Guideline Slaughtering/Deboning - QS
←
→
Page content transcription
If your browser does not render page correctly, please read the page content below
Guideline
Slaughtering/Deboning
Version: 01.01.2021
Status: • Release
Contents
1 Fundamentals............................................................................................ 6
1.1 Scope ................................................................................................................ 6
1.2 Responsibilities ................................................................................................ 6
2 General requirements................................................................................ 6
2.1 General scheme requirements .......................................................................... 6
2.1.1 General Business data ................................................................................................... 6
2.1.2 Incident and crisis management ..................................................................................... 7
2.1.3 [K.O.] Commissioning of service providers ....................................................................... 7
2.2 Company management ..................................................................................... 8
2.2.1 Handling of documents .................................................................................................. 8
2.2.2 Company Premises and Access Regulations ...................................................................... 8
2.3 Self-assessment and HACCP ............................................................................. 8
2.3.1 [K.O.] Conducting self-assessment ................................................................................. 8
2.3.2 [K.O.] HACCP concept ................................................................................................. 11
2.3.3 HACCP-Team ............................................................................................................. 12
2.3.4 Product description ..................................................................................................... 12
2.3.5 Flow chart.................................................................................................................. 12
2.3.6 Hazard analysis .......................................................................................................... 12
2.3.7 Critical control points (CCP) ......................................................................................... 12
2.3.8 Control points (CP) ..................................................................................................... 12
2.3.9 Limit values for CCP/CP ............................................................................................... 12
2.3.10 Monitoring and verification of limit values for CCP/CP ...................................................... 12
2.3.11 Corrective actions for CCP/CP ....................................................................................... 13
2.3.12 Responsibilities ........................................................................................................... 13
2.3.13 Documentation ........................................................................................................... 13
2.3.14 HACCP verification ...................................................................................................... 13
2.3.15 [K.O.] Salmonella reduction plan .................................................................................. 13
2.4 Good manufacturing and hygiene practice ...................................................... 13
2.4.1 Water quality ............................................................................................................. 13
2.4.2 Cleaning and disinfection ............................................................................................. 13
2.4.3 Pest control................................................................................................................ 14
2.4.4 Foreign substance management ................................................................................... 15
2.4.5 Production permission ................................................................................................. 16
2.4.6 Maintenance and repair ............................................................................................... 16
2.4.7 Monitoring of Test Equipment ....................................................................................... 16
2.5 Technical/structural condition........................................................................ 16
2.6 Room, equipment and plant hygiene .............................................................. 17
2.7 Ground Clearance ........................................................................................... 17
2.8 Staff hygiene .................................................................................................. 17
2.8.1 General rules of conduct .............................................................................................. 17
2.8.2 Staff rooms and sanitary facilities ................................................................................. 18
2.8.3 [K.O.] Hygiene sluice .................................................................................................. 18
2.9 Training of staff .............................................................................................. 18
2.9.1 [K.O.] Hygiene training/Protection against Infection Act .................................................. 18
2.9.2 Information on the QS scheme ..................................................................................... 18
2.9.3 Manufacturing and work instructions ............................................................................. 18
3 Requirements for slaughtering ................................................................ 19
3.1 General requirements ..................................................................................... 19
3.1.1 [K.O.] Animal welfare officer ........................................................................................ 19
3.1.2 Standard work instruction ............................................................................................ 19
3.2 Monitoring of livestock transport –transport practice ..................................... 20
3.2.1 [K.O.] Check of livestock transport company .................................................................. 20
Version: 01.01.2021
Guideline Status: • Release
Slaughtering/Deboning Page 2 of 43
3.2.2 Delivery..................................................................................................................... 20
3.2.3 Check of certificates of origin ....................................................................................... 20
3.3 Ramp area, stalls, waiting area ...................................................................... 20
3.3.1 Unloading facilities ...................................................................................................... 20
3.3.2 [K.O.] Treatment of animals ........................................................................................ 21
3.3.3 Technical/structural condition ....................................................................................... 21
3.3.4 Room, equipment and plant hygiene ............................................................................. 21
3.3.5 Climate conditions ...................................................................................................... 21
3.3.6 Drinking troughs and feeding ....................................................................................... 21
3.3.7 Resting times ............................................................................................................. 22
3.3.8 Sprinkler system ........................................................................................................ 22
3.3.9 Bay allocation............................................................................................................. 22
3.3.10 [K.O.] Identification of QS farmers................................................................................ 22
3.3.11 [K.O.] Sluice option .................................................................................................... 22
3.4 Slaughtering ................................................................................................... 23
3.4.1 Herding livestock to the stunning area........................................................................... 23
3.4.2 [K.O.] Effective stunning ............................................................................................. 23
3.4.3 Stunning system......................................................................................................... 24
3.4.4 Sticking ..................................................................................................................... 24
3.4.5 Skin/bristle/feather removal......................................................................................... 24
3.4.6 Removal of stomach and chest organs........................................................................... 25
3.4.7 Animal carcass splitting ............................................................................................... 25
3.4.8 Meat inspection .......................................................................................................... 25
3.4.9 [K.O.] Sluice option .................................................................................................... 25
3.4.10 Post-processing line .................................................................................................... 25
3.4.11 Technical/structural condition ....................................................................................... 25
3.4.12 Room, equipment and plant hygiene ............................................................................. 25
3.4.13 [K.O.] Order and organisation ...................................................................................... 25
3.4.14 Cutting utensil hygiene ................................................................................................ 25
3.4.15 Climate conditions ...................................................................................................... 26
