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19.4 DRESSING PROCEDURES

It is plant management's responsibility to ensure that all dressing procedures are conducted in a sanitary manner and result in non-adulterated meat products fit for human consumption or animal food. It is the responsibility of the inspection staff to monitor the plant employees' procedures.

19.4.1 Poultry Dressing Procedures

19.4.1.1 Bleeding

Bleeding must be conducted in a sanitary manner and the bleeding time shall not be less than 90 seconds.

19.4.1.2 Defeathering and washing

In the dressing of poultry carcasses, all hair, feathers, dirt, scurf, etc., must be completely removed and the carcass thoroughly washed prior to any further incision being made.

In order to reduce the attachment of Salmonella and other bacteria to the skin, spray washing of carcasses must occur within fifteen seconds after defeathering and after carcass transfer. Sprays at both washing stations shall be of sufficient volume and pressure, to completely remove visible foreign material from the surface of the carcass including the hocks and any exposed surfaces as a result of bleeding or decapitation.

19.4.1.3 Removal of oil glands, heads and feet

Oil glands, heads and feet may be removed from poultry carcasses, either before or after evisceration. Oil glands, heads and feet removed before evisceration, may only be removed after carcasses have been defeathered and thoroughly washed. However, heads may be removed with or without stunning by rapid decapitation in the stunning area prior to bleeding provided that the decapitation is performed in a humane manner (reference section 79, Meat Inspection Regulations). Feet presented with the carcass for post-mortem inspection or examination must be free of visible contamination (Eg manure).

19.4.1.4 Evisceration

Poultry carcasses must be eviscerated with respect to the following:

• They must be hung in a way that will allow for internal cavity, viscera and external carcass examination.
• Cross contamination is to be avoided (e.g. Heads and necks shall not drag over equipment along the evisceration line)
• Accumulated water present in the vent area, must be removed prior to opening the carcass.
• The incision made should be no longer than required to permit evisceration.
• Before hands or equipment enter the abdominal cavity, they must be visibly clean.
• The viscera must be properly exposed to allow for post-mortem examination. The applicable presentation standard described in Annex A must be met.
• Poultry carcasses shall be eviscerated in such a manner as to preclude faecal contamination.

Where higher than normal levels of contamination are encountered, upon request by the plant operator, the following statement is to added to the Condemnation Certificate:

"The local average for condemnation because of (faecal / crop) contamination is _______%. In the case of the lot identified on this certificate, the level of contamination has necessitated the condemnation, as reported by the plant operator, of _______(kg / #) of carcasses and _______kg of portions (if applicable) due to mainly (faecal / crop) contamination."

For liability reasons, no other statements are to be used, on the certificate or on any other documents, regarding the nature and/or the possible origin of the contamination.

After post-mortem inspection or examination, all (esophagus, crop, cloaca, lungs, trachea, kidneys and reproductive organs), shall be removed from the carcass before the final wash, and shall be handled as inedible material.

N.B. Kidneys and reproductive organs for young chicken under 2.7 kg average live weight or young ducks under 4 kg average live weight may be left in. Kidneys in portions intended for mechanically separated meat must be removed.

Oil glands, crops and tracheas are inedible products and may be used as mink food or for the preparation of other animal food.

Prior to the chilling system, the carcass shall be adequately washed by an approved inside/outside carcass washer. If inside/outside carcass washing is performed manually, the thoracic inlet must be penetrated for adequate washing and drainage.

Carcasses with internal contamination may be salvaged or reprocessed.

19.4.1.5 Application of a Water Film During Evisceration Procedures

Operators with evisceration equipment designed to completely detach the viscera, may spray the cavity and the viscera provided that:

• venting, opening and evisceration operations are controlled as a Critical Control Point (CCP) as part of a (HACCP) system
• the pressure and volume of the water used by all the spray nozzles applied to the carcass and/or viscera during venting, opening and evisceration operations as indicated by a pressure gauge and a totalizing water meter;
• ongoing testing for generic E. coli as specified in the USDA Pathogen Reduction/HACCP requirements as outlined in Chapter 11;,
• post-mortem examination is not compromised (e.g.: excessive water in the cavity);
• significant evidence of disease is not being lost; and

NOTE: operators with equipment which does not fully separate the viscera from the carcass are not permitted to shower carcasses or viscera unless the equipment first passes a test under the GENERIC PROTOCOL (see Annex H of this chapter)

19.4.2 Domesticated rabbit dressing procedures

The dressing of rabbit carcasses shall meet the following requirements:

• Prevent carcass-contamination from dirty hands, knives or pelts.
• After the pelt is removed, a water rinse of the carcass is permitted to remove fluffy hair. Carcasses must be free of all other types of visible contamination before they are subjected to the water rinse.
• Subsequent dressing procedures are similar to those described for poultry in this subsection.

19.4.3 Ritual Slaughter

In ritual slaughter, properly restrained food animals may be slaughtered (bled) without stunning, provided the slaughter is carried out by experienced persons.

Such slaughter shall be performed by a single cut which shall result in rapid, simultaneous and complete severance of the jugular veins and carotid arteries so as to cause rapid unconsciousness and exsanguination of the animal.

