Form Approved: OMB No. xxxx-xxxx
Expiration Date: xx/xx/xxxx
See OMB Statement on inside cover
Survey
of Meat Slaughter and
Processing Establishments
2014
This
survey applies only to the plant listed on this label.
Refer
to this label as instructed in the survey.
According to the Paperwork Reduction Act of 1995, an agency may not conduct or sponsor, and a person is not required to respond to a collection of information unless it displays a valid OMB control number. The valid OMB control number for this information collection is 0583-XXXX. The time required to complete this information collection is estimated to average 60 minutes per response, including the time for reviewing instructions, searching for existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information.
Send comments regarding this burden estimate or any other aspects of this collection of information, including suggestions for reducing this burden to:
Gary Noyes
Policy Analysis Staff
Office of Policy and Program Development
Food Safety and Inspection Service, USDA
Phone: (301) 504-3672
E-mail: [email protected]
If you have questions regarding your rights as a study participant, you may call RTI’s Office of Research Protection toll‑free at 1-866-214-2043.
The U.S. Department of Agriculture, Food Safety and Inspection Service (USDA, FSIS), has contracted with RTI International to conduct a survey of meat slaughter and processing establishments. This survey, a follow-up to a survey that was conducted in 2004, collects information about industry’s use of food safety technologies and practices. The purpose of this new survey is to understand changes in industry’s use of food safety technologies and practices and to collect accurate, up-to-date information to guide policy making and help FSIS fulfill its regulatory responsibilities with the minimum burden possible to industry.
Participation in this survey is important, and we thank you for your help. This survey research will benefit the meat slaughter and processing industry by improving the agency’s understanding of current industry practices. As a respondent to the survey, you will receive a summary report of the survey results.
Please answer all questions as they pertain to the specific establishment named on the mailing label attached to the front of this survey booklet. By “establishment” we mean all of the buildings and facilities used for slaughter and processing operations within the general area of the address shown on the mailing label.
Please consult with other members of your organization if you do not know the answer to a particular question. Please try to answer all of the questions. For questions that ask for numbers or percentages, your best estimate is acceptable. For purposes of this survey, certain words have particular meanings. For any word printed in bold type in a question, please read the definition provided in the margin near the question.
Participation in this survey is voluntary. The data you provide will be kept secure to the extent permitted by law. Responses to the survey will not be used as the basis of enforcement action against this establishment. We will provide data to FSIS that does not contain identifying information. The study results will be reported to the public only in aggregated form so that individual establishments or firms cannot be identified.
Please return the completed survey within 10 business days in the enclosed postage-paid return envelope, or to RTI International at (address).
Questions? |
If you have any questions as you complete the survey, please send an email to [email protected] or call toll-free at xxx-xxxx-xxxx. We operate the Helpline on weekdays from 9:00 a.m. to 5:00 p.m. EST. |
By pre-harvest we mean
any activity prior to the point of slaughter, including activities
at the farm, feedlot, or slaughter plant.
By probiotics we mean
live microbial feed supplements which beneficially affect the host
animal by improving its intestinal microbial balance.
2. Antibiotics as a feed additive
3. Probiotics as a feed additive
4. Vaccination for Salmonella or Shiga toxin-producing E. coli (STEC)
5. Bacteriophages used on farms
By bacteriophages we
mean viruses with the ability to infect and kill bacteria. This is
administered orally as a spray or as a liquid mixed into feed.
7. Clean and dry bedding for confined operations and holding pens
8. Hide washing before slaughter
9. Other (specify)
10. None of the above
11. Don’t know
By colicin producing E.
coli strains we mean antibacterial proteins produced
by some strains of E. coli that are lethal for related
strains of E. coli.
1. This establishment does not dehide carcasses
2. Skinning knife
3. Air knife
4. Mechanical side puller
5. Mechanical down puller
6. Mechanical up puller
7. Other
1.3 Which of the technologies listed below are currently used by this establishment during slaughter and fabrication operations? Circle all that apply.