3.4.16 [K.O.] Diagnostic data ................................................................................................. 26
3.4.17 [K.O.] Salmonella monitoring ....................................................................................... 27
3.4.18 Logistical slaughtering of Salmonella-positive herds (poultry) ........................................... 27
3.4.19 Turkey slaughtering: participation in PAI monitoring ....................................................... 27
3.4.20 Odour detection .......................................................................................................... 27
3.5 Cold storage (unpacked goods) ...................................................................... 27
3.5.1 Technical/structural condition ....................................................................................... 27
3.5.2 Room, equipment and plant hygiene ............................................................................. 28
3.5.3 Ground clearance........................................................................................................ 28
3.5.4 Stock management ..................................................................................................... 28
3.5.5 Species-specific product separation ............................................................................... 28
3.5.6 [K.O.] Temperature recording and monitoring ................................................................ 28
3.5.7 Cattle quartering ........................................................................................................ 29
4 Requirements for deboning ..................................................................... 29
4.1 Deboning ........................................................................................................ 29
4.1.1 Technical/structural condition ....................................................................................... 29
4.1.2 Room, equipment and plant hygiene ............................................................................. 29
4.1.3 Ground clearance........................................................................................................ 29
4.1.4 [K.O.] Order and organisation ...................................................................................... 29
4.1.5 Handling deviating products ......................................................................................... 29
4.1.6 [K.O.] Temperature recording and monitoring ................................................................ 29
4.2 Labelling and packaging ................................................................................. 30
4.2.1 Technical/structural condition ....................................................................................... 30
4.2.2 Room, equipment and plant hygiene ............................................................................. 30
4.2.3 [K.O.] Packaging material ............................................................................................ 30
4.2.4 [K.O.] Final product control .......................................................................................... 30
4.2.5 [K.O.] Product labelling ............................................................................................... 31
4.2.6 [K.O.] Recipes ............................................................................................................ 31
4.2.7 [K.O.] Sampling plans – final product ............................................................................ 31
Version: 01.01.2021
Guideline Status: • Release
Slaughtering/Deboning Page 3 of 434.3 Meat cold storage (packaged goods) .............................................................. 31
4.3.1 Technical/structural condition ....................................................................................... 31
4.3.2 Room, equipment and plant hygiene ............................................................................. 31
4.3.3 Ground clearance........................................................................................................ 32
4.3.4 Stock management ..................................................................................................... 32
4.3.5 [K.O.] Temperature recording and monitoring ................................................................ 32
4.4 Frozen storage rooms ..................................................................................... 32
4.4.1 Technical/structural condition ....................................................................................... 32
4.4.2 Room, equipment and plant hygiene ............................................................................. 32
4.4.3 Ground clearance........................................................................................................ 32
4.4.4 Stock management ..................................................................................................... 32
4.4.5 [K.O.] Temperature recording and monitoring ................................................................ 32
5 Other plant sections and areas ................................................................ 33
5.1 Cleaning rooms and material storage ............................................................. 33
5.1.1 Cleaning rooms .......................................................................................................... 33
5.1.2 Packaging material storage .......................................................................................... 33
5.1.3 Cleaning and disinfection agent storage ......................................................................... 33
5.1.4 [K.O.] Spice storage ................................................................................................... 33
5.2 Disposal .......................................................................................................... 33
5.2.1 Waste disposal logistics ............................................................................................... 33
5.2.2 Disposal area ............................................................................................................. 34
5.2.3 [K.O.] Slaughtering by-products and risk material .......................................................... 34
5.3 Vehicle fleet .................................................................................................... 34
5.3.1 Washing options for transporters .................................................................................. 34
5.3.2 Cleaning and disinfection ............................................................................................. 34
5.3.3 System for temperature monitoring .............................................................................. 35
6 Purchase, traceability, labelling, use of the certification mark and goods
separation.................................................................................................... 35
6.1 Incoming/outgoing goods .............................................................................. 35
6.1.1 Technical/structural condition ....................................................................................... 35
6.1.2 Room, equipment and plant hygiene ............................................................................. 35
6.1.3 Ground clearance........................................................................................................ 35
6.1.4 [K.O.] Incoming goods inspection ................................................................................. 35
6.1.5 [K.O.] Outgoing goods inspection ................................................................................. 35
6.1.6 [K.O.] Returns management ........................................................................................ 36
6.1.7 Complaints management ............................................................................................. 36
6.2 Labelling and use of certification mark ........................................................... 36
6.2.1 [K.O.] Labelling of marketed QS produce ....................................................................... 36
6.2.2 Use of QS certification mark ......................................................................................... 36
6.3 Traceability and origin of goods...................................................................... 37
6.3.1 [K.O.] Traceability method ........................................................................................... 37
6.3.2 [K.O.] Traceability test ................................................................................................ 37
6.3.3 [K.O.] Reconciliation ................................................................................................... 38
6.3.4 [K.O.] Check on QS eligibility of delivery ....................................................................... 38
6.4 Goods separation ............................................................................................ 38
6.4.1 [K.O.] Separation of QS produce/non-QS produce .......................................................... 38
7 Definitions............................................................................................... 38
7.1 Explanation of symbols ................................................................................... 38
7.2 Abbreviations ................................................................................................. 38
7.3 Terms and definitions ..................................................................................... 39
8 Annexes .................................................................................................. 39
Version: 01.01.2021
Guideline Status: • Release
Slaughtering/Deboning Page 4 of 438.1 Declaration of conformity with the food laws for food packaging made of
plastic (sample form) ..................................................................................... 39
8.2 Determination of pregnancy in female cattle during the slaughter process .... 39
Revision Information 01.01.2021 ................................................................ 41
Version: 01.01.2021
Guideline Status: • Release
Slaughtering/Deboning Page 5 of 431 Fundamentals
You can find basic information on the QS scheme such as organisation, participation conditions, use of
the QS certification mark and sanction procedures in the Guideline "General Regulations".