19.4.3.1 Halal Slaughter

To be developed

19.4.3.2 Kosher Slaughter

To be developed

19.5 ADDITIONAL EVISCERATION FLOOR PROCEDURES

19.5.1 Salvaging

Operators may elect to handle carcasses accidentally contaminated with gastrointestinal contents by salvaging the non-contaminated portions at either an off-line salvage and/or reprocessing station.

Salvage procedures may be conducted provided the following requirements are met:

• adequate facilities are provided (see Chapter 2)
• salvage operations are carried out expeditiously and hygienically.
• carcasses are handled according to the disposition criteria;
• station(s) do not become overloaded with a backlog of carcasses; and
• edible product is not contaminated by inedible product or contaminated equipment.

19.5.2 Off-line reprocessing/reconditioning

19.5.2.1 Definitions:

Off-line Reprocessing: The removal of contamination (faecal, bile, ingesta, extraneous material ) from within the abdominal cavity of carcasses by washing, vacuuming, trimming or combinations thereof at a designated off-line work station according to the establishment’s approved written protocol.

Off-line Reconditioning: The removal off-line of localized pathology (e.g. airsacculitis, cellulitis, salpingitis) by vacuuming, scraping, trimming, or combinations thereof at a designated off-line work station according to the establishment’s approved written protocol.

19.5.2.2 General requirements:

The following requirements must be met to ensure that contaminated carcasses are satisfactorily reprocessed, and that carcasses with localized pathology are satisfactorily reconditioned:

• The establishment’s written protocol has been approved by Veterinarian in Charge and the operator has received conditional acceptance to initiate a trial period.
• The operator must provide adequate facilities (see Chapter 2, of this manual) to carry out operations hygienically and expeditiously;
• Evisceration accidents shall be kept to a critical limit of 5 % or less so that reprocessing procedures are not used to compensate for inadequate control of venting/opening/evisceration operations.
• The operator may only use approved microbial control agents.

19.5.2.3 Reprocessing requirements:

The operator has the option of reprocessing faecal, bile, ingesta and/or extraneous material contamination. The written program shall specify which type(s) will be controlled by the off-line reprocessing procedure. If the original trial period does not include all types of contamination, adding a type would be considered a major change that would require revalidation.

Carcass rinsing procedures shall ensure that rinse water rapidly exits the cavity and does not pool.

The removal of crops prior to reprocessing is optional subject to the following:

• the written procedure shall specify if the crops will be removed prior to reprocessing or not;
• if crops are removed, it must be done hygienically and without further contamination;
• if the crops are left in the carcass, the written procedure shall stipulate that carcasses with obvious distension of the crop are not reprocessed; and
• carcass rinsing procedures shall ensure that rinse water does not pool and rapidly exits the cavity.

Please note that if carcasses are to be placed directly into the chill system after reprocessing, then all trimming and processing defects must be removed.

19.5.2.4 Reconditioning Requirements

The overall objective of these requirements is to minimize the additional CFIA activities required for lots of poultry with a high number of carcasses containing lesions from airsacculitis.

Carcasses affected with airsacculitis shall be subject to the disposition criteria described in subsection 19.7 of this chapter.

Training and Quality Control (QA) programs, approved by the Veterinarian in Charge, are required to ensure the removal of affected tissues and exudate (from the wing joints and the diverticula of the interclavicular airsac).

If the number of carcasses requiring salvage exceed the capacity of facilities and/or personal, affected carcasses shall be condemned by the establishment operator as "plant rejects" which are not to be recorded on the CFIA condemnation certificate

N.B. For turkey trucks/lots with carcasses having airsacculitis of the cranial airsacs, a veterinarian may determine that the in depth inspection is not required as per the following decision tree, in which case all carcasses with cranial airsac involvement shall be sent to salvage.

The following decision tree shall be used to determine which trucks/lots qualify as candidates for reconditioning.

19.5.2.4.1 Reconditioning Decision Tree

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19.5.2.5 Acceptance Process

In order to facilitate the CFIA acceptance of the plant-specific off-line reprocessing and/or reconditioning procedures, the following acceptance process shall be followed:

• A request is submitted to the Veterinarian in Charge.
• The Veterinarian in Charge and a poultry program specialist will conduct the pre-operational checklist (CFIA.ACIA06) on-site and analyze the plant’s written procedure which shall be accompanied by a process and employee flow diagram.
• Upon successful completion of the checklist, on-site analysis of facilities and written procedures, the of 20 shift-trial period may begin.
• After the 20-shift trial period, the results of the post-operational checklist, E. coli data and organoleptic monitoring data shall be analyzed by the area poultry program team. If the results are acceptable, the area poultry program specialist shall grant CFIA acceptance.

Reprocessing and/or reconditioning operations must be revalidated whenever significant changes are made to the CFIA accepted written procedure or to the reprocessing and or reconditioning facilities.

19.5.2.6 Trial Period

The effectiveness of reprocessing and/or reconditioning operations shall be validated during a trial period which shall be conducted according to a written protocol. Operators shall conduct separate validation trials for reprocessing and reconditioning. These separate trials may be conducted at the same time.