1. Bioluminescent testing system for preoperative sanitation checks (“ATP tests”)
2. Conveyor belts made from materials designed to prevent bacterial growth (for example, coated with silver ions)
3. Steam pasteurization systems (for example, the Frigoscandia)
4. Steam vacuum units
5. Organic acid rinse
6. Tempered carcass rinse/wash
7. Positive air pressure from clean side to dirty side
8. Foreign material detection (for example, metal detection equipment, x-rays, visual inspection systems)
9. Equipment for removal of spinal cord prior to carcass splitting
10. Air injection separation of cuts
11. None of the above
1.4 Which of the practices listed below are currently used by this establishment during slaughter and fabrication operations? Circle all that apply.
By written policies and
procedures we mean a document that describes the establishment’s
standard operating procedures.
2. Requires and documents that its animal producers use production practices to control chemical residues (for example, drugs or growth hormones)
3. Rotates sanitizing chemicals it uses in the slaughter area per manufacturers label or per scientific advice
By hazardous chemicals
we mean substances such as pesticides, detergents, sanitizers,
or lubricants.
5. Has written policies and procedures to control the use of hazardous chemicals
6. Has written policies and procedures that require humane handling of animals
7. Applies antimicrobial agents to raw products
8. Removes major lymph nodes
9. None of the above
All answers you give in this
survey will be kept secure to the extent permitted by law. Your best
estimates for product volumes are acceptable.
a. _________ head per hour
b. _________ head per day
By past year we mean
the most recently completed calendar or fiscal year (12 months).
HACCP Product Category |
Example Products |
Does Establishment Produce this Product Category? |
Annual
Production |
a. Raw, intact (raw not ground) |
Whole cuts and steaks, trimmings, mechanically tenderized cuts |
Yes No |
|
b. Raw, non-intact(raw ground) |
Ground beef, ground pork, fresh pork sausage, other raw sausages, preformed raw patties |
Yes No |
|
c. Thermally processed, commercially sterile |
Canned beef stew, canned pasta with meat, canned chili, baked beans with ham, canned soups, canned Vienna sausages, canned luncheon meat |
Yes No |
|
d. Not heat treated, shelf stable |
Fermented sausages, dry sausages, semi-dry sausages, summer sausage, pepperoni, dry salami, uncooked vinegar pickled product |
Yes No |
|
e. Heat treated, shelf stable |
Jerky, snack sticks, popped pork skins, cooked vinegar pickled product |
Yes No |
|
f. Fully cooked, not shelf stable |
Roast beef, hot dogs, luncheon meats, beef pot pie, burritos |
Yes No |
|
g. Product with secondary inhibitors not shelf stable |
Pastrami, corned beef, cured beef tongue, country-style ham, prosciutto |
Yes No |
|
h. Heat treated, but not fully cooked - not shelf stable |
Partially cooked meat patties, smoked sausage, bacon |
Yes No |
|
By further processing
we mean all processing beyond slaughter and fabrication.
1. Yes
2. No Go to Question 3.1 on page 6
By RTE we mean a
product that is edible without additional preparation by the
consumer to achieve food safety, but the product may receive
additional preparation for taste or appearance purposes.
1. Shelf stable ready-to-eat (RTE) products for consumers
2. Not shelf stable ready-to-eat (RTE) products for consumers
3. Raw or partially cooked products for consumers
4. Products that are shipped for further processing to another establishment
2.3 Which of the following practices does this establishment currently use in its further processing operations? Circle all that apply.
