SOPs / Programs
For Our company
Standard Operating Procedure #1
Live Animal Receiving
Purpose: To ensure that the animals are properly screened for visible signs of injury or disease before slaughter.
Person Responsible:Live Supervisor (duties assigned by Plant Manager)
Frequency: Every incoming shipment of animals
Procedure:
Screen animals for visible signs of injury or disease and report to inspector with problem animals.
Records:Ante-Mortem Record
Corrective Action:
If animals show visible signs of injury or disease, CFIA personnel and animal owners are notified.
Verification:
Meat inspector reviews health of all suspect animals and initials/dates records and corrective actions taken daily on Ante-Mortem Record. Plant manager randomly observes operator carrying out monitoring procedure monthly.
Standard Operating Procedure #2
Poultry Slaughter & Dressing
Purpose: To ensure that the poultry is properly prepared for human consumption.
Person Responsible:Slaughter floor personnel
Frequency: Every animal
Procedure:
- Employees will be dressed appropriately for work in the slaughter area (including wearing a yellow apron)
- Bleeding: prior to scalding, adequate time must elapse following stunning and sticking to ensure proper bleeding (not less than 90 sec).
- Plucking: carcasses are taken off the bleeding line and placed into mechanical plucker. Carcasses are taken out of the plucker and hung on eviscerating line.
- Cleaning of poultry carcasses: hair, feathers, pinfeathers, dirt and scurf must be satisfactorily removed and the carcass thoroughly washed, prior to any incisions being made in the carcass.
- Evisceration: carcasses should be hung in the 3-point suspension position (Broiler chickens and fowl may be hung in the 2-point suspension position). An incision is made and the viscera is left attached to the vent and exposed to allow for thorough visual examination and palpation.
- Heads and necks must not drag over equipment on the evisceration line. All poultry carcasses must be eviscerated so that fecal contamination of any part of the carcass is prevented. A vacuum machine is used to remove kidneys and lungs after the carcass has passed post-mortem inspection.
- Inspection and trimming: (the following is done under direct supervision of inspectors)
- Trimming and removing breast blisters, fractures, contamination and other undesirable or abnormal conditions
- Contaminated birds are placed on salvage rack for further action
- Correcting minor dressing errors
- Contaminated carcasses:
- Carcasses contaminated with grease, fecal material, crop contents may be trimmed with the contaminated parts removed
- Carcasses contaminated with volatile oils, poisons, petrochemicals which may permeate the tissues must be condemned
- Birds placed in the scald tank before they are dead (due to improper sticking) become contaminated as scald water is inhaled. If scald water is observed in air sacs, carcasses must be condemned.
- Removal of oil glands, heads, crops, tracheas and feet: oil glands, heads and feet may be removed from poultry carcasses either before/after evisceration and inspection. Crops and tracheas are removed after evisceration and inspection.
Records:Ante-Mortem Record
Monitoring Procedure:
Review health of animals visually and records information
Reviews records for accuracy (e.g. lot numbers)
Corrective Action:
If animals show visible signs of injury or disease, CFIA personnel are notified.
Verification:
Meat inspector reviews health of all suspect animals and initials/dates records and corrective actions taken daily on Ante-Mortem Record. Plant manager randomly observes operator carrying out monitoring procedure monthly.
Standard Operating Procedure #3
Shipping & Holding Cooler Operation
Purpose: To ensure that the shipping and holding cooler is operated under conditions to minimize any food safety hazard by following GMPs in the holding cooler.
Person Responsible:Shipper or designate
Frequency: Daily
Procedure:
Shipper or designate ensures that holding cooler is operational and properly loaded to ensure that air flow over product is suitable.
Cooler temperature should be 4°C or less depending on product.
Fans should be operational and condensation draining properly from evaporator units.
Floors and walls should be clean and free of debris.
All product should be dated before shipping. Product in containers should be covered prior to entering the cooler.
Records:Pre-operation Checklist
Monitored by: Plant manager
Monitoring Procedure:
- The plant manager observes the conditions in holding cooler.
- The Plant manager determines room temperature and records temperature at Pre-operation to ensure that temperature is less than 4°C.