For establishments that have two shifts, only one trial period is necessary for both slaughter shifts provided there are no significant operational differences between shifts. All reprocessed and/or reconditioned carcasses must have an equal opportunity of being sampled.

For establishments that slaughter multiple classes of poultry e.g. chicken broilers, spent hens and turkeys, a separate trial period shall be conducted for each class. Different weight ranges of the same class shall be considered as one class and require only one trial period, e.g. one validation trial for chicken broilers and roasters or for all weight ranges of turkeys.

19.5.2.6.1 E. coli testing

Procedures shall be validated by using sample collection and laboratory test procedures for generic E. coli as outlined in the Pathogen Reduction Program, Chapter 11, Exports, section on the United States, in this manual.

19.5.2.6.1.1 Sampling Plan

Collect 50 concurrent samples comprised of:

• one (1) control sample collected from the evisceration line just prior to the chilling system and
• one (1) treatment sample collected from the reprocessed and/or reconditioned carcasses after final washing, both collected at approximately the same time.

According to a written procedure accepted by the Veterinarian in Charge, samples shall be:

• randomly selected;
• identified in order to differentiate between treated and untreated carcasses; and
• selected after final washing and prior to the chilling system.

In order to pass the microbiological analysis portion of the trial period, the geometric mean of treated carcasses must be equal to or less than that of line run production or not significantly different as determined by statistical analysis.

19.5.2.6.2 Organoleptic testing

19.5.2.6.2.1 Sampling Plans

Reprocessed and/or reconditioned carcasses shall be retained and sampled a minimum of every 30 minutes by the designated plant monitor over 20 consecutive work shifts subject to verification by the inspection staff and as per the following tables.

N.B. The operator must ensure that untreated carcasses (eg: false positives) are excluded from the sampling of treated carcasses.

Based on Sampling Plan 2859-1, Inspection Level II

Statistical Aspects of Food Quality Assurance by Subhash C. Puri, Agriculture Canada

Original source: International Organization for Standardization (ISO), Central Secretariat, Geneva.

Carcasses shall be examined at facilities meeting the same requirements as for the prechill Finished Products Standards (FPS) tests (see Annex D of this chapter 19)

It is understood that most written reprocessing procedures will have a provision for sending carcasses to be salvaged if the contamination and/or local pathology cannot be removed effectively. Therefore, it is important to mention that only those reprocessed and/or reconditioned carcasses that are to be returned to the line shall be sampled.

19.5.2.6.2.2 Defect definitions

Reprocessing defects

• faecal greater than 3mm;
• bile greater than 3mm;
• ingesta or extraneous material greater than 5 particles, each particle greater than 1.5 mm in size).

Reconditioning defects

• airsacculitis lesions greater than 3mm
• localized pathologies (e.g. salpingitis)

Please note that the above criteria define defects for monitoring purposes and are not criteria for removal of carcasses from the evisceration line.

19.5.2.6.2.3 Unsatisfactory sampling results

A sample shall be deemed unsatisfactory if one or more carcasses in the sample has a defect as defined in this subsection. The operator shall then implement the following:

• all carcasses in the retained lot shall be reexamined with defective carcass(es) sent for salvage and acceptable carcasses allowed to reenter production.
• notify the veterinarian in charge
• determine the probable cause and implement applicable corrective actions
• amend the written reprocessing and/or reconditioning procedure as necessary
• retrain employee(s) if applicable

N.B. The 20-shift trial is reset to zero after three unsatisfactory samples have been accumulated.

19.5.2.7 Off-line procedures after CFIA approval

19.5.2.7.1 Microbiological sampling

Reprocessed and/or reconditioned carcasses may either continue to be tested for E. coli separately or combined with the regular carcasses for chilling. Corrective action as specified in the USDA Pathogen Reduction/HACCP (see Chapter 11 of this Manual) regulations must then apply to ALL applicable carcasses (i.e. reprocessed and/or reconditioned carcasses only, or if mixed with regular carcasses, then to all carcasses entering the chilling system).

If reprocessed and/or reconditioned carcasses are tested for E. coli separately, then a minimum of one reprocessed and/or reconditioned carcass shall be tested per shift.

19.5.2.7.2 Organoleptic Sampling

Once the 20-shift trial has been completed, the operator has the option of using the previously described ISO-based sampling plan to monitor the off-line procedure or to write an equivalent Statisitical Process Control (SPC). The frequency of sampling shall be a minimum of once per hour. The Veterinarian in Charge and the operator shall ensure that carcasses are being reprocessed and/or reconditioned according to the CFIA accepted written procedure.

19.5.2.7.2.1 Procedure monitoring by the Operator

The Veterinarian in Charge shall ensure that the operator’s written procedures specify a sample size, frequency, and that samples are representative (random sampling).

The written program shall also include carcass disposition, retest parameters and review of applicable written and practical procedures in the event of sample failure.

19.5.2.7.2.2 Finished Product Standards (FPS) monitoring

Please note that in an establishment operating under the CPIP or MPIP if reprocessed and/or reconditioned carcasses are placed directly into the chill system afterwards, they shall receive separate FPS monitoring at a minimum of twice per shift. If corrective action or process action is required as a result of these separate tests, it would only apply to the reprocessed and/or reconditioned product.

