Operational Code. Processing of Poultry. Part 2 Good Operating Practice. 17 November Issued by the Ministry for Primary Industries

Transcription

1 Operational Code Processing of Poultry Part 2 Good Operating Practice Issued by the Ministry for Primary Industries

2 TITLE Operational Code: Processing of Poultry COMMENCEMENT This Operational Code is effective from date of signing. ISSUING BODY This Operational Code is issued by the Ministry for Primary Industries. Dated at Wellington this 17 th day of November 2017 Judy Barker Manager, Animal Products Ministry for Primary Industries (acting under delegated authority of the Director-General) Contact for further information Ministry for Primary Industries (MPI) Regulation & Assurance Branch Animal and Animal Products Directorate PO Box 2526 Wellington Ministry for Primary Industries Page 1 of 148

3 Contents Page Introduction 4 Part 1: Structure of this Code General Layout of Parts Definitions 9 Part 2: General Requirements Document Control and Record Keeping Personnel Health and Hygiene Personnel Competencies and Training Operator Verification and Notifications Corrective Actions 33 Part 3: Design, Construction and Essential Services Scope Design and Construction of Buildings Design and Construction of Facilities Design and Construction of Equipment Essential Services Water 55 Part 4: Repairs and Maintenance Scope Requirements and Procedures Hygiene Practices Associated with Repairs and Maintenance Maintenance Equipment Maintenance Records 73 Part 5: Cleaning and Sanitation Scope Requirements and Procedures General Cleaning Procedures Cleaning of Areas and Facilities Cleaning of Equipment Cleaning Inspection Cleaning and Sanitation Monitoring Records 84 Part 6: Supporting Systems Incoming Materials Allergen Management Packaging Inventory Control and Traceability Labelling and Identification of Product Storage Transportation 96 Ministry for Primary Industries Page 2 of 148

4 6.8 Non-Complying Product and Recall Calibration of Measuring Equipment Control of Maintenance Compounds Pest Control Waste Materials 107 Part 7: Procurement of Poultry Material 109 Part 8: Primary Processing of Poultry Scope Requirements and Procedures Status of Poultry for Slaughter Hanging and Ante-Mortem Examination Primary Processing of Poultry Material National Microbiological Database Whole Carcass Rinse Sampling 121 Part 9: Secondary Processing of Poultry Scope Requirements and Procedures Whole Birds Maturing or Ageing Boning and Size Reduction Comminution Mechanically Separated Meat (MSM) Formulated Products Assembly, Wraps, Kebabs and Other Value Added Products Metal Detection Secondary Chilling Thawing Shelf life 129 Appendix 1 Schedule 1 Specification for Potable Water Supplied by Operator 130 Appendix 2 Responses to a Water Quality Transgression 139 Appendix 3 Campylobacter Troubleshooting 141 Ministry for Primary Industries Page 3 of 148

5 Introduction (1) The Processing of Poultry Code of Practice (the Code) assists poultry operators that undertake primary and secondary processing of poultry to: a) comply with the requirements of the Animal Products Act 1999 (APA) and relevant subordinate legislation of the Act; and b) process poultry products that are fit for its intended purpose. (2) The requirements in this Code only apply to poultry that is intended to be sold or traded for human consumption. (3) The Code also includes guidance on the recovery of poultry material for animal consumption. (4) Poultry, as defined in the APA and used in this Code, includes chicken, turkeys, ducks, pheasants, quail, guinea fowl, geese, partridges, poussin, pigeons and other game birds. (5) Poultry processors who operate under the Food Act 2014 (a Food Control Plan (FCP)), should use this the Code as guidance material: a) to assist them to establish Good Operating Practices (GOP) when developing new FCPs; or b) when reviewing existing programmes. (6) This Code has been developed by the Ministry for Primary Industries (MPI), in consultation with the Poultry Industry Association New Zealand (PIANZ). Purpose (1) The Code has been developed to assist operators who process poultry products for human consumption to meet the requirements of a Risk Management Programme (RMP). (2) The Code has been developed for primary and secondary poultry operators operating an RMP. It is also a useful resource for secondary processors of poultry who operate under the Food Act 2014 to develop a custom FCP. Background (1) This Code applies to operators that are involved in the primary and secondary processing of poultry which covers, slaughter and dressing of poultry and the cutting, boning size reduction of poultry into products and associated activities such as storage, packing and transportation of products. (2) This Code provides guidance on the procedures and requirements applicable throughout the poultry processing chain covering: a) General Requirements; b) Design, Construction and Essential Services; c) Repairs and Maintenance; d) Cleaning and Sanitation; e) Supporting Systems; f) Primary Processing of Poultry; and g) Secondary Processing of Poultry. (3) Additional parts will be included in this document as and when they are completed: a) Procurement of Poultry Material; b) Further Processing; and c) Products for Pharmaceutical/Technical Use. (4) Operators developing a custom FCP must ensure that they meet the requirements of the relevant legislation under the Food Act The Code identifies processes and procedures that are common to processors under the APA and the Food Act. Ministry for Primary Industries Page 4 of 148

6 (5) on when animal welfare should be considered has been indicated throughout this Code. Detailed animal welfare requirements are contained in the Animal Welfare Act 1999, and its subordinate legislation, including the relevant codes of welfare issued under this Act. All these documents must be read in full. (6) This Code has been developed based on New Zealand requirements only. It does not include overseas market access requirements (OMARs) or general requirements for export. Exporters should ensure they meet all overseas market access requirements relevant for their product and intended market. Who should read this Operational Code? (1) This Code applies to all operators involved in the following activities: a) supply of animal material to poultry operators for the production of poultry products; b) primary processing, i.e. slaughter/killing and dressing of farmed birds; and c) secondary processing of poultry. (2) This Code should be read by: a) poultry RMP operators; b) transport operators; c) evaluators; d) regulators; and e) verifiers. (3) This Code has been developed for processors who operate under the APA and uses terminology that is common to requirements and guidance written to support the implementation of the APA. Where this Code is used as a resource by a custom FCP operator under the Food Act 2014, terms such as RMP operator or RMP verifier may be read as FCP operator or FCP verifier etc. Why is this important? (1) This Code clarifies MPI s expectations on the relevant regulatory requirements. This will assist poultry processors and RMP verifiers to have a consistent understanding of the requirements and their applications. (2) A Code is intended to be a guide on how to meet APA requirements. If an RMP operator incorporates the whole or part(s) of the Code into their RMP, then the incorporated part(s) of the Code becomes mandatory (i.e. it is no longer a guide) and legally enforceable. (3) Poultry processors should comply with the procedures for compliance unless their alternative practices have been: a) documented within the operator s RMP; b) evaluated by a recognised evaluator, if necessary; and c) approved through registration by MPI. Those who wish to use an alternative approach should refer to the RMP Manual for guidance. Document History (1) The Processing of Poultry Code of Practice Part 2: Good Operating Practice replaces the following documents: a) NZFSA Code of Practice Processing of Poultry Part 2: Good Manufacturing Practice, Chapter 2: Repairs and Maintenance, August 2010; b) NZFSA Code of Practice Processing of Poultry Part 2: Good Manufacturing Practice Chapter 3: Hygiene and Sanitation, October 2009; Ministry for Primary Industries Page 5 of 148

7 c) NZFSA Code of Practice Processing of Poultry Part 2: Good Manufacturing Practice Chapter 5: Slaughter and Dressing, April 2009; d) NZFSA Code of Practice Processing of Poultry Part 2: Good Manufacturing Practice Chapter 9: Secondary Processing, April 2009; e) Industry Standard 2: Design and Construction and the Technical Directive: Poultry - Amendments to Industry Standard 2 (Construction and Design) TD 02/055; f) Poultry Industry Processing Standard 5 (PIPS 5) to be revoked on. (2) This revised version also reflects the changes made to the Animal Products Notice: Specifications for Products Intended for Human Consumption issued 1 March Other general updates have also been made. Main Legislation (1) Below is a summary of the legislation under the APA that is most applicable to poultry processing. Web links for documents were current at the date of issue of this Code (note this is not an exhaustive list). These may become out of date. To access all current legislation go to the general link: (2) It is the responsibility of the operator to be aware of and comply with all applicable current legislation: a) Animal Products Act 1999 (APA); b) Animal Products Regulations 2000; c) Animal Products (Contaminant Monitoring and Surveillance) Notice 2015; d) Animal Products Notice: National Microbiological Database Specifications 2016; e) Animal Products (Specifications for the Ante-mortem And Post-mortem Examination of Poultry Intended for Human or Animal Consumption) Notice 2005; f) Animal Products Notice: Specifications for Products Intended for Human Consumption signed 1 st March 2016; g) Animal Products Notice: Specifications for Products Intended for Animal Consumption signed 27 th April 2017; h) Animal Welfare Act 1999; i) Weights and Measures Act 1987; j) Approved Maintenance Compounds; k) Food Act 1981; l) Food Act 2014;and m) Australia and New Zealand Food Standards Code Parts 1 and 2. Other Codes of Practices and Documents (1) The following Codes of Practices have specific requirements and guidance for the processes not covered in this code: a) Further Processing Code of Practice; b) Processed Meats Code of Practice; c) Cold and dry stores Code of Practice; d) Rendering Code of Practice; e) Generic RMP Model: Poultry - and generic RMP for slaughter and dressing of broilers; f) Transport webpage for further guidance: g) Risk Management Programme Manual; and h) for the control of Listeria monocytogenes in ready-to-eat foods available at: Do you want to export? This Code covers the New Zealand standard for primary and secondary processing of poultry under the APA. Export requirements are additional to the requirements described in this Code. Ministry for Primary Industries Page 6 of 148

8 If you are wanting to export poultry products, you are responsible for: a) ensuring you meet relevant NZ standards, e.g. Food Act 2014 or APA; b) complying with the Official Assurances Specifications (OAS) for Animal Material and Animal Products (29 March 2017); c) complying with the importing country s legislation and eligibility requirements (Overseas Market Access Requirements); and d) registering as an exporter. Further information can be found on the MPI website at: If you have questions about exporting poultry products, info@mpi.govt.nz. Ministry for Primary Industries Page 7 of 148

9 Part 1: Structure of this Code 1.1 General (1) This Code is separated into Parts. Each Part specifies requirements and procedures relating to different aspects of poultry processing. (2) This Code sets out the following: a) General Requirements; b) Design, Construction and Building Services; c) Repairs and Maintenance; d) Cleaning and Sanitation; e) Supporting Systems; f) Primary Processing of Poultry; and g) Secondary Processing of Poultry. (3) GOP is essential for the consistent production of poultry products that are fit for their intended purpose and that meet relevant regulatory requirements. It provides guidance on hygienic practices and process control that directly or indirectly impact on the safety and suitability of products. Compliance with these measures will assist operators meet the requirements of the APA, particularly the current version of the Animal Products Notice: Specifications for Products Intended for Human Consumption. (4) GOP is the foundation for Hazard Analysis and Critical Control Point (HACCP) and of RMPs. 1.2 Layout of Parts (1) Parts 2-9 are generally laid out with the following subheadings: Purpose and Scope This describes the purpose and its scope of application. General requirements and procedures General requirements, recommended procedures and guidance information are distinctly differentiated in this document (2) Regulatory requirements, recommended procedures and guidance information are distinctly differentiated in this document. A regulatory requirement is identified by having a citation, at the end of the relevant sentence or clause, of the specific legislation from which the particular requirement is derived from. The word must is also used indicating its mandatory status. For example: All inputs, including raw materials, ingredients, additives and packaging must be handled, processed, and stored in a manner that minimises any potential contamination or deterioration [AP Reg 9]. In many cases, the mandatory requirements have been paraphrased. Operators should refer to the cited legislation for the actual wording of the legal requirement. Poultry processors must comply with all the regulatory requirements. The abbreviations used for legislation cited are: a) AP Reg - the Animal Products Regulations 2000; Ministry for Primary Industries Page 8 of 148

10 b) HC Spec - the Animal Products Notice: Specifications for Products Intended for Human Consumption signed on the 1 st March 2016; c) AM PM Spec - Animal Products (Specifications for the Ante-mortem and Post-mortem Examination of Poultry Intended for Human or Animal Consumption) Notice 2005 and Animal Products (Specifications for the Ante-mortem And Post-mortem Examination of Poultry Intended for Human or Animal Consumption) Amendment Notice 2005; d) AC Spec - the Animal Products Notice: Specifications for Products Intended for Animal Consumption signed on the 6 th October 2014; e) RMP Spec - the Animal Products (Risk Management Programme Specifications) Notice 2008; f) AW Code - Animal Welfare (Commercial Slaughter) Code of Welfare; g) FSC Australia New Zealand Food Standards Code. (3) Industry agreed requirements or recommended procedures are accepted or industry agreed means of achieving or complying with regulatory requirements. To differentiate them from regulatory requirements, the word should is used rather than must. MPI expects RMP operators to comply with the recommended procedures ( should ) that are applicable to their product and process unless they have proposed an alternative process, procedure or parameter that will achieve the same outcome. The operator should be able to demonstrate the validity and effectiveness of any proposed alternative. Any alternative process, procedure or parameter should be documented in their RMP. (4) or supplementary information material is presented in a box. It elaborates on relevant requirements ( must ) or recommended procedures ( should ) and provides explanatory information and options or examples for achieving a particular outcome or requirement. Any table prefaced with guidance is intended to be used as guidance. (5) Records This section gives the list of records that should kept by the operator. 1.3 Definitions (1) In this Code, unless the context otherwise requires: APA means the Animal Products Act 1999 amenities include toilets, wash rooms, locker rooms, change rooms, lunch rooms and cafeterias ante-room means a predefined area that enables the segregation of the animal housing area from the exterior environment approved maintenance compound means any maintenance compound that is approved by MPI or listed in specifications under the APA; and maintenance compound has the same meaning by-product means parts derived from slaughtered poultry other than meat flesh. This includes but is not limited to giblets, feet, neck, offals such as heart, liver, lungs, kidneys, and blood, bone and fatty tissue calibration is the act of checking or adjusting an instrument (scale, thermometers, etc.) against a standard to ensure it is performing with precision Ministry for Primary Industries Page 9 of 148

