Food > Meat and Poultry Products > Manual of Procedures > Chapter 19  

19.8 POULTRY CHILLING AND FREEZING PROCEDURES

19.8.1 Introduction

Methods similar to those used for poultry carcasses may be employed to chill rabbit carcasses in water provided control measures are in place to ensure that, at the time of packaging there is no increase of the hot weight of the carcass as a result of water chilling. Rabbit carcasses may also be hung on racks or chilled in coolers.

19.8.1.1 Regulatory requirements

There is no provision in the Meat Inspection Regulations for raw, single-ingredient meat products (e.g. giblets) to retain water as the result of post-evisceration processing in excess of naturally occurring moisture except as provided for dressed poultry carcasses (and therefore by extension, parts from dressed carcasses). The United States Department of Agriculture / Food Safety and Inspection Service (USDA / FSIS) implemented on January 9, 2003, regulations which have two objectives:

• limit water retained by raw single-ingredient meat products from post-evisceration processing, such as carcass washing and chilling, to the amount that is unavoidable in meeting applicable food safety requirements; and
• require labelling for the amount of water retained.

Raw single-ingredient meat products, including carcasses, carcass parts, giblets, etc. will not be permitted by FSIS to retain water resulting from post-evisceration processing unless the establishment preparing those products, demonstrates with data collected in accordance with a written protocol, that:

• any water retained in the products is an inevitable consequence of the process used to meet applicable food safety requirements; and
• the establishment will be required to disclose on the label the maximum percentage of retained water in the raw single-ingredient meat product.

The CFIA intends to amend the Meat Inspection Regulations to harmonize them with the US Finale Rule: Retained Water in Raw, Single-Ingredient Meat and Poultry Products (copied into Annex Y-1, US section, Ch. 11, of this manual).

As an interim measure, pending amendments to the Meat Inspection Regulations giblets, salvaged portions and detached necks may absorb and retain up to 8% added water as a result of post-evisceration contact with water on the condition that the operator develops and implements a written and validated retained water control program as per this section.

19.8.1.2 Definitions

Definitions applicable to refrigeration of poultry products:

Carcass Parts: Refers to parts from dressed carcasses as listed in Chapter 7, "Cutting and labelling requirements of poultry parts".

Salvaged Portions: Refers to edible poultry harvested as part of salvaging operations e.g. wings, wing drumettes, skinless breast fillets, legs, drumsticks and thighs.

Raw single ingredient meat product: Includes dressed carcasses, parts of dressed carcasses, salvaged portions, giblets (livers, hearts, and gizzards), ground poultry, finely textured poultry and mechanically separated poultry, either fresh or frozen.

19.8.1.3 Measures that prevent excess water retention

• control the pressure and amount of buffeting applied to carcasses by feather removal machinery so as to minimize its effect on loosening the skin;
• minimum exposure of flesh (small cuts, prevention of cutting or tearing of skin between thighs and abdominal wall, complete trussing);
• separation of neck skin from necks or removal of necks prior to washing and chilling of carcasses to promote drainage; operating the water immersion chillers at the coldest temperature possible without freezing the carcasses or the equipment;
• replace rocker arm or paddle type chillers with screw auger or drag type chillers to prevent the unintentional extended exposure of some carcasses to water;
• Operating the water immersion chillers at the coldest temperatures possible without freezing the carcasses or the equipment
• drain chill tanks or vats at least ½ hour before unloading;
• drain carcasses on drip line and manually drain subcutaneous water accumulations, as required; and
• use of automated equipment e.g. tumblers, shaker tables etc..

19.8.2 General Requirements

19.8.2.1 Salt addition to water or ice

In chilling, no objection will be made to the addition of common salt to the ice or chill water, provided this is declared on the label of the finished product. The immediate container or package for carcasses, parts or portions so chilled must bear the statement: "Turkeys (chickens, etc.) chilled in ice with salt added" or words of similar meaning.

19.8.2.2 Chilling in tanks

Where conventional tank - chilling is used, care must be taken to ensure that:

• sufficient overflow of water is provided to ensure the removal of extraneous matter prior to final icing; and
• poultry products are not kept in the chilling water for more than 24 hours. If kept in tanks for more than 24 hours, packing in ice with continuous drainage is required.

19.8.2.3 Make-up water required for water immersion chillers

A sufficient overflow of water shall be provided in water immersion chilling systems to ensure the removal of extraneous materials. Such continuous chilling systems are to be provided with a flow-meter, to measure total water used. The volume of the initial potable water and ice in the chilling system, plus subsequent amounts added, shall equate to not less than:

• 2L per carcass weighing 2.5 kg or less;
• 2.75L per carcass weighing between 2.5 kg and 6.5 kg; and
• 3.5L per carcass weighing more than 6.5 kg.

Water used in the inside/outside carcass washer may be credited as part of the preceding water volumes provided that:

• a flow-meter, to measure total water used, and a pressure gauge, is installed on the inside/outside carcass washer; and
• the inside/outside carcass washer is operated so as to effectively remove extraneous material from the outside and the inside of the carcass.

19.8.2.4 Chilling time / temperature requirements

All edible poultry products from live birds which are slaughtered and eviscerated in a registered establishment shall be chilled as part of a continuous chilling process immediately after evisceration.

19.8.2.4.1 Dressed poultry carcasses and parts

Immediately following evisceration and washing, all dressed poultry carcasses shall be chilled to 4°C. or lower within the following specified times:

An exception is made in the case of dressed poultry carcasses and parts from dressed carcasses which are intended for immediate cooking within the registered establishment.

As part of a CFIA recognized HACCP system, the following may be implemented provided the process is initially validated according to a protocol accepted by the Veterinarian in Charge, the Area Poultry Inspection Specialist and the Chief, Poultry Inspection Programs:

• Alternative times for chilling poultry carcasses and portions thereof to 4°C. or lower ; and/or,
• Packaging of poultry carcasses and portions before an internal temperature of 4°C is reached.

Dressed poultry carcasses, prior to being chilled to an internal temperature of 4°C, may be shipped from a registered establishment to another registered establishment for completion of chilling provided that:

• Both establishments operate under a HACCP system which includes the chilling of such product;
• The chilling process is continuous, including during transport, and achieves a deep muscle internal temperature of 4°C within the time indicated above;
• Product is not shipped prior to achieving a surface temperature of 7°C or lower; and
• The chilling process results in chilled product which complies with the pathogen reduction requirements as contained within the section on the United States in Chapter 11, Exports, of this manual.