However, if the reprocessed and/or reconditioned carcasses are placed back onto the evisceration line and mixed with line run production, then the FPS test results and any required corrective action would apply to the evisceration line and off-line procedures.

19.5.2.7.3 CFIA verification

At a minimum of once per shift, CFIA personnel should evaluate the operator’s process control by conducting a correlation test with the plant monitor. During the correlation test, CFIA personnel will ensure that the operator’s sampling frequency, random sampling methods, defect evaluation, defect recording, evaluation of results and corrective actions taken are acceptable.

If process control is assessed to be unacceptable, the operator must initiate immediate corrective actions. The Veterinarian in Charge shall decide if the written procedure is to be amended or revalidated.

19.5.2.7.4 Defect Log: Off-line Reprocessing / Reconditioning for Chicken, Turkey and Fowl

Please see Annex F of this chapter.

19.5.3 On-line reprocessing and reconditioning

19.5.3.1 On-line Reprocessing

19.5.3.1.1 Introduction

Poultry slaughtering establishments must be in the Data Collection (3rd) phase of MPIP to qualify for on-line reprocessing.

On-line reprocessing refers to the on-line removal either manually and/or by specially designed automatic equipment of contamination within the abdominal cavity of dressed carcasses by means of trimming and/or washing and/or vacuuming potentially followed by treatment with a bactericidal agent. Therefore, contamination within the abdominal cavity may be "passed" by the defect detectors and trimmer/helpers.

19.5.3.1.2 Requirements for On-line Reprocessing

Carcasses with faecal, ingesta, bile and extraneous material may be reprocessed on-line commencing in the Data Collection (3rd) phase of MPIP provided that:

• microbial hazards associated with feed withdrawal, evisceration accidents and on-line reprocessing are controlled by the operator’s HACCP system;
• laboratory tests for E. coli indicate compliance with the IALs for E. coli as per the Pathogen Reduction Program in Chapter 19
• an initial verification test confirms that the geometric mean of 100 reprocessed carcasses is equal to or better than the geometric mean of 100 carcasses processed at the establishment prior to commencing on-line reprocessing.
• After commencing on-line reprocessing operations, E. coli counts from a minimum of 100 carcasses (300 carcasses is the recommended sample size) are equal to or better than the average levels of the Canadian Microbiological Baseline Survey as per the following table:

• visible faecal contamination is completely removed from carcasses
• the application of an approved bactericidal agent may be used as part of on-line reprocessing procedures
• Organoleptic monitoring shall be conducted according to AQLs listed in this section.

19.5.3.1.3 CFIA International Standards Organization (ISO)-based Testing

MPIP ISO test methods and procedures (as described in this chapter) shall be used for on-line reprocessing.

The ISO - based test for pathology and processing defects shall be split into two (2) tests as follows:

• The first test shall be named the "Detection" test. It assesses the performance of the establishment defect detector(s) and is conducted at the same location by CFIA near the helper/trimmer. This test shall evaluate defects listed in table 19.5.3.1.6.1 (Specified Defect List for "Detector" Tests).
• The second test shall be named the "Prechill Test". It assesses on-line reprocessing performance and is conducted at the prechill FPS location. This test shall evaluate defects listed in table 19.5.3.1.6.2 (Specified Defect List for "Prechill" Tests). This test shall include a zero tolerance for identifiable faecal contamination and all remaining forms of contamination (bile, ingesta and extraneous material) shall be included within the AQLs for ISO-based tests performed at the prechill location.

19.5.3.1.4 Acceptable Quality Levels (AQLs) for On-line Reprocessing

* See table titled "Acceptance and Rejection Numbers Table".

19.5.3.1.5 Corrective Action(s) for On-line Reprocessing

Identifiable faecal contamination shall result in the failure of samples conducted at the "Prechill" location and require corrective action(s) as per the decision tree.

The "Decision Tree for ISO-based Testing for Pathology and Processing Defects" specifies follow-up action for each such test including tests performed for on-line reprocessing.

Results of CFIA performed ISO-based tests performed near the helper/trimmer and tests performed at the FPS prechill location shall be assessed independently of each other e.g. reduced level of inspection for "Detection" defects while testing at the tightened inspection level for "Prechill" defects.

19.5.3.1.6 Defect Lists for On-line Reprocessing

19.5.3.1.6.1 Specified Defect List for "Detector" Tests

¹ establishment must operate under a QC program included as part of a HACCP system which assures that Cellulitis lesions of 2 cm by 2cm size or smaller, other than Peri-Cloacal Cellulitis, are either trimmed on on-line or reconditioned off-line such that all Cellulitis lesions are removed prior to the FPS test location.

19.5.3.1.6.2 Specified Defect List for "Prechill" Tests

N.B. A zero tolerance applies for all visible evidence of faecal contamination. All defects listed in the previous table shall also be counted as defects if observed at the FPS location.

19.5.3.1.7 Acceptance and Rejection Numbers

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19.5.3.1.8 Defects Log for On-line Reprocessing / Reconditioning

Please see Annex F of this chapter.