1. Stipulates practices for controlling pathogens in purchasing specifications for raw meat
2. Stipulates practices for controlling chemical residues (for example, drugs or growth hormones) in purchasing specifications for raw meat
3. Treats drains with sanitizers for pathogen control
4. Uses chemical sanitizers or hot water for sanitizing hand tools such as knives used in further processing areas
5. Rotates sanitizing chemicals it uses in the further processing area per manufacturers label or per scientific advice
6. Treats food contact equipment and surfaces to remove biomatter during operations
7. Uses antimicrobial treatments for food contact equipment during operations
8. Applies antimicrobial agents to RTE product
9. None of the above
2.4 Which of the following technologies does this establishment currently use in its further processing operations for raw or partially cooked products? Circle all that apply.
1. This establishment does not produce raw or partially cooked products
2. Bioluminescent testing system for preoperative sanitation checks (“ATP tests”)
3. Conveyor belts made of materials designed to prevent bacterial growth (for example, coated with silver ions)
4. Foreign material detection (for example, metal detection equipment, x-rays, visual inspection systems)
5. Irradiation equipment
6. High pressure processing
7. Infrared technology
8. Other types of pasteurization processes (for example, steam and hot water treatments, ultraviolet light, microwave processing)
9. None of the above
2.5 Which of the following technologies does this establishment currently use in its further processing operations for RTE products? Circle all that apply.
1. This establishment does not produce RTE products
2. Bioluminescent testing system for preoperative sanitation checks (“ATP tests”)
3. Conveyor belts made of materials designed to prevent bacterial growth
4. Foreign material detection (for example, metal detection equipment, x-rays, visual inspection systems)
5. Irradiation equipment
6. High pressure processing
7. Infrared technology
8. Post-packaging pasteurization
9. Other types of pasteurization processes
10. None of the above
3.1 In addition to the generic E. coli testing of carcasses and Listeria testing of ready-to-eat (RTE) products required by FSIS regulation, does this establishment conduct microbiological testing?
1. Yes, using a company-owned lab
2. Yes, using an independent commercial lab
3. Yes, using both company and commercial labs
4. No Go to Question 3.5 on page 8
FSIS regulation requires establishments to conduct generic E. coli testing of carcasses and Listeria testing of ready-to-eat (RTE) products. Establishments may conduct other testing of products, equipment, and food contact surfaces that is voluntary. Please answer Questions 3.2–3.5 for voluntary testing that is conducted by this establishment. You may need to consult with other members of your organization or your testing laboratory to answer these questions.
3.2 During the past year, this establishment tested which of the following? Circle all that apply.
By RTE we mean a
product that is edible without additional preparation by the
consumer to achieve food safety, but the product may receive
additional preparation for taste or appearance purposes.
2. Carcasses before fabrication
3. Raw meat after fabrication
4. Lymph nodes
5. Shelf stable ready-to-eat (RTE) products
6. Not shelf stable ready-to-eat (RTE) products
7. Raw or partially cooked products
8. Product contact surfaces
9. Environmental (non-product contact) surfaces
10. Other (specify)
By Non-O157
STEC we
mean a strain of shiga toxin-producing E.coli that is not
O157:H7. Examples include O26, O103, O111, O121, and O145.
1. Aerobic plate count (APC)
2. Total plate count (TPC)
3. Total coliforms
4. E. coli O157:H7
5. Non-O157 STEC
6. Virulence genes (stx, eae, uidA, spi)
7. Enterobacteriaceae
8. Yeasts and molds
9. Bacillus cereus
10. Salmonella
11. Staphylococcus aureus
12. Trichinella
13. Toxoplasma gondii
14. Clostridium perfringens
15. Listeria species
16. Other (specify)
17. None of the above
3.4 During the past year, what microbial indicators and pathogens were tested for by this establishment during fabrication? Circle all that apply.
1. Aerobic plate count (APC)
2. Total plate count (TPC)
By fabrication we mean
the production of half- or quarter-carcasses, sub-primals, or
primals. This does not include ground product.
