in control. I informed

 and of the 

noncompliance. Fecal was contested and confirmed by Dr. The protocol for 

fecal failure was implemented. Quality Control performed a Recheck at 

approximately 0131 hours and it passed. This is a violation of the critical limits of 

CCP-2B, of the Plant's HACCP Plan for Slaughter. 

5333 P7632 HYE061703 

4409N-1 

03/09/2012 01C02 Operational SSOP 

Review and 

Observation 

C At 1316 hours while en route to perform a post chill finished products standards 

procedure at the exit of the north chiller, I observed that the birds had piled on the 

chiller rehang table to the point of overflowing. I proceeded to the north side of the 

table where I observed nineteen carcasses on the floor around the catch pan 

created to catch product overflow and on the grates where rehang employees 

stand. I observed three more birds fall to the floor with no one taking any effective 

corrective actions to regain process control. Regulatory control was taken of the 

process with the application of US Reject Tag B40193592. Regulatory control of the 

product was taken with the application of U.S. Retain Tag B40193593. 

was notified of the forthcoming documentation of the 

failure to comply with the regulatory requirements cited above. At 1318 hours 

regulatory control of the process was relinquished the acceptance of effective 

corrective actions to restore sanitary conditions,and the proposed preventive 

measure that the lead person and other employees responsible for the area would 

undergo additional training on how to more effectively handle product flow surges 

during returns from breaks and/or lunch. Regulatory control of the product was 

relinquished at 1330 hours after appropriate disposition was made. On 01/09/2012 

a similar noncompliance was documented where product surge in the chiller rehang 

area resulted in product pile up on the floor around the chiller rehang table. The 

preventive measure of "training supervisors and leads on management practices in 

Chiller Rehang to aid in proper bin flow" failed to prevent the recurrence of this 

noncompliance. 

(b) (6)
(b) (6)

(b) (4)

(b) (4)

(b) (4)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE472003 

2609N-1 

03/09/2012 01C02 Operational SSOP 

Review and 

Observation 

C At 1328 hours on March 09, 2012, while verifying the corrective actions of an 

earlier noncompliance in the Chiller Rehang area, I observed thick sheets of water 

pulsating out of the top of the neck chiller exit chute. I observed that this was the 

result of a backlog of necks which had accumulated and plugged the mouth of the 

exit chute. The thick streams of water shooting out of the top of the chute washed 

across the insanitary surfaces of the overhead pipes, all-thread, brackets and other 

nonproduct-contact surfaces and fell into the two bins of edible necks which were 

being collected chiller exit. The water also fell into an uncovered tote filled with 

edible gizzards. Regulatory control of the two bins of necks and the tote of gizzards 

was taken with the application of U.S. Retained Tags B38494989, B38494990 and 

B38494991, respectively. was notified of 

the forthcoming documentation of the failure to comply with the regulatory 

requirements cited above as well as Step Two of the Establishment's SSOP Plan for 

the department which states, " 

." At 1340 hours regulatory 

control was relinquished with the acceptance of effective corrective actions to 

restore sanitary conditions, make appropriate disposition of product and the 

proposed preventive measure that the associate assigned to the area will undergo 

training to ensure that the chute is not plugged prior to leaving the area. 

5308 M6137 BXL2606034 

208N-1 

03/08/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 2315hrs, I observed maintenance personnel working on the 

venting machine on Line in Plant 2. After maintenance personnel completed 

their work, an evisceration supervisor washed the machine with water and the 

production line was started. After running for a few minutes the line was stopped 

again for more repairs. This scenario was repeated three times, because 

maintenance personnel were having difficulty figuring out the problem. At no time 

did a SSOP, HACCP or QC personnel check the venting machine for sanitary 

condition or release the venting machine to production. At approximately 2330hrs, 

the line was started after the venting machine was washed down a final time and 

everything was working properly. The establishment failed to follow the procedures 

of their SSOP program. In the SSOP Program: Section II-Operational Sanitation; 

Operational Sanitation Procedures: Implementation, states in part 

". In the SSOP Program, the "Equipment 

Breakdown Procedure" Revised on 11/04/11 states in part " 

". 

(b) (6)
(b) (6) (b) (7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN431003 

0007N-1 

03/07/2012 01C02 Operational SSOP 

Review and 

Observation 

C On March 5, 2012 at approximately 1835 hours, while performing the PHIS task for 

review and observation of Operational SSOPs in the establishments fillet 

department, I observed a regulatory noncompliance of 9 CFR 416.15(b) and 

416.4(a). Previously, at 1715 hours, I had observed a broken sprinkler on the ceiling 

of the fillet room. The sprinkler sprayed water and an unidentifiable black foreign 

material all over cone lines 5 through 12 and the product on these lines. The 

establishment had already stopped production and a QC representative had all 

affected product and equipment on hold. The establishment indicated that they 

would take complete corrective actions and restore sanitary conditions prior to 

resuming operations in the fillet room. At 1830 hours, according to the Operational 

SSOP records, all affected equipment had been returned to sanitary conditions by 

the QC. At this time I elected to verify the establishments implementation of the 

SSOP corrective actions. As described in 9 CFR 416.15(b), regarding the appropriate 

corrective actions to be taken in response to direct product 

contamination,"corrective actions include procedures to ensure appropriate 

disposition of product(s) that may be contaminated, restore sanitary conditions, 

and prevent the recurrence of direct contamination or adulteration of product(s)." I 

inspected the cone lines and determined that sanitary conditions had not been 

restored. I observed several pieces of fat and meat on the food contact surfaces of 

affected cone lines 5 through 12. The conveyor belts were operational when the 

sprinkler started spraying water and unidentifiable black foreign material on cone 

lines 5 through 12 and the product on these lines. The establishment did not 

completely restore sanitary conditions, as they failed to remove all fat and meat 

residues from the contaminated product on the belts and cones for lines 5 through 

12. In addition, as described in 416.4(a) "all food contact surfaces, including food 

contact surfaces of utensils and equipment, must be cleaned and sanitized as 

frequently as necessary to prevent the creation of an insanitary condition and the 

adulteration of product." I immediately notified Mr. that the 

establishment failed to fully restore sanitary conditions and also notified him of the 

forthcoming noncompliance record. At 2030 hours CSI, inspected 

the affected equipment and found that sanitary conditions had been restored and 

released the area for production. The establishment elected to condemn all 3703 

pounds of affected product. 

(b) (6)
(b) (6)

(b) (6)

(b) (6)

(b) (6)

(b) (6) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1105031 

606N-1 

03/06/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C While performing Pre-Chill Finished Product Standard check, I observed 

noncompliance with the following regulatory requirements of regulation 9CFR 

381.65 (e) and 417.2 (c)(4). On 03/06/2012 at approximately 0038 hours, I 

randomly removed a 10 bird sample from Line #2 in Plant #1, I found one out the 

ten birds with visible fecal contamination inside the bird under the left fat area by 

the cavity of the kidneys. The fecal material was a smear measuring approximately 

3/4 inch diameter in size, brownish green in color and pasty in texture. This exceed 

the limit of Zero Tolerance for the process to be in control. I informed 

and of the noncompliance, the protocol 

for fecal failure was implemented. Quality Control performed a Recheck at 

approximately 0106 hours and it passed. The cause of the deviation was the 

Inside/Outside bird washer. This is a violation of the critical limits of CCP-2B,

 of the Plant's HACCP Plan for Slaughter. 

5308 M6137 BXL2115031 

905N-1 

03/05/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C While performing Pre Operational Sanitation Inspection in the Packaging area, I 

found the following noncompliances:1- At approximately 0840 hours, while 

inspecting the debonning Line, I found pieces of meat and fat ranging from 1/8" to 

1/4" all through out the conveyors; and also, approximately 70% of the white 

cutting boards around the debonning table, were dirty with meat particles and 

contained a dark build up of fat residue. Conveyor and cutting board on the 

debonning line are consider product contact surfaces. I immediately placed a U.S. 

Rejected tag N0. B31 406224 on the affected line. I notified 

of the noncompliance. 2- At approximately 0850 hours, while 

inspecting the tub wash room area, I noticed pieces of fat and meat affecting all the 

inside area of the Tub Wash Machine. These pieces of dried meat measured 

approximately 1/8' to 1/4" in size. I placed a U.S. rejected tag N0. B31 407519 on 

the affected equipment and then, proceeded to notify 

of the noncompliance. 3- At approximately 0855 hours while 

inspecting the Conveyor/Dumper area located in the packaging area next to the Tub 

Wash Room, I found two pieces of concrete each measuring approximately 1/4" in 

diameter. They were on top of the blue conveyor which is consider a food contact 

surface. I immediately placed a U.S. Rejected Tag N0. B31 406225 on the affected 

line. I notified of the third noncompliance. All affected areas 

were rewashed by sanitation. U.S.rejected tags were removed by USDA after 

sanitary conditions were restored. All areas were released at approximately 0920 

hours. 

(b) (6)
(b) (6) (b) (6)

(b) (6) (b) (6)

(b) (6) (b) (7)(C) (b) (4)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2619032 

402N-1 

03/02/2012 01D01 SPS Verification C At approximately 1315 hours,I notice a noncompliance with regulatory requirement 

of 9 CFR 416.4(b) which states "Non-Food-contact surfaces of facilities, equipment, 

and utensils used in the operation of the establishment must be cleaned and 

sanitized as frequently as necessary to prevent the creation of insanitary conditions 

and the adulteration of product." On the wall behind station #6 in plant 1, there 

was a squeegee holding a filthy sponge. This utensil is utilized to dried overhead 

condensation. The sponge was no longer yellow in color but black. It was torn and 

full of foreign material. I proceeded to place a U.S. Rejected tag NO. B31 407550 on 

the dirty squeegee. I then, notified of the noncompliance. She 

took immediate corrective action by disposing the dirty sponge and placing a new 

cleaned one in the squeegee. U.S. Tag was released by USDA after sanitary 

conditions had been restored. 