11 chillers are rooms where food or by-products are maintained in temperature and stored in a chilled preservation state clean: a) when used as a verb, means to remove visible contaminants from any surface; and b) when used as an adjective, refers to an item which is free from visible contamination cleaning is the removal of visible contaminants using physical or chemical aids cold stores are rooms where frozen foods or by-products are stored at the preservation temperature comminution means to reduce in size by methods such as mincing, slicing, dicing but does not include mechanical separation competent person is a person who can be shown to have sufficient experience, training and knowledge to perform the nominated function or task condemn means a decision made by the competent post-mortem examiner, or Animal Products Officer, that the material or products are not fit for human consumption contact surface is a surface in secondary processing area designed to come into direct contact with animal material or product intended for human consumption contaminant means any substance or thing which: a) is undesirable, potentially harmful, or unexpected in a particular product or process; b) is or may be present in, or in contact with, animal material or animal product; and c) contaminated has a corresponding meaning critical measurement means a parameter identified as critical in any specification or regulated control scheme, or a critical limit for a critical control point (CCP) in an RMP dead ends within a pipe system are unused pipe ends which are not routinely flushed within a potable water reticulation system edible support areas has the same meaning as food support facility equipment includes: a) the whole or any part of any utensil, machine, fitting, device, instrument, stamp, apparatus, table, or article, that is used or available for use in or for the preparing, marking, processing, packing, storing, carrying, or handling of any animal material, animal product, ingredient, additive, or processing aid; and b) any utensil or machine used or capable of being used in the cleaning of any equipment or facilities essential services includes the provision of process gases, lighting, ventilation, and water and waste management external environment includes, but is not restricted to, the grounds, roadways, engine rooms, external engineering workshops, water treatment plants, waste treatment facilities, and ponds (if applicable) facilities include amenities, internal engineering workshops, support areas, and processing areas food is any substance, including additives, whether processed, semi-processed or raw, which is intended for human consumption where appropriate Ministry for Primary Industries Page 10 of 148

12 food support facility is any facility: a) through which unprotected food, packaging, personal protective equipment, or processing equipment may pass; or b) where unprotected or wrapped ingredients, packaging, chemicals, personal protective equipment, processing equipment may be held and/or prepared; or c) where processing equipment is cleaned and/or sterilised prior to reuse freezers are rooms or equipment used to initially freeze food and by-products. Freezers reduce food or by-product temperatures to the required preservation temperature further processing in relation to this Code means any heat treatments (such as flash frying/par frying, curing, smoking, and cooking, etc.) and includes any associated crumbing, coating and comminution after the heat treatment. Examples include: commercial sterilisation, drying, smoking, acidification and high pressure processing good operating practice (GOP) means documented procedures relating to practices that: a) are required to ensure poultry material and product are fit for intended purpose; and b) are appropriate to the operating circumstances; HACCP (Hazard Analysis Critical Control Point) is a system adopted by the Codex Alimentarius Commission which identifies, evaluates and controls hazards which are significant for food safety handling means the movement, holding and conveying of food during processing until the food is preserved. Handling will have an equivalent meaning in respect of packaging, chemicals, protective clothing and processing equipment used for or during the production of food hazard means a biological, chemical or physical agent in, or condition of, food with the potential to cause an adverse health effect heavy foot traffic means an area where there is significant movement between areas in a factory or in and out of the facility by many different people (a small number of people moving between work stations in an area does not come within this definition) hygienic status refers to the level of microbial contamination on a poultry material or product or the area in which the products are processed. Products with a higher hygienic status have a relatively low microbial count, e.g. whole birds, compared to other poultry meat types that have a relatively higher microbial count, e.g. poultry offals hygienic envelope is a defined area where exposed product is processed or handled, which may include one or more processing operations that have the same sanitation requirements hygiene is a state of cleanliness as measured by levels of contamination. Hygiene, in relation to: a) processing operations, includes any condition of the production environment, including the condition of equipment that can affect the sanitary status of food during processing; and b) personnel, involves the control of contamination of food by personnel and includes food-borne diseases, clothing and equipment, and the sanitary practices adopted by personnel when in contact with food idle equipment means equipment in the processing area that is used on a periodic basis depending on the specific product being produced impervious gloves includes solid or coated-woven reusable gloves and examination/surgical-type disposable gloves that meet the composition and conditions of use requirements for indirect food additives (polymers) specified in the current US Code of Federal Regulations, Title 21, Part 177 (21 Ministry for Primary Industries Page 11 of 148

13 CFR 177). Refer to the U.S. GPO website available at: ingredient means any substance, including a food additive, used in the processing of food input means any animal material, animal product, additive, processing aid, ingredient, packaging or other associated thing where that associated thing is contained within, attached to, enclosed with, or in contact with, the animal material or animal product lairage means the area where live poultry is loaded in and held prior to slaughter maintenance compound means any substance: a) used for maintaining, repairing, servicing, cleaning, or sanitising equipment or surfaces that may be the source of, or result in, contamination of animal material, animal product or associated things; b) used for treating water; or c) used for pest control minimise to have taken all practical steps to reduce the potential hazard of concern non-product is any area, equipment, personnel or thing that does not have direct or indirect contact with any area, equipment, personnel or thing associated with the slaughter and dressing of animals or the processing, packing, storage or transport of unprotected or wrapped food monitoring (monitor) means checking: a) process parameters (e.g. temperature, ph) are within the limits (both operator and regulatory); b) documented procedures are being followed (e.g. handwashing procedures, load in checks etc.); and c) records are correctly completed monitoring records may include: d) visual and other sensory assessment of equipment and the environment, and e) documented checks of the supporting systems and GOP in action non-complying (non-compliance) means any material or product or input that fails to comply with regulatory requirements non-conforming (non-conformance) means any material or product or input that is suspected or known not to meet operator defined limits/criteria non-product contact surfaces include: a) surfaces not approved for food contact, e.g. walls, structures, fixtures and equipment, columns, floors, door jambs, gantries, scaffolding, steps, rise and fall stands, and certain fixed or coverable equipment; and b) coatings and materials that are not approved for food contact; and c) uncleaned surfaces, e.g. dirty food surfaces, contact points before inspection, contaminated food or personnel, carcasses prior to post-mortem examination, waste water non-potable water is any water that does not conform to the definition of potable water offal means the viscera and trimmings of a poultry removed in dressing operations that may be used for human consumption or animal consumption Ministry for Primary Industries Page 12 of 148

14 operator means an operator who processes animal material or product for human and animal consumption under a RMP outer packaging is the means a container or anything used to enclose packages of final product packaging: a) means any material that is intended to protect and that comes into immediate contact with an animal material or animal product; and b) includes rigid materials such as cartons and containers where animal material or animal product is filled directly into the carton or container; and c) includes any other material contained with, in, or attached to, the animal material or animal product (such as labels, satay sticks and heat sensors) personal protective equipment refers to protective clothing includes aprons, protective sleeves, gloves designed to protect the wearer and the poultry product and material from contamination personnel include employees, cleaners, other workers (e.g. maintenance contractors) and visitors pest is any free living animal which is not part of the normal operation of any premises. The term includes, but shall not be restricted to, cats, dogs, birds, rodents, mammals and insects or any other creatures likely to transfer contaminants to food potable water means water that: a) in relation to water supplied by an independent supplier (including a public or private supplier), is of a standard administered by the independent supplier under the Health Act 1956 and any regulations made under that Act; b) in relation to water supplied by an operator solely for the use of the operator (such as bore water, rainwater, surface water or groundwater): i) is of a standard equivalent to that referred to in paragraph a) as determined by the operator based on an analysis of hazards and other risk factors; or ii) complies with the requirements in Schedule 1 of the HC Spec (reproduced in Appendix 1 in this document); or c) meets the requirements of the current Meat Division Circulars 86/3/2 Surveillance of Potable Water in Meat and Game Export Premises and 86/3/5 Amendment of MDC 86/3/2, 86/14/5 on Surveillance of Potable Water in Meat and Game Export Premises issued by MPI poultry includes chickens, turkeys, ducks, pheasants, quail, guinea fowl, geese, partridges, pigeons and other game birds primary processing includes slaughter and dressing of poultry, and associated activities primary processor means a person who, for reward (otherwise than as an employee) or for purposes of trade: a) slaughters and dresses poultry; processes poultry that are killed wild birds or are killed as if they were wild birds; or b) removes or extracts or harvests any animal material from live poultry for the purpose of processing for human or animal consumption; or c) in the case of: i) a bird, or animal material derived from a bird, if in the opinion of the Minister it is appropriate that the primary processing of that bird or animal material should extend beyond the matters referred to in paragraphs (a) and (b); or ii) any other animal, or animal material derived from any other animal; Ministry for Primary Industries Page 13 of 148

15 processes those animals or that animal material to the extent specified by the Minister by notice in the Gazette after appropriate consultation in accordance with section 163 and after having regard to the following matters: iii) industry practice in relation to the animal material concerned; iv) the degree of processing and number of processing operations required in relation to the animal material; v) the risk factors involved in processing the animal material; vi) whether or not the processing of the animal material is or may be appropriately addressed by any legislative regime other than the APA; vii) such other matters as the Minister considers relevant in the particular circumstances: d) but does not include hunters within the meaning of paragraph (b) of the definition or primary producer process includes kill, slaughter, dress, cut extract, manufacture, pack preserve, transport and store processing aid means a substance listed in clauses 3 to 12 of Standard of the FSC and listed in schedule 18 of the FSC, and which is used in accordance with the Standard processing area is an area where: a) poultry is slaughtered or dressed; or b) unprotected product is processed, packed or temporarily held, including: i) wet processing areas; ii) dry processing areas; iii) thermal processing areas and storage areas or rooms processing period is the longest period of continuous operation before a complete clean down is required. This is normally 24 hours, but can be longer provided the maintenance of sanitary and hygienic conditions is validated in a manner acceptable to MPI and there is no detrimental effect on food safety, product suitability or spoilage programmed maintenance is the scheduled work involving checking, repairing, maintaining altering or constructing equipment, processing areas or the premises protected means sufficiently wrapped, packaged or enclosed to prevent the introduction of contaminants protective clothing means special garments intended to preclude the contamination of animal material or animal product that are used as outer wear by persons and includes head coverings and footwear protective cut-resistant gloves include all chain-mesh gloves, Kevlar or spectra/fibreglass fibrecored seamless knitted gloves ready-to-eat food means a food that is ordinarily eaten in the same state as which it is sold and is not subject to a process that eliminates pathogens, e.g. cooking rendering means the breaking down of animal tissues into constituent fat and protein elements, whether by the application of heat and pressure or otherwise Ministry for Primary Industries Page 14 of 148

16 rework: a) when used as a noun, means product that has been through some or all of the process and is reintroduced at an earlier stage of the process; and b) when used as a verb, means the reintroduction of product that has been through some or all of the process into an earlier stage of the process rinse means to apply water (with or without the addition of processing aids or approved maintenance compounds) to minimise contamination sanitary design: a) in relation to any premises or place, facility, internal structure, equipment, or conveyance, means designed, constructed, and located so that it: i) meets the requirements appropriate to the type of animal material or animal product and process, and which includes consideration of the movement of people, access, process flow; ii) can be readily maintained, cleaned, sanitised, and sterilised where required, to ensure that risk factors from contaminants and pests are minimised; b) in relation to any equipment or access way in any processing area, means that the equipment or access way is designed, constructed and located so that it: i) is easily accessible for maintenance, cleaning, operation, checking, and inspection; ii) minimises the contact of contaminants with any animal material (other than live poultry), or animal product or other equipment; and iii) precludes the harbouring or accumulation of any contaminants or pests sanitise means the application of an appropriate processing aid, approved maintenance compound or physical agent (including sterilising water) to minimise microbial contamination secondary processing, in relation to this Code means any processing and the associated activities beyond the slaughter and dressing of poultry, to the point of further processing. Examples include: cutting and boning, size reduction, portioning and marinating secondary processor means a person who, for reward (otherwise than as an employee) or for purposed of trade, processes animal material at any stage beyond its primary processing up to the point of further processing separate by distance means to separate to such an extent so as to avoid any possible contact, splash, contamination, etc., between specific functions, processes or personnel separate physically means to separate by floor to ceiling solid walls and doors, or to fully protect product/by-product by pipelines, enclosed vats, etc. separate by time means to end one function or process prior to starting a different function or process, and if necessary to avoid contamination with a cleaning operation in between sterilise in relation to equipment, means to clean with water at not less than 82 C at the point of use steriliser means equipment used to sterilise processing equipment store is a facility used for the storing of: a) containers; b) ingredients; c) chemicals; d) packaging; and Ministry for Primary Industries Page 15 of 148

17 e) finished food or by-product that is protected by outer packaging A store may be refrigerated or non-refrigerated and may utilise wet or dry cleaning procedures dependent upon construction standards suitably skilled person means a person who in the opinion of the operator is skilled in a particular activity or task through training, experience or qualifications support area has the same meaning as food support facility swarf is the fine metallic filings or shavings resulting from grinding or cutting of metal transportation outer means a package, other than a transportation unit, that: a) encases any packaged animal material or animal product for the purpose of transportation and distribution; and b) is either removed before the animal product is used or offered for retail sale, or is not taken away by the consumer of the product transportation unit includes vehicles, aircraft, railway wagons, ships, shipping containers, bulk bins, bulk tanks, trailers and any other form of transport used in the transport of animal material or product validation means a process by which evidence is obtained to demonstrate the process operating at defined parameters, is consistently capable of producing animal material or products that meet the requirements to be fit for purpose value-added product is the process of taking raw poultry meat and changing its form to produce a high quality end poultry product verification means a review of operator s procedures and processes to ensure that these are in compliance with regulatory requirements and check that these are being followed. This may include the following: a) monitoring records; b) documented procedures; c) reality check of processing; d) customer complaints; and e) audit outcomes wash means the use of water (with or without approved maintenance compounds) to remove all visible contamination waste material includes, without limitation: a) all solids, liquids and gases that the operator intends to dispose of as being unwanted and that may become a source of contamination; b) process scraps that are not fit for human or animal consumption; c) non-product material; d) waste-water; e) waste product; and f) waste packaging water activity (a w) is the ratio of the water vapour pressure of the food (p) to that of pure water (p o) at the same temperature: a w = p/p o Ministry for Primary Industries Page 16 of 148

18 When a solution becomes more concentrated, vapour pressure decreases and the a w falls from a maximum value of 1 for pure water water management plan means a documented programme that specifies the water quality standard and criteria, and procedures for the management of the water quality within a premises or place to ensure that the appropriate quality of water is delivered at the point of use water reticulation is the system of water supply throughout the premises from the source to the point of use. It includes the source of supply, means of treatment, storage, temperature modifying devices, distribution pipe work, backflow protection devices, etc. (2) References in this Code to subclauses, clauses, appendices and parts are references to subclauses, clauses, appendices and parts of this Code unless otherwise stated. (3) Any term or expression used in this Code that is defined in the APA or Regulations made under the APA and used, but not defined, in this Code has the same meaning as in the APA or Regulations. Ministry for Primary Industries Page 17 of 148

19 Part 2: General Requirements 2.1 Document Control and Record Keeping Scope (1) To ensure that: a) all RMP documents are managed under a document control system so they are current and authorised; b) obsolete documents are removed from use; and c) records are managed Requirements and Procedures (1) Operators must document the following in their RMP: a) processing procedures; b) product and process parameters; c) procedures for monitoring and verifying compliance to established processing procedures and parameters - in particular, critical limits at identified critical control points; and d) corrective actions for any non-compliance or deviation to any regulatory limit or operator-defined limit, procedures, and product and process parameters [RMP Spec 8, 9 and 11]. (2) Operators must maintain accurate records, particularly for the monitoring and verification of product and process parameters critical to product safety [RMP Spec 20 (2)]. (3) Operators should include the following in each of their documented supporting systems: a) purpose and scope; b) authorities and responsibilities; c) procedures (including monitoring, corrective action, preventative action and operator verification); d) records; and e) reference to other relevant documents as applicable. (4) Every document or part of a document that forms part of a RMP must be: a) legible; b) dated or marked to identify its version; c) authorised prior to use, either directly or within the document control system, by: i) the operator; ii) the day-to-day manager of the programme; or iii) a person nominated to do so in the programme s document control system [RMP Spec 19 (1)]. (5) Every document must be available when required to any person with responsibilities under the programme [RMP Spec 19 (1)]. (6) Operators must list all current RMP documents showing the document titles and their current versions and/or dates of issue [RMP Spec 12 (1)] Document Control (1) The operator must implement procedures to: a) control documents and records; and b) ensure that their RMP is up-to-date and reflects actual operations [RMP Spec 19 (2) and HC Spec 9.2 (1)]. Ministry for Primary Industries Page 18 of 148