19.8.2.4.2 Giblets, detached necks and salvaged portions

Giblets, parts of dressed carcasses harvested during the dressing procedures including detached necks and salvaged portions shall be chilled to 4°C or lower within two hours after evisceration. However, salvaged turkey breasts, breast fillets, legs, drumsticks and thighs shall be chilled to 4°C or lower within four hours after evisceration.

19.8.3 Retained water control programs

19.8.3.1 General Requirements

Operators are to write and validate a retained water control protocol for water which is absorbed and retained as a result of post-evisceration contact with water, for all raw single-ingredient poultry products including dressed carcasses, parts of dressed carcasses including detached necks, salvaged portions and giblets.

The method chosen in calculating water absorption and retention shall be reproducible and verifiable. For example, an operator may use:

• physical water pick-up tests, weighing carcasses post-evisceration, before the inside/outside carcass washer, and again just prior to final packaging and labelling.
• oven drying laboratory test method for naturally occurring and total water content of carcasses before and after the application of water for food safety purposes.

N.B. Further details on laboratory testing is contained at the end of Annex Y-1, US section., Ch. 11 of this manual. Please note that the same testing method used for validating the proposed retained water control protocols shall be used for ongoing testing of the resulting retained water control programs.

Operators may submit a proposed alternative Statistical Process Control (SPC) program, developed by a professional statistician, to the Veterinarian in Charge to be forwarded to the area poultry inspection program specialist and then to the Chief, Poultry Inspection Programs, CFIA, Ottawa, for an equivalency determination. At least several months will be required by CFIA to assess such a submission. If judged to be equivalent by a CFIA statistician and the Chief, Poultry Inspection Programs, then the proposed alternate SPC program may be implemented by the Operator.

19.8.3.1.1 Retained water declarations

Prepackaged giblets, shipping containers for bulk packed giblets and giblets contained within carcasses must be labeled with a retained water declaration as part of the product name. For carcasses containing giblets, the declaration must clearly refer to the giblets or must be truthful for both the carcass and the giblets. Further information on the labelling of retained water declarations is contained in Chapter 7 and in Annex Y-3 and Y-4 of the US section, Ch. 11, of this manual.

However, the labelling of dressed carcasses and parts, including detached necks and salvaged portions is voluntary until a date fixed by amendments to the Meat Inspection Regulations.

A statement may be included on the label to indicate that no water has been absorbed and retained when product has not been exposed to a post-evisceration process that adds water, or the establishment has data or information that establishes that the post-evisceration processes do not add water to the product. However, the test data and a copy of the corresponding carcass washing and chilling procedures shall be maintained on file and be copied to the Veterinarian in Charge.

19.8.3.1.2 Exempted products and processes

Multi-ingredient poultry products such as basted turkey carcasses, with/without giblets, are exempted. The giblets within a basted turkey carcass also do not require a retained water declaration.

Raw Kosher products (treated with salt and water in accordance with Judaic law) are exempt from the labelling requirement for a retained water declaration (refer to chapter 7 of this manual) but shall comply with the maximum amount of absorbed and retained water permitted by the MIR. Compliance shall be demonstrated by adhering to a retained water control program as described in this chapter for raw single-ingredient poultry products. 

An operator does not have to write and validate a retained water control program provided that documentation proving that products do not retain water as a result of post-evisceration contact with water are filed on-site and copied to the Veterinarian or Inspector-in-Charge.

The following are examples of post evisceration processes involving the use of water that would not require subject products to be processed under a retained water control program:

• flushing gizzards and chitterlings to remove digestive tract contents ;
• removing the lining from gizzards, the gall bladder from livers, and the pericardial sac from hearts;
• scalding of paws or feet ;
• washing with water to remove excess blood, e.g. washing hearts, livers, gizzards, paws and feet; and
• washing with water to remove the contents within oral cavities and nasal passages in heads for head and feet-on poultry.

However, if the flushed, washed or scalded products are then chilled by contact with water and /or ice, then the chilling procedures (only) require a written and validated retained water control protocol.

19.8.3.1.3 Non exempted products and processes

Crust frozen or ice-glazed poultry carcasses are subject to the requirement for a retained water declaration unless they are basted.

The following are examples of post evisceration processes involving the use of water with or without a microbial control agent that would require the subject poultry products to be processed under a retained water control program:

• post-evisceration washing, including on-line reprocessing systems;
• transportation in water within stainless steel pipes;
• water or ice chilling;
• post chill spraying;
• thawing; and
• iced necks and backs processed through an advanced meat recovery or mechanical deboning equipment.

Note: On a case-by-case basis, the Veterinarian or Inspector-in-Charge, in consultation with his or her Regional Veterinary Officer and the Area Poultry Inspection Program Network Team Specialist will evaluate other post evisceration processes involving the use of water to determine whether the resulting products require a retained water control program.

19.8.3.1.4 Food safety requirements

Food safety requirements that must be met and included in a retained water protocol shall include chilling time/temperature requirements as previously listed in this section.

Food safety requirements which should be met and which should be included in a retained water protocol include the applicable salmonella performance standards as described in Ch. 11, US section, Annex U, "USDA Performance Standards for Salmonella".

19.8.3.1.5 Programs required per species, class and age of poultry

These requirements are applicable to all raw single-ingredient poultry products. In this section, the word "carcass" is interchangeable with other raw-single ingredient poultry products such as livers, hearts, gizzards, detached necks, and salvaged portions such as breasts, breast fillets, wings, legs, thighs and drum sticks.

A retained water control program is required for:

• carcasses from each species and class of poultry listed in the regulations and age category; (e.g. young and mature poultry)
• each component of edible giblets (livers, hearts and gizzards);
• for detached necks; and
• for each type of salvaged portion such as breasts, breast fillets, wings, legs, thighs and drum sticks.

The same retained water control program may be used for giblets, salvaged portions and detached necks from all three (3) classes of turkeys listed in the regulations provided that:

• the same processes and equipment are used;
• the program scope includes product from all three (3) classes; and
• product from the three (3) classes is included during the validation testing.

However, a separate validation test must be performed for each poultry product from each of the three (3) classes of turkeys e.g. separate validation tests for livers, another set of tests for hearts, a third set of tests for detached necks, a fourth set for salvaged breast filets, etc..

The same retained water control program may be used for giblets, salvaged portions and detached necks from both chicken broilers and chicken roasters (but requires two (2) separate validation tests e.g. for livers from chicken broilers and for livers from chicken roasters, etc.).