5308 M6137 BXL4018030 

602N-1 

03/02/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 1114 hours, I found a zero tolerance fecal failure. I randomly 

selected 10 birds from line 1 plant 1. I found one out of the ten birds contaminated 

with feces. The fecal matter was dark yellow in color and pasty in texture. There 

were several smears of feces measuring approximately 1/16" on the bird's right leaf 

fat. There was also a chunk of feces measuring approximately 1/4" in diameter 

inside of the bird cavity by the kidney area. I immediately notified

 of the noncompliance. 

requested the Veterinarian's opinion. Dr inspected the affected carcass 

finding it to be contaminated with fecal matter. The establishment fecal protocol 

was implemented. According to the cause of deviation was 

the sprayers of the Inside Out Bird Washer. Quality Control recheck passed at 

approximately 1128 hours after the cause of deviation had been established and 

the deficiency had been corrected by maintenance. Suspect lot was determined to 

be from 1146 hours to 1238 hours. Quality Control performed rechecks at the post 

chill for chiller 1. All of the rechecks were found acceptable. At 1248 hours, product 

was deemed to be acceptable for shipping. 

5308 M6137 BXL5409032 

802N-1 

03/02/2012 03J02 Slaughter HACCP C On 03/02/2012 at approximately 0700 hours while performing a HACCP Slaughter 

supporting documentation review, I observed the following. The HACCP Monitoring 

Log CCP-2B ) dated on 02/28/2012 PM for Plant #1 was missing 

the Performed of Records Review, signature and time by the QC monitor. The 

Plant's HACCP Plan states 

". My findings indicate a noncompliance with regulations 

9CFR 417.5(a)(3) and 417.4 (a)(2)(iii). I notified of the 

noncompliance. 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6)

(b) (4)

(b) (4)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN420903 

0002N-1 

03/02/2012 04A06 Poultry Finished 

Product Standards 

C I was performing a FPS (Finished Products Standards) check at 0239 hours on the 

reprocessing line in the evisceration department when I noted the following 

noncompliance; The establishment failed to remove airsacculitis exudate from 

carcasses identified by USDA for air sac removal. (4) carcasses of the (10) carcass 

sample identified for air sac removal with a spit tail contained air sac exudates. The 

establishment's written procedure for air sac removal states

 The procedure also states states; 

. I initiated regulatory control by stopping the reprocessing line 

and immediately informed Ms. , and Mr. 

of the noncompliance. 

5333 P7632 HYE450503 

5402N-1 

03/02/2012 01C02 Operational SSOP 

Review and 

Observation 

C While performing an Operational Sanitation Review and Observation task in the 

Packaging Department at 0158 hours I observed the following noncompliance: 

Above Tray pack line condensation was present and dripping onto the product 

contact surface while establishment employees were tossing down grade chicken 

drums from line over the small divider to line cross contaminating the product. I 

took Regulatory control of Tray pack line with U.S. retain tag # B38494966 and 

informed ,of the 

noncompliance. Mr. took immediate action by having the affected 

product removed from the line to a reprocessing brown tub to which I applied my 

U.S. retain tag B38494980. Control of Tray pack line was relinquished at 0208 

hours after the product contact surface was resanitized and sanitary conditions 

were restored. The affected product was released after it was reprocessed per 

establishments procedure and passed FSIS reinspection. This noncompliance is 

linked to NR record number HYE1203012926N/1 

(b) (6)
(b) (6)

(b) (6)

(b) (6)

(b) (4)

(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN590903 

5801N-1 

03/01/2012 03J02 Slaughter HACCP C I was performing the slaughter HACCP verification task when I noted the two 

following noncompliance. I was reviewing the establishment HACCP records for CCP 

1-B zero tolerance checks at 0723 hours in the evisceration department to verify 

the establishment was meeting the regulatory requirements as per 9 CFR 417.5(b) 

when I noted the following noncompliance. The HACCP designee documented the 

incorrect time for the HACCP CCP 1-B monitoring check conducted 0712 hours. The 

establishment's written HACCP plan states the 

. The HACCP monitor documented the monitoring check for 

parts CCP 1-B at 0643 hours, the monitoring check for the reprocessing line CCP 1-B 

at 0656 hours, and the monitoring check for the paws CCP 1-B at 0612 hours. I 

notified the of the recordkeeping 

noncompliance. I was performing a records review verifying the establishments 

chilling procedures identified in a prerequisite program to verify compliance with 

the regulatory requirements when I noted the following noncompliance; The actual 

kill time of the carcass is not correctly identified and documented on the 

monitoring form associated to the temperature of the paws being verified. The 

correct time is required in order the verify that the paws have been chilled 

degrees F or below, in as outlined in the establishment's written 

procedures. The records I verified at the start of the shift show the first QC check for 

CP 3B paws to be acceptable at 2350 hours, with a temperature of 34.1 and a kill 

time of 2335. The actual kill time was approx. 2300 hours. I notified Mr. 

and Ms. of the recordkeeping 

noncompliance. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1805023 

229N-1 

02/29/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 02/28/2012 at approximately 2015 hours whole monitoring the 

Establishments' temperatures in the Plant #1 Cooler, I observed the following. A 

mechanic was repairing the ceiling mounted refrigeration unit closest to the staging 

cooler door. I returned at approximately 2200 hours and found numerous pieces of 

black (UFM) to approximately 1/8" on a pallet of clean tubs. The tubs are used to 

store finished product. The pallet was directly under the unit and a large amount of 

UFM had gotten inside of the protective plastic wrap. There was also a tank of 

WOG's, without the normal protective plastic covering, staged for that 

had several specks of UFM to approximately 1/8". There were numerous specks of 

UFM to approximately 1/8" on a portable table used to clean cartilage in the 

Deboning Room. There were specks to numerous to count to approximately 1/4" on 

the lids of a partial pallet of giblets. had available sanitation 

personnel take the pallet of clean tubs to the tub wash room. The portable table 

was removed to the Deboning Room of cleaning. The lids on 9 tubs of giblets 

were replaced. I later contacted who had the WOG's removed to 

the Room for reconditioning with chlorinated water. Sanitary conditions 

were restored by approximately 0030 hours. My findings indicated a 

noncompliance with 9 CFR 416.4(d). 

5333 P7632 HYE191102 

2829N-1 

02/29/2012 06D02 Other Inspection 

Requirements 

C At 0710 hours on February 29, 2012, while performing bird by bird antemortem 

inspection on Evisceration Line One, I observed an inordinate amount of birds being 

presented to me with the viscera still attached to the carcass. Due to the number of 

birds I received in this manner in succession and the manner in which the visceras 

were pinned between the carcass and the guide chain and/ot forced the posterior 

opening closed, my ability to properly inspect these carcasses was impeded to the 

point that some had to be hung back so that they could be presented in a manner 

conducive to appropriate inspection. This, along with carcasses being hung back for 

salvage, caused my hangback rack to become full and required line stoppage so that 

the rack could be cleared. During the time that the line was stopped I observed that 

the floor employee was removing the visceras from the carcasses hung back for 

improper presentation and tossing the visceras down the drain prior to rehanging 

the birds back on the line to be inspected. This does not comply with 9 CFR 381.76 

[a] which clearlystates, "Apost-mortem inspection shall be made on a bird-by-bird 

basis on all poultry eviscerated in an official establishment. No viscera or any part 

thereof shall be removed from any poultry processed in any official establishment, 

except at the time of post-mortem inspection, unless their identity with the rest of 

the carcass is maintained in a manner satisfactory to the inspector until such 

inspection is made." was notified of the 

forthcoming documentation of the failure to comply with the regulatory 

requirements cited above. 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6) (b) (7)(C) (b) (7)(C)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE421602 

3829N-1 

02/29/2012 04A06 Poultry Finished 

Product Standards 

C At 1050 I observed a plant associate performing the on line vacuum procedure. I 

immediately asked the on line inspectors and if they had 

been informed that the company was going to implement the on line vacuum 

procedure.They had not been informed. The plants on line vacuum procedure, 

Document #: E-14 (10/21/2009), Revision #: 008 (12/05/2011), states; 

. I informed and 

of the plants failure to follow the written procedures to inform 

Inspection Personal of the implementation of the on line vacuum procedure and of 

the forth coming documentation of the non-compliance. 

5308 M6137 BXL4013023 

728N-1 

02/28/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 1048 hours, I found a zero tolerance fecal failure. I randomly 

selected 10 birds from line 2 plant 1. I found one out of the ten birds contaminated 

with feces. The fecal matter was light yellow in color and pasty in texture measuring 

approximately 1/2" in diameter. It was located inside of the bird cavity near the tail 

area. I immediately notified of the 

noncompliance. The establishment's zero tolerance protocol was implemented. 

According to the cause of deviation was the Inside Out Bird 

Washer. Quality control recheck passed at approximately 1103 hours after the 

cause of deviation had been established and deficiency had been fixed by 

maintenance. Suspect lot was determined to be from 1145 hours to 1215 hours. 

Quality control performed rechecks at the post chill for chiller 2. All of the rechecks 

were found acceptable.Product was deemed to be acceptable. 

5308 M6137 BXL5909021 

828N-1 

02/28/2012 03J02 Slaughter HACCP C On 02/28/2012 at approximately 0544 hours while performing a Post-Chill Finished 

Products Standards test in Plant #1 on Line #1, I observed the following. After 

taking a random 10 bird sample, I observed one bird with visible fecal 

contamination. There was a cloaca attached inside the carcass at the tail with 

approximately 4" of intestine. The fecal contamination, a smear approximately 1/4" 

in size, was located on the left side leaf fat. The fecal material was light brown in 

color and sticky in texture. As there were no Packaging Department Supervisors 

available, I asked the establishment personnel hanging birds from Chiller #1 going 

to sorting and sizing to stop hanging. I asked a lead person nearby to tank the 

product coming from chiller #1. I contacted Plant #1 and 

showed him my findings. A recheck passed at 0547 hours. Two tanks of birds were 

placed on hold for rework. My findings indicated a noncompliance with 9 CFR 

417.(c)(4) and 9 CFR 381.65(e). 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (6)

(b) (6)

(b) (6) (b) (7)(C) (b) (7)(C)

(b) (4)

(b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE431102 

2528N-1 

02/28/2012 04C05 Poultry Good 

Commercial 

Practices 

C During a Good Commercial Practice visit by District Veterinary Medical Specialist Dr. 

, she and IIC Dr. toured the live hang and kill area of the 

estalishment. At 0825 hours, they observed a breathing bird entering the scalder. 

At 0828 hours, they observed a second breathing bird entering the scalder. These 

birds were later identified as cadavers as they exited the pickers. The cuts on both 

birds were insufficient to allow for effective bleed-out. 

was present during the event and was immediately 

notified of the forthcoming documentation of the failure to comply with the 

regulatory requirements cited above. Ms. performed an immediate 

correlation with the appropriate supervisory staff. 