20 (2) Details of all amendments to the RMP, including significant and minor amendments, must be identified and described in the amendment register [RMP Spec 19 (2)(a) and (b)]. (3) All amended RMP documents or parts must be authorised (and registered in the case of a significant amendment to an RMP) prior to issue and use [RMP Spec 19 (2)(c)]. (4) Amended RMP documents or parts must be replaced with the current versions at all distribution points, without unnecessary delay [RMP Spec 19 (2)(d)]. An amendment register may be presented in a table with the following column headings: document name or reference; details of amendment; reason for amendment; date of change; and approved by. In addition to completing an amendment register, amendments should also be identified in the document itself (e.g. by use of italics, highlighting the amended text, etc.). RMP operators should refer to sections 3.3 and 4.6 of the RMP Manual for more detailed information regarding amendment requirements Record Keeping Procedures (1) The operator must produce records demonstrating that the requirements of relevant animal product regulations, notices and the registered RMP are being met [HC Spec 9.2 (1)]. (2) The operator must ensure that all records are: a) legible; b) stored for four years, or for the shelf-life of the product to which the records relate (whichever is longer); c) stored in a manner which protects the records from damage, deterioration or loss; and d) can be retrieved and made available within two working days of any request [RMP Spec 20 (1)]. (3) Records relating to the RMP s monitoring, corrective action and operator verification activities must include: a) the date and, where appropriate, the time of the activity or observation; b) a description of the results of the activity or observation; and c) the identity of the person(s) who performed the activity [RMP Spec 20 (2)]. (4) Records should accurately reflect any observations taken and remain legible throughout their entire storage period. The requirements given in Part Record Keeping Procedures apply to both paper and electronic records. Dates and times should be recorded appropriate to the activity being monitored. For example, the monitoring of certain critical process time and/or temperatures may require the recording of the exact date and time when the observation is made. Monitoring a more general time period may be acceptable (e.g. shift) for the observation of certain GOP programmes, such as checking for compliance with personal protective equipment requirements. For paper records, consideration should be given to: the durability of paper on which records are kept (e.g. pen does not write well on wet paper); Ministry for Primary Industries Page 19 of 148

21 its suitability for storage (e.g. thermal papers can fade over time); and writing tool used (e.g. pencil is not suitable because it is easy to erase or alter, use specific freezer pens). Any alterations made to records should be made alongside the original entry and initialled by the person amending the record. Single pen strokes should be used to delete errors. White out (e.g. Twink ) is not acceptable to auditors and verifiers as it is not possible to see the original entry. For electronic records, consideration should be given to: systems for backing up the documents and files; security of documents and files; and version control of documents when amending the record Accessibility and Retention of RMP Documents and Records (1) The operator must retain one copy of all obsolete RMP documents and records for four years: a) in a manner that protects the documents from damage, deterioration or loss; and b) prevents confusion with current documents [RMP Spec 19 (3) and HC Spec 9.2 (2)(b)]. (2) The operator should have an effective backup system for maintaining electronic RMP documents and records. (3) The operator must ensure that: a) RMP documents; b) all reference material relating to the RMP; and c) any archived documents are accessible or can be retrieved and made available within two working days of any request to: Records i) recognised persons; ii) Animal Product Officers (or Food Compliance Officers); iii) the Director-General; and iv) persons authorised by the Director-General [RMP Spec 19 (4), 20 (1)(c), 20 (3), HC Spec 9.2 (2)(a) and (c)]. (1) Keep records to demonstrate compliance with document control and record keeping procedures [RMP Spec 20(2)]. (2) Examples of Document Control and Record Keeping records to keep; a) list of the current RMP documents showing document titles and version and/or date of issue; b) all RMP records (including process control, monitoring, corrective action and verification records); c) internal and external audit reports; d) important correspondence with their verifier and with MPI; and e) amendments and obsolete documents. 2.2 Personnel Health and Hygiene Scope (1) To ensure that all personnel are medically fit to perform their duties and that they comply with good hygienic practices so as to prevent or minimise the contamination of poultry and poultry products, other inputs, packaging, equipment, and the processing environment. Ministry for Primary Industries Page 20 of 148

22 2.2.2 Health of Personnel (1) The operator must document and implement personnel health procedures to ensure that any person who is: a) confirmed as or suspected of suffering from or being a carrier of a disease as described in section A, Part 1 of Schedule 1 of the Health Act 1956 that is likely to be transmitted through poultry material, product or associated things; b) confirmed as or suspected of suffering from or being a carrier of another disease or condition of public health concern; or c) suffering from boils, sores, infected wounds or any other condition that cannot be adequately prevented from becoming a source of contamination; does not handle poultry material or product in, or enter, an area where he or she may adversely affect the suitability for processing of poultry material or the fitness for intended purpose of poultry product [HC Spec 4.2 (1)]. (2) The operator should ensure personnel and visitors are aware of and comply with the personnel health procedures. (3) The personnel health procedures should include the following: a) instructions for personnel to inform their supervisor or manager if they are (or suspect that they are) suffering from diarrhoea, acute respiratory infection or diagnosed with an illness as described in clause 4.2 (1) of HC Spec; b) actions to take so that medically unfit personnel do not work as product handlers or enter areas where the person may adversely affect the safety or suitability of any poultry material or product; c) clearance requirements (e.g. submission of medical certificates) for personnel resuming work after being diagnosed with an illness mentioned in clause 4.2 (1) of HC Spec; and d) procedures for treating injuries, wounds or cuts. (4) Any injury, wound, or cut sustained during processing must be treated immediately and dressed with a secure waterproof dressing to prevent contamination of poultry products, packaging or equipment, with blood or other fluid discharge. The dressing must be kept clean and properly secured to prevent it from becoming loose or falling off. Awareness and compliance with heath procedures could be achieved through: pre-employment agreements; ongoing staff education; staff declarations when they resume work after extended periods of leave or premises shut-down; and declarations from contractors and visitors entering the premises. Brightly coloured and metallised dressings are recommended as these can be detected by metal detectors or easily seen in products if they become dislodged Hygienic Practices (1) Operators must ensure that all personnel whose presence or action within processing areas may result in contamination of poultry or poultry product: a) wear appropriate protective clothing, where necessary; b) follow an appropriate personal hygiene routine (refer to Part Hygiene Routines); and c) behave in such a manner as necessary to minimise contamination of poultry and poultry products, other inputs, packaging and the processing environment [AP Reg 12]. Ministry for Primary Industries Page 21 of 148

23 (2) The operator should develop and implement hygienic practices and procedures for all personnel (including product handlers, cleaners, office personnel, maintenance personnel, contractors and visitors) appropriate to their task and area of work. (3) The operator should ensure that all personnel are adequately trained and competent on the required hygienic practices and procedures. (4) The following activities are not permitted inside processing or packing areas: a) eating of any food; b) smoking; c) spitting; and d) any other activity that may be determined by the operator to have the potential to cause contamination of any product or product contact surface [AP Reg 12 (c)] Hygiene Routines (1) The operator should ensure no one works or enters any processing area unless they comply with the hygiene routine. If a person enters a processing area without complying, appropriate corrective actions should be taken, e.g. re-training, warnings, re-cleaning etc.. (2) The operator should implement hygiene routines for personnel when changing between activities of lower to higher hygienic status: a) moving from lairage to primary processing activities; b) moving from primary to secondary processing activities; or c) moving from handling poultry offal to whole carcasses or other cuts of meat. (3) The hygiene routine should include as a minimum: a) a complete change of all product contact personal protective equipment (except overalls which only need to be changed if entering ready-to-eat areas); b) washing and drying, or sanitising (where required) of the hands and arms; and c) washing or changing footwear and personal protective equipment. (4) Personnel should thoroughly wash and dry hands and exposed portions of the arms: a) when entering or leaving any processing or packing areas; b) before handling poultry, poultry product, ingredients or exposed packaging; c) before gloves are put on, and after gloves are removed; d) after any toilet activity; e) when moving from areas or activities of lower to higher hygiene status; f) after hand contamination from sneezing, coughing or touching the face, mouth or nose. Where possible, hands should also be sanitised; and g) whenever they become contaminated (e.g. after handling waste or contaminated surfaces or material). (5) Rubbish bins should be provided for used hand towels in close proximity to the hand wash station and should be emptied as soon as they become full. (6) Personnel handling unprotected product should: a) keep fingernails clean and short; and b) not wear fingernail polish or any other fingernail adornment (e.g. false nails, gel nails, nail art etc). (7) Visible body hair, such as beards, should be covered to minimise contamination of product. (8) Clean hats (e.g. paper, cloth, plastic), hairnets, beard nets, food industry balaclavas or other items should be worn to contain hair on the head and face. (9) Personnel should not wear exposed jewellery that could come into direct or indirect contact with unprotected ingredients and product. Ministry for Primary Industries Page 22 of 148

24 Where possible, the operator should assign personnel to activities where the hygienic status of all procedures they are required to do is the same. Hand-washing and drying should involve the following: cleaning under each fingernail using warm running water, soap and a nail brush; washing hands with warm running water and soap, rubbing vigorously (front, back and between fingers); and drying hands thoroughly (front, back and between fingers). Sanitisers may also be used as part of this process. Single use hand towels are preferable to air driers when drying hands. Operators should set their own policy on acceptable facial hair length. As a guide, facial hair longer than stubble would require containment. Jewellery includes earrings, rings, bangles, bracelets, brooches, necklaces, studs, exposed body piercings and wristwatches. Plain wedding rings (i.e. no stone) and medical alerts may be worn provided they: will not dislodge; are cleaned sufficiently in the same manner as hands; and could be covered by a glove Personal Protective Equipment (1) All personnel who enter any processing or storage areas must wear suitable clean protective clothing and footwear [AP Reg 12 (a)]. (2) Personnel should not take personal items (e.g. sweets, cigarettes, mobile phones and other electronic items) into the processing area, as they may be a source of contamination. (3) The operator should have procedures to ensure personal protective equipment does not become a source of contamination. This includes specific procedures for activities conducted outside processing areas, and staff conducting cleaning activities. (4) Personal protective equipment should be: a) maintained in a hygienic condition; b) made of readily cleanable materials; c) cleaned or changed whenever it becomes a source of contamination during processing; and d) stored in a manner that protects it from contamination. (5) Disposable or damaged personal protective equipment should be: a) discarded after use, when damaged (e.g. torn), or if it cannot be effectively cleaned when required during use; or b) repaired. (6) Street clothing should not be visible over protective clothing or worn over protective clothing. Personal protective equipment generally includes the following: overall or coat, which may be of any colour, provided the presence of any contaminant, relative to the type of work, is clearly distinguishable; hairnets, beard nets; Ministry for Primary Industries Page 23 of 148

25 gloves and sleeves; waterproof apron, as appropriate; and waterproof footwear. Personal protective equipment that comes in direct contact with unprotected product should be stored in a dedicated storage area when not in use. The colour of protective clothing should make visible contamination (relative to the type of work) clearly distinguishable Gloves (1) Gloves should be clean before use, and should be cleaned or replaced: a) between tasks (e.g. after handling raw product and before handling cooked product etc.); and b) whenever gloves become visibly contaminated. (2) Cleaning of the following type of gloves should be at a frequency specified in the cleaning and sanitation programme: a) protective gloves (including the web-strapping at the top of chain-mesh gloves); b) gloves designed for handling frozen or chilled product (i.e. woollen gloves); and c) reusable impervious gloves. (3) Product scraps should be removed from gloves before gloves are placed in a sanitiser. (4) Protective cut-resistant gloves should be sanitised unless they are covered by an impervious glove. If covered by an impervious glove, then only the impervious glove should be cleaned or changed. (5) Impervious gloves should be discarded whenever the impervious surface is punctured, or becomes damaged such that they cannot be adequately cleaned. Refer to Part 5 Cleaning and Sanitation for cleaning frequencies. If gloves are inspected and remain impervious, they may be reused during the processing period, provided they are effectively cleaned while on the hand. The full sanitation programme should achieve a microbiological outcome at least equivalent to that of clean hands (for aerobic plant count (APC) this is 1 x 10 4 cfu/cm 2 ). The following sanitation programmes will achieve the microbiological outcome above for gloves: All protective cut-resistant gloves: i) soak in quaternary ammonium sanitiser overnight using dilutions recommended by the manufacturer; and ii) rinse with warm water prior to use. Chain-mesh gloves: i) hose with hot water to remove visible soil, soak in alkaline cleaner following the manufacturer s instruction; and ii) soak in 90 C water for no less than 15 minutes, rinse with hot water, and hang to dry in a glove cabinet. Knitted gloves: i) hose with hot water to remove visible soil, soak in quaternary ammonium sanitiser following the manufacturer s instruction; ii) rinse with hot water; and Ministry for Primary Industries Page 24 of 148

26 iii) hang to dry in a glove cabinet Personnel Movement (1) Personal protective equipment directly in contact with product should not be taken into any toilet areas. (2) People handling unprotected product should wear waterproof sleeves over fabric sleeves, unless fabric sleeves are rolled up to above the elbow and hands and arms are washed. (3) People handling unprotected product in wet processing areas should wear a clean waterproof covering that covers the potential food contact zone. (4) Personal protective equipment should not be worn outside the RMP boundary. Covering of the potential food contact zone will, in the majority of cases, only require a coat that covers the body to below the knee. For example, for personnel working at tables, the potential food contact zone would be from the shoulder line to below the level of the work surface Records (1) Keep records to demonstrate compliance with the requirements [RMP Spec 20 (2)]. (2) Examples of Personnel Health and Hygiene records to keep; a) illness records, including sighting of medical certificates prior to personnel returning to work (when required); b) declarations of understanding of the operator s health procedures by personnel; c) declarations of health by personnel; d) registers for injuries; e) staff training records of health practices and procedures; and f) visitors logbook. 2.3 Personnel Competencies and Training Scope (1) To ensure personnel have the knowledge and skills necessary to perform their assigned tasks effectively, and comply with hygienic practices and procedures, so that poultry products are fit for intended purpose Requirements and Procedures (1) The operator must identify the following (either by position, designation or name) in their RMP: a) the day-to-day manager or person responsible for the day-to-day running of the RMP; b) the person(s) who authorises all or parts of the RMP document; and c) personnel involved in process control, monitoring, corrective action and operator verification activities [RMP Spec 15 (1)]. (2) The operator must document the skills or competencies needed by the persons identified above to enable the effective operation of the RMP [RMP Spec 15 (2)]. These competencies should be documented in job descriptions. The day-to-day manager or person authorising all or part of the RMP should be familiar with the RMP and have the following attributes: Ministry for Primary Industries Page 25 of 148