19.8.3.1.6 Carcasses with low water retention

No further ongoing testing is required by the operator to monitor retained water for dressed carcasses, as shipped or when packaged as portions, if the initial validation data (50 carcass test as described later in this subsection) indicates that :

• the average percentage weight increase for the group of 50 sampled carcasses is less than half that permitted by the regulations; and
• none of the individual carcass weight increases exceeds that permitted by the regulations.

However, the initial 50 carcass validation test for retained water must be repeated at least once each year to verify that the above two (2) listed conditions are still being met. Records of this annual verification must be kept on file and be copied to the Veterinarian in Charge.

Moreover, for carcasses which are labeled with the claim "air chilled" or a similar phrase, refer to the information on air chilling near the end of this section.

19.8.3.2 Writing a Water Retention Control Program

These requirements are applicable to all raw single-ingredient poultry products. In this section, the word "carcass" is interchangeable with other raw-single ingredient poultry products such as livers, hearts, gizzards, detached necks, and salvaged portions such as breasts, breast fillets, wings, legs, thighs and drum sticks.

19.8.3.2.1 Elements of a Written Retained Water Control Program

The proposed retained water control protocol is to be comprised of the following nine (9) elements and include information for each element as follows:

1. Purpose statement: State the primary purpose of the protocol. The primary purpose should be to determine the amount or percentage of retained water that is unavoidable while achieving compliance with the time/temperature chilling requirements as contained within this chapter. Additional purposes could be to evaluate product quality and to determine chilling system efficiency.

Indicate which species or classes of poultry, and list all products, which are covered by the protocol.

2. Type of washing and chilling system used by the establishment. Describe any post-evisceration washing or chilling/cooling processes that affect the water retention levels by, and microbial loads, on raw products. Describe the chiller types, eg., the drag-through, the screw type, the paddle type and the rocker-arm type, identified by the mechanism used to transport the carcasses through the chiller or to agitate the water in the chiller.

3. Configuration and any modifications of the chiller/cooling system components. Describe the chiller/cooling system configurations and any modifications of the chiller system components including the number and type of chillers/coolers in a series, arrangements of the chilling/cooling system components, and the number of evisceration lines feeding into a chiller/cooling system. Accurately describe the purpose and type of equipment used if there is a pre-chilling/cooling step in the process. Describe any mechanical or design changes to the chilling/cooling equipment.

4. Special features in the chilling/cooling process. Describe any special features in the chilling/cooling process, including microbial control agents, length and velocity of the dripping line, and total time allowed for dripping. Explain any special apparatus, such as a mechanism for removing excessive water from chilled carcasses.

5. Description of variable factors in the chilling /cooling system. Describe the variable factors that affect water absorption and retention. Such factors include:

• scalding temperature;
• pressure and amount of buffeting applied to the carcasses by the feather removal machinery and its effect on loosening the skin;
• method used for opening the carcass for evisceration;
• temperature of the pre-chiller;
• temperature of the chiller;
• agitation including air agitation if used; and
• time in the chiller water.

Identify the settings of all the key points. Key points refer to those operational settings which affect added and retained water and which could be modified during a workshift e.g. water pressure within the inside/outside carcass washer, transit time and temperature for water chillers, chain speed and exposure time to water sprays within the air chiller, time on the drip line, whether cut-up and prepackaged as parts.

6. Standards to be met by the chilling system. For establishments eligible to export to the USA, specify the applicable Salmonella performance standard as contained in Annex U, US section, Ch. 11, MOP. Although the USA has not published an applicable Salmonella standard for turkey carcasses, a guidance standard has been published by the USA for turkey carcasses as follows:

• Performance Standard (percent positive for Salmonella) 49.9%
• Number of samples tested (n)^a 56
• Maximum number of positives to achieve Standard (c)^a 13

^a The values for Salmonella n and c are the criteria for evaluating sample results to determine whether an establishment is meeting the standard. The number of samples n was selected by the USA to be greater than 50 so as to measure establishment performance over a minimum period of time. The value for n and c are selected so that an establishment has an 80% chance of passing when operating at the standard level. Because (n, c) must be integers, exact probabilities of 80% cannot be expected.

Note: The chilling/cooling system must be designed and operated so as to comply with the applicable time/temperature requirements listed in this chapter for reducing the deep internal muscle temperature down to 4°C.

7. Testing methods to be employed. Describe testing methods used, both for measuring water absorption and retention and for sampling and testing product for pathogen reductions at various chilling equipment settings and chilling time-and-temperature combinations. The method for calculating water absorption and retention must be reproducible and statistically verifiable. The sample collection locations, number of samples, type of samples, sampling time period, whether carcasses will be chilled with/without necks, type of testing or measurement e.g. weighing procedures, and test results are to be included.

The trials shall represent processing procedures that can be maintained in the establishment. It is understood that very small plants or those establishments producing a very small volume of the product may experience a greater variation in measurements than in plants producing a large volume of the products.

Initially, the Operator would perform several trials to determine the amount of unavoidable retained water, if any, in achieving the food safety standards listed under element number 6 (above). The Operator would have to determine the variables in the process that would affect the amount of retained water. For example, water temperature in the chiller/cooler may be a variable to consider. Similarly, agitation e.g. paddle rotation speed, may be a variable to consider. If a microbial control agent was added, the amount of time in the chiller/cooler may be reduced. In each trial of the various water temperature and agitation settings the water retention data would be plotted.

The trials are to be conducted using the existing chilling/cooling equipment and facilities in the establishment. If the water or air temperature cannot be lowered without causing equipment problems due to ice formation, and considering that warmer water or air interferes with rapid carcass chilling, then only the current water or air temperature should be used for the trials. Similarly, if water and carcass agitation cannot be adjusted due to the design of the equipment, then various agitation settings cannot be tested. If such is the case, indicate why the water temperature and agitation settings cannot be changed.

Note: Water absorbed and retained by carcasses as a result of post evisceration contact with water must not exceed the maximum percentage of weight increase permitted by section 25, Meat Inspection Regulations. Operational procedures and/or chilling equipment may require changes to achieve compliance with regulatory requirements.

If the chilling/cooling variables do not require changes so as to reduce the amount of absorbed and retained water, then the latest series of salmonella test results are to be included with the submitted data. However, if as a result of the trials the chilling/cooling processing operations are modified or changed, then a new series of salmonella tests must be conducted to reflect the new chilling/cooling process operations.

8. Reporting of data and evaluation of results: Explain how data obtained are to be reported and summarized. Examples of reported information include, but are not limited to, the number of sample replicates, reporting of salmonella, and the calculation or formula used to determine the level of water retention.