5308 M6137 BXL2909025 

424N-1 

02/24/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C On 2/24/2012 at approximately 0240while preforming a ZeroTolerance Fecal check 

in plant 1 on line2 , I observed the following .After taking a ten bird random 

sample,I observed the following one bird out of the ten contaminated with visible 

fecal in two seperate areas . There was fecal covering the tip of the hock in a 1/8 to 

3/8" area the other site was on the left side of the opening cut also ranging from 

1/8 to 3/8". the fecal was watery in texture and greenigh brown in color.I notifyed

 who notifyed and also 

of my findings. The companys fecal protocol was immediaately impelmented. 

Quality Controls recheck passed at 0303 putting the company back in compliance. 

My findings indicate a noncompliance with CFR 381.65(e) and 417.2(c) 

of the companys HACCP plan. 

5308 M6137 BXL4509023 

224N-1 

02/24/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C On 02/24/2012 at approximately 0540 hours while performing a Finished Products 

Standards check on line in Plant #2, I observed the following. After taking a 

random 10 bird sample, I observed one bird with visible fecal contamination. There 

was a gizzard with a piece of intestine approximately 12" long inside the carcass. 

There was visible fecal contamination to approximately 1/2" at several spots in the 

kidney area. The fecal material was medium brown in color and was starting to 

dissolve into the . I contacted who 

implemented the Establishments' protocol for mainline fecal failure. A recheck 

passed at 0618 hours. My findings indicated a noncompliance with 9 CFR 417.(c)(4), 

9 CFR 381.65(e), and the critical limit of CCP-2B of 

the Plants Plan for Slaughter. 

(b) (6)
(b) (6)

(b) (6)

(b) (4)

(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE121502 

2124N-1 

02/24/2012 01C02 Operational SSOP 

Review and 

Observation 

C At 1049 hours on 02/24/2012 while performing the review and observation 

component of an operational sanitation inspection procedure in the drumstick 

tray-pack area in 2nd Processing, I observed an associate washing down the floor 

with a high pressure hose. As he washed the floor he sprayed water and debris from 

the floor across, over and on two totes of uncovered drumsticks situated on a stand 

next to the tray-pack lines. Regulatory control of the product was taken with the 

application of U.S. Retained Tag B34776917 and 

z was notified of the forthcoming documentation of the failure to comply 

with the regulatory requirements cited above. This includes the establishment's 

SSOP plan which states, " 

." At 1251 hours regulatory control of the 

product was relinquished with the acceptance of effective corrective actions 

including the restoration of sanitary conditions, appropriate disposition of product 

and the proposed preventive measures that the associate would undergo training 

on the importance of protecting product during rinse downs. 

5308 M6137 BXL0710022 

723N-1 

02/23/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C On 02/23/2012 at approximately 0548 hours while performing a Finished Products 

Standards check on Line in Plant #2, I observed the following. After taking a 

random 10 bird sample, I observed one bird with visible fecal contamination. There 

was a piece of intestine approximately 12" long attached at the tail. Fecal material, 

approximately 3/8" by 1/4", had leaked from the cut end onto the mid joint of the 

right wing. The fecal material was olive brown in color and pasty in texture. I 

contacted who implemented the establishments protocol for 

mainline fecal failure. A recheck passed at 0632 hours. My findings indicated a 

noncompliance with 9 CFR 417.(c)(4), 9 CFR 381.65(e), and the critical limit of 

CCP-2B of the Plants HACCP Plan for Slaughter. 

(b) (6)
(b) (6)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (4)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1310024 

723N-1 

02/23/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 02/23/2012 at approximately 0310 hours while monitoring the establishments' 

Operational Sanitation Procedures in Plant #2, I observed the following. Lines were 

stopped due to multiple pieces of malfunctioning equipment. Tanks were full at the 

rehang station, where birds are moved from the kill line to the eviscerating line. An 

empty backup tank is normally located between lines but that tank had 

already been filled. A tank was brought from Packaging Dept by 

and shoved over approximately 30 birds in a pile on the floor increasing 

the level of contamination of the affected birds. The birds were rinsed and rehung 

onto the eviscerating line. At approximately 0408 hours, birds were brought into 

the eviscerating floor before plant employees scheduled lunch was over. Line 

was stopped causing a pileup again at the rehang station. The birds were dropping 

on the floor as all the tanks were full with over scalded birds condemned by the 

establishment before lunch. At approximately 0435 hours the kill line was reduced 

by 12.5% or . At approximately 0442 hours the kill was reduced to 25% 

allowing birds on the floor, approximately birds, to be rinsed and hung onto 

the eviscerating line. The last birds were picked up be approximately 0457 hours. As 

there is only one bird wash hose at the rehang station birds are tossed across 

space of several feet to condense the piles. The floor at the rehang area is 

contaminated with varying amounts of blood and debris from the kill line. The 

establishments' SSOP 'Reconditioning Procedure' under #1 states "

 and (a) states that " 

." Birds should be 

slaughtered in a sanitary manner using Good Commercial Practices. My findings 

indicated a noncompliance with 9 CFR 416.4(d). 

(b) (6)
(b) (6) (b) (6) (b) (4) (b) (4) (b) (4)

(b) (4)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5003021 

623N-1 

02/23/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 02/22/2012 at approximately 0128 hours while monitoring the Establishments' 

Operational Sanitation Procedures in Plant #2, I observed the following. Line 4B had 

stopped causing a backup at the rehang station where birds from the kill line are 

transferred to the processing line. The tank, catch tray, and the conveyor belt were 

full with birds. Approximately birds were on the floor in an area extending from 

the tank to the rehang belt. observed what I saw and reduced 

the live hang by 12.5% or birds. Three tanks were filled with excess birds 

before the kill was reduced by 25%. At 0138 hours birds were again falling on the 

floor as the rehang belt and all available tanks were full. Not until approximately 

0144 hours was the kill reduced to less then 50% so that the pileup could start to 

be reduced. The last birds were picked up by approximately 0151 hours. As there is 

only one bird wash hose at the rehang station birds are tossed across a space of 

several feet to condense the piles. Birds that end up under equipment are dragged 

out using a hook. The floor area involved is contaminated with varying amounts of 

blood and debris from the kill line. The establishments SSOP 'Reconditioning 

Procedure' under #1 states 

." and (a) states that " 

" Birds should be slaughtered in a sanitary manner using Good 

Commercial Practices. My findings indicated a noncompliance with 9 CFR 416. 4(d). 

5308 M6137 BXL3309022 

118N-1 

02/18/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C On 02/18/2012 at approximately 0654 hours while conducting a Finished Products 

Standards check, I observed the following. After taking a random 10 bird sample 

from Line #1 in Plant #1, I observed one bird with visible fecal contamination. There 

was a cloaca and approximately 4" of intestine. The intestine was attached at a 

point approximately 3" inside the carcass. Fecal material, approximately 1/8" in 

size, was leaking from the cut end of the intestine into the area of the kidneys. 

There was also a tear in the intestine approximately 1" from the cloaca and fecal 

material approximately 1/4" by 1/16" in size had leaked onto the inside of the 

carcass at the base of the tail. I contacted who implemented the 

Protocol for mainline fecal failure. A QC recheck passed at approximately 0717 

hours. My findings indicated a noncompliance with 9 CFR 417.2(c)(4), 9 CFR 

381.65(e), and the critical limit of CCP-2B of the 

Plants HACCP Plan for Slaughter. 

(b) (6)
(b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN361502 

3217N-1 

02/17/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 1050 hours while performing the PHIS task for zero tolerance on 

the reprocessing line I observed one carcass of a ten carcass sample with visible 

fecal material on the carcass. The fecal material was located on the carcass at the 

area were the breast and thigh is joined together and was approximately one 

quarter of an inch in diameter with a paste-like texture and brownish in color. I 

immediately took regulatory control of the reprocessing line and showed my 

findings to Mr. , and the 

QC technician assigned to that area. That the establishment would have allowed a 

carcass with visible fecal material to enter the chilling tank represents 

non-compliance with 9 CFR 381.65(e). A similar non-compliance was documented 

on 01/25/2012 NR # NJN5216011625N in which the establishment proffered the 

further planned action of retraining the employees. This further planned action was 

not effective in the elimination or reduction to an acceptable level the recurrence of 

this non-compliance. This document serves as written notification that your failure 

to comply with regulatory requirement's could result in additional regulatory or 

administrative action. 

5308 M6137 BXL4205023 

016N-1 

02/16/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 02/15/2012 at approximately 2355 hours while monitoring the establishments' 

Preoperational Sanitation Procedures, I observed the following. In Packaging Area 

#1, there was a large amount of soured tissue to approximately 2" in size on the 

stainless and white support brackets under the transfer conveyor after the x-ray 

machines and on the first couple of feet of the associated incline conveyor that 

transports product to the final trim station. There was dried blood and tissue on 

the stainless frame on at least a 20' section of the overhead boneless breast 

conveyor belt adjacent to the crust tunnel. Per their policy the affected areas were 

rinsed with potable water restoring sanitary conditions by approximately 0015 

hours. My findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 

416.4(a) & (b), and 9 CFR 416.13(c). 

(b) (6)
(b) (6)

(b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE080702 

0816N-1 

02/16/2012 01D01 SPS Verification C This non compliance record replaces non compliance record HYE5202010210N. This 

non compliance record has been reclassified from an SSOP verification to a SPS 

verification non compliance record which was previously recorded on 1/10/12. At 

approximately 0020 hours while performing the SPS verification task in the second 

processing department (bag line), I observed the following non compliance; during 

the start of the bag line, baskets were being brought in from the degree cooler 

which had fat particles and frozen blood from previous days production. One of the 

baskets had a part of a gizzard in it which I observed employees using these baskets 

to put bagged product onto. I informed 

) of the forthcoming non compliance record. 9CFR.4 (b) 

states; "Non food contact surfaces of facilities, equiptment, and utinsils used in the 

operation of the establishment must be cleaned and sanitized as frequently as 

necessary to prevent the creation of insanitary conditions and the adulteration of 

product." 

5333 P7632 HYE381202 

5516N-1 

02/16/2012 01C02 Operational SSOP 

Review and 

Observation 

C At 0938 hours on February 16, 2012, while performing an operational sanitation 

inspection procedure in 2nd Processing I observed a night shift employee handle a 

wooden pallet. Without sanitizing his hands he started placing liners into 2 bulk 

product cases and then proceeded to place 10 lb. bags of leg quarters into the 

cases. I placed US Retained Tag #B38 494958 on the cases. Mr. was 

informed of this situation, the case of product with the leg quarters was removed 

from the pallet to be reworked and the liner was removed from the other case. At 

0945 hours regulatory control was relinquished after effective corrective actions 

which included restoration of sanitary conditions. 