27 good knowledge of product safety, and hygienic procedures and practices written in this Code; good knowledge of regulatory requirements relevant to the development and implementation of RMPs and poultry processing; have technical knowledge and experience in the processing or manufacturing of poultry; and effective organisational and communication skills. The person responsible for the development and review of the HACCP application within the RMP should have a good understanding of the HACCP principles and how they are applied to the processing or manufacturing of poultry. Personnel involved in process control, monitoring, corrective action activities and operator verification should have: appropriate level of knowledge and skills in implementing their assigned task; and a good understanding of, and be able to consistently comply with, hygienic practices and procedures Ante-Mortem and Post-Mortem Examiners (1) Operators involved in slaughter activities must ensure that persons responsible for the ante-mortem or post-mortem examination of farmed poultry meet specific qualifications outlined in the current version of Animal Products (Specifications for the Ante-mortem and Post-mortem Examination of Poultry Intended for Human or Animal Consumption) Notice. (2) Trainee ante-mortem and post-mortem examiners may carry out ante-mortem or post-mortem examinations provided they are under the direct supervision of a person who meets the competency requirements of clause (1) of HC Spec and who is accountable for the decisions that are made [HC Spec 5.3 (3)] Skills Maintenance (1) The operator must ensure that the skills of those persons involved in the following are maintained on an ongoing basis: a) process control and monitoring; b) corrective action; c) operator verification; and d) if applicable, activities given in Part [HC Spec 5.3 (1)] Training (1) The operator should develop a training programme which includes: a) the identification of skills and competencies required for key roles; b) training schedules (including refresher training); and c) training records of all personnel. (2) All personnel, including temporary workers, service contractors and administrative staff, should be appropriately trained before commencing work. (3) The operator should provide induction training to all new workers and ensure that they are supervised until they are adequately trained to perform assigned tasks and procedures on their own. (4) The training programme should be reviewed at least annually to: a) ensure that training of workers remains up-to-date and effective; and b) identify requirements for new training or refresher training. Ministry for Primary Industries Page 26 of 148

28 Training should be appropriate to the nature of the person s assigned task or activity and level of responsibility. Training includes; induction training, regular in-house meetings, on-the-job training and external training courses. Induction training should cover job or task descriptions, health requirements, and hygienic practices. Basic training for all process personnel should cover: health and personal hygiene; movement of personnel and materials; cleaning and sanitation; handling of chemicals; and hygienic handling of materials and products. Personnel should also be trained against written instructions or procedures for their specific tasks, including machine operation and monitoring of product and process parameters. Specific training requirements, where applicable, such as training in HACCP, monitoring procedures and internal auditing, should also be identified Records (1) Keep records to demonstrate compliance with the requirements [RMP Spec 15 (3) and 20 (2)]. (2) Examples of Personnel Competencies and Training records to keep; a) assessments and evidence of personnel competencies; b) individual training records; c) identity of both internal and external training providers; d) competency of trainers; and e) any training materials (e.g. manuals or instructions). 2.4 Operator Verification and Notifications Scope (1) To ensure that the RMP continues to be effective and that MPI or the verifier is notified of issues as required Requirements and Procedures (1) The operator must develop and implement a verification programme, which includes: a) the activities to be performed and their frequencies; b) procedures or methods used (who, what, when, where, how); c) corrective actions to be taken when there is a non-compliance; d) corrective actions to be taken when all or part of the RMP is ineffective; and e) any recording and reporting requirements [RMP Spec 16 (1)]. (2) The operator should review verification records for repetitive defects or non-compliance trends. They should investigate, correct and prevent the causes of identified trends and repetitive non-compliances. (3) The operator should document and implement the verification procedures that make up their verification programme. Ministry for Primary Industries Page 27 of 148

29 Operator verification includes several types of activities that together will provide the operator (and the verifier) with confidence that the RMP and GOP are working effectively. Operator verification activities are not restricted to internal verification audits by the operator. Although internal verification audits are important, they need to be completed in conjunction with information from the day-to-day operator verification and monitoring of the process. Daily and/or ongoing operator verification activities: routine surveillance and monitoring checks (e.g. daily process control); reality checks of processing; specific monitoring of process parameters or CCPs; monitoring record reviews; product sampling results may provide evidence of how the system is working; general oversight and supervision of the operation; and identifying issues and transferring those to the corrective action system if necessary. Scheduled operator verification activities: internal verification audits usually an RMP operator will have a schedule of internal operator verification audits which covers all systems at least annually. The outcome of the internal audit should be used to schedule the next internal audit. RMP review an RMP operator should review their RMP at least annually: this check should include the following; has there been any significant changes to the process, equipment, building, products, staff in positions of responsibility, verifier etc.? HACCP application review usually an RMP operator will review their HACCP applications at least annually: this check should include a check of the process flow, inputs or outputs and possible hazards. Corrective action system Some RMP operators will use a central register for all non-compliances which will simplify tracking of corrective and preventative actions. Identifying the root cause of defects or issues will ensure that corrective actions are effective. Repetitive issues may result from: poorly maintained equipment or processing environment; poor control of the process; inadequately trained staff; lack of resourcing; lack of supervision; or poor standard of operator verification Internal Audits and Reviews (1) Observations made during internal audits and corrective actions taken must be recorded [RMP Spec 16 (1)]. (2) The operator must ensure that, wherever possible, persons carrying out operator verification are independent of the activities being verified [RMP Spec 16 (2)]. (3) The operator should document and implement an internal audit programme. (1) Internal audits or operator verification activities should be undertaken by a suitably skilled person at a frequency sufficient to: a) ensure ongoing compliance with the documented RMP procedures; and b) enable prompt identification of non-compliances. Ministry for Primary Industries Page 28 of 148

30 Internal audits should consist of the following: person(s) responsible for conducting the audit; audit schedule specifying when each programme is to be checked; audit process; audit scope; a review of written procedures; review of records; a reality check of the programme being audited; confirmation that deficiencies or non-compliances identified from the last internal audit have been rectified; and a clear description of when corrective action must be taken. The person responsible for undertaking internal audits should have: auditing skills; a good understanding of the operations, processes and supporting systems covered by the RMP; be independent from the procedures being audited; and have a good understanding of relevant regulatory requirements. The frequency of internal audits of the different parts of the RMP programmes should be determined by the operator, considering various factors such as: the importance of the particular programme on product safety, suitability and hygienic operations; the frequency of non-compliances; the effectiveness of the programme; and skills and training of personnel implementing the particular programme. To achieve this it is recommended that every month a different programme is audited at random or based on past audit outcomes or the premises Performance Based Verifications (PBV), e.g. pest control, waste disposal. The operator should have a process to increase the frequency of audits when repetitive non-compliances occur or the programme is found to be ineffective, and perform root cause analysis. All non-compliances found at previous internal and external audits should be followed up using a noncompliance system Reviewing Documents and Records (1) A review of the relevant parts of the RMP should be undertaken when: a) a change is made to a product, process or the premises; or b) there are indications that certain programmes or procedures are ineffective. Written procedures should be reviewed and updated to ensure that they: are up-to-date with current legislation and standards; and reflect reality. The RMP review may be undertaken as a single operation or staggered throughout the year based on an established timetable (e.g. review certain parts of the RMP each month). Indications that the RMP or parts of it are not working effectively include: a series or trend of non-compliance or out of specification product test results; Ministry for Primary Industries Page 29 of 148

31 customer complaints; product recall; or failed external verification audit. Records should be reviewed for: completeness and accuracy of required information; appropriateness of corrective actions taken; any trends, new hazards, recurring problems; and compliance with documented control procedures Reality Checks or Visual Inspections (1) Reality checks should be made before, during processing operations, and as a part of the internal audit: a) a pre-operational hygiene check programme; b) an inspection during processing of poultry material; and c) a reality check of the programme under internal audit review. (2) The reality check programme should include: a) person(s) responsible for conducting the check; b) frequency of the checks; c) areas to be checked, including processing, associated food support areas and equipment; d) hygiene standards expected in each area, and for equipment; and e) a clear description of when corrective action must be taken and what outcome is expected. (3) The reality check during processing (including GOP) should monitor that an adequate state of hygiene is maintained during processing and personnel are using appropriate hygienic practices. Reality checks should include observations of : workers performance and compliance to hygienic practices and process control procedures; compliance to established process parameters such as processing times and temperatures; and the hygienic status of the premises internal and external environment, facilities and equipment Pre-Operational Check (1) The pre-operational check programme should monitor that: a) all equipment is ready and fit for processing; and b) an adequate state of hygiene exists: i) in facilities before processing begins; or ii) after repairs and maintenance activities. (2) If a pre-operational check shows a problem: a) fix the source of the contamination (immediately if there is a food safety risk); b) increase the frequency of cleaning sufficiently to manage the problem; and c) correct equipment deficiency. (3) Observations made during pre-operational inspection and corrective actions for any non-compliances identified should be documented in an appropriate check sheet or record form. Pre-operational inspections are not required on the external environment or dormant areas of the premises (e.g. areas not being used or only used for access to other functioning areas). Ministry for Primary Industries Page 30 of 148

32 The person responsible for doing pre-operational checks should: have good knowledge of the cleaning methods and the criteria for assessing cleanliness; be able to assess the potential effect of particular defects on product safety and determine appropriate corrective actions for any non-compliance; and have a knowledge of processing to assess the equipment for deficiencies Ingredient and Product Testing (1) Where appropriate and necessary, product testing should be done to verify compliance to relevant regulatory limits or operator-defined limits written in the RMP. (2) Samples of products should be: a) representative of the particular batch or lot of product or ingredient being tested; b) hygienically collected by a person who has appropriate training and/or experience; and c) held and transported under conditions which will not affect the particular parameter that the ingredient or product is being tested for. (3) Any in-house testing for chemical and physical parameters (e.g. moisture content, water activity and/or ph) should be done using standard methods by a person who has appropriate training and/or experience in the particular test. The operator should document the product testing programme and should include information on: products or ingredients to be tested; frequency of testing; number of samples; tests to be done; the identity of the suitably skilled person or laboratory that will perform the tests; and corrective actions to be taken Notification Procedures (1) Notify the Director-General in writing, without unnecessary delay, of any change to the name or position or designation of the person(s) responsible for the day-to-day management of the RMP [RMP Specs 13 (1)]. (2) Document procedures for notifying the Director-General of any emerging, new or exotic biological hazards or new chemical hazards that come to the operator's attention in relation to the RMP without unnecessary delay [RMP Specs 13 (2)]. (3) Document procedures for notifying the recognised RMP verifying agency in writing, without unnecessary delay, of the following issues relating to the operation of the RMP: a) any significant concern about fitness for intended purpose of any poultry product; b) where the cumulative effect of minor amendments necessitates the registration of a significant amendment to the RMP; c) where the RMP is considered to be no longer effective; d) where the premises are not or are no longer suitable for their use; and e) where anything within the physical boundaries of the RMP is used for additional purposes or by other operators and the RMP has not adequately considered relevant hazards or other risk factors [RMP Spec 13 (3)]. (4) Ensure your RMP is amended (except where they are done on a trial basis and the affected poultry product and/or material is not traded) when: a) making major alterations to the processing facilities or equipment and sometimes the boundaries; b) relocating processing operations to a new physical address; Ministry for Primary Industries Page 31 of 148

33 c) processing animal material or animal product that is not covered by the RMP, except: i) where the product and process are similar, and ii) a documented risk factor identification and hazard analysis has shown that all risk factors associated with that animal material or animal product are already adequately addressed by the RMP. d) setting up a new process or process modification that is not covered by the RMP, except: i) where the process or process modification is similar to existing processes; and ii) a documented risk factor identification and hazard analysis has shown that all risk factors associated with that process are already adequately addressed by the RMP. e) making any other changes that introduce new risk factors, or adversely impact on existing risk factors; f) merging 2 or more registered RMPs; g) splitting a registered RMP into 2 or more RMPs; and h) adding a business to a multi-business RMP except where the Director-General s approval under section 17A of the Act applies to a type of business, premises or place rather than to specific businesses [RMP Spec 22]. If you need to amend your RMP, the amendment will either be classified as significant or minor. Information on amending an RMP can be found in the RMP Manual. If you are exporting and considering undertaking more activities, check with the relevant export requirements e.g. Overseas Market Access Requirements (OMARs) if those activities can be undertaken within your RMP Non-compliances (1) Non-compliances identified during verification activities should be rated according to their potential to affect food safety. This is done by considering the nature of the non-compliance and the proximity to product or processing operations. For further guidance on non-compliances, refer to Part 2.5 Corrective Actions Records (1) Keep records to demonstrate compliance with the requirements [RMP Spec 20 (2)]. (2) Examples of Operator Verification and Notification records to keep; a) internal audit reports; b) records from any monitoring or verification activities (e.g. reality check records, audit reports, testing results, non-compliances found) for each GOP and supporting system; c) trend analysis of monitoring findings; d) records that show non-compliance criteria ratings; e) any corrective action taken (including restoration of control, product disposition and prevention of recurrence);and f) copies of any communication sent to MPI or to your verification agency. (3) The person who performed the monitoring or verification should sign and date the record. (4) The person responsible for ensuring the effectiveness of any corrective action undertaken should counter-sign and date the record. Ministry for Primary Industries Page 32 of 148

34 Signing can be manual or electronic, as long as changes can be tracked. 2.5 Corrective Actions Scope (1) To ensure if non-compliances occur that they are managed appropriately; including restoration of control, product disposition, root-cause analysis and prevention of recurrence Requirements and Procedures (1) Operators must ensure that compliance to requirements and procedures is regularly checked, e.g. monthly, by the responsible person at a frequency that will ensure consistent and ongoing effectiveness of the programme [RMP Specs 16 (1)]. (2) Operators must ensure that corrective actions for any non-compliance include an assessment to determine the root cause and extent of the issue and address: a) immediate restoration of control; b) identification and disposition of any affected poultry or poultry product; and c) prevention or recurrence of the non-compliance [RMP Spec 11 (2)]. (3) The root cause(s) of the problem should be identified and be addressed by the corrective and preventative actions. (4) Corrective actions should be undertaken in an effective and timely manner. (5) A register of non-compliances with the corrective actions, including follow-up checks, and outcome should be maintained. (6) Non-compliances should be categorised based on their potential effect on product contamination and product safety and its fitness for intended purpose, using risk analysis. Refer to Part 6.8 Non-Complying Product and Recall for further information on managing non-compliances and recall of affected products. Refer to Part 2.4 Operator Verifications and Notifications for further information. Time frames for corrective actions should be set e.g. a minor defect should be corrected within 6 months, whereas a critical should be rectified immediately. It is common practice to categorise non-conformances/non-compliances into the following three categories: critical, major and minor. This will assist in the setting of appropriate time frames for rectifying the noncompliances. Refer to Table 1 for examples. Examples of managing the risk to product could include: continually monitoring processing or product on production days to ensure the risk to product is minimal; or preventing equipment from being used until repairs can take place. Ministry for Primary Industries Page 33 of 148