1.1 Scope
Slaughtering/Deboning of red and white meat (meat, innards and by-products suitable for foodstuff)
Slaughtering/deboning companies are entitled to trade and store QS meat and QS meat products. A
separate certification for the production scope meat wholesale is not required. With the approval on this
stage in the QS scheme they are entitled to produce minced meat and seasoned/marinated meat
products.
The following requirements apply to slaughtering/deboning businesses and relate to all processes that
take place on the production site.
1.2 Responsibilities
The scheme participant is responsible for ensuring:
The compliance with the requirements,
The complete and correct documentation,
The self-assessment,
The adequate and timely implementation of corrective actions,
The correct use of the QS certification mark and product labelling.
The scheme participant must always comply with the requirements of the QS scheme and be able to
demonstrate compliance with said QS requirements. They must ensure compliance not only with the
requirements of this guideline and all related documents (Guideline "General Requirements", Guideline
"Salmonella monitoring pig", Guideline "Salmonella monitoring and reduction programme for poultry
meat production", Guideline “Diagnostic Data in Poultry Slaughtering”, Guideline "Livestock Transport",
Guideline "Certification" and “Paper of incident”) but also with the applicable legal provisions both within
the country in which the QS products are produced as well as the country in which they will be marketed
by the scheme participant.
2 General requirements
2.1 General scheme requirements
2.1.1 General Business data
The following master data must be entered in the database by the scheme participants and always be
kept up to date:
Address of main company and all production sites with EU approval numbers
Company name
Phone number, e-mail address, legal representative, contact
Crisis manager
Details of the type of company and on the production (e. g. slaughtering of red meat, deboning of
white meat, etc.)
Number of slaughtered animals
Details on the working hours
Version: 01.01.2021
Guideline Status: • Release
Slaughtering/Deboning Page 6 of 43In addition, a business overview must be drawn up (existing documentation may be used, e. g. QM or
HACCP), which as well as the information listed above also includes the following data:
All production and storage sites with EU approval numbers (this includes external companies, e. g.
frozen storage; where rooms are shared by several companies, all rooms belonging to the company
must be identified in a business plan.)
Details of existing quality management and audit systems (e. g. ISO 9001, IFS, BRC)
Commissioned laboratories (current address, phone number, e-mail address) and their fields of
analysis
Company overview/QS database
2.1.2 Incident and crisis management
QS has developed a comprehensive crisis management system that ensures the provision of active
support to scheme participants in the event of an incident or crisis. The scheme participants must inform
QS immediately and - where a legal obligation exists - also the competent authorities about critical
incidents and public product recalls where these are of relevance for the QS scheme.
Critical incidents are occurrences that pose or could pose a risk to humans, animals, assets or the QS
scheme as a whole.
In particular, the scheme participants must inform QS in cases in which:
Nonconformities occur in the procurement of goods, or in production or marketing that might pose a
risk to food safety,
Preliminary proceedings are initiated due to violation of regulations to secure food safety or regarding
animal welfare
Investigations are carried out by the media, there are critical reports in the media, or public protests
are held on issues of food safety.
All scheme participants must have access to a paper of incident so that they can pass on all necessary
information in a targeted manner in the event of an incident. Moreover, all scheme participants must
name a crisis officer, and this officer must always be reachable. The name of the crisis officer must be
entered in the QS database.
A procedure of conduct in the event of incidents or crises must be defined and implemented, as well as
verified at regular intervals, but at least once a year (approx. every 12 months).
It must include the following points:
Creation of a crisis team
Emergency call list
Procedure for product recall and return
Communication plan
Customer information
Paper of incident, procedure for conduct in the event of incidents or crises
2.1.3 [K.O.] Commissioning of service providers
Storage
The scheme participant may only commission companies with the storage of QS meat and QS meat
products that have a QS approval which includes the requirements for the storage of meat and meat
products.
Version: 01.01.2021
Guideline Status: • Release
Slaughtering/Deboning Page 7 of 432.2 Company management
The production process must be organised in line with REG (EC) No 852/2004 that contamination of
food stuff is prevented.
2.2.1 Handling of documents
A procedure for archiving the documentation must be in place and applied in the company. All relevant
records must be kept in a detailed and seamless manner. The documents and records of internal
inspections must be retained for a period of at least two years – provided that no longer retention periods
are stipulated by law.