19.5.3.2 On-line Reconditioning

To be developed

19.5.4 Preparation of offal for edible purposes or animal food

Poultry giblets (heart, liver and gizzard) may be prepared for human food provided they are free of pathological lesions. It is essential that contamination of these organs be prevented during preparation and inspection.

Giblets shall be chilled immediately after they are harvested and prepared. Accumulation of giblets for later preparation shall not be permitted.

19.5.4.1 Hearts

Poultry hearts may be prepared for human food. Hearts shall have the pericardium removed prior to washing and chilling. After washing, hearts shall be drained and refrigerated.

19.5.4.2 Livers

Poultry livers may be prepared for human food. Livers shall be separated from the viscera and the gall bladder shall be removed without release of bile on edible product, before washing and chilling. Abnormal livers (see subsection 19.7) may be salvaged for animal food.

19.5.4.3 Gizzards

Gizzards shall be separated from viscera, opened and the contents and lining removed, before washing and chilling. Contaminated fat on the outside surface of gizzards shall be removed.

19.5.4.4 Kidneys

Kidneys from poultry may not be prepared as an edible product.

19.5.4.5 Necks

Poultry necks that are separated from the carcass may be prepared for human food provided they are free of contamination.

19.5.4.6 Ova from fowl

The salvage of ova from slaughtered laying hens is permitted, provided the following conditions are met:

• Only ova from approved carcasses are collected. Collection shall be done after inspection.
• Ova collection is done under sanitary conditions.
• The product shall be refrigerated immediately after collection to a temperature below 4°C. The product shall be subsequently stored and transported under refrigeration to a registered processing egg station for pasteurization.
• All containers of ova must be identified as such.

19.5.4.7 Poultry feet or paws

19.5.4.7.1 Requirements for edible poultry feet or paws:

The salvage of edible poultry feet or paws must be conducted according to the following requirements:

• if feet are removed prior to PM inspection /detection, the operator must have a written protocol that has been approved by the Veterinarian in Charge to ensure that feet are harvested from approved carcasses only;
• if feet remain attached to the carcass until after the PM inspection /detection, they must not present a contamination hazard. Feet, carcass and equipment surfaces must be maintained visibly clean during operations;
• epidermis and the toenails are removed;
• only feet or paws free of faecal contamination are transferred to the edible product processing area ;
• all edible feet or paw contact surfaces located in non-refrigerated rooms shall be cleaned as per Chapter 3, of this manual;
• sorting, trimming and packaging operations shall be performed such that feet or paws ready for packaging are not contaminated by defective feet or paws. There shall be sufficient spatial separation from other processing operations such that the poultry feet or paws do not present a contamination hazard to other processed poultry products;
• edible poultry feet or paws shall be chilled to 4°C or lower within 4 hours after scalding operations;
• the operator’s written protocol for the production of edible poultry feet or paws shall be validated and monitored according to the microbiological and organoleptic requirements included in this section; and
• if the establishment has more than one shift, all microbiological and organoleptic sampling described in this section shall be equally distributed amongst the shifts.

19.5.4.7.2 Organoleptic Defect Definitions

19.5.4.7.3 Validation Procedures

19.5.4.7.3.1 Microbiological requirements:

E. coli counts from packaged, chilled, edible poultry feet or paws shall be validated using the Pathogen Reduction/HACCP systems final rule for poultry carcasses as contained in Annex T, of the US section of ch.11 of this manual.

Sufficient samples (minimum of 10 paws per sample) shall be collected to complete one "moving window" for each class of poultry. If the results indicate compliance with the prescribed criteria (eg. no samples above 1,000 cfu and a maximum of 3 samples greater than 100 cfu in a moving window of 13) then the microbiological validation is deemed to be acceptable.

19.5.4.7.3.2 Organoleptic requirements:

During validation, ISO-based sampling shall be conducted by randomly selecting one case of packaged feet or paws at a frequency of once per half shift as per the following table:

The validation period is completed once 10 consecutive shifts (20 samples) are accepted.

19.5.4.7.4 Post-Validation Procedures

19.5.4.7.4.1 Microbiological Requirements:

Once the validation procedure is successfully completed, the sample (as per Annex T, of the US section of ch. 11) frequency may be reduced to once per week for 2 months and if the samples still meet the criteria, then the testing frequency may be reduced to one randomly selected sample per month. If at any time the samples do not meet the aforementioned criteria, then an investigation shall be conducted to determine the probable cause and corrective action taken as indicated. The Veterinarian in Charge shall decide if the written procedure is to be amended and whether or not feet or paw operations should be revalidated.

19.5.4.7.4.2 Organoleptic Requirements:

Once the validation of poultry paw collection has been successfully completed, the operator has the option of continuing to use the ISO sampling plan begun in the validation step or to write an equivalent plant-specific SPC program. Whether ISO or a plant specific SPC is used, the frequency of sampling shall be conducted as per the following table as a minimum.

19.5.4.7.5 Corrective actions following a rejected sample

If a sample fails a test, the entire carton shall be reworked and another case selected for sampling from the same half shift. If the second case fails, the entire half shift shall be reworked, an investigation conducted to determine the probable cause, corrective action taken as indicated. The Veterinarian in Charge shall decide if the written procedure is to be amended and whether or not feet or paw operations should be revalidated.