35 Table 1: Examples categories, the corresponding appropriate corrective action and suggested timeframes Noncompliance Critical Major Minor Definition Will result in direct contamination of a product: dirty product contact surfaces; condensation from an overhead structure directly above exposed products or product contact surfaces; flaking paint in processing area above exposed product. May result in direct or indirect contamination of a product: dirty/contaminated surfaces which are handled by workers; residue build-up on door handles or equipment knobs; dirty surfaces that are in close proximity to a product contact surface; cracks in the floor in processing area, if water blasted pieces could be dislodged to product contact surface areas and be a source of contamination. Unlikely to result in contamination of a product: dirty surfaces that are not near a product contact surface and are unlikely to come into contact with exposed product, product contact surfaces, packaging or workers; an isolated speck of product residue on a table leg, wall or drain; exposed wood in food support areas. Corrective Action Must be corrected immediately. Processing must cease if taking the corrective action will have a direct effect on product safety. Must be corrected at the first available opportunity during the day in which it occurs. It must be corrected before the start of the next processing period, unless it can be shown that a further delay will not have an effect on product safety. If multiple major defects occur, their combined effect on product safety must be considered. Where there is a direct effect on product safety, these defects must be corrected with appropriate urgency. Must be corrected as the opportunity arises. The operator must set a date for correction of the defect Extenuating Circumstances (1) In extenuating circumstances where a non-compliance cannot be corrected within the timeframes suggested above, the operator should ensure that the non-compliance is managed appropriately and the risk to product is minimised. (2) The following should be reported to the recognised verifier: a) a non-compliance that affects the fitness of purpose of product; b) a description of the problem and the non-compliant product; c) a summary of the assessment made; d) the decision on the disposition of the product; and e) any corrective actions taken to prevent the recurrence of the non-compliance. Extenuating circumstances may include: unforeseen events, e.g. floods, fires, and earthquakes; Ministry for Primary Industries Page 34 of 148

36 replacement equipment and parts not being immediately available; unavailability of contractors; and circumstances where processing must continue for animal welfare reasons etc Preventative Actions (1) Preventative actions to minimise the occurrence of non-compliance may include: a) amending documented programmes to correct deficiencies; b) increasing the frequency of reality checks or internal audits; c) revising supervision or training programmes of staff, visitors or contractors if they re not following GOP as required; d) issuing warnings to repeat offenders; and e) a series of escalating responses is recommended for repetitive non-compliances Records (1) Keep records to demonstrate compliance with the requirements [RMP Spec 20 (2)]. (2) Examples of Corrective Action records to keep; a) trend analysis of monitoring; b) non-conformance rating decisions; c) root cause analysis; d) any corrective actions and preventative actions taken; and e) any reports given to the verifier. Ministry for Primary Industries Page 35 of 148

37 Part 3: Design, Construction and Essential Services 3.1 Scope (1) To ensure that all buildings, facilities and equipment are designed, constructed, installed and operated in a manner that minimises contamination of product, packaging, other inputs, equipment, and the processing environment References Applicable to Design, Construction and Building Services (1) This Part only covers those aspects of design and construction relevant to compliance with the requirements of the APA and its pursuant regulations. Premises design and construction will also need to comply with relevant requirements of local territorial authorities and Acts, including the Building Act (2) Additional references applicable to the design and construction of poultry premises are listed below. Refer to the latest versions of the texts unless stated: a) Animal Welfare Act b) Australian/New Zealand Standard AS-NZS :2003 Plumbing and Drainage. Part 1: Water Services c) Building Act d) Building Regulations e) New Zealand Building Code (First Schedule to the Building Regulations 1992) f) Resource Management Act g) Codex Alimentarius Commission, CAC/RCP , Rev. 4 (2003) General Principles of Food Hygiene h) Drinking Water Standard for New Zealand (DWSNZ) i) Health (Drinking Water) Amendment Act 2007 j) Handbook of Filter Media, 2 Ed, EU5, DIN Part 2 k) Health and Safety in Employment Act l) Health and Safety in Employment Amendment Act m) AS/NZS :199.7 Interior lighting -Part 2.4: Industrial tasks and processes n) New Zealand Standard 5807: Code of Practice for industrial identification by colour, wording or other Coding. o) Health (Drinking Water) Amendment Act p) Water Supplies Protection Regulations q) Water Supplies Protection Regulations 1961: revoked, on 1 July 2008, by section 20 of the Health (Drinking Water) Amendment Act 2007 (SR 2007/92) r) US Code of Federal Regulations Title 21 parts , current version Verification of Compliance (1) The operator must provide appropriate validation of design, construction and installation attributes that will enable effective verification of compliance to standards [AP Reg 10 and HC Spec 2.2]. (2) This is particularly important where alterations and additions require professional expertise, e.g. refrigeration systems, back flow prevention systems and water treatment systems. on validation can be found in the RMP Manual and What is validation? which are available from the MPI website. Ministry for Primary Industries Page 36 of 148

38 3.2 Design and Construction of Buildings Scope (1) To ensure that all buildings are designed and constructed in a manner that minimises contamination of poultry material and products and meet the requirements Requirements and Procedures (1) Buildings must be designed and constructed using good sanitary design principles which should support GOP and allow the product to be processed and maintained so that it is fit for its intended purpose [AP Reg 10]. (2) Advice should be obtained from a competent person on the design of new buildings, and alterations to existing buildings that substantially affect the sanitary environment of the buildings. (3) Any material or interior surface finish used in the building or maintenance of the buildings, or internal structures must: a) be impervious, non-absorbent, and free from depressions, pits, cracks, and crevices that may harbour contaminants; b) be easily cleaned and sanitised; c) be durable, resistant to fracture, and capable of withstanding effective cleaning and sanitising; d) be unaffected by any corrosive substance with which it is likely to come into contact; and e) not be a source of physical, chemical or microbiological contamination [HC Spec 2.2 (1)]. (4) The buildings and internal structures, that may affect the suitability for processing of poultry material or the fitness for intended purpose of poultry product, must be of sanitary design [HC Spec 2.2 (2)]. (5) The design and construction of the buildings must be fit for intended purpose [HC Spec 2.2 (1)]. (6) The buildings must be designed, constructed and maintained in a manner that prevents the harbourage and entry of pests [AP Reg 10]. (7) Holes, drains and other places where pests are likely to gain access should be sealed or covered with screens or similar materials (e.g. pest exclusion devices) that prevent the entry of pests. These requirements are also good principles to apply to the design and construction of buildings, facilities, and equipment for live birds. Consideration should be given to animal welfare. Refer to the Animal Welfare Code of Practices. Windows, doorways, drains and other openings that would admit pests should be equipped with effective pest exclusion devices. Refer to Part 6.11 Pest Control for more detailed information regarding managing pests in the processing area. Thermal Properties of Materials Materials should be capable of maintaining their original properties when subjected to temperature extremes that may occur during normal conditions of use. The thermal movement of materials should be consistent with fixings, jointing systems and backing materials Site (1) The layout of the site must be suitable for the intended operations of the premises [AP Reg 10]. (2) Where appropriate, premises should be provided with adequate: a) potable water and energy supply to ensure all activities can be carried out efficiently; b) waste and effluent disposal systems; and Ministry for Primary Industries Page 37 of 148

39 c) vehicle access ways constructed and maintained so that they drain surface water and do not create dust or other environmental contamination. (3) Factors that should be considered and addressed in site selection include the following: a) staff access and amenities; b) future possible expansion; c) neighbouring industries and facilities; d) flood plains; e) winds, ventilation and process air intakes; f) vehicle access; and g) fuel storage and handling facilities Floors (1) Floors should be installed and maintained to eliminate all cracks, open joints, depressions or other low areas that would accumulate moisture or harbour contamination. (2) Floors subject to wet cleaning should be adequately graded and free-draining. Commonly used acceptable materials are sealed concrete, floor tiles, vinyl and synthetic materials. Concrete or mortar floors which incorporate an approved latex or synthetic resin finish have better resistance to meat, fats and acids. Floor junction coving to a radius of 80 mm has been found to work well in wet cleaning areas. Suitable drainage should be provided so that any discharge or overspill from processing areas goes directly into a drain rather than on the floor. Ideally floors should be sloped so that water will flow to floor drains. Floor falls of 1 in 50 have been found to work well in wet processing areas. Wash areas normally have a 1 in 25 fall. As a safety precaution, excessively smooth floors should be avoided in areas subject to wet cleaning Floor to Wall Junctions (1) Floor-to-wall junctions must be constructed to facilitate easy cleaning and, if subject to wet cleaning, shall be coved to provide a smooth junction [HC Spec 2.2(1)]. (2) Coving to a radius of 80 mm has been found to be satisfactory in wet cleaning areas Interior Walls (1) Interior walls must be constructed to be fit for purpose [HC Spec 2.2(2)] Ceilings (1) Ceilings, including false ceilings, must be constructed to be fit for purpose. Associated installations, equipment and fittings must be designed and installed to facilitate effective cleaning [HC Spec 2.2(1) and (2)] Windows (1) Windows should must be flush with the inside surface of the wall. (2) Glass windows should not be used where glass could contaminate product if the window breaks. As an alternative safety glass could be used. Ministry for Primary Industries Page 38 of 148

40 If a window sill has an inside ledge, this should be sloped downwards at an angle (of at least 45 ) to prevent the build-up of dust, and to facilitate effective cleaning Protrusions within the Walls, Ceilings or Floors (1) Where fittings and services such as pipes, wiring, ducting and trunking pass through walls, ceilings or floors, they should be: a) flashed and sealed to eliminate gaps on both the interior and exterior surfaces to prevent water seepage, and harbourage or entry of pests; b) constructed to prevent accumulation of dust and contaminants; and c) effectively cleaned at the frequency required for the function of the room or area. (2) The use of insulation materials on pipes within food areas and food support areas should: a) not be a food safety risk; and b) be cleanable under the normal conditions of use Doors (1) Doors should be installed where their opening and closing from external surroundings or other areas of lower hygiene status (e.g. waste area) will not result in contamination of: a) poultry material and products; and b) processing equipment and the processing area. (2) All doors opening from the exterior or by-product areas directly to food areas or food support areas should be self-closing. (3) Doors should be properly sealed to prevent water seepage, entry of pests and contamination from external environment. (4) Door openings and passageways should be designed and constructed to ensure that unprotected food does not come into contact with the door jambs or walls. (5) The time doors are opened for traffic should be minimised to reduce contamination from areas of lesser hygiene. (6) Plastic strips used in doorways should be: a) installed with sufficient overlap to provide continuous coverage; and b) maintained in a clean, sanitary and good working condition. Doors in areas where processing and/or packing is carried out should not open directly to the outside environment. An ante-room is recommended for providing two doors between the processing or packing room and the outside. Emergency exits are not considered doors, if solely used for that purpose. Air curtains in doorways are not regarded as doors and should not introduce contamination. Plastic strips may be used in doorways as the only door to food areas and food support areas, provided they are fit for its intended purpose and do not open directly to the exterior or to by-product or other nonproduct areas. Ministry for Primary Industries Page 39 of 148

41 Stairs, Decks and Walkways (1) Where stairs, decks or walkways are located over exposed product or product contact surfaces they should be constructed of impervious material with solid treads and closed risers to prevent contamination of food by splash or fallout. (2) All stairs, decks and walkways should be constructed to prevent the pooling of water and should be sloped to drain points. Side curbs at least 150 mm high measured at the front edge of the treads have been found to work well. Where the process is fully enclosed and there is no danger of food being contaminated, open grid type stairs, decks and walkways may be used Working Space (1) Adequate working space should be provided to allow for the following: a) personnel access and flow; b) product flow; c) equipment installation; d) storage and access of materials; and e) the hygienic performance of all operations Process Flows (1) Building and facilities should be designed to facilitate hygienic operations by means of an organised process flow from the arrival of the live poultry and raw materials at the premises to the finished poultry products and/or by-product. To adhere to good sanitary design principles; buildings, services and equipment should be designed around the process flow path. The principle of one-way-flow of food or by-products should be implemented wherever possible. Without good sanitary design at the onset, food safety and sanitation programmes can be less effective and become significantly more costly. Problems such as food poisoning, spoilage, insect infestations and foreign material contaminations are more likely to occur Cross Contamination (1) Buildings and facilities must be designed to provide separation, by partition, location or other effective means, between operations (including waste disposal) that may cause contamination of poultry products [AP Reg 9 and 10]. (2) Whenever possible, separation should be provided between the following functions: a) handling of unclean and clean raw food where there is a potential for cross contamination; b) primary and secondary processing of poultry; c) processing of wet and dry food; d) primary processing and packing; and e) unprotected food and by-product storage and transportation. (3) The layout of premises should separate, as appropriate, microbiologically high and low risk materials, processes and the personnel working within them. Ministry for Primary Industries Page 40 of 148

42 (4) Where appropriate, premises should be designed so that personnel flows and access can be controlled to prevent cross contamination. Consider all points of cross contamination that may occur at the premises and ensure that measures are in place to manage the hazards. Common practices used to provide separation is typically categorised into: separate by distance - to separate to such an extent so as to avoid any possible contact, splash, contamination etc., between specific functions, processes or personnel. separate physically - to separate by floor to ceiling solid walls and doors, or to fully protect product/byproduct by pipelines, enclosed vats, etc. separate by time - to end one function or process prior to starting a different function or process, and if necessary to avoid contamination with a cleaning operation in between. 3.3 Design and Construction of Facilities Scope (1) To ensure facilities are designed and constructed in a manner that minimises contamination of poultry product and material and are fit for intended purpose and meet the requirements Requirements and Procedures (1) Facilities must be designed and constructed using good sanitary design principles which should support GOP and allow the product to be processed and maintained so that it is fit for its intended purpose [AP Reg 10]. (2) Specific processing facilities and equipment must be operated within their design capability and capacity [AP Reg 10]. (3) Advice should be obtained from a competent person on the design of new facilities, and alterations to existing facilities that substantially affect the sanitary environment of the facilities. (4) All premises must provide access to facilities that are sufficient for recognised verifiers and Animal Product Officers to perform their role [HC Spec 2.3 (5)]. (5) Any material or interior surface finish used in facilities, maintenance of facilities, or internal structures must: a) be impervious, non-absorbent, and free from depressions, pits, cracks, and crevices that may harbour contaminants; b) be easily cleaned and sanitised; c) be durable, resistant to fracture, and capable of withstanding effective cleaning and sanitising; d) be unaffected by any corrosive substance with which it is likely to come into contact; and e) not be a source of physical, chemical or microbiological contamination [HC Spec 2.2 (1)]. (6) The facilities and internal structures, that may affect the suitability for processing of poultry material or the fitness for intended purpose of poultry product, must be of sanitary design [HC Spec 2.2 (2)]. (7) The design and construction of facilities must be fit for intended purpose [HC Spec 2.2 (1)]. (8) Facilities must be designed, constructed and maintained in a manner that prevents the harbourage and entry of pests [AP Reg 10]. (9) Cleaning and sanitation facilities, and equipment must be provided to ensure that personnel hygiene, hygienic condition of equipment, vehicles, conveyances and premises can be maintained [HC Spec 2.3 (4)]. Ministry for Primary Industries Page 41 of 148