9.Conclusions. Explain what the data demonstrate, the conclusions reached, and how the conclusions were reached. Include the amount of retained water which is to be declared on the labels of the packaged products. Indicate how the operator will maintain compliance with regulatory requirements and describe examples of corrective action.

Further information on writing and validating retained water protocols is contained in Annex Y, US section, Ch. 11, of this manual.

19.8.3.3 Validation of the program

19.8.3.3.1 Sampling procedure for validating a retained water protocol

Physical water pick-up test: A minimum of fifty (50) whole untrimmed (Grade A) poultry carcasses are to be randomly selected, identified and weighed individually. Each carcass shall be weighed twice and the weights recorded. The initial weight of each carcass is determined by weighing it prior to the first inside-outside carcass washer after inspection. The final weight is determined by weighing the same carcass after the normal chilling and drainage time prior to packaging as a whole carcass (or as parts if the operator never packages any whole carcasses).

A data collection sheet shall contain the following:

• The percentage weight increase or decease for each carcass corresponding to the initial and final weights;
• The average weight increase or decrease for the entire group of 50 carcasses shall be calculated and entered; and
• The number of carcasses shall be indicated which have retained water above the maximum permitted by the regulations plus a 20% tolerance to account for inherent biological, processing and measurement variability.

The completed data collection sheet shall then be attached to the proposed retained water control program to serve as part of the validation data.

Giblets, detached necks and salvaged portions: A minimum of 50 e.g. hearts, or livers, or skinless breasts, etc. may be weighed as a bulk sample to obtain both the initial weight and the final weight. The post-chilling bulk sample shall contain the same number of units as the initial sample and be collected from the same lot as used for the initial weight.

Oven drying laboratory method: Initially the operator needs to determine what is the natural level of water as contained within the carcass parts or giblets or salvaged portions and to determine the amount of water which must be declared. To accomplish this, the operator collects a sample comprised of five (5):

• livers, or hearts or gizzards (after removal of the pericardial sac or the gall bladder or the gizzard contents and mucosa, as applicable); or
• carcass parts (eg. detached necks or skin less breast fillets or bone-in skin-on or skinless leg quarters or thighs, etc.); or
• salvaged portions (e.g. wings or breast fillets or legs, etc.)

The products listed above shall be from the same lot and collected prior to contact with water or ice as used to transport or chill the sampled product.

A similar group of five (5) products is collected after chilling and drainage, (including drainage which occurs during cut-up and boning), immediately prior to packaging from the same lot. Samples must be packaged so as to prevent moisture loss during storage and transport to the lab.

N.B. In the case of gizzards, gizzard pieces approximating the weight of five whole ready-to-chill gizzards may be used rather than whole gizzards.

At the lab, pre chill samples are dry oven tested for water content. A similar test is performed on the post chill sample from the same lot. The two samples are recorded and the corresponding net difference is reported as the amount of water which was absorbed and retained by the lot based on paired sampling.

The results from fifty (50) paired samples collected from 50 consecutive lots of poultry are used to determine the :

• percentage of retained water to be declared on the packaged product; and
• natural amount of water contained by the e.g. hearts or livers or giblets or skin-less breasts, or bone-in leg quarters, etc..

Paired sampling is not required thereafter since the amount of absorbed and retained water in packaged product can be based on the natural moisture level as was determined using the 50 paired samples as described above.

19.8.3.3.2 Assessing the results of validation tests

Operations for the washing, chilling and drainage of carcasses are to be deemed to be in compliance with the regulations if :

Physical water pick-up tests

For water chilling:

• the average weight increase (or decrease) of the group of 50 carcasses (or parts from the 50 carcasses) does not exceed the stipulated regulatory maximum in sec 25 of the Meat Inspection Regulations (MIR); and
• no more than six (6)* carcasses exceed the aforementioned regulatory maximum plus 20% (e.g. for chicken carcasses which are prepackaged and are permitted to retain a maximum of 8% absorbed and retained water, no more than six (6)* carcasses from the group of 50 sampled carcasses may exceed 9.6%.)
  *N.B. Validation pass/fail criteria: (ISO sampling plan 2859-1)
  • Single sampling plans for normal inspection
  • Sample size of 50

For air chilling:

• the average weight increase for the 50 carcasses shall not exceed 0.0%;
• a maximum of 25 individual carcasses from the group of 50 sampled carcasses may have an increase exceeding 0.0% (to account for scale variability); and
• no individual carcass shall exceed 2.0% absorbed and retained water.

For the oven drying laboratory method: A maximum of 6 out of the 50 paired samples may exceed the amount of water declared plus 20% e.g. to declare "Up to 8% water added", no more than 6 of the 50 samples may exceed (8 plus 20% of 8 which is 1.6% or) 9.6% similar to the pass/fail criteria for validating proposed chilling protocols for poultry carcasses.

The results of the validation tests along with a completed proposed retained water control program are to be submitted to the Veterinarian in Charge for evaluation. If judged to be satisfactory by the CFIA, the proposed program is accepted and becomes an approved retained water control program. No deviations are permitted except that the chill-media temperature may be lower than that recorded on the validated program; the drip line or drain times may be extended; and/or the chilling system may be speeded up at the end of the day to empty the chiller provided carcasses are chilled to an internal temperature of 4°C.

19.8.3.4 On-going testing under an approved retained water control program

Whichever method was used for validation testing, (physical water pick-up tests or dry oven laboratory test method) shall be used for ongoing testing.

Procedures shall be monitored on an on-going basis and the settings of the key points shall be recorded at minimum on an hourly basis by a designated plant employee as part of the HACCP system. Key points refer to those settings which could be modified during a work shift and affect the % of water absorbed and retained in the chilled carcasses. Other settings may only be checked once at the beginning of each shift.

19.8.3.4.1 Giblets, detached necks and salvaged portions

Validation test results for poultry giblets, detached necks and salvaged portions (from all the classes listed in the regulations) shall be assessed to determine which giblet, detached neck or salvaged portion absorbed and retained the maximum percentage of water. Ongoing testing is limited to the giblet or detached neck or salvaged portion with the highest % of absorbed and retained water.

19.8.3.4.1.1 Sampling

Physical water pick-up tests: A minimum of 50 e.g. livers should be used for ongoing testing. If a test is failed, a larger sample size is recommended for subsequent tests.

Oven drying laboratory test method: Paired sampling is no longer required for ongoing testing since the natural level of moisture content for the particular raw single-ingredient poultry product was determined during validation of the applicable retained water control program.

A single group of five (5) e.g. livers or wings or detached necks is required for each post-validation test for retained water (rather than the sample size specified in the subsequent table).