- The Plant manager visually inspects that product is being handled safely and employee hygiene is monitored to ensure that food safety is not compromised.
Corrective Actions:
If room temperature is above 4°C, Plant manager will inform maintenance lead hand. Plant manager will decide if product safety has been compromised and will ensure that product is removed if required to facilitate maintenance.
If room is unclean, lead hand is informed to ensure that area is kept clean.
Standard Operating Procedure #4
Packing Room Operation
Purpose: To ensure that the packing room is operated under conditions to minimize any food safety hazard by following GMPs.
Person Responsible:All packing room employees
Frequency: Daily
Procedure:
Plant manager ensures that the packing room with its equipment is ready for operation.
Employees will follow good work practices and personal hygiene in the packing room:
- Be dressed appropriately (including a white apron)
- Place cardboard cartons on conveyor or on clean pallet only (not on floor).
- Wash hands before handling product or plastic bags/liners and after handling dirty pallets or equipment.
- Ensure that work surfaces and knives are properly cleaned and sanitized before use and that work stations are kept neat and tidy to prevent accidents.
- Any product in process will be covered during break periods or moved into chill cooler.
- Employees will be designated for different operations
- Only trained employees will be using the labeling scale
- Ensure that the correct label is placed on the cardboard carton
- When using knife, please ensure that a stainless steel glove is worn to protect hands
- Any cuts must be addressed immediately with proper first-aid / cuts to be covered with bandage and glove
- If an employee notices a quality or safety issue, he/she should inform the supervisor in charge of that area.
Records:Pre-operation Checklist
Monitored by: Plant manager
Monitoring Procedure:
- The plant manager observes the conditions in the packing room.
- The Plant manager determines room temperature and records temperature at Pre-operation to ensure that temperature is less than 10°C / product temperature should be 4°C or less.
- The Plant manager visually inspects that product is being handled safely and employee hygiene is monitored to ensure that food safety is not compromised.
Corrective Actions:
If room temperature is above 10°C, Plant manager will inform maintenance lead hand. Plant manager will decide if product safety has been compromised and will ensure that product is removed if required to facilitate maintenance.
If room is unclean, lead hand is informed to ensure that area is kept clean.
If carcasses fall on floor or on a dirty surface, the carcass will be washed immediately and inspected by the lead hand or plant manager. If carcass has been damaged, the damaged portion will be cut away using a sanitized knife and discarded.
Standard Operating Procedure #5
Receiving (Non-Food) Operation
Purpose: To ensure that incoming materials are properly checked and handled under conditions to minimize any food safety hazard by using GMPs in the receiving area.
Person Responsible:Receiver or designate
Frequency: Daily
Procedure:
- Lead hand or designate ensures that area is clean and operational before use.
- Receiving of non-food orders:
- Sign off as received on waybill
- Check that materials received are food grade as per order.
- Store material as appropriate.
Records:Way bill
Monitored by: Plant manager
Monitoring Procedure:
The receiver inspects the interior of transport vehicle for cleanliness and contamination and notes problems on way bill.
The receiver inspects the condition of shipment for contamination and compliance with bill of lading.
Shipment is unloaded and checked for damage.
Shipment is stored as appropriate:
Packaging material is placed in designated area
Chemicals are placed in designated chemical storage area
Corrective Actions:
If inside of transport vehicle or contents are considered contaminated, shipment will not be received into plant.
In the event that product is missing or damaged or not approved, the supervis0r shall immediately be informed. The supervisor shall check the remainder of the load and make a report of “all” deficiencies to Plant Manager or designate..
Verification:
Plant manager will monthly review shipping documents for completeness and inspect any non-conforming shipments for action as necessary.
Standard Operating Procedure #6
Pre-Operation Facility Inspection
Purpose: To ensure that facilities and equipment are properly cleaned, sanitized and in place before operation starts and maintained during operation.
Person Responsible:Plant manager or designate
Frequency: Daily
Procedure:
The Plant manager or designate shall inspect the facilities and equipment in all product areas before operation starts for adequate cleanliness, sanitation and operational condition using the Pre-Operation checklist.
