Annex C: HACCP Based Slaughter Inspection Program (HIP) for Swine
11.0 Rework Procedures for Failed Lot(s)

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The operator shall notify the CFIA when rework procedures are being performed on any detained lot. The frequency of rework procedure monitoring by the CFIA shall be at the discretion of the VIC. Operators and the CFIA shall refer to Appendix E – Decision tree for carcass rework for the details on process actions required for carcass product rework procedures.

The operator has the option to rework the entire lot associated with the FPS test failure (section 11.2) and verify the rework was effective through rework evaluation Or to subject the lot to verification testing (section 11.1). The operator's written program will clearly indicate how plant personnel will:

  • identify lots/sub-lots of carcasses subject to rework procedures;
  • rework or perform verification testing, as applicable to the rework procedure chosen by the operator;
  • evaluate rework; and
  • respond to any failure of the rework procedures.

Lots (sub-lots) under verification testing or under rework evaluation will normally be tested only for those defects that originally failed the FPS test sample set. However, in the case of FPS-FS I, finding of any zero tolerance defects (i.e. not only the FS I defect that originally failed the sample set, but also any other FS I) will fail the lot/sub-lot and lead to rework of the entire lot.

In all cases, any other defect (i.e. FPS-FS or OC defects not associated with the original lot failure) that is detected during rework procedures will also be sanitarily removed but not scored.

11.1 Lot Verification Testing

Under this elective option, the operator will carefully examine

the specific lots of carcasses retained for rework procedures for the presence of the defect that lead to the lot failure (OC) or in the case of FPS-FS I, any zero tolerance defects.

Note:
For FPS-FS I failures, the lot verification testing option can only be used when a failure occurred in Reduced or Normal mode. If the FPS-FS I failure occurred in Tightened mode, lot rework and evaluation must be implemented.

For lot verification testing, the operator will randomly select the specified number of carcasses for verification testing. The sample size should be representative of the entire population and should vary depending on the size of the original failed lot. Table 11.1 provides minimum sample size number of carcasses that shall be collected for the testing. The entire population of the lot shall have an equal opportunity of being selected for testing.

Table 11.1: Minimal number of carcasses to randomly collect for lot verification testing.
Number of carcass units per lot Minimal number of random samples to collect
2-15 2
16-25 3
26-90 5
91-150 8
151-280 13
281-500 20
500-1200 32
  • Rejection criteria: If one or more samples are rejected, regardless the number of carcasses sampled, the lot fails
  • If a defect is found in the lot, the lot will have to be fully reworked. See section 11.2 for the next steps.
  • If the lot is free of defects, the entire lot can be released for further processing.

A responsible plant employee shall inform the VIC/delegate whenever a failure occurs.

11.2 Lot Rework and Evaluation

When rework is to be performed, such as in case of a failure in Tightened mode for FPS-FS I testing or when rework is chosen in lieu of procedures in section 11.1 or when a failure is found during procedures of section 11.1, the operator may choose to rework the lot during the cooling process. Every carcass belonging to the lot shall be reworked at an appropriately equipped rework trim station as per section 12.2.10.

The operator will select one of the following options:

  • 1) The reworked lot may be kept intact or divided into sub-lots. Once the specified lot has been reworked for the appropriate defects, a minimum number of carcasses, as indicated in the table below, will be randomly selected from the reworked lot or sub-lot for evaluation . The entire population of each lot/sub-lot shall have an equal opportunity of being selected for testing. If the lot/sub-lot is less than 25 carcasses, the procedure in Subsection 11.2 (2) shall be followed. The operator must achieve a satisfactory test result before releasing the lot/sub-lot for further processing. All carcasses associated with a lot/sub-lot that failed the test shall be reworked once again. The reworked lot/sub-lot must be re-tested using the same statistical testing procedures and pass the test before the lot/sub-lot can be released for further processing.
    Table 11.2: Minimal number of random carcasses to collect for the rework evaluation.
    Number of carcass units per lot or sub-lot Minimal number of random samples to collect
    25-124 3
    125-149 4
    150-199 5
    200-349 6
    350-499 7
    500-649 8
    650-799 9
    800-949 10
    950-1099 11
    1100-1199 12
    More than 1200 13

    Rejection criteria: If one or more samples are rejected, regardless the number of carcasses sampled, the lot fails

    A responsible plant employee shall inform the VIC/delegate whenever a failure occurs.

  • 2) If the lot is reworked on-line prior to or upon leaving the carcass cooler area, immediately following the rework trim station procedure, every carcass shall be re-examined by an accredited plant employee at a properly equipped station. The plant employee shall verify that those defects that failed the entire lot and all FS I and II defects have been removed from each carcass during the initial rework trimming step. A carcass that fails the evaluation step shall be immediately isolated and reworked or reworked while on line (subject to VIC approval), and no carcass shall be released for shipping or further processing until it has been refurbished to edible standards or alternately deemed inedible. Only those carcasses which have passed both the first and second steps(i.e. trimming and evaluation) may be released for shipping or further processing.

11.3 CFIA Responsibilities for Rework & Rework Verification and Evaluation Testing

The CFIA will periodically monitor the rework procedure to ensure that the establishment is meeting the requirements of the HIP program. The frequency of CFIA rework monitoring shall be at the discretion of the VIC/delegate.

11.4 Voluntary Rework

Due to extraordinary circumstances beyond the operator's immediate control, certain groups of carcasses may be presented with non-food safety conditions on the evisceration floor that significantly bias that group towards failure of the performance standards for Finished Product Standards testing. In such circumstances and at the discretion of the VIC, the operator may request that such a group of affected carcasses be exempted from FPS testing provided the operator agrees to properly identify and retain the affected group for rework as described in this section. The exempted group of carcasses must pose no food safety concerns and the operator must have an established pre-approved procedure for the handling of such carcasses in the company's written program.

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