2.2.2 Company Premises and Access Regulations
All buildings and operating facilities must be protected from unauthorized access and be kept closed. For
this reason, an access regulation must be defined. Operating sites in which food is produced or stored
may not be accessible to unauthorized persons. Outside persons may only have access to the operating
areas accompanied by authorization or by permission. All external personnel with the exception of drivers
loading their transport vehicles, must receive instructions prior to entering production areas. If external
vehicles, e. g. livestock transports or disposal vehicles, enter the business premises, the potential risks
involved must be considered.
Access regulations
2.3 Self-assessment and HACCP
2.3.1 [K.O.] Conducting self-assessment
Testing methods – limit and reference values
The specifications of the currently valid version of REG (EC) No 2073/2005 (or equivalent inspection
methods) are used for testing. The adequate analytical reference methods are:
Testing for Salmonella ISO 6579 or PCR
Aerobic colony count ISO 4833 prior to cooling
Enterobacteriaceae ISO 21528-2 prior to cooling
Campylobacter ISO 10272-2 after cooling
Escherichia coli ISO 16649-1 or 2
The company is required to adhere to sampling plans (see tab. 1 and tab. 2). The analysis must be done
accordingly to the standard procedure. A trend analysis must be carried out and measures must be taken
in the event of unsatisfying or negative results.
Examination of carcasses
Sampling frequency
Five samples per week must be taken on one slaughtering day each – with typical distribution over the
slaughtering process – on varying days of the week (rotation principle).
Sampling method
Cattle, calves and pigs
When sampling for Salmonella testing, samples must be taken using an abrasive sponge. Locations
should be chosen where the probability of contamination is greatest (ham, belly, back and jowl at the pig
and rump, flank, brisket and neck at the cattle). The total sampling surface must cover an area of at
least 400 cm2.
Version: 01.01.2021
Guideline Status: • Release
Slaughtering/Deboning Page 8 of 43When sampling to test for Enterobacteriaceae and the aerobic colony count, a choice can be made
between destructive and non-destructive methods in line with REG (EC) No 2073/2005.
The "punching sample" method can be used; it is tried and tested and shows a high rate of bacteria
recovery:
Punching samples: area of 4 x 5 cm2 (to test for Enterobacteriaceae and the aerobic colony count)
If tests are also to be conducted for Salmonella by means of a “punch sample”, the following conditions
must be satisfied:
The responsible food company must prove to the responsible authority that the sensitivity of the
punch sample does not deviate considerably or systematically from that of the prescribed scratching
sponge method and
that the punch sample is a “method with at least equivalent guarantees”.
Sampling is to be executed when entering cold storage or, where electrocution was used, in the post-cold
storage room, provided that no alternative official approval is available.
Poultry
When testing for Campylobacter and Salmonella, sampling must be differentiated according REG (EC)
No 2073/2005 Annex I, Chapter 3.2 whether the tests for Salmonella and Campylobacter are carried
out in one laboratory or in different laboratories.
Note: If limit values are exceeded, in Germany the document “Fleischhygiene zur Prävention
lebensmittelhygienischer Risiken bei der Geflügelschlachtung” (issued by the working group on meat and
poultry meat hygiene and issues relating to foodstuffs of animal origin, available only in German)
provides information for the introduction of improvement measures.
Version: 01.01.2021
Guideline Status: • Release
Slaughtering/Deboning Page 9 of 43Tab. 1: Process hygiene criteria(1) for carcasses after trimming and prior to cooling and meat and meat
products upon the manufacturing process (from REG (EC) No 2073/2005)
Food category Microorganisms Sampling plan(2)/Limit values
Aerobic colony count(3) m=3.5 and M=5.0 log CFU/cm² daily mean log
Enterobacteriaceae (3) m=1.5 and M=2.5 log CFU/cm² daily mean log
Cattle carcasses
n=50(4) and c=2(5)
Salmonella
not detected in the area tested per carcase(6)
Aerobic colony count(3) 4.0 and 5,0 log CFU/cm² daily average log value
Enterobacteriaceae (3) 2.0 and 3.0 log CFU/cm² daily average log value
Pig carcasses
n=50(4) and c=3(5)
Salmonella
not detected in the area tested per carcase(6)
Poultry carcasses n=50(4) and c=7(5)
of broilers and Salmonella spp.(7) not detected in 25 grams of a pooled sample of
turkeys neck skin(3)
n=50(4) and c = 15(8)
Carcasses of
Campylobacter spp. from 1.1.2025: c = 10
broilers
1.000 CFU/g(6)
n=5 and c=2
Aerobic colony count(9)
m=5x105 and M=5x106 CFU/g
Minced meat
n=5 and c=2
Escherichia coli(10)
m=50 and M=500 CFU/g
n=5 and c=2
Meat preparations Escherichia coli(10)
m=500 and M=5.000 CFU/g or cm²
(1)
"Process hygiene criterion": a criterion that specifies the acceptable functionality of the manufacturing process.
Such a criterion does not apply to goods already in the trading process. It is used to define a reference value for the
level of contamination that calls for corrective actions to be implemented when this value has been exceeded in order
to maintain process hygiene in compliance with food law.