However, one (1) skin-on or skinless breast is a sufficient sample size for poultry breasts due to their extremely low level of retained water and their high value. Generally, poultry breasts should qualify for the low volume of retained water rate of testing which is a once per year verification testing after the initial series of validation tests (refer to the preceding subsection).

19.8.3.4.1.2 Switching rules

Initially, for the giblet, salvaged portion or detached neck with the highest amount of absorbed and retained water, one test is required per production shift ("1/shift"). Results shall be assessed based on the average % of absorbed and retained water and may not exceed 8%.

• If ten (10) consecutive "once/shift" tests pass, the testing frequency may be reduced to once per five (5) consecutive production shifts.
• If ten (10) consecutive "once/ 5 shift" tests are passed, then the testing frequency may be further reduced to once per 20 consecutive production shifts.
• If ten (10) consecutive "once /20 shift" tests are passed, testing frequency may be decreased to once per three (3) months (quarterly testing).

19.8.3.4.1.3 Corrective actions

If a test indicates greater than 8% absorbed and retained water, then the next available lot shall be tested. If results again exceed 8%, then:

• the affected product, and all subsequent product shall be segregated and be either drained until below 8%; or
• be used in processed product which permits water as an added ingredient; or
• be discarded as inedible material, and;
• the operator must then conduct an investigation to determine the probable cause and take effective corrective action. The written retained water control program(s) shall be amended if operational parameters have changed. All written retained water control programs for giblets, detached necks, and salvaged portions, which indicated greater than 4% absorbed and retained water shall then be (re)validated.

19.8.3.4.2 Whole Carcasses

In the definition of the chilling procedure as contained within the validated program, if the transit time includes periods when the carcasses are not emptied from the chillers during either the breaks or meal periods, then the chilling system may be halted during these periods. But if the chilling procedures do not take into consideration the breaks and/or meal periods, then the chilling system shall be kept operating allowing the tanks to be normally emptied during these periods.

N.B. The operator may choose to use the oven drying laboratory test method as described at the end of Annex Y-1, US section., Ch. 11 of this manual.

19.8.3.4.2.1 Sampling plan:

The sampling plan used is based on the ISO sampling plan, ISO sampling plan 2859-1, Special Inspection level S-4.

19.8.3.4.2.2 Lot selection and size

The size of each lot is set at a maximum of 10,000 carcasses. A separate lot is required for each species and class of poultry listed in the regulations.

Prior to the beginning of operations, the operator shall:

• divide a single day’s production into lots;
• determine the number of lots to be tested during a day’s production using the table below;
• randomly determine which lots will be tested so that each lot has an equal chance of being tested; and
• weigh a sample of carcasses selected from each lot.

Example: (140 chicken (< 3.0 kg) carcasses/minute for 8 hours equals 67, 200 carcasses. Therefore production would be divided into 6 lots of 10,000 carcasses plus a seventh lot of 7,200 carcasses.

19.8.3.4.2.3 Number of lots to be sampled

19.8.3.4.2.4 Sample size:

A group of carcasses shall be randomly selected from each lot which has been selected for sampling according to the preceding table. The carcasses selected for sampling are referred to as the "sampling group". The size of the sampling group is determined by the inspection level as follows:

19.8.3.4.2.6 Selection and weighing of carcasses:

Within each lot selected, the operator shall perform pre and post chill weighing of a sample of carcasses as per the preceding table.

Additional carcasses may be weighed, so as to ensure the minimum number required in the event that any carcasses are lost, provided that weighing procedures stop once the required number of carcasses are obtained at the post-chilling location.

If sufficient carcasses cannot be obtained from a sample group to determine the final weight, then the data for that lot shall be discarded and be replaced by sampling the next available lot.

The first weight prior to chilling is referred to as the initial weight, and the post chill weight as the final weight. The carcasses, making up the sample for each lot, must be representative for the lot.

Carcasses to be weighed shall be selected prior to the first inside-outside carcass washer after inspection or detection, referred to as the initial weight, and be identified. Carcasses shall be weighed individually. Each initial carcass weight shall be recorded. The initial carcass weights shall be totalled.

At a predetermined point, as identified by the operator, after the normal chilling and drainage time, the identified carcasses shall be weighed a second time to determine their final weight. Each final weight shall be recorded such that the final weight corresponds to the initial weight on the operator’s report. The final carcass weights from a sample shall be totalled and recorded.

Whenever the final carcass weight exceeds the corresponding initial weight, the difference shall be calculated as a percentage of the initial weight and be recorded adjacent to the corresponding final weight.

19.8.3.4.2.7 Calculating the percentage weight gain or loss

Percentages shall be calculated based on the initial weight for all the carcasses.

Example: Calculating the maximum percentage weight gain permitted for six (6) of the 50 sampled carcasses during the validation step of the retained water protocol.

• For broiler chicken, the specified regulatory maximum is 8%.

  Adding 20% = 9.6 % (20% of 8=1.6%). Therefore, no more than six (6) out of the 50 weighed carcasses may exceed 9.6% .

Example: Calculating the percentage weight gain or loss for a group of sample carcasses after the validation step (during ongoing testing).

• Broiler chicken on Reduced Inspection

  total initial weight of 13 individual carcasses = 1,500 g

  total final weight of 13 individual carcasses = 1,600 g

  (individual weights recorded on the chart specified in the retained water control program )

  Total weight gain (or loss) for the group of 13 carcasses

  

19.8.3.4.2.8 Lot acceptance/rejection:

Physical water pick-up tests

For carcasses chilled in water

• The average weight increase (or decrease) of the group of sampled carcasses does not exceed the stipulated regulatory maximum in the regulations
• The number of weighed carcasses with a net weight increase at or above the regulatory maximum plus 20% is equal to or less than the accept number for the corresponding inspection level (normal, reduced or tightened) in the preceding table, the lot is accepted.
• If the number of carcasses with a net water absorption and retention at or above the maximum specified in the regulations plus 20% (for inherent biological, processing and measurement variability) is greater than the accept number but less than the reject number, accept the lot but switch to normal inspection for the next test.

For carcasses labeled as "air chilled":

• A lot is assessed to be in or out of compliance with the retained water control requirements for air chilled carcases based on the total number of (individual) carcasses with a net water absorption and retention at or above 0.5 %. This allowance of 0.5% is intended to compensate for scale variability. This allowance is not to be used as a tolerance; and
• If the number of weighed carcasses with a net water absorption and retention at or above 0.5 % is equal to or less than the accept number for the corresponding inspection level (normal, reduced or tightened) in the preceding table, the lot is accepted.
• For reduced sampling, if the number of carcasses with a net water absorption and retention at or above 0.5 % is greater than the accept number but less than the reject number, accept the lot but switch to normal inspection for the next test.