19.5.4.7.6 Evaluation of process control by CFIA personnel

Once per week, CFIA personnel should evaluate the operator’s process control as per the requirements of this section. An organoleptic evaluation may be conducted in two ways.

• Evaluate the operator’s monitoring methods (e.g: sampling frequency, random sampling methods, defect evaluation, defect recording, evaluation of results, corrective actions taken).
  • If monitoring methods are assessed to be unacceptable, the operator must initiate corrective actions.
• Perform a test as per the sampling plan described in the validation period at the start of this section.
  • If a sample is rejected, the establishment must initiate an immediate retest and implement correctives measures as necessary.
  • If faecal material is found, immediate corrective action must be initiated.

In regards to the microbiological evaluation, CFIA personnel should ensure that the operator is in compliance to the Pathogen Reduction/HACCP systems final rule for poultry carcasses (Annex T, of the US section of ch. 11) as contained in this manual.

19.5.4.7.7 Defect log for Poultry Paws or Feet

If the ISO sampling plan is utilized, the defects may be recorded on the Defect Log for Poultry Feet and Paws contained in Annex F of this chapter.

19.5.4.8 Chitterlings

To be developed

19.5.5 Specific Quality Control Programs

19.5.5.1 Head and feet-on poultry carcasses

This policy is also applicable to poultry with just head attached or just feet attached.

The uropygial or oil gland may be left on carcasses with the head and feet attached provided that:

• the carcass is labeled so as to indicate the presence of the oil gland; and
• the oil glands are removed from any portions to ensure that the glands are never incorporated into meat products such as mechanically deboned meat (MSM);

19.5.5.1.1 Requirements for head and feet on carcasses

Dressing of poultry carcasses with head and feet on may be conducted under the following conditions:

• heads and feet must not present a contamination hazard. All carcass and equipment surfaces must be maintained visibly clean during operations;
• the oral cavity and nostrils must be free of extraneous material prior to chilling;
• epidermis and the toenails are removed prior to chilling;
• the feet must be free of faecal contamination prior to the venting and/or opening of the abdominal cavity;
• the removal of processing and trimming defects of head and feet on carcasses shall be done prior to chilling;
• the operator’s written protocol for the production of head and feet on carcasses shall be validated and monitored according to the microbiological and organoleptic requirements included in this section;
• if the establishment has more than one shift, all microbiological and organoleptic sampling described in this section shall be equally distributed amongst the shifts; and
• The written procedure must be accepted by the Veterinarian in Charge.

19.5.5.1.2 Organoleptic Defect Definitions

19.5.5.1.3 Validation Procedures

19.5.5.1.3.1 Microbiological requirements:

The operator’s written protocol for the production of head and feet on carcasses shall be validated by using sample collections and laboratory test procedures for generic E. coli as outlined in the USDA Pathogen Reduction/HACCP regulations, Chapter 11, section on the United States, in this manual.

Microbiological validation consists of the collection of 50 concurrent samples. A concurrent sample is comprised of one carcass without head and feet on (control population) and one carcass with the head and feet on (target population) collected from the evisceration line just prior to entering the chilling system.

The written procedure shall specify the sampling location, how carcasses shall be identified and the random sampling procedure

In order to pass microbiological validation, the geometric mean of the head and feet on carcasses must be equal to or less than that of carcasses without head and feet on or not be significantly different as determined by statistical analysis.

The operator shall submit to the CFIA Area poultry program specialist the results of all E. coli tests for statistical analysis. Results of the analysis shall be supplied to the Veterinarian in Charge and the operator.

19.5.5.1.3.2 Organoleptic requirements:

During validation, ISO-based sampling shall be conducted by randomly selecting enough cases to perform a 20 carcass sample at a frequency of once per half shift as per the following table:

The validation period is completed once 10 consecutive shifts (20 samples) are accepted.

19.5.5.1.4 Post-Validation Procedures

19.5.5.1.4.1 Microbiological Requirements:

The production of head and feet on carcasses shall be monitored by using sample collections and laboratory test procedures for generic E. coli as outlined in the USDA Pathogen Reduction/HACCP regulations, Chapter 11, section on the United States, in this manual.

Once the validation has been successfully completed, the testing frequency may be reduced to once per week for 2 months and if the samples still meet the criteria, then the testing frequency may be reduced to one randomly selected sample per month. If at any time the samples do not meet the aforementioned criteria, then an investigation shall be conducted to determine the probable cause and corrective action taken as indicated. The Veterinarian in Charge shall decide if the written procedure is to be amended and whether or not feet or paw operations should be revalidated.

19.5.5.1.4.2 Organoleptic Requirements:

Once the validation of head and feet on production has been successfully completed, the operator has the option of continuing to use the ISO sampling plan begun in the validation step or to write an equivalent plant-specific SPC program. For both options, the frequency of sampling shall be conducted as per the following table as a minimum.