4. E.coli O157:H7
5. Non-O157 STEC
6. Virulence genes (stx, eae, uidA, spi)
7. Enterobacteriaceae
8. Yeasts and molds
9. Bacillus cereus
10. Salmonella
11. Staphylococcus aureus
12. Trichinella
13. Toxoplasma gondii
14. Listeria species
15. Clostridium perfringens
16. Other (specify)
17. None of the above
3.5 What actions does this establishment take when test results indicated that sampled raw product is presumptive positive for Salmonella and Shiga Toxin producing E. coli (O157:H7 or non-O157 STEC)? Please check all that apply for each pathogen.
Salmonella |
Shiga Toxin producing E. coli (O157:H7 or non-O157 STEC) |
|
|
||
|
||
|
||
|
||
|
||
|
||
|
||
|
||
|
4 Packaging & Labeling
4.1 Does this establishment use any of the following types of modified atmosphere packaging systems? Circle all that apply.
1. Vacuum packaging
2. Mixtures of gases
3. None of the above
Your best estimates are
acceptable.
Type of Packaging and Labeling |
Type of Branding |
Percentage |
Packaged and labeled for consumers |
a. Name brand (also known as national or regional brand name) |
|
b. Store or private label brand |
|
|
Packaged and labeled for foodservice |
c. Labeled with establishment’s own company brand name |
|
d. Labeled with another company’s brand name (for example, restaurant brand) |
|
|
Bulk product for further processing |
e. Labeled for further processing |
|
Other |
f. Specify: ___________________ |
|
Total |
|
100% |
4.3 On average, how often does this establishment update its label?
1. At least twice a year
2. About once a year
3. About every 2 years
4. About every 3 years
5. Less frequently than every 3 years
6. Does not update label
By digital printing we
mean printing directly from a digital image using a laser or inkjet
printer and without the use of printing plates.
1. By an outside company using printing plates
2. By an outside company using digital printing
3. By the establishment or parent company using digital printing
4. Other (specify)
__________________________________________________________________________________
By special statement or
claim we mean a written statement on the label that relates to
the nutrient content of product and its effect on human health,
whether product is organic or natural, how the animal was raised, or
instructional and disclaimer statements concerning pathogens (e.g.,
“for cooking only” or “not tested for E. coli
O157:H7”).
1. This plant does not package products for retail sale
2. None
3. 1 to 25%
4. 26 – 50%
5. 51 – 75%
6. 76 – 100%
By food safety training
we mean training to teach concepts and practices for handling food
to control biological, chemical, and physical hazards.
1. Written food safety training materials are given to new hires
2. Informal, unscheduled on-the-job food safety training
By newly hired, full time
permanent production employees we mean any full time
production employee who has worked at the establishment less than
1 month.
4. Formal food safety course conducted by establishment personnel
5. Formal food safety course administered on a computer at the establishment
6. Formal food safety course conducted by professional trainers
By formal food safety
course we mean a designed course of study that uses prepared
materials and follows a specified outline of content.
5.2 What food safety training is provided for temporary and part-time production employees of this establishment? Circle all that apply.
1. Written food safety training materials are given to temporary hires
By temporary and part-time
production employees we mean those employees that are hired for
temporary periods or part-time to work on the production floor,
including seasonal employees.
3. Scheduled on-the-job food safety training conducted by establishment personnel
4. Formal food safety course conducted by establishment personnel
5. Formal food safety course administered on a computer at the establishment
6. Formal food safety course conducted by professional trainers
By production employees
we mean those employees that work on the production floor, either in
supervisory or line positions.
5.3 How many employees were trained in the past year? Enter zero if none.
|__|__|__|__| newly, hired full time permanent production employees
|__|__|__|__| temporary and newly hired part-time production employees
By continuing food safety
training we mean training provided periodically to employees
that is designed to refresh or extend the initial food safety
training the establishment provides to new hires.
1. Written refresher materials are given to employees
2. Continuing informal on-the-job food safety training
3. Scheduled on-the-job refresher food safety training conducted by establishment personnel
4. Formal, periodic refresher course work conducted by establishment personnel
5. Formal, periodic refresher course work conducted by professional trainers
6. None of the above
5.5 During the past year, what types of training did permanent employees of this establishment receive? For each type of employee, check () each type of training that was received.