(2)
n = number of units comprising the sample; c = number of sample units giving values between m and M
(3)
The limits (m and M) shall apply only to samples taken by the destructive method. The daily mean log shall be
calculated by first taking a log value of each individual test result and then calculating the mean of these log values .
(4)
The 50 samples shall be derived from 10 consecutive sampling sessions in accordance with the sampling rules and
frequencies laid down in REG (EC) No 2073/2005.
(5)
The number of samples where the presence of Salmonella is detected. The c value is subject to review in order to
consider the progress made in reducing the Salmonella prevalence. Member States or regions having low Salmonella
prevalence may use lower c values even before the review.
(6)
m=M
(7)
Where Salmonella spp. is found, the isolates shall be further serotyped for Salmonella typhimurium and Salmonella
enteritidis in order to verify compliance with the microbiological criterion set out in REG (EC) No 2073/2005.
(8)
Satisfactory, if a maximum of c/n values are > m, unsatisfactory, if more than c/n values are > m.
(9)
This criterion shall not apply to minced meat produced at retail level, provided that the shelf life of the product is
less than 24 hours.
(10)
E.coli is used here as an indicator for faecal contamination.
Version: 01.01.2021
Guideline Status: • Release
Slaughtering/Deboning Page 10 of 43Tab. 2: Food safety criteria(1) regarding meat and meat product put into circulation during the shelf-life
(excerpt from REG (EC) No 2073/2005)
Food category Sampling plan(2)/Limit
Microorganisms
values
Minced meat and meat preparations intended Salmonella n=5 and c=0
to be eaten raw(3) not detected in 25 g
Minced meat and meat preparations made Salmonella n=5 and c=0
from poultry meat intended to be eaten not detected in 25 g
cooked(3)
Minced meat and meat preparations made Salmonella n=5 and c=0
from other species than poultry intended to not detected in 10 g
be eaten cooked(3)
Meat products intended to be eaten raw, Salmonella n=5 and c=0
excluding products where the manufacturing not detected in 25 g
process or the composition of the product will
eliminate the Salmonella risk(3)
Meat products made from poultry meat Salmonella n=5 and c=0
intended to be eaten cooked(3) not detected in 25 g
Fresh poultry meat(3) (4) Salmonella typhimurium(5) n=5 and c=0
Salmonella enteritidis not detected in 25 g
(1)
“Food safety criteria”: a criterion which determines the acceptability of a product or a lot of food and which applies
on products in the market.
(2)
n = number of units comprising the sample; c = number of sample units giving values between m and M
(3)
m=M
(4)
This criterion shall apply to fresh meat from breeding flocks of Gallus gallus flocks, laying hens, broilers and
breeding and fattening flocks of turkeys.
(5)
As regards monophasic Salmonella typhimurium only 1,4[5],12:i- is included.
In case that other products are made than the ones in the food categories mentioned above the product
hygiene can also be determined with the following guidance and warning values.
Tab. 3: Reference and critical values of raw beef, raw pork and raw poultry(a) for orientation
guidance value (CFU/g) critical value (CFU/g)
Enterobacteriaceae 1x104 1x105
Escherichia coli (beef and pork) 1x10² 1x10³
Escherichia coli (poultry) 5x102 5x103
Coagulase-positive Staphylococcus 5x10² 5x10³
Listeria monocytogenes(b) --- 1x10²
Pseudomonas 1x106 ---
Salmonella not detected in 25 g
Aerobic colony count
5x106 ---
(pork and poultry)
not seasoned or pre-packaged
(a)
For detection and assessment of L. monocytogenes the requirements of REG (EC) No 2073/2005 must be
(b)
observed.
Sampling plans for surfaces, test results
2.3.2 [K.O.] HACCP concept
The company must develop, apply and maintain a system for hazard control in line with HACCP principles
(REG (EC) No 852/2004) in order to ensure food safety that is comprehensible for third parties.
Version: 01.01.2021
Guideline Status: • Release
Slaughtering/Deboning Page 11 of 43The process from the incoming goods stage to the outgoing goods stage must be such that contamination
of raw materials, partially processed products, finished products, packaging materials, machines and all
other substances coming into contact with the foods is avoided. It must be ensured that effective
measures are taken to minimise physical and/or microbiological and/or chemical contamination.
If changes that are HACCP-related are made to a product, a manufacturing process or a production,
processing, storage or sales stage, the company must review and if applicable modify the HACCP
concept. The thawing and tempering of goods must be considered process-specifically in the HACCP
concept.
Self-assessment records, checklists
2.3.3 HACCP-Team
To develop an efficient HACCP concept, the requisite knowledge must be available. The HACCP-Team
must be documented in a written form. If required, the HACCP-Team must be trained. In this case,
record of the training must be kept.
2.3.4 Product description
A complete description of the product / the article group must be compiled, and the intended purpose
must be defined. This must include:
Composition of the product/the article group
Physical and chemical structure
Antimicrobial/Static treatment
Packaging
Shelf life
Storage conditions
Distribution channels (e. g. foreign countries/inland, status, loose goods/prepacked, etc.).
2.3.5 Flow chart
A schematic flow chart must be prepared. The flow chart must include all operating processes and
product groups.