The Plant manager or designate shall inspect the facilities and equipment in all product areas during the shift to ensure that cleanliness and temperature is maintained as required and that employees are following proper personal hygiene and good manufacturing practices
Records:Pre-operation checklist
Monitored by: Plant manager
Corrective Actions:
- Any areas or equipment improperly cleaned and sanitized will be cleaned before operation starts.
- Any stations lacking proper sanitary supplies (e.g. soap, towels, etc.) will be replenished.
- Any employees that are observed not following proper hygiene and good manufacturing practices will be asked to follow proper procedures. If the problem persists, re-training may be required.
Verification: Plant manager will weekly review checklists and randomly audit areas and equipment checked.
Standard Operating Procedure #7
Equipment Calibration
Purpose: To ensure that equipment affecting food safety is properly calibrated at appropriate intervals.
Person Responsible:Maintenance lead hand or designate
Frequency: Every 4 months
Procedure:
- Protocols and calibration methods are established for monitoring devices which may include thermometers, refrigeration unit controls, scales, recording thermometers.
Equipment requiring calibration;
Refrigeration:
Wall thermometers are monitored daily by Plant manager and recorded on the Preoperational check sheet.
The Plant manager, utilizing a digital thermometer, performs random checks of temps via carcass checks, etc.
All thermometers are checked for proper calibration and verified semi-annually by the Plant manager. Adjustable thermometers are adjusted as required and non-adjustable are replaced if more than 2°F over or under. Ice water is used because of the primary operating range of these thermometers except for smokehouse where hot water is used.
Thermometers: Wall thermometers
Recording thermometers - Records in Maintenance file
Pocket thermometers
Scales: Scales are zeroed daily before use. Minimum annual re-certification and more often as required, performed by Maintenance. A 20-kg calibrated weight is available and is used to calibrate scales as required.
Records:Maintenance Calibration checklist
Monitored by: Plant manager
Corrective Actions:
- Adjustable thermometers are adjusted as required.
- Non-adjustable thermometers are replaced if more than 2°F over or under.
Verification: Plant manager will monthly review checklists and randomly audit areas and equipment checked.
Standard Operating Procedure #8
Shipping Operation
Purpose: To ensure that outgoing products are properly checked, handled and packaged under conditions to minimize any food safety hazard by using GMPs in the shipping area.
Person Responsible:Shipper or designate
Frequency: Every shipment
Procedure:
- Shipper or designate ensures that shipping area is clean and operational before use.
- Shipping guidelines for product:
- Carcasses: maintained at 4C or less
- Packaged product: maintained at 4C if fresh or -18C if frozen
- Transport unit must be clean and capable of protecting meat against contamination and freezing if necessary.
Records:Invoices
Monitored by: Shipper or designate
Monitoring Procedure:
The shipper or truck driver inspects the interior of transport vehicle for cleanliness and contamination and notes problems on invoice if necessary.
The shipper or truck driver inspects the condition of shipment for contamination and compliance with invoice.
Shipment is loaded as appropriate and checked for damage.
Corrective Actions:
If inside of transport vehicle or contents are considered contaminated, truck will not be loaded until clean.
In the event that the reefer temperature is too high, trucker is notified to reduce temperature. Loading will not occur until temperature is satisfactory.
Verification:
Plant manager will monthly review shipping documents for completeness and inspect any non-conforming shipments for action as necessary.
Standard Operating Procedure #9
Pest Control Program
Purpose: To ensure that procedures are in place to prevent contamination of product and facilities by rodents and insects.
Person Responsible:Maintenance person or designate
Frequency: Every two weeks
Procedure:
- Maintenance person checks bait stations and traps for activity every two weeks.
- Traps are emptied and reset as necessary.
- Bait stations are checked and new bait added as necessary.
- Tempo is sprayed outside of plant as necessary to reduce insect activity near plant.
Records:Pest control activity log / Bait station and trap map
Monitored by: Maintenance person
Corrective Actions:
If rodent activity is noted, additional bait stations or traps may be added as necessary.
If insect activity is noted, Tempo will be sprayed around plant as necessary.
Verification:
Plant manager will monthly review pest control activity log monthly.
File revised (date)