Oven drying laboratory test method: The water content for the poultry product (collected immediately prior to packaging) indicated on the lab report is compared to the amount of naturally occurring moisture in the applicable raw single-ingredient poultry product as determined during the initial series of validation tests.

After subtracting the natural moisture content from the water level on the lab report, the remaining water, which is the amount of absorbed and retained water, must not exceed that which is declared on the product label plus an additional 20% (to compensate for inherent biological, processing and measurement variability).

19.8.3.4.2.9 Switching rules:

Sampling begins at the normal rate. Once 10 consecutive sample groups (or lots) are shown to be in compliance, the operator qualifies for Reduced Inspection with a minimum of one test per production shift.

If an additional 10 consecutive lots are accepted under Reduced Inspection, the sampling frequency may be reduced even further, based on good compliance, to one lot per 5 consecutive production shifts.

If an additional 10 consecutive lots are accepted under Reduced Inspection, the sampling frequency may be reduced even further, based on continuing good compliance, to one lot per 20 consecutive production shifts.

Thereafter, the operator may group all classes of poultry carcasses that qualify for testing at the reduced frequency of once per 20 consecutive production shifts. Only the class of poultry with the highest relative level of absorbed and retained water (closest to the max. % permitted) needs to be tested. However, each retained water control protocol needs to be revalidated each year.

If the reject number is reached or exceeded, the lot is rejected. If a lot is rejected, the chilling process may be out of control. The Veterinarian in Charge or an inspector is to be notified, the operator shall determine the probable cause and then take immediate corrective action as indicated within the operator’s retained water control program.

Non compliant product: Raw single-ingredient meat products containing absorbed and retained water above that permitted by regulatory requirements may be :

• handled as inedible material (e.g. giblets for animal food); or
• drained until in compliance;
• cut-up and/or skinned and/or boned out (provided the packaged product is in compliance); or
• used in processed meat products (e.g. basted turkey carcasses).

The latter option is restricted to operators who have implemented a control program acceptable to CFIA, (at both the slaughtering and the processing establishment), and which assures that all non complaint product is used only in processed product which may contain water as an added ingredient.

19.8.3.4.2.10 Decision Tree For Retained Water Control Program

Click on Image for Larger View

[D]

*A test at normal inspection may be performed at any time as an additional assurance of process control and may be requested by the operator or the inspection staff.

19.8.3.5 Amending approved retained water control programs

The operator may establish or change a plant specific retained water control program at any time provided it results in the production of a product in compliance with the Meat Inspection Regulations, 1990, the written procedure is amended and validated, and the new proposed protocol is approved by the Veterinarian in Charge.

19.8.4 Air-Chilled Poultry Products

19.8.4.1 Introduction

Poultry abattoirs have begun to use alternatives to conventional water tank or water immersion (bath) chilling of poultry. "Air Chilled" is commonly used to describe poultry and poultry cuts which, after the inside/outside carcass washer step, have been chilled with cold air. Water sprays or misting devices are generally used during air chilling processes to prevent skin dehydration.

19.8.4.2 Labelling and advertising claims

Refer to chapter 7 of this manual for the use of phrases or claims such as "air chilled" and "no water added".

19.8.4.2.1 Requirements regarding the voluntary use of the term "Air chilled" in the labelling and advertising of poultry

Operators of slaughtering establishments wishing to label poultry products with the term "air chilled" shall have a written procedure, signed off by the Veterinarian in Charge, which assures that only eligible product (refer to the next subsection) is labeled with the claim "air chilled" or similar phrases. For example, operators handling both water and air chilled poultry must specify that only air chilled poultry be labeled with the phrase "air chilled"

Operators of processing establishments wishing to label poultry carcasses and/or portions with the term "air chilled" shall have a written procedure, signed off by the Inspector in Charge, which assures that only eligible product (refer to the next subsection) is labelled with the claim "air chilled" or similar phrases. For example, the specifications for received poultry products may be amended by the operator to require all eligible product to be labelled on the main panel of the bulk shipping container with the phrase "air chilled".

NOTE: The operator may at any time elect not to label air chilled product as "air chilled", or with a similar phrase, in which case the operator shall comply with water absorption and retention requirements.

Use of the term "air chilled" or similar phrases shall be restricted to carcasses or portions which are chilled;

• without the immersion of carcasses or portions in a water bath*;
• by means of cold air with/without water sprays or mists which apply the minimum water necessary so as to prevent excessive dehydration of the skin ; and /or
• are individually frozen or crust frozen by means of nitrogen or carbon dioxide gas; and
• the Operator demonstrates through a written quality control program and validation data that there is no net increase in the weight of the carcasses as a result of post evisceration washing, chilling and drainage.

*Note: carcasses may be dipped briefly in a microbial control solution provided that any water absorbed and retained is controlled as part of the retained water control procedure as recorded on the applicable Established Chilling Procedure (CFIA 4673), and that the dip is not used to chill the treated carcasses.

19.8.5 Roles and Responsibilities

19.8.5.1 Operator

• providing scales, weights, identification devices, measuring or monitoring devices, and other supplies necessary to monitor the program;

Note: The scale increment should not exceed 10 grams. For example, for a carcass weighing one kg, the maximum error should not exceed 0.5%.

• approved procedures of washing, chilling, draining, and freezing (if applicable) that consistently result in no weight gain beyond the regulatory limits;
• changing approved retained water control procedures only after
  • notifying the veterinarian in charge in writing of his intention,
  • conducting a 50 carcass (or equivalent) retained water test and providing the results to the Veterinarian in Charge;
• following the newly approved procedure through all its steps and by monitoring the procedure on an on-going basis and recording the settings of the key points on at minimum an hourly basis by a designated plant employee or by automatic recording devices;
• on-going testing at the specified frequency (normal, reduced or tightened);
• keep records indicating the date of slaughter, sample carcass identity and pre-chill and corresponding post-chill carcass weight(s) for the carcasses or product sampled. Corrective action shall also be recorded: and
• maintaining all records on-site for 12 months.