2.3.6 Hazard analysis
The HACCP concept is based on the determination of hazards that must be avoided, eliminated or
reduced to an acceptable level.
2.3.7 Critical control points (CCP)
Critical control points must be defined if control is required, in order to avoid, eliminate or reduce any
hazards to an acceptable level.
2.3.8 Control points (CP)
Control points must be determined at which measures for monitoring of certain quality and/or hygiene
criteria of goods are required.
2.3.9 Limit values for CCP/CP
Limit values for the critical control points and the control points must be defined with regard to the
avoidance, elimination or reduction of identified hazards.
2.3.10 Monitoring and verification of limit values for CCP/CP
Procedures for monitoring and verifying critical control points and control points must be defined and
implemented. These procedures must be applied regularly.
Version: 01.01.2021
Guideline Status: • Release
Slaughtering/Deboning Page 12 of 432.3.11 Corrective actions for CCP/CP
Corrective measures must be defined if monitoring shows that a critical control point or a control point
exceeds the set limit values.
2.3.12 Responsibilities
Responsibilities must be clearly defined in an organigram.
2.3.13 Documentation
Records suited to the type and size of the abattoir in order to verify that the actions outlined in 2.3.1 to
2.3.12 must be implemented.
2.3.14 HACCP verification
The implementation of the HACCP concept must be checked (verified) at least once a year (approx. every
12 month).
2.3.15 [K.O.] Salmonella reduction plan
A concept for the reduction of Salmonella infection in the slaughtering process (Salmonella reduction
plan) of pig and poultry must be drawn up in line with the HACCP principles and implemented in the
abattoir.
Salmonella monitoring and reduction programme
2.4 Good manufacturing and hygiene practice
2.4.1 Water quality
Irrespective of origin and aggregation state, water that is used for the manufacture, treatment,
conservation or marketing of food as well as the cleaning of objects and facilities that come into contact
with food must comply with the current version of the Drinking Water Ordinance. Drinking water must
be provided in suitable quantities and may not pose any risk of contamination.
A tapping point plan must be present within the company. There must be a risk-based sampling of the
tapping points in accordance with the current version of the Drinking Water Ordinance. The sampling
has to be risk based according to purpose A, purpose B or purpose C of the DIN EN ISO 19458.
Type and frequency are to be defined in the sampling plan of the company.
Tapping point plan
2.4.2 Cleaning and disinfection
Based on a risk analysis, cleaning and disinfection plans must be drawn up that detail the following:
Responsibilities
Used products and their instructions for use
Areas and plants (incl. cooling areas and break rooms) requiring cleaning or disinfection
Cleaning intervals
Recording obligations
Hazard symbols (if required)
Implementation of the cleaning and disinfection plans must be documented.
Cleaning and disinfection proof
Training
Cleaning personnel must undergo training that includes first aid and labelling practices.
Version: 01.01.2021
Guideline Status: • Release
Slaughtering/Deboning Page 13 of 43Requirements for the monitoring of cleaning and disinfection measures The frequency of sampling should be defined according to the size of the company as well as the results of previous analyses. Samples must, however, be taken from at least 10 (up to 30 in large production rooms) different places in the company and spread across the year. Monitoring and assessment of the cleaning and disinfection measures is to be carried out in line other approved procedures (e. g. CEN, ISO). Sampling Sampling should be carried out before the start of production in areas that have a direct influence on product hygiene (e. g. knives, knife sterilizers). Once selected, sample extraction points should be used on an alternating basis. Sampling must be performed in line with a recognised procedure and defined in a sampling plan. Furthermore, the requirements of the current version of the Regulation on the monitoring of zoonoses and zoonotic agents in food law must be considered. Assessment In order to determine the hygienic status of a company, the samples must be tested for aerobic colony count as well as Enterobacteriaceae and Listeria. The assessment should be repeated within 4 weeks. The assessment can be conducted according to the assessment schedule (see tab. 4). Tab. 4: Assessment schedule for monitoring the success of cleaning and disinfection Area Bacteria type Limit Surfaces that get in contact with Aerobic colony count
Within the implementation of pest monitoring and control, measures and qualifications of the user must
comply with the legal requirements of the country as well as the particular product specifications.
Monitoring and bait points need to be controlled at least every month as long as no other control interval
is determined on the basis of a risk assessment. In order to guarantee the safety of the food as well as
that of the employees, suitable pest control methods and pesticides must be used. This pest control
treatment must not endanger the safety of the produced or stored products.
A permanent baiting (without infestation) with rodenticides is only permissible in exceptional cases if the
implementation takes place via a professional and qualified pest controller who meets the legal
requirements of the appropriate country. The exceptional case needs to be proven and documented in
the context of an annual risk assessment of the pest controller. Only baits that are approved for this
purpose may be used, if applicable, different legal regulations apply abroad and must be complied with
accordingly.