5308 M6137 BXL5403023 

515N-1 

02/15/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 02/15/2012 at approximately 0000 hours while monitoring the Establishments' 

Preoperational Sanitation Procedures, I observed the following. In Packaging Area 

#1, there were numerous pieces of fat to 3" all along both the product and tray 

belts associated with line . The line was returned to service by approximately 

0016 hours. In Packaging area #2, the deboning room, there were several red 

paint chips to approximately 1/8"on a small portable table used near line #1 to trim 

miscut wings. There were several pieces of fat and tissue to 2" on the large belt that 

collects the skin from line . There was a thick layer of black (UFM) that appeared 

to be mold on the stainless and white nylon support brackets of the same belt. Also 

on line there was a patch, approximately 3" in diameter, of black (UFM) with the 

consistency of mold on the stainless vertical bracket associated with the belt that 

transports the skin from line to the boxing area. There were also two red paint 

chips to approximately 1/4" on a small conveyor belt associated with line . 

Sanitary conditions were restored by rinsing the affected items with potable water 

per establishment policy by approximately 0036 hours. My findings indicated a 

noncompliance with 9 CFR 416.1, 9 CFR 416.4(a) & (b), and 9 CFR 416.13(c). 

(b) (6)
(b) (6)

(b) (6)

(b) (6)

(b) (7)(C) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3609021 

914N-1 

02/14/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 02/14/2012 at approximately 0335 hours while monitoring HACCP Raw Intact 

functions in Packaging, I observed the following. There was a partial rack of five 

baskets containing bulk wrapped breast meat in the bulk side of the Crust Tunnel. 

The baskets were mis-stacked causing product to be forced out of the bags and 

through the sides of the baskets. The exposed product had changed color to light 

brown and had become a semi-solid mass due to the chilling process. As the 

baskets are not considered to be a product contact surface, I attached U.S. Retained 

Tag #B31407506 to the rack labeled #14660, Day Shift, Feb 13,2012 and product 

code #227. I contacted who sorted the product that was still 

wrapped and condemned the rest. Approximately 80 pound of product was placed 

in a inedible container. My findings indicated a noncompliance with 9 CFR 416.4(d). 

5308 M6137 BXL5713020 

613N-1 

02/13/2012 04A06 Poultry Finished 

Product Standards 

C At approximately 0918 hours, while performing a Finish Product Standard check at 

the post chill area of chiller #2, I found the following noncompliance: I observed 

foreign material on the carcasses coming out of the chiller. Black speck were very 

noticeable on the breast area near the neck. I notified Packaging 

and SCSI of my findings. I extended my check finding several 

more birds affected with foreign material. USDA took immediate corrective action 

by having production tank off the product coming out of chiller #2. There were 7 

tanks retained for rework. Each one of these tanks was identified by the 

establishment with a red hold tag. At approximately 0945 hours, carcasses coming 

out of the chiller were found to be acceptable by USDA. Production was resumed. 

All retained carcasses were reworked birds by bird by the establishment. USDA 

performed several rechecks on the reworked product, finding it acceptable. 

5308 M6137 BXL3614024 

411N-1 

02/11/2012 01C02 Operational SSOP 

Review and 

Observation 

C On Saturday at approximately 1210 hours while walking by the packaging storage 

area located next to the weigh and price office, I found the following 

noncompliance. I noticed a clear plastic bag full of approximately 140 yellow trays 

labeled 52P325P. This bag was on a pallet located under the box conveyor leading 

to weigh and price. These yellow trays are utilized to pack edible product, therefore 

they are consider to be product contact surfaces. The boxes being transported on 

the upper box conveyor create cardboard dust that could contaminate any 

uncovered edible material located underneath. As I got closer, I noticed fresh 

chunks of fat and bloody moisture on these trays. These trays had been used by 

packing during the night shift and stored to be used the next working day, Monday. 

I Immediately placed a U.S. Rejected/Retained Tag No. B31 407451 on the affected 

packaging material. I then, proceeded to notified 

of the noncompliance. He took immediate corrective action by 

disposing of the contaminated trays. The U.S. Tag was released by USDA after 

sanitary conditions had been restored. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4)

(b) (4)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN010702 

4210N-1 

02/10/2012 03J02 Slaughter HACCP C I was performing a Slaughter HACCP verification procedure, verifying the 

establishment's prerequisite program for the use of an OLR (On Line Reprocessing) 

agent when I noted the following non compliance. The 

supporting documentation does not state the significance of the temperature 

to carcass temperature, the solution is not applied as described in the SIP 

letter, and the establishment does not have records documenting the temperature 

of carcasses at the time the is applied. The protocol listed in the 

establishment's Salmonella Initiative Program (SIP) letter dated February 7, 2012 

states: 

To verify the implementation of the 

SIP program I reviewed the establishment's records monitoring the 

temperatures and performed a hands on verification task. I reviewed several weeks 

of records and noted the temperature of the solution fluctuates from 

degrees F to degrees F on a daily basis but the establishment had no records 

documenting the temperature of the carcasses. I took the temperature of a carcass 

prior to entering the cabinet using a calibrated thermometer and compared it 

to the temperature of the solution. The internal breast temperature of the 

carcass was degrees F and the solution temperature was degrees F. 

The solution exceeded the carcass temperature. This is a deviation from the SIP 

protocol. I informed , of the non compliance. 

5333 P7632 HYE572102 

1810N-1 

02/10/2012 01D01 SPS Verification C On January 13, 2012, at approximately 0157 hours while virifying Sanitary 

Performance Standard (SPS) Requirements in the degree cooler I observed the 

following non compliance: I observed two employees pushing racks of product onto 

the robot cage track with their boots. Upon closer observation at the end of the 

transfer belt at line , I noted grimme and dirt on two of the baskets and dirt and 

grimme on some of the packages of product inside baskets that were ready to be 

placed on the line to be priced. I took regulatory control of the two baskets and the 

product with the application of U.S. Reject Tags #B40219474 and #B39415933, and 

informed Mr. 

and , of the non compliance. By the 

request of the establishment this NR was reclassified from SSOP to SPS to replace 

NR #HYE2406011714N/1 recorded on January 13,2012 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3308021 

809N-1 

02/09/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 02/09/2012 at approximately 0230 hours while monitoring the Establishments' 

Operational Sanitation Procedures, I observed the following. In the Plant #2 Cooler 

there were numerous specks of black (UFM),several to approximately 1/2", on the 

lids of two pallets of salvaged parts tubs located under the refrigeration unit closest 

to the Packaging Department door. There were also several tanks with numerous 

specks of black (UFM) and pieces to 3/8" on the plastic used to cover the tanks. The 

larger pieces of UFM had a consistency of blackened dust. I contacted 

who had the lids on approximately 15 tubs and the plastics on 6 tanks replaced 

by approximately 0236 hours. As Packaging production normally starts by 0030 

hours, I checked several tanks in use but found no UFM. I returned at approximately 

0410 hours and again there were numerous pieces of black (UFM) ranging in size 

from specks to 3/8"on the plastic covers of 8 tanks in front of the refrigeration unit 

closest to the Packaging Department door. I contacted who was 

again nearby. The plastics were replaced and all the tanks were moved to the other 

side of the cooler. The plastic covers on two tanks of ice had holes where the pallet 

jack grabs onto the tank. There was black (UFM) in the ice directly under the hole in 

the plastic covers. The affected ice was discarded. Sanitary conditions were restored 

by approximately 0425 hours. My findings indicated a noncompliance with 9 CFR 

416.4(d). 

5308 M6137 BXL3514023 

809N-1 

02/09/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 02/08/2012 at approximately 1840 hours, I observed the following 

noncompliance in plant 2 cooler. There was a wood pallet holding 5 brown tubs full 

of product. The lids covering this product were affected with foreign material (dust, 

dirt and wood chips). I placed a US Retained/Rejected Tag No: B31 407495 on the 

edible containers. I also noticed four carboard bin with edible ice, a couple of 

cleaned empty stainless steal bins covered with blue liners and a partially covered 

tank with dirty ice. All of these containers were affected with foreign material. I 

proceeded to tape around the affected containers and placed a US 

Retained/Rejected Tag No. B31 407475. I notified 

of the noncompliance. He took immediate corrective action by disposing of 

the affected ice and contaminated liners. Dirty lids covering edible brown tubs were 

replaced by cleaned lids. USDA tags were removed after sanitary conditions had 

been restored. 

(b) (6)
(b) (6) (b) (6) (b) (6)

(b) (6)

(b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5208021 

709N-1 

02/09/2012 01D01 SPS Verification C On 02/09/12 at approximately 0204 Hr's while performing SPS verification checks 

in the rotisserie room I observed the following non-compliance to 9 CFR 416.2(d) 

and 9 CFR 416.1. I observed heavy beaded condensation under the box conveyor 

line leading from the box assembly machine to the packing area. I immediately took 

regulatory control by applying U.S Reject tag # B31407225 to the area under the 

conveyor line and informing of my observation. Ms.

 took immediate corrective action in my presence by having the 

condensation wiped off to restore sanitary conditions. Regulatory control was 

relinquished at 0216 Hr,s after sanitary conditions were restored 

5308 M6137 BXL5914021 

909N-1 

02/09/2012 01D01 SPS Verification C On 02/08/2012 at aproximately 1900 hours, I observed a noncompliance in the 

Rotisserie Room. There was a wood pallet holding approximatelly 20 dusty and 

sandy bags. There was a couple of open bags on top of the pallet. The inside 

of this bags was contaminated with black specks. I immediately placed a US 

Reject/Retained tag No: B31 407474 on one of the bags and also a Tag No. B31 

407494 on the second bag. is a restricted ingredient which is 

diluted in water and utilized as a prechill antimicrobial intervention for carcasses. 

On 02/09/2012 I notified of the noncompliance. She took 

inmediate corrective action by properly disposing of the contaminated USDA 

tags were removed after sanitary conditions had been restored. 