19.8.5.2 CFIA Personnel

CFIA personnel is responsible for:

• verifying the washing, chilling and testing procedures to ensure that the operator carries out his responsibilities;
• conducting or closely supervising a retained water test as specified by the Multi-Commodity Activities Program (MCAP) and the compliance of the operator ;
• Assessing amended procedures and approving acceptable procedure changes ;
• monitoring management's 50-carcass retained water validation tests ;
• ensure adequate corrective actions and/or initiation of a 50 carcass test when:
  • a test shows non-compliance, or
  • unapproved change in procedures is detected
• monitoring the net weight statement on consumer pre-packaged poultry products and retained water declarations to assure compliance with the Meat Inspection regulations and Ch. 7 of this manual; and
• maintaining a complete file for a 12 month period :
  • Results of the inspector's tests,
  • Changes in chilling procedures, and
  • Current approved chilling procedures.

19.8.6 Freezing

19.8.6.1 Crust freezing

Rapid chilling methods, for poultry carcasses or parts, which temporarily freeze a thin outer layer of skin and muscle (usually 3-4 mm thick) may be allowed under the following conditions:

• the operator must submit, to the veterinarian-in-charge, a written documented protocol, for each class of poultry processed, outlining how product will be identified and segregated into lots, the packaging method, type and temperature of the coolant, the duration of exposure to sub-freezing temperatures and the time period and location for the equilibrium of internal and external product temperatures such that an internal temperature is achieved at or below 4ºC (but above -2ºC);
• the surface crusting must disappear within 2.5 hours (150 minutes) of completing the crust freezing process;
• the process shall be monitored, by a designated plant employee, a minimum of every two (2) hours for crust disappearance and internal product temperature;
• product shall be labelled as either "previously frozen" or "frozen" whenever crust disappearance takes more than 150 minutes; and
• records demonstrating compliance with all the above listed requirements shall be stored at the establishment for at least one year for each lot of product which is crust frozen.

19.8.6.2 Blast freezing

Poultry carcasses and portions thereof are to be frozen to an internal temperature of -18ºC or lower, and this shall be accomplished within 24 hours from the time freezing commences. Freezing should commence as soon as possible after packaging. Whenever outside freezing facilities are utilized, packaged poultry shall be kept at a storage temperature of 2ºC or lower until freezing commences. The length of time from the commencement of chilling until placement in a freezer should normally not exceed 72 hours. Poultry shall be adequately protected to prevent freezer burn during freezing and freezer storage.

19.8.6.3 Liquid freezing

Where liquid immersion or spray freezing is employed, poultry shall be packaged to prevent contact with the refrigerant. Poultry carcasses or portions contaminated with refrigerant are considered adulterated and shall be condemned, except where the contamination with refrigerant is slight and limited to the surface areas. In such cases, the protective bag or wrap shall be immediately removed and the carcass or portions decontaminated in the following manner:

The contaminated carcass or portions are placed in a tank of changing water and soaked to dilute the refrigerant. The carcass or portions are then removed, drained briefly and placed in a second tank of changing water for further dilution, then rinsed in a third tank of changing water. The carcass or portions may now be passed as fit for food, provided that the inspector is satisfied that the refrigerant has been removed. Inspectors in Charge should submit decontaminated carcasses and portions, from time to time, for laboratory examination to determine the effectiveness of the removal procedures.

An approved colouring agent shall be used in immersion refrigerants to make the detection of leakers easier.

Colouring agents other than those listed in the "Reference listing of Materials and Agents" should be submitted by the manufacturer to: Program Officer, Hygienic Environment Program, Canadian Food Inspection Agency.

The following liquid immersion refrigerants have been approved:

• Brine (common salt)
• Calcium chloride
• Propylene glycol

N.B. Neither Sodium Chromate nor Di-chromate are permitted in immersion freezers.

Poultry carcasses may be packaged in either clear or opaque bags for immersion in liquid refrigerant freezers. Operators are to monitor such freezing operations according to the following protocol:

• all packaged carcasses should be verified by a designated plant employee after the shrink tunnel and before the immersion freezer for bag and clip integrity.
• process action, for the purposes of this protocol, is defined as tagging and segregating all products back to the time of the last satisfactory lot test, reinspection of each tagged carcass for evidence of adulteration and/or loss of package integrity, releasing satisfactory packages and the removal of refrigerant and repackaging of satisfactory carcasses.
• operators commence testing at the Normal Inspection Level. Thereafter, subsequent testing for the next shift continues at the same level as occurred at the end of the previous shift except that for shifts ending under process action, operators may elect to test at the Normal Inspection Level for the subsequent shift.
• a unit refers to a bagged poultry carcass.
• Subgroup tests require sample sizes which vary dependant on the production volume and the compliance or inspection level as per ISO Table 2859-1.
• before the start of each shift, regardless of the applicable inspection level, operators must randomly select hourly subgroup test times for each production hour and record these times before product reaches the sampling location.
• samples are to be randomly selected at the exit chute of the immersion freezer.
• each sample should be visually and manually examined. The visual verification will verify the bag integrity, and for opaque bags, a mandatory palpation shall be made to detect soft spots indicative of the presence of coolant liquid.
• inspection staff is to verify the implementation and ongoing application of this protocol (minimum one verification per half shift or at the same frequency as per finished products standards). The inspection verification will consist of reviewing plant records and once per day, observing one test as performed by the designated plant employee.
• the protocol consists of three (3) inspection levels and is based on ISO table # 2859-1, for an Acceptable Quality Level of 1% at special inspection level # S-3.

The operator shall:

Normal Inspection Level: conduct 13 unit subgroup tests at preselected random times for line speeds up to 3,200 carcasses per hour. For production ranging from 3,201 to 10,000 carcasses per hour, 20 units per hour should be selected (see Normal Inspection, Code E and F respectively, ISO Table 2589-1).

• if defect(s) are found, see below and the flow chart; if no defects are found, the lot shall be considered acceptable.
• if 10 consecutive lots are found acceptable, than the operator can elect to adopt a reduced inspection level.

Reduced Inspection Level: conduct five (5) unit subgroup tests at preselected random time for line speeds up to 3,200 carcasses per hour (see Reduced Inspection, Code E, ISO Table 2859-1). For production ranging from 3,201 to 10,000 units per hour, eight (8) units per hour should be selected (Reduced Inspection, Code F, ISO Table 2859-1).

• if defect(s) are found, see below and the flow chart; if no defects are found, the lot shall be considered acceptable.

Defects for Normal or Reduced Inspection Levels: if the number of defects found is equal to or greater than one, the operator should initiate an immediate retest to eliminate the possibility of a statistical aberration and/or confirm that the lot is not acceptable.

The retest shall be made at the retest inspection level, and Code # G or H (corresponding to the production volume), i.e., require an increased subgroup test sample size as per ISO Table 2589-1.