The documentation must contain at least the following information:
Information on used products for pest prevention and control
Date of treatment as well as the specification of the applied quantities
Proof that the employees involved in pest control are suitably qualified
Checkpoint plans showing the positioning of monitor- and bait stations
Records of pests found (findings)
Measure plans in case of pest infestation
Documentation of pest control
2.4.4 Foreign substance management
An appropriate and effective foreign matter management has been implemented in the company, which
excludes or reduces the entry of foreign matter into food. Based on risk assessments, hazards and
possible sources of entry must be identified and evaluated for at least the following categories of foreign
matter:
metall
hard plastic
soft plastic
glass
stone
pests
paper
wood
lubricants
lacquers / Coatings (Teflon)
species-specific foreign matter (e.g. bone, cartilage)
In general, foreign matter detectors (e.g. X-ray or metal detectors) should be used, the necessity is
checked in a risk assessment. Detection limits, functional tests (including rejection) for the individual
devices are defined and are demonstrably complied with. For products to be delivered to the final
consumer, a technically possible detection size for metallic foreign matter ofThe responsible employees must be trained regularly on the prevention and control measures.
Documentation of foreign matter management
2.4.5 Production permission
Before production begins each day, a site inspection must take place for the production area to be
approved. An optical check of successful cleaning as well as damages must be performed. This approval
must be documented in a corresponding form.
In case of deviations corrective measures must be defined. Implementation of the corrective actions is
documented.
Documentation of the production permission, Implementation of corrective measures
2.4.6 Maintenance and repair
To guarantee that all processes can be performed in a hygienic and safe fashion, a maintenance plan
including planned maintenance measures must be compiled and implemented for all business premises,
facilities and equipment (e. g. stunning equipment) that serve to ensure or have a direct influence on
product safety. Maintenance work must not compromise food safety. Maintenance and repairment work
must be documented.
The maintenance plan must include the following elements:
(Business) areas and operations rooms
Facilities and (internal) transport systems
Conformity of the used excipients and lubricants
Responsible employees (own staff or from external companies)
Frequency
Maintenance plan, documentation of maintenance and repairment work
2.4.7 Monitoring of Test Equipment
When calibrating and monitoring the functionality of the instruments and devices used as test equipment
(e. g. thermometers), the intervals stipulated by the manufacturers must be complied. If a manufacturer
has not made any specifications in this regard, the test equipment must be calibrated or checked in line
with the perceived estimation of the risk but at least once a year (approx. every 12 months). The
measuring methods of the various test devices must be taken into consideration. The calibration or check
procedure is described for each test device. The results must be documented, and clearly traceable to
each piece of test equipment (incl. deviations, corrective actions). The measuring precision, reliability and
functionality of operational test equipment must be guaranteed.
Proof of calibration and surveillance of measuring equipment
2.5 Technical/structural condition
In line with REG (EC) No 852/2004, Annex II, facilities involved in the handling of food and rooms in
which food products are stored, prepared, treated or processed must be well maintained and clean. They
must be designed and built in such a way that they permit adequate cleaning and/or disinfection, avoid
airborne contamination or reduce it to a minimum level and ensure that sufficient work surface is
available to permit proper and hygienic work steps.
All rooms in which foods are stored, prepared, treated or processed must be designed and built in a way
that ensures proper food hygiene and prevents contamination between and during work steps.
Version: 01.01.2021
Guideline Status: • Release
Slaughtering/Deboning Page 16 of 43The following requirements must be fulfilled:
All floor and wall coverings must be kept in a flawless condition and must be easy to clean and, if
required, easy to disinfect. They must be waterproof, water-repellent and abrasion-resistant and
consist of non-toxic material. Where applicable, floor surfaces must be fitted with a suitable drainage
system. Wall areas must have a smooth surface up to the height that is appropriate for the work
processes that are performed.
Ceilings (or if there are no ceilings, interior roofs) and ceiling structures must be built and treated in
such a way that any accumulation of dirt is avoided and that condensate, undesired mould and the
peeling away of material particles is reduced to an absolute minimum.
Windows and other openings must be designed in a manner that avoids the accumulation of dirt.
Openings extending outward require insect mesh that can be easily removed for cleaning. If opened
windows promote contamination, they must remain closed and sealed during the entire
manufacturing process.
Doors must be easily cleaned, and if required, disinfected. They must have water-repellent and
smooth surfaces.
Surfaces (including equipment surfaces) in areas in which food materials are handled, and in particular
surfaces that come into contact with food, must be kept in a flawless condition and must be easy to clean
and, if required, to disinfect. They must be made of smooth, abrasion-proof, corrosion-proof and non-
toxic material.
2.6 Room, equipment and plant hygiene
All rooms, plants and machines in which foods are stored, prepared, treated or processed must be in a
clean, hygienic and dirt free condition. Pooling of water in "dead areas" and larger patches of corrosion on
the equipment and machines must be avoided. Equipment (knives, saws, etc.) are to be kept functional
and clean.
2.7 Ground Clearance
Products may not come into direct contact with the floor. The goods must be stored and transported in
such a way that there is no risk of contamination. Containers approved for the transport of foods may not
stand directly on the ground and must be kept on pallets or mobile plates.
This does not apply to industrial containers (e. g. BIG Boxes), whose runners and legs are concepted to
be standing on the floor. In case these containers are stacked, internal rules must be followed so that a
contamination is prevented.