5308 M6137 BXL4205020 

307N-1 

02/07/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C On 02/07/2012 at approximately 0056 hours while performing a Finish Products 

Standards check on line in Plant #2, I observed the following. After selecting a 10 

bird random sample, I observed one carcass with visible fecal contamination. There 

was a cloaca attached by a small piece of tissue at the tail with approximately 3" of 

intestine. There was visible fecal material leaking from the cloaca on to the outside 

of the carcass at a point approximately 1" below the tail. I showed 

my findings. He contacted who implemented 

the protocol for fecal failure. The fecal material was approximately 3/8"in size, olive 

green in color and pasty in texture. The recheck passed at approximately 0135 

hours. My findings indicated a noncompliance with 9 CFR 417.2(c)(4), 9 CFR 

381.65(e), and the critical limit of CCP-2B of the 

Plants HACCP Plan for Slaughter. 

(b) (6)
(b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE071202 

1003N-1 

02/03/2012 01D01 SPS Verification C At 0754 hours on January 26, 2012, while performing an operational sanitation 

inspection procedure in 2nd Processing, I observed a machinist working on the 

Enhanced Line. I observed him handle equipment and other various 

nonproduct-contact surfaces with his soiled, bare hands. After making adjustments 

to the machine, he did not wash or sanitize his hands or put on gloves. He went 

immediately to the end of the line and picked up three packages of product and 

inspected them for effective sealing. He then tossed the packages back into the 

process flow without washing, wiping, or sanitizing the packages, nor did he take 

any other action to demonstrate that sanitary conditions had been maintained. The 

employee at the end of the line commingled the packages with the other product in 

the baskets to be sent to shipping. The SPS regulation in 9 CFR 416.5(a) requires 

persons working in contact with product, food-contact surfaces, and 

product-packaging materialsto adhere to hygienic practices while on duty to 

prevent adulteration of product and the creation of insanitary conditions. The 

machinist took no steps to demonstrate that his hands were maintained in sanitary 

condition after handling nonproduct contact surfaces. This does not comply with 

the regulatory requirement. No steps were taken to demonstrate that this did not 

create insanitary conditions on the packages which could contaminate the product 

when the customer opened them. This does not comply with 416.4[b] which states 

that nonproduct-contact surfaces must be cleaned and sanitized as often as 

necessary to prevent the creation of a sanitary condition. Regulatory control of the 

the affected product (48 packages in four baskets) was taken with the application of 

US Retain Tag #B38 494939 and was notified of 

the forthcoming documentation of the noncompliance. At 0800 hours, regulatory 

control of the product was relinquished to the QC department for appropriate 

disposition. This noncompliance was originally documented as an operational 

sanitation noncompliance on NR HYE5710010326N/1. On 01/30/2012, the plant 

appealed the classification of the noncompliance, contending that the outside of a 

sealed package is not considered to be a product contact surface. Consultation with 

PDD supported this position. Therefore this noncompliance is being documented 

more appropriately as an SPS noncompliance. 

(b) (6)
(b) (6) (b) (6) (b) (6)

(b) (6) (b) (6)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3705024 

102N-1 

02/02/2012 04B04 General Labeling C On 01/28/2012 at approximately 2100 hours while monitoring Establishment 

HACCP, prerequisite programs and supporting documents, I observed the following. 

The Retained Moisture Evaluation document dated 01/27/2011 PM shift, Plant #2, 

chiller #3 indicated a moisture gain for the sampled product of 10.47%. I review the 

Establishments' documents in the Moisture Protocol binder but could not find a 

current protocol that would show the maximum moisture gain percentage allowed 

and corrective action if that percentage was exceeded. I contacted 

who after consulting with determined that the 

existing protocol was out dated but that the revised protocol would be based upon 

previous testing and that the maximum moisture gain would be established at 

,at which time in the future corrective actions would be implemented. The 

10.47% gain on 01/27/2012 exceeded the acceptable percentage and no corrective 

action was taken. A review of the Retained Moisture Evaluation file for the week of 

1/23 to current revealed that on 02/01 PM shift plant #2 chiller #3 therecorded 

moisture gain for the shift was 10.35%, on 01/25 PM shift Plant #2 Chiller #3 the 

recorded moisture gain for the shift was 11.48%, on 01/24 PM Plant #2 Chiller #3 

therecorded moisture gain for the shift was 11.73%, and for 1/23 PM Plant #1 

chiller #2 the recorded moisture gain was 11.06%. My findings indicated a 

noncompliance with 9 CFR 441.10 (a). 

5333 P7632 HYE180702 

4002N-1 

02/02/2012 04A06 Poultry Finished 

Product Standards 

C I was conducting the Poultry Finished Product Standard verification task in First 

Processing on the reprocessing offline at approximately 0437 hours when Iobserved 

the following non compliance: I selected ten birds marked for cellulitis reprocessing 

with a horizontal slash across the back after all plant interventions had taken place. 

Two of the ten birds had yellow flakes of cellulitis exudate on the inner thigh of the 

birds. I then stopped the line and applied U.S. retain tag B3849463 and showed my 

findings to 

performed two rechecks and found one out ten with cellulitis exudate in 

both rechecks, both failed. The third recheck passed and regulatory control of the 

Offline was relinquished at 0450 hours and

 was informed of the non compliance. 

(b) (6)
(b) (6)

(b) (6) (b) (6) (b) (6) (b) (4)

(b) (4)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE001201 

2328N-1 

01/28/2012 01D01 SPS Verification C At 9:25 am while performing an SPS (sanitation performance standards) procedure, 

in 2nd processing, I observed the following non compliance.In the small storage 

room to the west of the tub wash area,mold was observed approximately 4 foot 

high by 3 foot wide on the west wall. I informed 

of the finding and of the forth coming non-compliance.Mr

 informed me that he would notify sanitationtohave thewalls 

properlycleaned. The requirements of 9CFR 461.1 and9 CFR 416.2(b) (2) were not 

met.9CFR 416.1 states; " Each official establishment must be operated and 

maintained in a manner sufficient to prevent the creation of insanitary conditions 

and to ensure that product is not adulterated."9CFR 416.2(b)(2) states; "Walls, 

floors, and ceilings within establishments must be built of durable materials 

impervious to moisture and be cleaned and sanitized as necessary to prevent 

adulteration of product or the creation of insanitary conditions." 

5308 M6137 BXL0305013 

528N-1 

01/27/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C On 01/28/2012 at approximately 0105 hours while performing a Finished Products 

Standards check on Line in plant #2, I observed the following. After selecting a 10 

bird random sample, I observed one bird with visible fecal contamination. There 

was a cloaca attached at the tail. Approximately 2" of intestine was attached to the 

cloaca with approximately 1/4" of fecal material leaking from the cut end onto the 

exterior upper thigh area. The fecal material was light brown in color and pasty in 

texture. This exceeded the limit of Zero Tolerance for the process to be in control. I 

showed my findings. He implemented the protocol for fecal failure. 

The recheck passed at 0131 hours. My findings indicated a noncompliance with 9 

CFR 417.2(c)(4), 9 CFR 381.65(e), and the critical limit of CCP-2B 

of the Plants HACCP Plan for Slaughter. 

5333 P7632 HYE120301 

2926N-1 

01/26/2012 01C02 Operational SSOP 

Review and 

Observation 

C While performing an Operational Sanitation Review and Observation task at 0021 

hours in the Packaging Department I observed the following noncompliance: 

Above tray pack lines a large amount of condensation was present and 

dripping directly onto product. The two over head light structures above tray 

pack lines were also contaminated with dry particles of meat, fat, and blood 

from the previous day’s production. I took regulatory control of both tray pack lines 

with the application of retain tag #B39415922. The affected product, seven 

brown tubs of bulk salvaged product, was retained with retain tag #B39415926. I 

informed of the 

noncompliance. Control of lines was relinquished at approximately 0041 hours 

after sanitary conditions were restored. Product was released at 0245 hours after I 

reinspected the seven brown tubs and product acceptable. 

(b) (6)
  

(b) (6)

(b) (6) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE571001 

0326N-1 

01/26/2012 01C02 Operational SSOP 

Review and 

Observation 

C At 0754 hours on January 26, 2012, while performing an operational sanitation 

inspection procedure in 2nd Processing I observed a machinist working on the 

Enhanced Line.I observed him handle nonproduct-contact surfaces with his 

insanitary, bare hands. After making adjustments to the machine, he went to the 

end of the line without washingor sanitizing his hands or putting on gloves. 

Hepicked up three packages of product to inspect them for effective sealing. After 

inspecting the packages, he tossed them back into the production process without 

wiping or sanitizing the packages. A second employee collecting the packaged 

product at the end of the line did not wipe, wash or sanitize any of the three 

packages prior to placing the packages into product baskets with the other 

packaged product which had been tray-packed under sanitary conditions, nor did he 

wash or sanitize his gloves prior to handling other package product going into the 

product baskets. This commingled the three packages exposed to conditions 

whereby they may have been adulterated with product which had not been 

previously exposed to insanitary conditions. Regulatory control of the affected 

product - 48 packages in four baskets - was taken with the application of US Retain 

Tag #B38 494939 and was notified of the 

failure to comply with ther regulatory requirements cited above. At 0800 hours 

regulatory regulatory control was relinquished with the acceptance of the effective 

corrective actions which included restoration of sanitary conditions, product 

released to QC for appropriate disposition, and the proposed preventive measure 

that maintenance personnel would undergo training to ensure that they handle 

product in a sanitary manner. On 01/30/2012, the establishment appealed to have 

the NR reclassified to an SPS noncompliance based on the contention that once 

packages were sealed, the exterior of the package was no longer considered a 

product-contact surface. Consultation with PDD cofirmed this position and it was 

determined that it was a SPS noncompliance. A new NR documenting this as a SPS 

noncompliance will be issued. 

5309 P6137A NJN521601 

1625N-1 

01/25/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C While performing PHIS Task (Fecal  Zero Tolerance) at 0919 hours on the 

reprocessing line, I observed one carcass in a ten carcass sample with visible fecal,

 greenish brown in color of a paste-like material, approximately 1/4 inch in length 

and 1/8 inch in width on the inside of the carcass at the keel bone area. I 

immediately took a regulatory control action and stopped the line. Mr. 

, was called over and agreed with my findings. I 

informed him of the forthcoming noncompliance and released the bird to 

production. 