43 (10) Holes, drains and other places where pests are likely to gain access should be sealed, or covered with screens or similar materials (pest exclusion devices) that prevent the entry of pests Facilities (1) Dedicated areas should be provided for the following: a) storage and/or preparation of dry ingredients and/or other shelf-stable packaged ingredients used in the manufacture of poultry products; b) storage of cleaning equipment; c) storage and/or preparation of maintenance compounds; d) storage and/or make-up of packaging materials; and e) storage of personal protective equipment when employees are not in processing areas. (2) Hygiene facilities appropriate to the nature of the process should be provided. (3) Separate areas (physically or by distance), as appropriate to the process, should be provided for: a) cleaning and packaging facilities; b) cleaning and/or sterilising of equipment; and c) knife-sharpening facilities. (4) Packaging material facilities should be able to store packaging materials off the floor. (5) Wet cleaning facilities should have an adequate supply of hot and cold potable water. (6) Facilities should be designed and constructed to store cleaned and/or sterilised equipment so as to: a) prevent contamination; and b) transport cleaned equipment back to the point of use without re-contamination. (7) Washing facilities of personal protective equipment should be provided at personnel entry points to food processing areas (e.g. wash hand basins, apron washes, boot washes or boot change facilities and apron hooks). A dedicated area could be a room or simply a cupboard within the appropriate environment, dependent upon the requirements of the premises. Steam and splash from wash water or cleaning chemicals are a potential source of contamination to food being processed, packed, stored or transported. Hot water should be at least 60 C for sanitation and 82 C for sterilisation. A separate ante-room with these washing facilities should be provided wherever possible Food Support Facilities (1) Food support facilities including storage rooms, dry stores, laundry rooms and packaging rooms must be fit for intended purpose [HC Spec 2.2 (1)]. (2) Items held and/or prepared within a food support facility should be of compatible status with other items and the intended purpose of the facility Stores (1) Separate compartments or rooms, as appropriate to the stored items, should be provided for foods and items liable to taint or otherwise contaminate each other, unless contained by appropriate packaging. (2) Dedicated secure facilities should be provided for the storage of maintenance compounds. (3) Dedicated and separate facilities should be provided for engineering workshop equipment and tools. Ministry for Primary Industries Page 42 of 148

44 Refer to Part 6.10 Control of Maintenance Compounds for more information Amenities (1) Amenities including toilets, wash rooms, locker rooms, change rooms, lunch rooms and cafeterias must be fit for intended purpose [HC Spec 2.2 (1)]. (2) Amenities should be located to prevent contamination of the holding, processing areas, packing, storage and transport of poultry products. (3) Amenities should be designed, constructed and maintained to: a) provide sufficient space and facilities for employees to consume food, change clothes, store personal belongings and attend to personal hygiene; b) facilitate cleanliness and tidiness; and c) preclude direct opening onto any food area Lockers (1) All lockers provided for the storage of clothing and other personal belongings in the amenities should be constructed so that: a) there is adequate free space to allow for easy cleaning of lockers and their surrounding area; and b) no material can be stored on top of the lockers or set flush with the walls. (2) Where personal protective equipment is stored in lockers, there should be provision for physical separation from all other items. (3) Where appropriate, dedicated facilities should be provided for: a) depositing dirty clothing; b) storing clean clothing; and c) laundering of dirty personal protective equipment on the premises or by contract arrangement. Lockers with sealed wooden surfaces may be used in amenities Lairage and Hanging Facilities (1) Appropriate lairage facilities must be: a) provided where birds are held prior to slaughter; b) fit for its intended purpose; and c) operated within their design capability and capacity [HC Spec 2.3 (1)]. (2) Appropriate facilities for checks, including ante-mortem examination of birds, must be: a) provided where appropriate; and b) operated within their design capability and capacity [HC Spec 2.3 (2)]. (3) Lairage facilities should be designed, constructed and located to: a) ensure compliance with animal welfare requirements; b) effectively contain the poultry; c) allow ante-mortem examination functions to be effectively carried out; d) minimise the risks to primary processing; and e) minimise the risks to packing, storing and transport of poultry product. (4) Structures and construction materials should be designed to be appropriately cleaned and to contain poultry. Ministry for Primary Industries Page 43 of 148

45 (5) The floors of hanging and lairage facilities should be: a) adequately paved and graded; b) free-draining; c) capable of being cleaned; and d) allow good drainage of liquid and solid waste. Wherever there are floors on which birds are held, there is an expectation that the 'floor' can be cleaned. Liquid and solid waste should be contained and rapidly removed to prevent it from flowing into a processing area and contaminating the birds awaiting slaughter Temperature-controlled Processing Rooms (1) Temperature-controlled processing rooms and equipment must be operated within their design capability and capacity. These rooms must deliver any temperatures specified in legislation or in the RMP [HC Spec 2.3 (3)]. In the poultry industry, it is common practice for processing areas to be maintained at 12 C or cooler, except when: conditions are sufficient to maintain the temperature of the meat and/or mix at 7 C or cooler; and/or processing areas are used for thermal processing or where a higher temperature is either not detrimental to product safety or is required for its manufacture Primary Processing Areas (1) Primary processing facilities, which include slaughter and dressing facilities, should be designed and constructed to: a) ensure hygienic slaughter and dressing; b) facilitate hygienic product flows; c) allow effective cleaning; d) ensure compliance with poultry welfare requirements; and e) facilitate post-mortem examination functions. (2) The location of the slaughter and dressing facilities should be in close proximity to the hanging area so that poultry can be slaughtered without undue delay. (3) Slaughter and dressing should be separated from lairage and hanging facilities to minimise cross contamination. (4) The bleeding area should be designed and constructed to confine blood to that area and facilitate its removal. (5) Where carcass washing is carried out during processing, carcass wash areas should be constructed to confine wash water to that area and allow effective drainage of wash water. (6) Adequate facilities should be provided to ensure each carcass and its viscera (excluding feet and heads) are correlated and presented so as to facilitate post-mortem examination. (7) Facilities producing inedible products adjoining to primary processing facilities should be: a) physically separated from slaughter and dressing facilities; b) designed and constructed on the basis of good sanitary design in accordance with the requirements for by-product facilities; and c) fit for its intended purpose. Ministry for Primary Industries Page 44 of 148

46 Secondary Processing Areas (1) The design and layout of the secondary processing facilities, e.g. boning and cutting rooms, should facilitate inspection of operations and ensure an orderly flow of: a) personnel; b) product; and c) packaging. (2) Poultry secondary processing areas should be designed and constructed to maintain a temperature and/or humidity that is appropriate to: a) the nature of the food; b) the type of processing; and c) the intended state of preservation. (3) Temperatures of temperature controlled processing areas should be monitored or recorded. (4) Unprotected carcasses and portions should be transferred by means that will minimise contact with non-product contact surfaces. (5) Facilities should be provided to contain and dispose of waste material. (6) Facilities, or alternatively appropriate procedures, should be in place for the handling of product that has come in contact with non-product contact surfaces. (7) Facilities for holding packaging materials for immediate use during production in secondary processing areas should be designed, constructed and located to facilitate the hygienic delivery of the materials. The room temperature should be recorded at intervals of no greater than one hour or monitored by Calibrated Automatic Temperature Recorders (CATRs) or Supervisory Control and Data Acquisition (SCADA) equipment Refrigeration Facilities (1) Refrigeration facilities (chillers, freezers and cold stores) and equipment must have the: a) capability to reduce product temperature to the required temperature within the prescribed time or maintain product temperature at or below the required temperature; and b) capacity appropriate for the volume of products likely to be processed or held in the refrigeration facility at any one time [HC Spec 2.3 (3)]. (2) Novel or alternative refrigeration technologies must be designed and constructed and operated within their design capabilities and capacity [HC Spec 2.3 (3)]. (3) Freezer and chiller temperatures should be monitored by CATR or SCADA equipment. (4) Cold stores should be designed, constructed and operated to ensure that frozen food and poultry is maintained at -12 C or colder during storage and loading. (5) Temperature sensor(s) should be positioned so they accurately monitor the temperature within a room using a sufficient number to monitor the temperature range in different parts of the room. (6) If only one temperature sensor is used it should be located in the return air flow to the evaporator unit, as this usually has the highest temperature. Chiller and freezer temperatures should be recorded at intervals of no greater than one hour. For cold stores, the interval should be no greater than 4 hours. Ministry for Primary Industries Page 45 of 148

47 Refer also to Cold and Dry stores Code of Practice, available at: Ice Production (1) Ice that may come into contact with food directly or indirectly must be made from potable water [HC Spec 2.5 (1)]. (2) Facilities should be provided for its storage, handling and transport that will not contaminate the ice Products for Animal Consumption and Waste Materials (1) Systems should be in place for the secure handling of products intended for animal consumption and waste materials. For example, labelling on diverted products for animal consumption or waste materials should prevent products to be scanned out and it should be held in a designated area Load In and Load Out (1) Environmental loading facilities should be designed and constructed to: a) protect food from environmental hazards; and b) ensure maintenance of the temperature of food during load in or load out. Sealed docking bays or fully enclosed environmental loading facilities should be provided for unprotected food. 3.4 Design and Construction of Equipment Scope (1) To ensure that equipment is designed, constructed and maintained in a manner that minimises contamination of poultry material and products, and meets the requirements Requirements and Procedures (1) All equipment must be: a) impervious, non-absorbent and free from depressions, pits, cracks, and crevices that may harbour contaminants; b) easily cleaned and sanitised; c) unaffected by any corrosive substance with which it is likely to come into contact, to the extent necessary to ensure that it will not harbour contaminants and is not a source of contamination; d) durable resistant to fracture, and capable of withstanding repeated exposure to normal cleaning and sanitising; and e) able to withstand exposure to heat, water and all products expected to be processed under normal operating conditions [HC Spec 2.2 (1)]. (2) All equipment that comes into contact with any product should be designed, constructed, installed and operated in a manner that: a) ensures the effective performance of the intended task; b) ensures effective cleaning and sanitation; c) facilitates effective process control and monitoring; and Ministry for Primary Industries Page 46 of 148

48 d) does not contaminate the product. (3) All equipment should; a) be installed and operated in accordance with the manufacturer s specifications (alternative uses of the equipment that may jeopardise the hygienic safety of poultry material and products should be avoided); b) be designed to eliminate excessive build-up of poultry material, waste material and waste water for the normal period of operation; c) where appropriate, have interior surfaces which come in contact with poultry material so that the equipment is self-emptying, self-draining or designed to be easily evacuated of water; d) where appropriate, have internal corners or angles with a continuous smooth radius of at least 7 mm (a lesser radius may be used where necessary for proper functioning of parts or to facilitate drainage, provided that such areas can be readily cleaned); e) be installed and operated so as to protect the poultry material from external contamination while in use; and f) be arranged to ensure an orderly flow and hygienic handling of the poultry material Materials of Construction (1) Plastic, synthetic materials and resin coatings used as product contact materials should meet: a) the appropriate requirements specified in the current US Code of Federal Regulations, Title 21, Parts ; or b) any other standard recognised by the Director-General as being equivalent to the standard specified above (clause (1)a)). (2) The operator should obtain a written guarantee from the manufacturer or supplier of the equipment that the material(s) comply with the above requirements. (3) The guarantee should contain the following information: a) the identity of material, i.e. the distinguishing brand name or code designation appearing on or with the material; b) the specific part(s) of Title 21 or other recognised standard that is applicable to the material; c) the specific conditions of use, such as temperature limits or any other pertinent limits, particularly those which are stipulated by the US regulation; d) the signature of an authorised agent for the manufacturer or the supplier; e) whether the guarantee is limited to a specific shipment of an article, in which case it may be part of or attached to the invoice covering such a shipment; and f) whether the guarantee is generic and continuing. The guarantee should be considered to have been given at the date such article was shipped by the person who gives the guarantee. (4) The following materials should not be used in any equipment that can come into direct contact with poultry product: a) toxic metals such as cadmium, copper, lead and their alloys; b) metals whose contact with liquid or other material may create harmful chemical or electrolytic action; c) porous materials such as sponge rubber, stone slabs, linoleum, leather and fabric (excluding strainers and filters); and d) wood. Equipment which will be used in direct contact with poultry material should be provided with a letter of guarantee from the supplier certifying its acceptability for food use. The guarantee provides approval for the composition of the product contact material only and is not an approval for any constructed piece of equipment. The responsibility for compliance with the specification for composition of any product contact material rests with the manufacturer or supplier. Ministry for Primary Industries Page 47 of 148

49 Stainless steel (300 series or better) is the preferred material for equipment that comes into contact with poultry material. Aluminium is not recommended. It can: warp; be susceptible to the effects of both oxidation and certain types of corrosion, especially from alkaline cleaning chemicals; and be susceptible to pitting and scratching. Galvanised metal is acceptable for non-product contact surfaces but the finish should be of a high quality commercial hot dip or equivalent Motors, Drives and Pumps (1) Motors, drives and pumps, including vacuum pumps, associated with processing equipment should be: a) appropriately designed and managed; and b) suitably maintained so that lubricants and/or smoke does not contaminate poultry material. (2) Lubricants should meet the requirements of Part 6.10 Control of Maintenance Compounds Equipment Identification (1) Equipment should be adequately identified to ensure edible products are separated from inedible products (waste materials and products intended for animal consumption) Monitoring Equipment (2) Monitoring equipment should have the capability, accuracy and precision appropriate for: a) the product, process, facility or equipment it is fitted to; and b) the measurement being taken. (3) Monitoring equipment should be: a) installed where it can be easily read; b) able to take accurate readings of the relevant parameter (e.g. warmest temperature of the refrigeration equipment or facility); and c) adequately protected from physical and chemical damage. (4) Measuring equipment that is used to carry out a critical measurement must be calibrated [HC Spec 6.2 (2)]. (5) The accuracy of every monitoring or measuring device should be calibrated against a reference standard at a frequency in Part 6.9 Calibration of Measuring Equipment. (6) Visual and/or audible alarm systems required for monitoring equipment should be located to ensure immediate action can be taken in the event that the monitored equipment fails. In addition, there should be a system to notify the operator that the alarm has been activated out of normal processing hours. (7) Temperature indicators are required at the point of use in all circumstances where a particular temperature should be achieved. (8) CATRs and SCADA equipment should be provided to monitor the temperature of temperaturecontrolled rooms where required. Permanent temperature indicators for equipment sterilisers and other specified temperatures are not required if a manual measurement can be taken. Alternatively, the thermometer may be remote from the Ministry for Primary Industries Page 48 of 148