Type of Training |
Type of Employee |
|
Management Employees |
Production Employees |
|
a. HACCP |
|
|
By management
employees we mean employees that supervise other
employees, including shift managers and line managers. |
|
|
c. Humane handling |
|
|
d. Recall procedures |
|
|
e. Quality control |
|
|
f. Records and documentation |
|
|
g. Lock out/tag out (LOTO) |
|
|
h. Food defense |
|
|
i. Sampling procedures |
|
|
j. Sanitary dressing |
|
|
k. Good Manufacturing Practices (GMPs) |
|
|
l. Allergens |
|
|
5.7 During the past year, what FSIS resources did this establishment use for training? Circle all that apply.
1. None
2. FSIS Web site
3. CDs/DVDs produced by FSIS
4. FSIS-sponsored workshops/webinars
5. FSIS notices and directives
6. Compliance guidelines
7. Other FSIS resources (specify)
__________________________________________________________________________________
By guidance documents
we mean documents prepared by FSIS to assist establishments with
compliance. For example, FSIS has guidance documents that describe
how to develop and implement sanitation procedures, how to meet
sampling and microbial testing requirements, how to meet validation
requirements, etc. They can be found at
http://www.fsis.usda.gov/wps/portal/fsis/topics/regulatory-compliance/compliance-guides-index
1. During the validation of HACCP systems
2. During the verification of HACCP systems
3. During the development of Sanitation Standard Operating Procedures (SSOPs)
4. Upon receipt of a noncompliance record (NR)
5. Before/during a food safety assessment (FSA)
6. During the training of employees
7. Other (specify)
__________________________________________________________________________________
6.1 What is the approximate percentage of the square footage of the production space of this establishment that is under 5 years old, 5 years to just under 20 years old, or 20 years old or more? Responses should sum to 100 percent.
|
Percentage of Production Space (%) |
a. Under 5 years old |
|
b. 5 years to just under 20 years old |
|
c. 20 years old or more |
|
Total |
100% |
6.2 Who conducts independent, third-party audits of this establishment’s food safety procedures? Circle all that apply.
By audits we mean
review and verification of the establishment’s processes by
independent, third-party auditors.
2. Independent, third-party auditors that are hired by this establishment or by corporate headquarters
3. Independent, third-party auditors that are hired by customers of this establishment
4. Customers of this establishment (for example, food service, military)
5. None of the above
6.3 When independent, third party audits are conducted, which practices are audited? Circle all that apply.
1. Microbiological testing
2. Residue testing
3. Humane handling
4. Sanitary dressing
5. Fabrication
6. Further processing
7. HACCP system
8. Good Manufacturing Practices (GMPs)
9. Sanitation Standard Operating Procedures (SSOPs)
10. Food defense
11. Other (specify)
__________________________________________________________________________________
12. None
6.4 Who conducts independent, third-party audits of this establishment’s humane handling procedures? Circle all that apply.
1. This establishment’s humane handling procedures are not audited by independent, third-party auditors
2. Independent, third-party auditors that are hired by this establishment or by corporate headquarters
3. Independent, third-party auditors that are hired by customers of this establishment
4. Customers of this establishment (for example, food service, military)
5. None of the above
By certification we
mean an accredited third party visits an
organization, assesses its management and production system, and
issues a certificate to show that the organization abides by the
principles set out in the standard.
1. None
2. Global Food Safety Initiative (GFSI) (includes ISO 22000, BRC, IFS, Dutch HACCP, and SQF)
3. Customer-specified requirements
4. Organic certification
5. Other (specify)
By cleaned we mean
removing soil (including food residue) from equipment, utensils, or
other surfaces, usually by suspending the soil in water with the aid
of a detergent. Cleaning is different from sanitizing (the reduction
of bacterial contaminants to safe levels) and from disinfecting
(freeing from infectious microorganisms, typically with the aid of
chemicals).