(b) (6)
(b) (6) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4109015 

625N-1 

01/24/2012 04A06 Poultry Finished 

Product Standards 

C On 01/24/2012 at approximately 0230 hours while monitoring Establishment 

Finished Product Standards in Plant #2, I observed the following. The Finished 

Products Standards log for line documented that a Quality Control failure 

occurred at 0138 hours with 51 weighted nonconformance points in the Processing 

Category. At that point CUSUM had reached the Action Number and the process is 

judged to be out of control. The last passing check by QC on line was done at 

0004 hours.  A required recheck had been done at the Post-Chill location at 0149 

hours. A recheck was done at the prechill station at 0205 and 0210 hours bringing 

the process back into control. However, the Establishment was still responsible for 

the failed product in the chilling system. I reviewed the logs toward the end of the 

shift and found that a second post-chill recheck had been done at 0225 hours. 

Based upon a moisture check on chiller #4 for the shift dwell time for product in 

chiller #4 at 0512 hours was 63 minutes. I used that time as an estimate of the time 

product was in the chilling system at the timer of the failure. Meaning that failed 

product in the chilling system for Chiller #4 should have been monitored for 63 

minutes after the prechill recheck passed at 0205 hours until approximately 0308 

hours. 9 CFR 381.76 (b) states that corrective action shall be taken as set forth in 9 

CFR 381.76 (b)(3)(iv)(d)(4) which states that "In no case shall the time between 

retests exceed 30 minutes of production time." The rechecks performed do not 

meet that requirement. The post-chill retests documented at 0149 hours and 0225 

hours reflects a period of 36 minutes between tests. Plus the time between 0225 

hours and the end of the failed product exiting the chilling system estimated at 

0308 hours allows another 43 minutes between tests. This 43 minutes also includes 

the time at approximately 0240 hours when the product identified by the 0138 

hours initial failure would have been exiting the chiller. Consequently no product 

was retained or reworked based upon the post-chill rechecks taken. I discussing the 

issue with . My findings indicated a noncompliance 

with 9 CFR 381.76(b). 

(b) (6)
(b) (6) (b) (6)

(b) (6)

(b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL1709010 

021N-1 

01/20/2012 01D01 SPS Verification C On 01/21/2011 at approximately 0405 hours while monitoring Establishment 

shipping temperatures, I observed the following. There was a trailer on the loading 

dock #7415 with heavy dripping condensation.There were7 bins and 4 pallets of 

tubs on the trailer. I observed noproduct being loaded. The trailers are not treated 

as product contact surfaces. The bins are not covered and any contaminant that 

gets into the bin or on the liner couldbe transferred to the product during 

dumping.I checked the other trailers on the dock and they were all operating 

normally. As the loading dock personnel were on break, I went to Packaging and 

contacted and showed himthe trailer. The onlyvisible difference 

between the trailers was that thewhite tarp that runs from the compressor to the 

rear of the truck wasnot attachedat the compressor end on trailer #7415. The 

condensation was wiped from the rear of the trailer. The bins were removedfrom 

the lefty side of the trailer.The tarp on the front endof the trailer, approximately 

20',was dry. The tarp was reattached to the compressor. The product was removed 

from the right side of the trailer and the remaining condensation that was still in a 

liquid state was removed restoring sanitary conditions by approximately 0435 

hours. My findings indicated a noncompliance with 9 CFR 416.1 and 9 CFR 

416.4(d).. 

5308 M6137 BXL1705014 

520N-1 

01/19/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 01/20/2012 at approximately 0015 hours while monitoring the Establishments' 

Preoperational Sanitation Proceduresin Packaging Area #1, I observed the following. 

There were several small pieces of tissue on a removable tray on Breast Processer 

#12. The tray directs wings to a collection belt below the machine. I removed the 

tray and gave it to an Establishment employee to rewash. The breast 

processormachine under the traywas covered with a large amount of liquified fat 

and several pieces of tissue to 3". At approximately 0012 hours there 

werenumerous pieces of fat and tissue to 2"on the chain and front loading area 

onLeg Processor #9. Theequipment was rewashed with potable water and returned 

to service by approximately 0021 hours. My findings indicated a noncompliance 

with 9 CFR 416.1, 9 CFR 416.4(a) and 9 CFR 416.13(c). 

5309 P6137A NJN190601 

0519N-1 

01/19/2012 01C02 Operational SSOP 

Review and 

Observation 

C On January 19, 2012, at approximately 0245 hrs I was in the packaging department 

verifying operational sanitary conditions when I observed the following non 

compliance:  the two white belts of the tray conveyer on line had a dry 

orange pasty material on them from the previous day’s production. The white belts 

are a direct product contact surface.  The orange pasty material on the belts was a 

residue from the “ rub which contains ingredients that the establishment 

has identified as an allergen.  I notified and 

of the non compliance.  I did not initiate regulatory control of 

the unit since the establishment initiated immediate corrective actions to restore 

sanitary conditions.  There was no product involved. 

(b) (6)
(b) (6) (b) (6)

(b) (6)

(b) (4)

(b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5309 P6137A NJN200901 

0619N-1 

01/19/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C I was performing pre operational sanitation inspection at the start of operations in 

the Fillet department at 0650 hours after the QC technicians had performed their 

pre operational sanitation inspection and released the area for production when I 

noted the following noncompliance:  One of the bearings on singulagtor # 3 had a 

black oily substance with an oil like texture seeping out from under the bearing 

mount, and there was an excessive amount of grease on the gears and the gear 

shaft on the underside of the singulator belt.  The singulator belt is a direct product 

contact surface.  I applied USDA Reject tag # B39415993 to singulator # 3 at 0650 

hours and informed Mr. of the 

noncompliance. After corrective actions to restore sanitary conditions were 

implemented the unit was released at 0630 hours on 1/20/12 the following 

morning. 

5308 M6137 BXL5721014 

218N-1 

01/18/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 1920 hours, while walking thru the Room area, I 

observed picking up from the floora pile of approximately 

25 pounds of tenders and placing them on a brown lid. He then, took the product 

tothe reprocessing sink.Istood by to verified proper reprocessing procedure as 

described on the establishment's SSOP program. The employee working on the 

reprocessing sink grabbed with both hands approximately fifteentenders.He hold 

theproduct under the runningchlorinated water for a few seconds and then, placed 

the "reconditioned" product into a brown tub right next to the reprocessing station. 

He continued to reprocess the rest of the tenders using the same procedure until he 

was done. There was no ice added to the product at any time. When the employee 

was ready to return the product back to production without waiting 5 minutes for 

Quality Control reinspection; I immediately, prevented him from returning the 

product back to the production line.I notified 

of the noncompliance. Quality Control had the employee to recondition the 

tenders one piece at the time and place them into a clean container. Product was 

released after it was reprocessed properly. The establishment's SSOP procedure for 

proper reconditioning of product states under PROCEDURES: " 

" " 

". This 

scenario representsthe establishment's failure to properly implement his 

reprocessing procedure. 

(b) (6)
(b) (6)

(b) (4)

(b) (4)

(b) (4)

(b) (4) (b) (4)

(b) (4)

(b) (4)

(b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5723010 

918N-1 

01/18/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 01/18/2011 at approximately 2015 hours while monitoring temperatures in 

Plant #2 cooler, I observed the following. The overhead refrigeration unit on the 

Packaging side of the cooler was apparently in the defrost cycle as fluids were 

spraying from the unit onto 4 covered stainless tanks and four pallets of brown 

product tubs. There was also condensing fluids dripping from the ceiling directly in 

front of the unit. A tub of boneless skinless breasts was uncovered so I attached 

U.S. Retained Tag #B31407411 to it. I contacted and discussed my 

concerns. The boneless skinless breasts approximately 60 pounds were condemned 

by production and placed in a gray inedible barrel. A refrigeration mechanic was 

called. He said it was the normal defrost cycle that lasts about 45 minutes. The 

tanks were moved and the plastic protective covers were replaced. The covers on 

the brown product tubs were covered with numerous black specks of (UFM) in 

addition to the fluids spraying from the refrigeration unit.  The lids on 

approximately 25 brown product tubs were replaced. As the refrigeration unit was 

still spraying a small amount of fluid and with the cooler near capacity plastic 

sheets were used to cover the affected pallets. I returned later and the defrost cycle 

was apparently over restoring sanitary conditions by approximately 2100 hours. 

My findings indicated a noncompliance with 9 CFR 416.2(d) and 9 CFR 416.4(d). 

5309 P6137A NJN121601 

5918N-1 

01/17/2012 03J02 Slaughter HACCP C While reviewing the establishment’s hazard analysis for the paws production I 

observed the following non-compliance. The establishment determines 

The justification for this determination is “ 

.”  In the establishment’s hazard determination they state a “ 

” which is CCP1-B ) and CCP2-BC 

( ) these measures are applied to the carcass after the 

paws are removed.  The establishment also states 

.  The establishment determines 

.”  The establishment’s own 

determination shows the potential of fecal to be on the paw prior to the 

picking/scalding step.  Fecal material is a known vehicle for pathogens.  The 

establishment was not able to provide any records to support the decision made in 

their hazard analysis that the hazard identified at live receiving was reduced to an 

acceptable level or eliminated as required by 9 CFR 417.3.  The establishment does 

not have any written corrective actions in response to a deviation from a critical 

limit or measures to prevent reoccurrence.  The establishment has no CCP in place 

for the paws production. 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6)

(b) (6)

(b) (6)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE091901 

3017N-1 

01/17/2012 03J02 Slaughter HACCP C At 1200 hours on January 17, 2012, while reviewing the establishment’s hazard 

analysis for slaughter, I observed the following noncompliance: At Step 13 

“Venting” and Step14 “Eviscerator” in the Hazard Analysis, the plant recognizes the 

potential food safety hazard of , and determines it as reasonably likely 

to occur because, 

"  The necks are still attached to the carcass during these 

steps, but are removed prior to the CCP put in place to control the biological food 

safety hazard associated with fecal material.  There is no CCP in place to address 

necks, nor is there any supporting documentation or justification proffered in the 

hazard analysis to demonstrate that necks would not be exposed to the food safety 

hazard determined to be reasonably likely to occur at these two steps in the 

evisceration process.  That the establishment identified a food safety hazard that 

was determined to be reasonably likely to occur in their hazard analysis, but failed 

to implement measures to control the hazard represents noncompliance with 9 CFR 

417.2 (b) (1). was notified of the forthcoming 

documentation of the failure to comply with the regulatory requirements cited 

above. On January 11, 2012, NR No. HYE5816010611N documents a similiar 

noncompliance where the establishment failed to effectively address a hazard 

reasonably likely to occur in their hazard analysis. 