50 point of use if it can be proven that temperature loss does not occur. For example, in the case of equipment sterilisers that the line between the point of use and the thermometer is free from taps or any other variable flow regulating device Personal Processing Equipment (1) Personal processing equipment (including knives, manual hock-cutters and evisceration tools) should be: a) rinsed at a frequency that minimises contamination between carcases and at least when visibly contaminated; and b) cleaned and sanitised at least every three hours, to minimise contamination between carcases. The intent of the above clauses is to rinse, or clean and sanitise equipment as often as possible in order to minimise contamination. It is desirable for equipment to be visibly clean. When equipment is visibly soiled, all reasonable attempts should be made to remove this soiling without delay Poultry Processing Equipment (1) Poultry restraining and stunning equipment must comply with the requirements set out in the AW Code. (2) Defeathering equipment should be: a) accessible for cleaning and for the removal of any accumulated feathers and contamination; and b) constructed to minimise the scattering of feathers or cross contamination of other poultry processing areas. (3) All primary processing equipment which comes into contact with defeathered poultry should be rinsed as often as possible but at least at each break in processing which is greater than 15 minutes long. (4) Surfaces of automated primary processing equipment that contact defeathered poultry should be rinsed continuously where practicable. (5) Where an antimicrobial agent is added to rinse water it should be an approved processing aid and should be used according to the manufacturer s instructions. (6) Equipment should be fully cleaned and sanitised at the end of each day s operations. (7) Chutes and receptacles should: a) be clearly identified and labelled; b) be leak proof; and c) prevent contamination of product. For more guidance on animal welfare requirements, refer to the Animal Welfare (Commercial Slaughter) Code of Welfare The earlier rinses occur after steps that could increase contamination the better. Prolonged contact allows bacterial attachment to the skin to occur Cleaning Equipment (1) Cleaning equipment should not be a source of contamination to poultry products or materials, ingredients, packaging and other material. (2) Cleaning equipment should be: a) used for cleaning purposes only; Ministry for Primary Industries Page 49 of 148

51 b) stored in a hygienic manner when not in use; and c) maintained in a good state of repair. (3) Vacuum cleaners or systems should be: a) cleaned according to the cleaning and sanitation programme; and b) moved away from processing areas before dismantling, changing filters or removing dust bags. (4) The frequency of filter changes should be defined in the cleaning and sanitation programme. Areas with a different hygiene status should have dedicated cleaning equipment, e.g. separate cleaning equipment for primary processing and secondary processing. Where possible, single use cleaning equipment is recommended. Multiple-use cleaning equipment (e.g. reuseable cloths, brushes, squeegees etc.) should be cleaned and sanitised daily or at a frequency to minimise cross contamination between cleaning activities Hoses (1) Where required, premises should be equipped with an adequate number of hose connection points to enable effective cleaning. (2) Appropriate facilities should be provided for the storage of hoses, where fitted, to ensure hose ends are free from contact with the floor. (3) Hose materials should: a) not be a source of contamination to any product; b) be able to be adequately cleaned and maintained under the normal conditions of use; and c) kept in good repair Cleaning and Sanitising Units for Equipment (1) Sanitising units for equipment should be provided to ensure products do not get contaminated. (2) Aerosols or vapour emanating from hygiene equipment should be minimised where it may come in contact with and/or contaminate exposed poultry material or products. (3) Water supply control valves for continuously operating hygiene equipment should be either out of easy reach from the work station or operable by hand tools only. Hot water used for sterilisation should be at least of 82 C at the point of use Dry Cleaning Equipment (1) Suitable dust extraction systems should be installed to reduce airborne dust levels. (2) Vacuum systems should be equipped with a filter system for air leaving the system. (3) Cross contamination should be avoided by providing two different sets of attachments and tubes; one for product contact surfaces, the other for floors and room surfaces. (4) Vacuum systems and attachments should be stored in a dry state, free from moisture and food residues. Vacuum systems should be chosen on the recommendation of a supplier of vacuum systems that are specifically designed for the purpose of dry cleaning. Ministry for Primary Industries Page 50 of 148

52 Consideration should be given to the desired effectiveness, intended use and the ease of maintenance and cleaning, including accessories, exterior design, dust collector, filters, apparatus surfaces, etc. The filter system should consist of: a coarse filter to trap large dust particles; and fine micro-filters upstream from the coarse filter to retain fine particles, including bacteria, yeasts and moulds. Outgoing air from the vacuum system into food processing areas should be filtered through air filters that comply with at least the standard set out in Class F5, DIN Part Personal Hygiene Equipment (1) Hand washing units should be: a) sufficient in number to allow for effective personnel hygiene; b) non-hand operable (e.g. foot, knee, sensor or another approved method); c) located in areas that are readily accessible to all persons working in or entering a processing area; d) located close to points of the process involving manual handling of the product; and e) provided with warm potable water and approved soap dispensers. (2) Single use towels or other hand drying facilities that do not contaminate washed hands or the surrounding area should be provided adjacent to hand wash units. Note: that the nature of some processing will be exempt from this requirement (e.g. some slaughtering operations). (3) Facilities should be provided for disposal of single use hand drying towels, where appropriate. (4) Facilities for washing waterproof clothing (e.g. boots, aprons, gloves) should be provided. (5) Wash facilities should be designed, constructed and located: a) to suit the operator, the protective clothing that is worn and the equipment that is used; and b) in a manner that minimises splashes onto surrounding areas, products and equipment. The recommended temperature range for warm potable water for hand washing is C at the point of use. Roller towels and air dryers should not be used in processing areas. During manual processing of poultry, hand basins and knife rinsing / sterilising equipment should be conveniently located for easy access by the workers to reduce cross contamination between carcases Clean-in-Place Systems (1) Sanitation procedures for clean-in-place (CIP) systems should be as effective as those for cleaning and sanitising disassembled equipment. (2) Only equipment which meets the following criteria may be cleaned in place: a) cleaning solutions, sanitising solutions, and rinse water comes in contact with all interior surfaces of the equipment in the CIP system; b) all internal surfaces are either designed for self-draining or physically disassembled for draining after rinsing; c) pipe interiors are constructed of highly polished stainless steel or some other appropriate smooth-surfaced material; d) easily removable elbows with quick disconnect mechanisms are placed at each change of direction; and Ministry for Primary Industries Page 51 of 148

53 e) appropriate sections of the system are capable of being completely disassembled for periodic inspection of the internal surfaces. (3) Any equipment or portions of equipment not meeting these requirements should be disassembled for routine cleaning and inspection at a frequency specified in the cleaning and sanitation schedule. 3.5 Essential Services Scope (1) To ensure essential services (e.g. drainage, sewage, and air) are designed, constructed and maintained in a manner that minimises contamination of poultry product Drainage and Sewage (1) Drainage systems should be designed, constructed and located to: a) effectively remove solid and liquid waste; b) prevent odours, pests, other objectionable material and storm water from entering the premises; and c) prevent contamination of products, packaging and equipment from aerosols and splashes from drains. (2) Drains should be positioned and of sufficient capacity (i.e. size and fall) to ensure liquid and solid waste is contained and rapidly removed to minimise the spread of waste across floors. (3) Effluent and sewage should be contained and disposed of hygienically and by means that prevent the contamination of potable water supplies and food. For wet processing areas, one drainage outlet should be allowed for each 40 m 2 of floor area. Where channel, spoon or similar drains are used, a distance of 5-10 m between drainage outlets should be allowed. Channel drains should be of sufficient size and suitable fall to allow self-draining and ease of cleaning. The drainage system should also be designed to accommodate the possibility of future alterations to room functions and layouts. Floor drainage lines should have a diameter of at least 100 mm. Drainage lines should not pass from dirty to clean processing areas. The flow should be considered in the process flow design of the plant, so it does not flow from areas of high contamination to areas of low contamination. Sewerage lines from toilets and urinals should not be connected with any drainage lines within the premises and should not discharge into sumps from which any recovery for further processing is done. To prevent the possibility of any sanitary drainage backing up and entering the premises, sewerage lines should either be: directed to an adequate septic system located at a safe distance from any processing building; or discharged into the local sewerage system at a point sufficiently remote from the premises. Ministry for Primary Industries Page 52 of 148

54 3.5.3 Lighting (1) Lighting must be of a sufficient intensity and quality to enable satisfactory performance of all operations which might affect the suitability for processing of poultry material or the fitness for intended purpose of poultry product [HC Spec 2.4]. (2) Light bulbs, fixtures, skylights, or other glass should be of the safety type, or otherwise protected to prevent contamination in the event of breakage, over: a) products; b) exposed packaging material; or c) equipment. (3) Illumination levels should comply with the relevant provisions of AS/NZS :1997 Interior lighting - Part 2.4: Industrial tasks and processes. Refer to Table 2 below. Table 2: Acceptable lighting intensities Facility Poultry lairage and holding facilities, areas where ante-mortem examination is performed, measured 1 m above the floor Areas where quality control inspections (PM inspection and QA checks) are performed, measured at the working plane Processing rooms, measured at working plane 500 Spin chillers, measured at the water level 150 Stores with constant operation, breakdown, make-up, despatch measured at the floor aisles 300 Stores and loading bays with infrequent access, measured for identification of labels 150 Laboratories, measured at the bench 750 Canteens, cafeterias, dining rooms, measured at the table 300 Staff rooms, changing rooms, locker rooms, cleaners rooms, lavatories, measured at the floor 150 Lux Air Quality (1) The operator must document and implement control measures to ensure the air quality of processing and support areas is appropriate for processing product [RMP Spec 11]. (2) Adequate ventilation and air flow should be maintained in the processing and storage areas to: a) minimise airborne contamination of product; b) remove excessive heat, steam and condensation; and c) minimise the entry of odours, dust, vapours or smoke. (3) Ventilation systems should be designed and constructed to ensure that air flows from: a) processing areas to by-product or waste areas; b) secondary processing to primary processing areas; and c) primary processing to hanging and lairage areas. Ventilation systems should be designed to take into account such factors as: the size of the premises; the number of persons working within food areas; processes undertaken in the room (e.g. plucking, spin chilling); heat gain (e.g. from equipment, personnel or food load); Ministry for Primary Industries Page 53 of 148

55 water emission; relative humidity; condensation; and general climatic conditions. Air intakes should be located and constructed so that contamination from exhaust stacks, roof-deposited debris (e.g. faecal material from wild birds) or other environmental contamination cannot be taken into the process area. Air intakes to processing areas should be provided with an effective filtration stage. Filters should be: capable of withholding particles that have the potential to cause contamination of poultry material and processing areas; and readily removable for replacement or cleaning. The choice of filter should be in accordance with the conditions of use. This will depend on the type of the product(s) and process(es), and the size, nature and concentration of the particulate matter to be removed. Operators should have an understanding of the requirements for air filters for air ventilation to processing areas that are set out in standard Class F5, DIN Part Airborne Contamination (1) The operator must minimise sources of airborne contaminants that may cause poultry product and material to be unfit for its intended purpose [AP Reg 10 and 11]. (2) The operator must stop processing if airborne contamination introduces a new hazard to a processing area, unless the hazard can be immediately managed [AP Reg 10 and 11]. (3) If the operator wishes to salvage product involved in, or near, an airborne contamination event (e.g. fire, chemical leaks such as ammonia or refrigerant fluids etc.), then a suitably skilled person must assess the affected product to ensure it is fit for its intended use [AP Reg 11]. Airborne contamination can include: dust, sand, smoke or ash from any source not associated with the usual processing or handling of the type of product; gases, fumes or odours, including internal combustion engines, welding and unfiltered exhausts from pneumatic tools, chemical compounds, ammonia and refrigerants; and airborne microorganism (bacteria and fungi). Airborne contamination does not include airborne substances associated with the usual processing or handling of the type of product (e.g. smoke from a smokehouse). Factors that enable determination of combustion by-product hazards include: the nature of the burnt materials (e.g. lubricants, plastics, electrical cables, switch boards etc.); and the combustion temperature Process Gases (1) Process gases that come in to direct contact with poultry material or product must: a) not contaminate any product; and b) meet the FSC Section Identity and Purity [HC Spec 2.12 (1)]. (2) When compressed air is generated on site and comes in direct contact with poultry material or product, the air must be filtered and the source must be clean and external to the building [HC Spec 2.13 (1)]. Ministry for Primary Industries Page 54 of 148

56 (3) The filters for filtering air that is in contact with poultry material or product, or is in contact with product contact surfaces, must comply with: a) the air purity classes for solid particulate, water and total oil as defined in the current International Organization for Standardization standard Compressed air Part 1: Contaminants and purity classes, Ref. No. ISO ; or b) any other international standard recognised by the Director-General as being equivalent to the international standard specified above in clause (3)a) above [HC Spec 2.13 (2)]. 3.6 Water Scope (1) To ensure that an adequate supply of potable water (including ice and steam) is available for hygienic operations so as to minimise contamination and maintain the fitness for intended purpose of poultry products General Requirements and Procedures (1) The operator must ensure that an adequate supply of potable water is available for hygienic operations [AP Reg 10, HC Spec 2.5 and 2.6]. (2) To ensure the safety and suitability of product and the hygienic operation of the premises, the following should be available: a) an adequate supply, volume and pressure of potable water; and b) appropriate facilities for its storage, distribution and temperature control Potable Water (1) Water that comes into direct contact or indirect contact with poultry material or product must be potable water, at the point of use [HC Spec 2.5 (1)]. (2) Potable water can be sourced from: a) a registered supplier (e.g. council supply); or b) an operator s own supply (e.g. water sourced from bore, stream, river or roof) provided it complies with the requirements in Schedule 1 of the HC Spec (Appendix 1). (3) Potable water should be used for the following situations: a) contact with product or, if water is used in processing areas and food support areas; b) during the slaughter and dressing of poultry; c) the processing, packing, storing and transport of poultry material or products; d) wet cleaning of all rooms, utensils, equipment, and drains in all areas where poultry is slaughtered and dressed and poultry is processed, packed, stored or transported; and e) staff cafeterias, staff amenities, equipment wash rooms and hygiene equipment such as apron washes, boot washes, sterilisers and food area hoses, throughout the premises. (4) The operator may use an alternative water quality standard as determined by the operator provided: a) the water quality standard is determined by an analysis of hazards and other risk factors; and b) suitability for processing of poultry material or fitness for intended purpose of poultry product is not adversely affected [HC Spec 2.5 (2)]. The Water Supply Assessment Checklist (Part 2 of Appendix 1) is used to determine whether the water source is secure or satisfactory, and what, if any, additional treatment and/or other corrective action the operator should apply. It also provides a simple way of documenting the water management plan. Ministry for Primary Industries Page 55 of 148