1. No
2. Yes, it is cleaned between species changes
3. Yes, it is cleaned at the end of the shift
4. Yes, it is cleaned mid-shift
6.7 Does this establishment operate a separate clean-up shift for the slaughter area after the production shift is done? Circle all that apply.
1. No
2. Yes, performed by establishment personnel
3. Yes, performed by contractors
6.8 Is the fabrication area of this establishment cleaned during each production shift? Circle all that apply.
1. No
2. Yes, it is cleaned between product type changes
3. Yes, it is cleaned at the end of the shift
4. Yes, it is cleaned mid-shift
6.9 Does this establishment operate a separate clean-up shift for the fabrication area after the production shift is done? Circle all that apply.
1. No
2. Yes, performed by establishment personnel
3. Yes, performed by contractors
6.10 Approximately how many production employees are employed at this establishment? Provide an average number over the past year for each type of employee. If none, enter zero.
a. Full-time employees |__|__|__|__|
By part time we mean
working fewer than 30 hours per week.
c. Temporary employees |__|__|__|__|
6.11 Approximately how many laboratory employees are employed by this establishment? Provide an average number of full-time employees over the past year. Do not include personnel employed by third-party labs that work onsite at the plant.
a. Full-time employees |__|__|__|__|
6.12 Approximately how many full-time employees at this establishment work in a quality control/quality assurance (QC/QA) department, including food safety?
1. None Go to Question 6.14
2. 1 to 5
3. 6 to 10
4. 11 or more
6.13 For the person who manages the QC/QA department, what percentage of their time is devoted to managing QC/QA activities?
1. 1 to 24 percent
2. 25 to 49 percent
3. 50 to 74 percent
4. 75 to 99 percent
5. 100 percent
By imported we mean
animals born or raised in another country and then transported to
the United States.
1. None
2. 1 to 9 percent
3. 10 to 24 percent
4. 25 to 49 percent
5. 50 to 100 percent
6.15 What percentage of this establishment’s product is exported outside of the United States?
1. None
2. 1 to 24 percent
3. 25 to 49 percent
4. 50 to 74 percent
5. 75 to 100 percent
6.16 Which of the following traceability practices does this establishment currently use in its operations? Circle all that apply.
1. Identifies and tracks its products using a traceable code, by production lot, backward to specific animal supplier
2. Identifies and tracks its products using a traceable code, by production lot, forward to specific customers
3. None of the above
By crisis management we
mean the process by which an organization deals with a major
unpredictable event such as a voluntary food safety recall of
products or a severe weather event.
1. Conducts mock recalls of lot codes delivered to specific customers
2. Conducts mock recalls of lot codes backwards to raw material suppliers
3. Documents mock recall exercises and conducts a self assessment
4. Has a written crisis management program beyond the scope of product recalls
5. Conducts crisis management exercises
6. Has recall insurance
7. Has business continuity plan
8. None of the above
9. Other (specify)
__________________________________________________________________________________
6.18 What was the approximate value of total establishment sales revenue during the past year?
1. Under $249,999
2. $250,000 to $499,999
All answers you give in this
survey will be kept secure to the extent permitted by law. Your best
estimates for sales are acceptable.
4. $1.5 million to $2.49 million
5. $2.5 million to $24.9 million
6. $25 million to $49.9 million
7. $50 million to $99.9 million
8. $100 million to $249.9 million
9. $250 million to $499.9 million
10. $500 million or more
By upgrades we mean the
investment in replacement or updated facilities and equipment.
1. 0-5%
2. 6-10%
3. 11-15%
4. 16-20
5. 21% or more
6.20 During the past year, what portion of the total investment in upgrades and expansions of plant facilities and equipment was related to food safety?
1. 0-10%
2. 11-25%
3. 26-50%
4. 51% or more
Thank you for completing the survey.
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