5308 M6137 BXL2014010 

516N-1 

01/16/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C While monitoring the Establishments' Preoperational Sanitation Procedures, I 

obseved a noncompliance with regulations 9CFR 416.4(a) and 416.13 (c). At 

approximately 0506 hours while inspecting shell and tubes in Plant #1, I inspected 

inside the chiller water tube and I found a chunk of compressed  feathers and fat 

measuring  approximately 5" long and 1" wide, I informed 

of the noncompliance. The tube was cleaned and released at approximately 0509 

hours. At approximately 0525 hours, I inspected a pipe that transfers Livers to the 

Giblets Chiller and I found red residue inside the pipe, I informed 

and of the noncompliance. The pipe was cleaned 

and released at approximately 0540 hours.  At approximately 0550 hours, 

I inspected a pipe that transfers Gizzards to the Giblets Chiller and I found a thick 

layer of light brown residue, I informed and 

of the noncompliance. The pipe was cleaned and released at 

approximately 0626 hours. This a repetitive noncompliance. 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (4) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3105012 

617N-1 

01/16/2012 06D02 Other Inspection 

Requirements 

C On 01/17/2012 at approximately 0135 hours while monitoring Establishment 

Facilities in Plant #1 Line #1( )  after a scheduled break, I observed the 

following. There appeared to an excessive number of missing viscera. I reviewed the 

shift - NO VISCERA Monitoring Log  and found a Quality Control entry (13) 

made at 2330 hours. I conducted a no viscera check and found 30 no viscera at 

approximately 0139 hours. As the limit at BPM is no viscera, I contacted

 who called . A Quality Control 

recheck failed with 22 no viscera at 0143 hours so the line was slowed to 126 BPM.

 Repairs were apparently made during the lunch break however a recheck by 

Quality Control failed again at 0402 hours at 126 BPM with 17 no viscera. The limit 

at 126 BPM is 11 no viscera. Quality Control rechecks at 0642 and 0647 

hours brought the process back into compliance.  My findings indicated a 

noncompliance with 9 CFR 381.76(a). 

5333 P7632 HYE420401 

1816N-1 

01/16/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C While performing the monthly Dry Inspection, CIP/Pre-Operational Sanitation 

Review and Observation in Area 1, I observed the following noncompliance: At the 

bottom of the B line scalder there was one pipe corroded with rust that had flaked 

off onto the bottom of the scalder. I took regulatory control of the B line scalder 

with the application of U.S. Retain tag B39415949. I informed 

at 2020 hours of the noncompliance. Mr. proffered 

corrective actions that the pipe would be scrubbed clean of all rust and that the B 

line scalder would be rewashed and free of all rust. With the corrective actions 

completed I reinspected the scalder and found it free of all rust and released the 

scalder for B line at approximately 2105 hours. 

5308 M6137 BXL2318012 

013N-1 

01/13/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C While performing Pre-Chill Finished Product Standard check, I observed 

noncompliance with the following regulatory requirements of regulation 9 CFR 

381.65 (e) and 417.2 (c)(4). At approximately 1050 hours, I randomly removed a 10 

bird sample from Line #2 in Plant #1, I found one out the ten birds with visible fecal 

contamination inside the bird under the right leaf fat area. The fecal material was a 

smear measuring approximately 2" long and 3/4" wide, brownish green in color and 

pasty in texture. This exceed the limit of Zero Tolerance for the process to be in 

control. I informed and of the 

noncompliance, the protocol for fecal failure was implemented. Quality Control 

performed a Recheck at approximately 1108 hours and it passed. This is a violation 

of the critical limits of CCP-2B, of the Plant's HACCP plan 

for slaughter. 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (6) (b) (6)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL5705013 

412N-1 

01/11/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 01/12/2012 at approximately 0038 hours while monitoring Establishment 

Facilities in Plant #2, I observed the following. The ice being collected from the ice 

machine had numerous black (UFM) specks to approximately 1/4". I contacted

 who contacted refrigeration maintenance personnel.  The tank 

being filled was replaced after the black specks appeared to stop coming out of the 

dispenser shoot. I observed the ice in use at several stations and found no visible 

UFM. The ice was condemned and the tank was rinsed with potable water 

per company procedure restoring sanitary conditions by approximately 0046 hours.

 was informed. My findings indicated a noncompliance with 9 CFR 

416.2(g). 

5309 P6137A NJN440501 

4511N-1 

01/11/2012 01C02 Operational SSOP 

Review and 

Observation 

C I was in the evisceration department at approximately 0225 hours when I noted the 

following noncompliance;  I observed one of the spray nozzles positioned on the oil 

gland removal machine for "A"  line was overspraying water from the carcasses 

onto and into the ice bin hopper and ice conveyor/chute that delivers ice into the 

foot chiller.  The ice hopper/ chute is a direct product contact surface because it 

delivers ice into the foot chiller to aid in the chilling of the poultry feet.  I informed 

Mr. and of the noncompliance. 

After the establishment restored sanitary conditions the ice hopper and coveryor 

were released.  No product was involved. 

5333 P7632 HYE581601 

0611N-1 

01/11/2012 03J02 Slaughter HACCP C At 1400 hours on January 11, 2012, while reviewing the establishment’s hazard 

analysis for slaughter, I observed the following noncompliance: At Step 13 

“Venting” and Step14 “Eviscerator” in the Hazard Analysis, the plant recognizes the 

potential food safety hazard of , and determined it to be reasonably 

likely to occur because, 

."  There are no statements or supporting 

documentation for such statements in the establishment’s HACCP Plan that giblets 

would not be exposed to the food safety hazard determined to be reasonably likely 

to occur at these two steps in the evisceration process.  There is no CCP in place for 

giblets.  That the establishment identified a food safety hazard that was determined 

to be reasonably likely to occur in their hazard analysis, but failed to implement 

measures to control the hazard represents noncompliance with 9 CFR 417.2 (b) (1).

 was notified of the forthcoming 

documentation of the failure to comply with the regulatory requirements cited 

above. 

(b) (6)
(b) (6) (b) (6) (b) (4)

(b) (4)

(b) (4) (b) (4)

(b) (4) (b) (4)

(b) (4) (b) (4) (b) (4)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE520201 

0210N-1 

01/10/2012 01C02 Operational SSOP 

Review and 

Observation 

C At approximately 0020 hours whileperforming the SSOP verification task in the 

second processing department ( bag line), I observed the following non 

compliance;during the start of the bag line, baskets were being brought in from 

the degree cooler which had fat particles, frozen blood from who knows what 

previous days production,and a part of a gizzard in it whichI observed employees 

using these baskets to putbagged productonto. The establishment failed to meet its 

SSOP, section 2-5 Packaging - step #7 which states; " 

" I 

informed of the forthcoming 

non compliance record. 9CFR 416.4 (b) Sanitary Operations 

states; " Non-food-contact surfaces of facilities,equipment, and utensils used in the 

operation of the establishment must be cleaned and sanitized as frequently as 

necessary to prevent the creation of insanitary conditions and the adulteration of 

product." 

5308 M6137 BXL2600012 

711N-1 

01/09/2012 03J02 Slaughter HACCP C On 01/09/2012 at approximately 2100 hours while monitoring the 

Establishments'Hazard Analysis-Slaughter and supporting documents, I observed 

the following. The HACCP Monitoring Log-CCP-7B Plant #1 for 

01/06/2012showed that at 1808 hours the antimicrobial rinseconcentration was 

.89%.The Log lists the acceptable range as Under 'Comments' it stated that 

"

 The previous documentedcheck was .30% at 1722 

hours and a documented recheck at 1822 hourswas .55%.A review of the 

establishments' Hazard Analysis for Plant #1 under step 28 

andidentifies only one supporting document, Supplement #2. Supplement #2 isFSIS 

Dir 7120.1 Safe and Suitable Ingredients Used in the Production of Meat, Poultry, 

and Egg Productswhich under Antimicrobial 

and states " "The 

Establishments' Supplement #10 ' ' under 'Purpose' 

states " 

." Under 'corrective action' list actions to be taken if theconcentrationfalls 

below but does not list actions to be taken when the FDA limit of .8% is 

exceeded.. I discussed the issue with . My findings 

indicated a noncompliance with 9 CFR 417.3(b), 9 CFR 417.3(b)(1),(2),(3),(4) and 9 

CFR 417.2(c)(3). 

(b) (6)
(b) (6)

(b) (6)

(b) (6) (b) (7)(C) (b) (7)(C) (b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL3905015 

110N-1 

01/09/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C On 01/10/2012 at approximately 0227 hours while conducting a Zero Tolerance 

fecal check on Line in plant #2, I observed the following. After

 randomly selected a 10 bird sample, I observed one bird with visible fecal 

contamination. The fecal material was approximately 3/8" by 1/4" in size and was 

located on the left side kidney area. There was also several small 

smears approximately 1/16" to 1/4" in size on the right side of the carcass under 

the fat flap. The fecal material was greenish brown to white in color and pasty in 

texture. This exceeded the limit of Zero Tolerance for the process to be in control.  I 

showed my findings. He implemented the protocol for fecal 

failure. The recheck passed at 0250 hours. My findings indicated a noncompliance 

with 9 CFR 417.2(c)(4), 9 CFR 381.65(e), and the critical limit of CCP-2B 

of the Plants HACCP Plan for Slaughter. 

5333 P7632 HYE261301 

5309N-1 

01/09/2012 01C02 Operational SSOP 

Review and 

Observation 

C At 1010 hours on Janaury 9, 2012, Inspector  observed water 

overflowing from the overhead drip pan under the Giblet Shackle Wash Cabinet and 

above the kick out wheel at his inspection station (#4) on Evisceration Line #1.  He 

notified the plant of his suspicions that the situation could lead to potential 

product contamination.  Getting no response and the water continuing to fall onto 

the wheel, Inspector requested the presence of offline inspection 

personnel.  Upon arrival at Station 4, Line 1, at 1017 hours, I immediately 

observed three steady streams of water overflowing the drip pan and one of them 

was flowing directly on the nonproduct contact surfaces of the Station #4 kick-out 

wheel.  The water then flowed to the bottom side of the wheel and dripped onto 

the product and the product contact surfaces of the product shackles on Line One. 

Regulatory control of Evisceration Line One was taken with the application of US 

Reject Tag #B38 494940 and was notified of the 

forthcoming documentation of the failure to comply with the regulatory 

requirements cited above. At 1027 hours regulatory control was released with the 

acceptance of effective corrective actions to restore sanitary conditions and 

appropriate disposition of product as well as the profferred preventive measure 

that production would turn down the water in the cabinet and monitor it until 

maintenance could identify and eliminate the cause of the overflow. 