2.8 Staff hygiene
2.8.1 General rules of conduct
Documented guidelines must be in place for staff hygiene and communicated to staff during training
sessions. The staff hygiene guidelines must be followed and observed by all persons (employees, service
providers, etc.). The guidelines must at least cover the following points:
Cleaning and disinfection of hands
Eating, drinking, smoking and chewing gum
Steps to be taken in the event of any injuries
Fingernails, jewellery, piercings and watches
Hair and beards
Version: 01.01.2021
Guideline Status: • Release
Slaughtering/Deboning Page 17 of 43Each member of staff must be provided with adequate protective clothing as well as headgear (eventually
beard protection). There must be sufficient options to ensure hand hygiene and instruction signs on use
of the disinfectant. Hand hygiene facilities in the production area must at least fulfil the following
requirements:
Running hot and cold water from hands-free fixtures (sensors/knee switches)
Liquid soap and disinfectant from dispensers
Device for hygienic hand drying
If coat hooks are present, they must be mounted in a suitable and appropriate location.
A process must be in place for the regular monitoring of systematic implementation of staff hygiene in
the company. The findings must be evaluated, and optimisation measures taken where necessary. All
persons whose activities directly affect product safety must have the necessary experience/training.
Procedure for implementation and monitoring of staff hygiene
2.8.2 Staff rooms and sanitary facilities
Staff and external persons must have access to suitable changing rooms. Outdoor and protective clothing
must be stored separately. The sanitary facilities and staff rooms must be in a clean condition. If showers
are available, they must be intact and properly maintained.
2.8.3 [K.O.] Hygiene sluice
All individuals may only enter the production area through an inevitable hygiene sluice (exceptions are
only allowed in the event of an emergency). Shoes and hands must be cleaned and disinfected
thoroughly.
2.9 Training of staff
2.9.1 [K.O.] Hygiene training/Protection against Infection Act
Based on REG (EC) No 852/2004, hygiene training courses are to be held in the company every year
(approx. every 12 month). Documented training programmes must be defined for employees in line with
the product requirements and their areas of activity.
This training plan must contain the following points:
Contents
Training intervals
Participants and trainer
Languages
Staff is to be trained in line with the provisions of the Infection Protection Act and this training must
be documented. Such training courses are to be staged at least once a year (approx. every 12 month).
Training plan and training proof, Instruction/certificate from the health authorities
2.9.2 Information on the QS scheme
All responsible employees must be informed about the requirements of the QS scheme manual. This
includes not only the basic principles of the QS scheme but also the specific requirements in the area of
activity of the employees in question.
2.9.3 Manufacturing and work instructions
Manufacturing and work instructions must be prepared for all relevant processes related to product
safety. The employees must be made aware of the up-to-date instructions.
Version: 01.01.2021
Guideline Status: • Release
Slaughtering/Deboning Page 18 of 433 Requirements for slaughtering
3.1 General requirements
The carcasses form cattle and pigs must be labelled with a consecutive slaughtering number (e. g. stamp
or label).
The requirements of REG (EC) No 1099/2009 on the protection of animals at the time of killing and the
national Ordinance on the protection of animals in connection with slaughter must have been
implemented in the company.
3.1.1 [K.O.] Animal welfare officer
The company must appoint an animal welfare officer. The responsibilities of the animal welfare officer are
defined in the standard work instructions of the abattoir. The animal welfare officer must meet the
requirements of REG (EC) No 1099/2009, Article 17 and perform the tasks outlined in the regulation.
These include:
Monitoring of the animal welfare work of the employees (observation of staff during stunning,
sticking).
Ensure that the inspection and maintenance of the equipment required for stunning and slaughtering
in terms of damage, maintenance level, functionality and electrical specifications is done daily.
Daily inspection and documentation of the stunning success (for cattle and pigs) twice a day or
spread over the day at 10% of the average hourly slaughter rate or at (poultry for) approx. 1% of
the daily slaughter capicity. If necessary, documentation of measures taken.
Obligation to provide proof of competence in handling and care as well as stunning and bleeding of
animals.
Appointment of a deputy with a proof of competence in the handling, care, stunning and bleeding of
animals.
Regular participation in further training (internal/external) at intervals of max. 3 years.
Documentation of measures taken regarding animal welfare.
Reports directly to the management on animal welfare matters.
Ensures that all consignments with animals are checked by a qualified person and that this is
documented and that animals that require special care are treated accordingly.
Ensures that the general wellbeing and state of health of animals in the waiting area/pen is checked
regularly.
3.1.2 Standard work instruction
The standard work instructions must be available for all areas from unloading to bleeding and the form
(e.g. film, pictures etc.) of the handing-over must be regulated. When developing the standard work
instructions for cattle, calves and pigs, the national guidelines according to Regulation (EC) No.
1099/2009 must be observed. In Germany these guidelines "Bewährte Verfahrensweisen für eine
tierschutzgerechte Schlachtung", "Handbuch Tiertransport" and "Handbuch Tierschutzüberwachung bei
der Schlachtung und Tötung" are available in the member area of the VDF or on the homepage of the
FLI. If in the country of the scheme participant no guidelines according to Regulation (EC) No. 1099/2009
are available, guidelines from other EU Member States for the corresponding animal species should be
considered.
The standard work instructions must include the following points:
clear objectives,
responsibilities,
procedures,
measurable criteria and
procedures for monitoring and recording.
Version: 01.01.2021
Guideline Status: • Release
Slaughtering/Deboning Page 19 of 43You can also read