19.5.5.1.5 Corrective Action

If a sample fails a test, the affected case(s) shall be reworked and another sample conducted from the same half shift. If the retest fails, the entire half shift shall be reworked, an investigation conducted to determine the probable cause, corrective action taken as indicated. The Veterinarian in Charge shall decide if the written procedure is to be amended and whether or not head and feet on operations should be revalidated.

19.5.5.1.6 Evaluation of process control by CFIA personnel

Once per week, CFIA personnel should evaluate the operator’s process control as per the requirements of this section. An evaluation may be conducted in two ways.

• Evaluate the operator’s monitoring methods (e.g.: sampling frequency, random sampling methods, defect evaluation, defect recording, evaluation of results, corrective actions taken).
  • If monitoring methods are assessed to be unacceptable, the operator must initiate corrective actions.
• Perform a test as per the sampling plan described in the validation period at the start of this section.
  • If a sample is rejected, the establishment must initiate an immediate retest and implement correctives measures as necessary.
  • If faecal material is found, immediate corrective action must be initiated.

In regards to the microbiological evaluation, CFIA personnel should ensure that the operator is in compliance to the Pathogen Reduction/HACCP systems final rule for poultry carcasses (Annex T, of the US section of ch. 1) as contained in this manual.

19.5.5.1.7 Defects Log for Head and Feet-On Carcasses

A Head and Feet On Carcass Defects Log has been provided in Annex F of this chapter to record the sample results.

19.5.5.2 Head-on rabbit carcasses

A domesticated rabbit may be dressed with the head-on.

The establishment’s written protocol must include the applicable conditions from the head-on poultry subsection and must be approved by the Veterinarian in Charge.

19.5.5.3 Removal of condemned poultry legs

19.5.5.3.1 General Requirements

An approved written quality control program is required to ensure that all condemned legs are removed prior to the chilling system.

A written quality control program must consist of the following parts:

• A flow chart of the operation indicating the position of employees identifying legs for removal, removing the legs and where checks on the effectiveness of the system are made.
• Quality control programs using knife cuts as identification may be approved providing that the cut:
  • is easily seen from all sides of the carcass at normal line speeds; and
  • is distinguishable from any other cuts;
• A description of the following controls:
  • the frequency and method of monitoring;
  • the records that will be kept and
  • the action that will be taken if condemned or marked legs are missed.

Any proposed program should be discussed with the veterinarian-in-charge for approval.

19.5.6 Application of Microbial Control Agents

19.5.6.1 Reference Listing of Accepted Non-Food Chemical Products

Industry representatives desiring information on how to obtain CFIA listing for a microbial control agent should be referred to :

Chemical Health Hazard Assessment Division,
Food Directorate, Bureau of Chemical Safety,
Health Canada,
Banting Building, Address Locator : 2201B1,
Ottawa, Ontario K1A 0L2
Telephone : (613) 957-1543 fax: 990-1543

Please see the "Reference Listing of Accepted Construction Materials, Packaging Materials and Non-Food Chemical Products" at the following URL. http://www.inspection.gc.ca/english/ppc/reference/z1e.shtml

19.5.6.2 General conditions for the use of microbial control agents

Conditions of use for treating raw meat (including poultry) carcasses or parts with microbial control agents during evisceration or chilling operations :

• The biological and chemical hazards associated with the use of microbial control agents shall be controlled by an establishment specific Hazard Analysis Critical Control Point or HACCP system. These process controls shall cover slaughter, evisceration and chilling operations and ensure that microbial control treatment(s) are used to facilitate, not in place of, Good Manufacturing Practices (GMPs).
• The operator shall develop a written protocol including the method of monitoring the concentration of the microbial control agent, and if indicated in the following subsections for a specific microbial control agent, the solution temperature and/or immersion/exposure time.
• Operators shall submit for review and acceptance by the Chief, Plant and Equipment Evaluation, Food of Animal Origin Division (FAOD):
  • specifications on facilities; and
  • specialized equipment* (eg. pumps, filtration system, etc) * if the equipment has either direct product contact surfaces and/or recirculates the treatment solution and is not listed by CFIA.
• Operators recirculating microbial control solutions shall have documented cleaning procedures, validated by bacteriological tests, for cleaning all pipes, tanks, pumps, etc.
• Only chemicals listed by CFIA, or covered by a letter issued by Health Canada and indicating no objection for the intended use, shall be used to formulate microbial control solutions ;
• Microbial control treatment solutions and/or treated water shall be tested and results recorded by a continuous recorder, or if recorded manually, a minimum of once per 4 hours. The HACCP system shall ensure ongoing compliance with -
  • the maximum concentration (and if applicable, temperature and/or time) as indicated by Health Canada for use on raw poultry; and
  • the minimum concentration (and if applicable, temperature and/or time) needed to ensure microbial control efficacy ;
• Provision shall be made for the removal of carcasses from tanks or other treatment equipment in the event of a line stoppage. Operators shall have written procedures for:
  • the segregation and either disposal of affected carcasses or parts subjected to excess time and/or temperature and/or concentration of treatment solution.