(b) (6)
(b) (6) (b) (6)

(b) (6) (b) (6)

(b) (6)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5333 P7632 HYE501101 

1509N-1 

01/09/2012 01C02 Operational SSOP 

Review and 

Observation 

C At 0908 hours on January 9, 2012, while performing a post chill finished products 

inspection procedure at the exit end of the North Chiller, I observed that the 

catch-screen placed beneath the inclined feeder belt to the rehang table was 

overflowing with carcasses and there were already more than twenty-two carcasses 

on the floor.  Regulatory control of the product was taken with the application of 

US Retained Tag #B38 494934 and was 

notified of the forthcoming documentation of the failure to comply with the 

regulatory requirements cited above. At 0917 hours regulatory control was 

relinquished with the acceptance of effective corrective actions to include the 

restoration of sanitary conditions, the appropriate disposition of product, and the 

proposed preventive measure that management personnel undergo further training 

to keep bins and other tools in place to achieve a more effective response when 

product backs up at the rehang area. 

5333 P7632 HYE320701 

1409N-1 

01/08/2012 04A06 Poultry Finished 

Product Standards 

C I was conducting the verification procedure for  Poultry Finished  Product  Standard 

on the Off line at approximately 0434 hours when I observed the following non 

compliance: Three carcasses out of the ten bird check were contaminated with 

ingesta. All three carcasses had injesta around the breast, neck area. I immediately 

stopped the line and applied US Retained tag #B40193565 and showed my findings 

to and 

and informed them of the non compliance. Regulatory control of 

the OFF-line was relinquished at approximately 0443 after sanitary conditions were 

restored and a recheck was performed in my presence by

 and found his recheck to be acceptable. Plants Reprocess/Salvage 

procedure in part A- 1, states in part, ( 

). 

5308 M6137 BXL4519011 

406N-1 

01/06/2012 04A06 Poultry Finished 

Product Standards 

C While monitoring the establishments' reprocessing procedure on Line in Plant 

#2, I observed a noncompliance with the following regulatory requirements of 

regulation 9 CFR 381.84. At approximately 1614 hours, I randomly removed a 10 

bird sample for my reprocessing test, I found four out of nine birds split tails in the 

sample that contained Airsacculitis exudates. This is an automatic failure. I 

immediately took regulatory control action by stopping the line.I informed

 of the noncompliance, she immediately took action by 

retaining the product into a tank. I placed a U.S. Retained Tag # B31407471 on the 

tank. At approximately 1626 hours I performed a retest and it passed. The retained 

product was reworked and releasedat approximately 1710 hours. This is a repetitive 

noncompliance. 

(b) (6)
  

(b) (6) (b) (6) (b) (6) (b) (6) (b) (4)

(b) (4)

(b) (4)

(b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL4605013 

006N-1 

01/05/2012 04A06 Poultry Finished 

Product Standards 

C On 01/06/2012 at approximately 0115 hours while monitoring the Establishments' 

Reprocessing Line in Plant #1, I observed the following. After randomly selecting 

a 10 bird sample, I found two of the birds with split tails that still contained 

airsacculitis exudates. The establishment marks birds by splitting the tail 

when directed by IPP to identify that for whatever reason a bird needs to be 

vacuumed. I showed  my findings. As it was near break time, I 

informed that I would be performing the recheck. He 

acknowledged, so I selected a second 10 bird sample of only split tail birds and 

found two more birds with Airsacculitis Exudates. By 0117 the line was stopped for 

company break. After break an extra person was assigned to vacuum birds.  Product 

was tanked until the affected birds were collected for rework. The reworked birds 

were later released by Quality Control.  QC personnel performed a reckeck on the 

line which passed at 0139 hours.  My findings indicated a noncompliance with 9 

CFR 381.84. 

5308 M6137 BXL5405012 

006N-1 

01/05/2012 01C02 Operational SSOP 

Review and 

Observation 

C On 01/06/2011 at approximately 0130 hours while monitoring the Establishments' 

Operational Sanitation Procedures in Plant #1, I observed the following.  During the 

Establishments break, a mechanic was repairing the peeler assembly on the gizzard 

processing table located between lines 1 & 2. There was a cardboard parts box 

and various tools on top of the perforated portion of the table where gizzards 

collect. There were gizzards on the table in various stages of washing and 

peeling. The repairs were finished just as production started.  I contacted

 and discussed the issue. I contacted the SSOP and asked for the 

shifts SSOP Equipment Breakdown Log. There were no entries on the log. I showed 

the log to .  A review of the SSOP Section II-Operational Sanitation 

under 'Implementation- Daily Procedure' states that 

. The Equipment Breakdown Procedure dated Nov 15,2010 

updated Nov 4, 2011 under 'Purpose' states that " 

." Under "Scope" it states that 

" 

."  A review of the file of SSOP-Equipment Breakdown Logs for the past 

several weeks showed that there were no logs filed for the AM shift.  My findings 

indicated a noncompliance with 9 CFR 416.4(d), 9 CFR 416.13(b), 9 CFR 416.15(a), 

and 9 CFR 416.16(a). 

(b) (6)
(b) (6) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2517010 

204N-1 

01/04/2012 01D01 SPS Verification C While monitoring the establishment's AQL procedure at the giblet chiller exit, plant 

1, I observed a noncompliance with the following regulatory requirements of 9 CFR 

381.65(a) and 416.4(a). At approximately 1410 hours, I found a piece of intestine 

measuring approximately 2" long inside of a brown tub half full with hearts. This 

piece of intestine had visible fecal material leaking from both sides and coming in 

contact with the product. The fecal material was dark brown in color, pasty in 

texture with a very strong odor.  I informed of the 

noncompliance, she immediately condemned the product by placing it in a gray 

inedible barrel. Brown tub was washed. 

5308 M6137 BXL5105013 

205N-1 

01/04/2012 01B02 Pre-Op SSOP 

Review and 

Observation 

C On 01/05/2011 at approximately 0012 hours while monitoring the Establishments' 

Preoperational Sanitation Procedures, I observed the following. In Packaging Area 

#1 there were numerous pieces of fat and tissue on a brown product belt associated 

with line . A section of the belt approximately 20 feet long had tissue to 2" with a 

large number of pieces attached to the metal pins used to attached the two ends. 

The inside surfaces of the same belt were covered with black (UFM) specks along 

the entire length and width of the belt. The product contact surfaces of the belt 

were rinsed with potable water and returned to service. The nonproduct contact 

surfaces will be cleaned with the next scheduled chlorine application. Using 

Establishment procedures sanitary condition were restored by approximately 0017 

hours. At approximately 0025 hours in the Deboning Room along Line #1, 

there was a small conveyor belt and associated stainless steel brackets that was 

covered with fat and product from the previous days production to approximately 

1". The belt was rinsed with potable water and returned to service. There were 

numerous white product cones also along Line #1 with large pieces of fat to 3" on 

the internal surfaces and several cones had smaller pieces of tissue stuck to the 

rough worn exterior product contact surfaces. The fat was removed and sanitary 

conditions were restored using Establishment procedures by approximately 0032 

hours. My findings indicated a noncompliance with 9 CFR 416.1, 9 CFR 

416.4(a) & (b), and 9 CFR 416.13(c). 

(b) (6)
(b) (6) (b) (6) (b) (6) (b) (4) (b) (4) (b) (6)

Est ID Est Nbr NR Number Date 

Procedure 

Code Regulations Status Description 

5308 M6137 BXL2318010 

103N-1 

01/03/2012 04A06 Poultry Finished 

Product Standards 

C While monitoring the establishments' reprocessing procedure on Line in Plant 

#2, I observed a noncompliance with the following regulatory requirements of 

regulation 9CFR 381.84. At approximately 1409 hours, I randomly removed a 10 

bird sample for my reprocessing test. I found two out of seven birds with split tails 

in the sample that contained Airsacculitis exudates. I performed a recheck at 

approximately 1413 hours, in which one of the ten birds contained Airsacculitis 

exudates. I immediately took regulatory control action by stopping the line and 

informed and of my findings, they then 

began to retain the product and slowed the line. I performed another recheck at 

approximately 1425 hours and two out of ten birds contained  Airsacculitis 

exudates. At approximately 1428 hours I performed another recheck and it passed 

bringing the process back in to compliance. The retained product was reworked and 

released by Quality Control at approximately 1536 hours. This is a repetitive 

noncompliance. 

5308 M6137 BXL4123012 

403N-1 

01/03/2012 01D01 SPS Verification C On 01/03/2012 at approximately 2000 hours while monitoring temperatures in the 

Plant #1 cooler, I observed the following. The center refrigeration unit on the Plant 

#1 side of the cooler was apparently in the defrost cycle as fluids were dripping 

from the unit onto a pallet of salvage part tubs. There were also fluids dripping 

from the ceiling and piping directly in front of the unit, and droplets were spraying 

from the fan assembly. There were droplets of fluid covering most of the surface 

area of the plastic sheets covering 10 tanks directly in front of the unit.  As there 

was no production I did not hang USDA retained tags but instead contacted

 who had the affected tanks with product 

moved. The refrigeration unit returned to normal operation so the spraying and 

dripping stopped. The lids on the salvaged parts tubs were changed along with the 

plastic sheets on the tanks. A mechanic arrived but made no adjustments or repairs 

as the unit was back in normal operation. Sanitary conditions were restored by 

approximately 2020 hours.  My findings indicated a noncompliance with 9 CFR 

416.1 and 9 CFR 416.2(d). 

5308 M6137 BXL2813010 

602N-1 

01/02/2012 03J04 Poultry Zero 

Tolerance 

Verification 

C At approximately 900 hours, while performing a Finish product Standard check on 

line 2 of Plant 1, I found a zero tolerance noncompliance. After randomly removing 

10 birds from line 2 in plant 1, I found one out of ten birds contaminated with 

feces. This failure reflected a violation of the CCP2B, of the 

Plant's HACCP Plan for slaughter. The fecal material was located on the bird's right 

wing, midjoint area. It was dark brownish color and pasty in texture, measuring 

approximately 1/8" in diameter. I immediately notified management of the 

noncompliance. The zero tolerance protocol was implemented by the 

establishment, bringing the process back in control. 

(b) (6)