• if the number of defects found is equal to or less than one, the lot shall be considered acceptable and sampling should return to the previous sampling level, i.e., normal or reduced.
• if the number of defects found on the retest is greater than one, the lot shall be considered not acceptable, i.e., rejected. Adequate corrective measures should be taken on the production line, process action must be initiated immediately and the sample size adjusted to the Tightened Inspection Level (see below and flow chart).

Tightened Inspection Level: sample size is increased to 20 units for line speeds up to 3,200 (see Code F, Tightened Inspection, ISO table 2589-1) and to 32 carcasses for production rates between 3,201 and 10,000 carcasses per hour (Tightened Inspection, Code G, ISO Table 2589-1).

• if no defects are found than the lot is accepted: individual verifications can be stopped and the monitoring may be adjusted to the normal level.
• if defect(s) are found, the lot shall be rejected, i.e., additional corrective measures should be taken and the individual carcass verifications continued until process action is completed. Sample shall continue at the tightened inspection level until a sample is accepted whereafter monitoring of new production may be adjusted to the normal inspection level.

Further information for this statistical process control is included in ISO Table 2589-1 and the associated flow chart.

¹ carcasses/hour

² numbers of carcasses or units to be selected

³ number of defective packages (i.e., containing refrigerant)

19.8.7 Thawing Poultry in Water

When ready-to-cook poultry is thawed in water, the thawing practices and procedures shall be such as will prevent the product from becoming adulterated by the absorption of moisture. Such poultry shall be thawed by one of the following methods:

• in continuous running tap water of sufficient volume and for such limited time as is necessary for thawing. The thawing medium shall not exceed a temperature of 21ºC;
• in re-circulated water, maintained at a temperature not in excess of 10ºC, for such limited time as is necessary for thawing;
• the placing of frozen ready-to-cook poultry into cooking kettles, without prior thawing, is permitted only when a representative sample of the entire lot has been thawed and found to be sound and unadulterated. Thawing practices and procedures shall result in no net gain in weight over the frozen weight, when whole carcasses or parts thereof are thawed for repackaging. Thawed poultry may be held in tanks of crushed ice with continuous drainage, pending further processing or packaging.

19.8.7.1 Water immersion of poultry carcasses for rehydration, etc.

The plant chilling system may be used for immersing previously chilled poultry carcasses, e.g. to rehydrate or restore bloom or to "soften-up" ice packed carcasses prior to automatic cut-up machines, provided that:

• the water temperature does not exceed 4ºC;
• the average moisture pick up does not exceed 2% and this is confirmed by tests conducted by plant personnel for each lot. The testing will be monitored by inspection staff;
• the tank is drained and cleaned prior to use for rehydration; and
• carcasses are not immersed with or after current production.

Where tanks or vats, in which poultry carcasses remain in non-agitated water, are employed for this purpose, the above conditions also apply.

The above conditions are intended to prevent carcass adulteration with excess moisture as well as preventing cross-contamination by food poisoning bacteria, e.g. salmonella and by relatively higher counts of spoilage bacteria between lots of fresh and previously chilled poultry carcasses.

19.8.8 Refrigeration of Rabbit Meat Products

Methods similar to those used for poultry carcasses may be employed to chill rabbit carcasses in water, provided control measures are in place to ensure that, at the time of packaging there is no increase of the hot weight of the carcass as a result of water chilling.

Rabbit carcasses may also be hung on racks or chilled in coolers.

19.9 POST-CHILL PROCEDURES

19.9.1 Cut up and boning

For a description of poultry parts generally prepared in registered establishments, please refer to Chapter 7 of this manual.

19.9.2 Turkey Basting

This policy is to be developed.

19.9.3 Mechanically Separated Meats

For a description of mechanically separated meat and finely textured meat prepared in registered establishments, please refer to Chapter 4 of this manual.

19.10 PACKAGING and LABELLING

Please refer to Chapter 7 of this manual.

19.11 SHIPPING AND RECEIVING

Please refer to Chapter 8 of this manual.

19.12 Product Reinspection

19.12.1 Poultry Reinspection Program

See Annex E of this chapter.

19.12.2 Returned Turkey Carcasses in the Event of an Actual or Perceived Malicious Product Tampering

The following protocol was developed by industry and assessed by CFIA and Health Canada personnel. It is intended to be used, under CFIA supervision, to recover whole turkey carcasses when the product is withdrawn from distribution and retail as a result of claimed or threatened product tampering. Before the protocol is used, the likelihood of tampering having occurred will be carefully assessed by representatives of industry and the CFIA. In the event of a suspected or actual tampering incident, the Chief, Poultry Inspection Programs should be the primary point of contact regarding application and interpretation of the conditions pertaining to the protocol, with the Director, Food of Animal Origin Division, serving as an alternate.

For fresh turkey:

1. Pump air into the bag using a needle
   • while carrying out this step, hold the bag tightly around the needle
2. Withdraw needle and stick a piece of tape on the injection point
3. Dip the inflated bag into water to detect any holes
4. If the bag is intact, repack the product in a new bag and ship again to market
5. If the bag leaks, the product must be discarded

For frozen turkey:

1. Let the bag reach room temperature to allow the bag to be inflated
2. Pump air into the bag using a needle
   • while carrying out this step, hold the bag tightly around the needle
3. Withdraw needle and stick a piece of tape on the injection point
4. Dip the inflated bag into water to detect any holes
5. If the bag is intact, repack the product in a new bag and ship again to market
6. If the bag leaks, the product must be discarded

Under this protocol, industry or its representatives will be responsible for conducting any testing and interpretation of results. Returned products will be kept segregated according to where they have been, to enable differentiation according to probability of exposure to tampering or adulteration. All testing and subsequent repackaging and/or destruction of the product will be conducted in a federally registered establishment, under the supervision of inspection staff from the CFIA in a verification role. Precautions will be taken to prevent cross-contamination of product during testing and further manipulations.

The exterior of packaging material surrounding the products being tested will be examined visually for physical evidence of resealing of a puncture, e.g. blob of glue or tape, prior to immersion in water. Packages that fail either the visual examination or the test itself, and their contents, will be examined thoroughly for evidence of tampering or adulteration, for investigational purposes, after which they will be destroyed.

Products that have been in consumer hands should be tested for evidence of tampering for investigational purposes but will not be eligible for salvage if temperature control cannot be assured.

Applicability of the protocol, criteria for interpretation of results and disposition decisions may have to be adjusted by mutual agreement depending on the specific circumstances of an incident.