  or

  • storage of the affected product pending submission of all information requested by CFIA and/or Health Canada (HC) including test results (conducted at the operator’s expense), as required for a (food safety) health risk assessment by HC ;
• Moisture absorption (if potentially affected by the use of the microbial control agent e.g. TSP) procedures shall be revised to reflect the use of microbial control treatment solutions. Refer to section 25 the Meat Inspection Regulations;
• Operators shall dispose of spent treatment solutions in compliance with federal and provincial environmental requirements ;
• The operator shall supply the Veterinarian in Charge (VIC) with a current Material Safety Data (MSD) sheet for each microbial control agent (including for each ingredient if mixed on-site) and shall conduct an information session with the resident CFIA inspection staff, as arranged with the Veterinarian in Charge, prior to the use of a microbial control agent; and
• Operators shall demonstrate ongoing compliance with applicable federal guidelines and provincial occupational health and safety requirements for concentrations or levels of microbial control agents and their byproducts within the ambient air surrounding the treatment site.

19.5.6.3 Responsibilities of CFIA

CFIA shall supply the operator with a copy of the current federal human safety guidelines for exposure to ambient air concentrations of microbial control agents.

The Veterinarian in Charge or a delegated inspector shall:

• Ensure that all chemical ingredients of the microbial control solution are listed by CFIA;
• Ensure that a copy of the MSD Sheet for the microbial control agent and all chemicals added to the treatment solution are maintained on file; and
• Verify treatment facilities and solution conditions (e.g.: concentration, temperature and immersion/spray time) for compliance with the establishment’s HACCP system and written protocol as specified within the Multi-commodity Activities Program (MCAP).

Note: CFIA staff must not perform actual tests for concentrations of microbial control agents due to potential OSH hazards.

19.5.6.4 Approved Microbial Control Agents and Specific Conditions for Their Use

The following microbial control agents (including conditions of use) have been reviewed by Health Canada and are hereby listed for use on raw poultry carcasses or parts:

19.5.6.4.1 Trisodium phosphate

Trisodium phosphate (TSP) as a pathogen reducing agent may be used for pre-chill or post chill application on raw poultry carcasses based on the following general conditions of use:

• TSP must be dissolved in (recirculated) water to a concentration between 8% and 12% by means of an on-line spray system for the pre-chill drench application or a post-chill immersion/drench application;
• TSP shall not be applied directly into the water immersion chill tanks;
• The TSP treatment solution must be maintained at a temperature between a minimum of 7.2°C (45°F) and up to that of warm carcasses (as freshly eviscerated);
• Collected and recirculated TSP treatment solution must be continuously circulated through a filtration system; and
• Exposure of the carcasses to the TSP solution shall not exceed fifteen seconds (15 sec.) for the prechill or the postchill treatment.

Chlorine may be applied as follows:

• Carcass spray washers / Chiller make-up water Operators may add 20 - 50 ppm total available chlorine in order to reduce the bacteria count on:
  • line-run poultry carcasses;
  • reprocessed poultry carcasses; and
  • in chiller make-up water*.

*Note: A maximum of 5 ppm total available chlorine is permitted in the poultry chiller overflow water

• Automatic poultry evisceration equipment

Carcass contact surfaces of automatic poultry evisceration equipment may be sprayed with water containing 20 - 200 ppm total available chlorine provided the surfaces are well drained prior to contact with poultry carcasses or parts.

19.5.6.4.3 Acidified chlorine

Acidified chlorine (HOCL) is composed of sodium hypochlorite and phosphoric acid. A maximum of 10 ppm total available (acidified) chlorine may be contained in water sprayed on poultry carcasses or parts provided that treatment is followed by a rinse with potable water.

19.5.6.4.4 Chlorine dioxide

Operators may apply Chlorine Dioxide (ClO₂) as per the following requirements:

• the air surrounding and/or within the treatment equipment is exhausted to comply with occupational health and safety requirements.
• An initial validation test of the ClO₂ generation system should verify that the generator effluent contains at least 90% (by weight) of ClO₂ with respect to all chlorine species as determined by an internationally accepted method e.g. as published in "Standard Methods for the Examination of Water and Wastewater".
• In water immersion chillers, the water, may contain up to 50 ppm total available chlorine dioxide such that a maximum of 3 ppm (mg/l) residual chlorine dioxide is detected in the chiller overflow water.

19.5.6.4.5 Acidified Sodium Chlorite Solutions

Poultry carcasses may be sprayed or dipped with acidified solutions of Sodium Chlorite. Treatment solutions shall contain sodium chlorite concentrations between 500 and 1,200 ppm, equivalent to a concentration of 50 to 266 ppm chlorous acid, in combination with a food grade acid at levels sufficient to achieve a solution pH of 2.5 to 2.9.

19.5.6.4.6 Lactic acid

Poultry carcasses may be sprayed with water containing up to 4.25 % lactic acid with or without buffered sodium lactate provided that the acid treatment is immediately followed by a rinse with potable water.

19.5.6.4.7 Ozone

The ozone generator shall not generate ozone into the air, incidental to their normal operation, at a level in excess of 0.05 ppm. Ozone may be used for treating recirculated poultry chiller water. Residual ozone shall be removed (e.g. filtered) from the treated chiller water prior to its contact with edible poultry carcasses or parts.