57 For guidance on: ways to keep roof water safe - see Water Collection Tanks and Safe Household Water, Ministry of Health, September 2014 (code 10148); and protecting bore and well water - see Secure Groundwater (Bores and Wells) For Safe Household Water, Ministry of Health, March 2000 (code 1129). Both documents are available on the Health Ed website at: For more information on water safety and tank installation, see Household Water Supplies (code 4602), available from your local public health service or local authority (council). If you are concerned about your water supply, contact a Health Protection Officer at the local public health service or an Environmental Health Officer at the local council. They will be able to recommend a local water testing laboratory Criteria for potable water (1) The criteria for potable water are given in Table 3 [HC Spec Schedule 1 Part 1]. Table 3: Quality of Potable Water Measurement Escherichia coli or faecal coliforms Chlorine (when chlorinated) Criteria ph (when chlorinated) 6.5 to 8 Turbidity Must not be detectable in any 100 ml sample Not less than 0.2mg/l (ppm) free available chlorine with a minimum of 20 minutes contact time Should not routinely exceed 1 NTU, must not exceed 5 NTUs Note that local councils may only provide E. coli results as faecal coliforms are no longer measured as part of the DWSNZ Water Sampling and Testing (1) Potable water at the point of use must meet the criteria set out in Table 3. The minimum testing frequency required is given in Table 4 [HC Spec Schedule 1 Part 1]. (2) Microbiological testing must be done by an MPI Recognised Laboratory with the required analysis within the laboratory accreditation scope [HC Spec 2.10]. Table 4: Frequency of ongoing testing Daily water use¹ Using <100 m 3 /day and product packaged at all times Using m 3 /day and product packaged at all times Microbiology (Escherichia coli or faecal coliforms) Turbidity 2 ph 3 Chlorine 3 1 per 6 months 1 per 6 months 1 per 6 months Daily 1 per 3 months 1 per 3 months 1 per 3 months Daily Using <2000 m 3 /day 1 per month 1 per month 1 per month Daily Ministry for Primary Industries Page 56 of 148

58 Daily water use¹ Using m 3 /day Using > m 3 /day Microbiology (Escherichia coli or faecal coliforms) Turbidity 2 ph 3 Chlorine 3 1 per 2 weeks 1 per 2 weeks 1 per 2 weeks Daily 1 per week 1 per week 1 per week Daily 1 Average daily water use (while processing). 2 The frequency of turbidity testing will depend on the degree of protection of the water source and whether the operator elects to filter the water. Alternative frequencies may be used where validated in the risk management programme. 3 Chlorine and ph testing applies if the water is chlorinated. Daily means every day when a premises has staff present and is operating. The testing laboratory needs to have at least accreditation to the international standard ISO/IEC (by IANZ) as a minimum. MPI has updated the new Animal Products Notice: Specifications for Laboratories that has some additional requirements for laboratories to meet (such as non-compliance reporting to MPI). Operators who use an independent water supply that is not further treated on site do not have to carry out water testing. They should consider using simple, low cost techniques such as monitoring free available chlorine levels and temperature to pick up any changes in water quality. Resources should be in place to take microbiological and chemical samples should these checks indicate a potential issue. The operator should: take samples from a number of points in the reticulation system to ensure that the sampling is representative of the system as a whole; record the location of each sampling point so the source can be identified (e.g. identifying sampling points on the reticulation plan); where chlorine is used ensure the sample bottle contains sodium thiosulphate to neutralise the free available chlorine in the water sample; ensure that samples are collected by trained personnel; have a documented procedure to ensure samples are taken, handled and transported so there is no significant change in the quantitative value of the determinants; and ensure that microbiological samples are analysed promptly. If the laboratory cannot analyse samples within one hour of collection the operator should: immediately chill the samples to 10 C or cooler (but do not freeze) and deliver them to the laboratory within 6 hours of collection; or immediately chill the samples to 2-5 C and deliver them to the laboratory within 24 hours of collection Hot Water (1) The premises should have a supply of hot water that is sufficient to maintain the required hygiene standards in relation to the proposed operations and functions of the premises. (2) Hot water should be provided at an appropriate temperature, at the point of use, when it is used for the sterilisation of food processing equipment. Ministry for Primary Industries Page 57 of 148

59 The recommended temperature range for warm water is C at the point of use. When hot water is used for the sterilisation of processing equipment and other product contact surfaces, it should be at least 82 C at the point of use. Mixing of steam and potable water is acceptable for producing hot water. Hot water and steam lines should be insulated and strategically positioned in order to maintain temperature Steam (1) Steam used in direct or indirect contact with product or product contact surfaces should not contain any substance which may: a) be hazardous to health; or b) contaminate the poultry material or poultry product. (2) Steam should be produced from potable water for the purposes of poultry processing or when mixed with other potable water. Only approved maintenance compounds may be used for treating boilers and steam lines, where the steam may come into contain with edible product. Refer to Part 6.10 Control of Maintenance Compounds Non-Potable Water (1) Non-potable water not coming into contact with poultry material or product must be determined by the operator as to its fitness for intended purpose: a) by an analysis of hazards and other risk factors; and b) taking into consideration the intended use of the water [HC Spec 2.6 (2)]. (2) The use of non-potable water must be identified in the water management plan [HC Spec 2.9]. (3) Non-potable water, of a standard that does not risk the safety and suitability of the product and is satisfactory to the evaluator, may only be used in the following situations: a) firefighting; b) boiler water, except where used for poultry processing or mixing with other potable water; c) toilets and urinals; d) wash down for poultry holding facilities (structures not live-birds); e) paved areas, roadways, truck turning aprons etc.; f) wash down in the raw processing side of inedible product areas; g) conveying and washing of inedible material; h) cooling towers and condensers; i) washing down sumps and external drains; j) wash facilities for poultry conveyances; and k) inedible product facilities. (4) Every water line conveying non-potable water should be: a) separate from potable water lines, unless the connection is required for firefighting purposes; b) clearly identified at all outlets and any other place where identification is necessary; and c) connected in a manner that prevents contamination of potable water supply. Ministry for Primary Industries Page 58 of 148

60 The code used for identification of water lines may be that as described in NZS 5807:1980 Industrial Identification by Colour, Wording or Other Coding. Operators can determine their own identification system which should be documented as part of the RMP Water Reticulation Management Plan (1) The operator must implement a reticulation management plan for potable water used within a premises or place, where the water is supplied by an independent supplier [HC Spec 2.8 (1)]. (2) The reticulation management plan must include: a) systems to ensure that the water that is reticulated throughout the premises in a manner to ensure the intended water quality is delivered at point of use; b) systems to ensure that there is no unintentional mixing of water of different standards; and c) an action plan with appropriate sanitation procedures to be implemented in the event of noncompliance with the reticulation management plan [HC Spec 2.8 (2)]. (3) The water reticulation system must be designed, installed and operated in a manner that prevents: a) cross connections between potable water and non-potable water; b) stagnant water (i.e. no dead ends or unused pipes in the system); and c) backflow that may cause contamination of the water supply [HC Spec 2.8 (2)]. (4) Water pipes, storage tanks and facilities and other parts of the reticulation system must be maintained in good condition [HC Spec 2.2 (2)]. (5) The reticulation system should be flushed to ensure that stagnant water, rust, scale or other material is flushed out of the system when: a) water is not used for an extended period; and b) after any repairs to the system. The documented reticulation management plan should also include: an up-to-date plan of the reticulation system; and procedures for systematic checks: on all water reticulation pipe work, equipment and storage facilities; on integrity of all backflow prevention devices and valves connecting potable and non-potable water reticulations; and for evidence of leaks. Operators should also consider the provisions AS apply to: any new premises, alterations and additions to existing premises; and potable cold, warm and hot water reticulation systems (devices must be fit for the purpose intended). A code of compliance or building consent, if available, is good evidence of meeting the requirements of the Building Act and any local council regulations Identification of Water Lines (1) All water lines should be identified so that potable water and non-potable water lines are distinguishable. (2) Water lines conveying non-potable water should be clearly identified at: a) all outlets; b) junctions and valves; c) both sides of all wall penetrations; and Ministry for Primary Industries Page 59 of 148

61 d) any other place where identification is necessary to distinguish water type Water Management Plan (1) The operator must implement a water management plan for water described in Part Potable Water supplied by: a) an independent supplier and is subjected to any treatment by the operator; b) the operator solely for the operator s use; or c) an alternative water quality standard [HC Spec 2.9 (1)]. (2) The water management plan must include: a) any additional treatment: i) as required by the independent supplier or operator supplying potable water; or ii) as determined through an analysis of hazards and other risk factors; b) the water quality standard (including criteria) as determined through an analysis of hazards and other risk factors; c) a water sampling and testing programme; d) an action plan in the event of non-compliance with the water management plan; and e) the requirements of the reticulation management plan described in Part Water Reticulation Management Plan [HC Spec 2.9]. (3) The operator must reassess each applicable potable water source used by completing the Water Supply Assessment Checklist (Part 2 of Appendix 1): a) at least once every 3 years; b) prior to using a new operator source of potable water (i.e. the source changes or a new source is added); and c) within one month of any changes to the environment in or around the water source that may affect the potable water quality [HC Spec Schedule 1]. Schedule 1 of the HC Spec is reproduced in Appendix 1 of this Code. Refer to Part Non-Complying Water for further guidance on corrective actions in the event of a nonconformance Water Treatment (1) The water treatment system must be installed and maintained in accordance with the manufacturer s instructions [HC Spec 2.2 (2)]. (2) The operator must document details of the treatment in the water management plan including the following: a) the type of water treatment; b) parameters; c) procedures for control, monitoring and testing; d) acceptable limits; e) a water sampling and testing programme for monitoring the effectiveness of the specific water treatment applied; and f) corrective action procedures when the water source is found to be unsatisfactory based on the results of any tests done [HC Spec 9.2 (1)]. Examples of water treatment that may be applied by the operator to an independent supply or their own supply include chlorination, UV treatment, heating, coagulation, ozonation, flocculation and filtration. Ministry for Primary Industries Page 60 of 148

62 The operator should consult with a water treatment expert to determine the most appropriate treatment for their supply. The operator should discuss with the supplier of the particular treatment, the types and frequency of the water testing necessary to: confirm the effectiveness of the treatment; and ensure that it does not adversely affect the quality of the water Chlorine Disinfection (1) Where a water supply is treated with chlorine, the chlorination system should be designed and operated to ensure sufficient free available chlorine is maintained throughout the reticulation system. (2) When a water supply is treated with chlorine, a free available chlorine level of 0.2 mg/i (ppm) should be maintained throughout the reticulation system and at all the outlets. (3) The system should be designed so that the chlorine has a minimum contact time of 20 minutes prior to use of the water, and must be monitored on a regular basis to demonstrate that there has been adequate disinfection. (4) The ph of the water should be and turbidity should be low for chlorine to work effectively. A ph of greater than 8 and high turbidity can decrease the efficiency of chlorine disinfection. Options for monitoring include: fitting automatic water chlorination systems with alarm devices that indicate when the systems have ceased to function correctly; or manual checking of the system Ultra-violet (UV) Light Disinfection (1) The UV light disinfection unit should be adequate to disinfect the maximum flow of water for the system. As UV disinfection has no residual sanitising ability, UV-treated water can be re-contaminated immediately after treatment. To control this hazard, there should be no holding tanks or reservoirs between the disinfection unit and the point of use Water Treatment Systems (1) Automatic water chlorination systems should be fitted with alarm devices that indicate when the chlorination systems has ceased to function correctly. (2) UV light water disinfection systems should be fitted with monitoring and alarm systems to automatically shut down the water supply to the UV water treatment unit in the event of: a) power failure to the treatment unit; b) lamp failure of the treatment unit; and c) excessive water turbidity. (3) Novel or alternative water treatment systems should be fitted with an appropriate monitoring and alarm system. Ministry for Primary Industries Page 61 of 148

63 Alternative Disinfection Technology (1) Alternative disinfection technology must be designed and constructed in a manner that will: a) manage hazards [AP Reg 10]; and b) ensure water is potable at point of use [HC Spec 2.5 (1)] Non-Complying Water (1) This clause applies only to water to which Part Potable Water applies. (2) All operations requiring the use of potable water must cease with provision if: a) the independent supplier (e.g. local council) advises the operator that the water is not fit for drinking without additional treatment [HC Spec 2.11 (2)]; b) the operator has reason to believe that the water is not fit for use, and the operator has no other means described in the RMP to ensure the water is potable at the point of use [HC Spec 2.11 (2)]; c) water used is supplied by the operator, and the operator fails to comply with any of the requirements of the water management plan (including corrective actions), and has no other means described in the RMP to ensure the water meets the original standard at the point of use [HC Spec 2.11 (3)]; or d) a 'boil water' notice is issued and the operator is not able to: i) comply with it in respect of all potable water; ii) treat the water to ensure that it is potable; or iii) use an alternative supply which meets the standards [HC Spec 2.11]. Operators should cease operation if there are no preventative measures in place to manage food safety after non-complying water is introduced to the product Non-Compliance with Microbiological Criteria (1) The supplier of an independent water supply must notify the operator whenever E. coli or faecal coliforms are identified in that supply. (2) In the event of a boil water notice for an independent supply and an E. coli non-conformance with an operator s own supply, the operator should: a) start daily point-of-use sampling; b) take steps to prevent poultry continuing to be received for slaughter or use an alternative potable water supply; and c) if necessary, continue to slaughter and dressing of poultry to prevent animal welfare issues for birds on site. (3) If E. coli or faecal coliforms are identified at the point of use, the operator must: a) re-sample the water supply; and b) investigate the cause of the problem and take corrective action [HC Spec Schedule 1]. (4) All product from the date of notification of the boil water notice or last clear E.coli test for the operator s own supply must be put on hold pending an assessment by a suitably skilled person [RMP Spec 11]. For further guidance, follow the corrective action flow path outlined in Figure 1 of Appendix 3. The following super-chlorination options may be used to disinfect the reticulation system after microbiological contamination. Ministry for Primary Industries Page 62 of 148

64 Option 1: Flush the entire water system including storage tanks and distribution pipes with superchlorinated water (>40 ppm) for at least 30 minutes. Follow by an overnight soaking (12 hours) of the entire system with super-chlorinated water. The ph of the water must be for chlorine to work effectively. After the overnight soaking, test the water for free available chlorine at the point of use from 5 randomly selected sampling points, and then drain the water out. If no free available chlorine is detected, repeat the super-chlorination procedure. Otherwise refill the system with potable water. Option 2: Flush the entire water system with super-chlorinated water at 200 ppm and leave for 30 minutes. Test the water for free available chlorine at the point of use from five randomly selected sampling points and drain the water out. If no free available chlorine is detected, repeat the super-chlorination procedure. Otherwise rinse the system Non-Compliance with Chemical Requirements (1) If Maximum Acceptable Values (MAVs) for chemicals are exceeded, the operator must take the following corrective actions: a) follow the requirements of the DWSNZ in relation to non-compliance with a chemical MAV; b) resample the water supply, investigate the cause of the non-compliance and take appropriate action; and c) continue weekly sampling until the levels of chemicals detected are less than the relevant MAVs [RMP Spec 8]. (2) If radiological limits are exceeded, the operator must follow the requirements of the DWSNZ for noncompliance with the relevant radiological MAV [RMP Spec 8]. (3) The operator should consider consulting a drinking water assessor (DWA) or competent person to assist with corrective actions Options for Alternative Supply in Event of Boil Water Notice or Non-Compliance (1) In the event of a boil water notice or non-compliance, alternative supplies must provide potable water at point of use. This may be to an alternative standard (refer to clause (4)) [HC Spec 2.5 (2)]. (2) The operator should use a competent person to develop and document a specific water management plan for the alternative supply. (3) The alternative water supply management plan should be approved as part of the RMP evaluation process. The local council may issue a 'boil water' notice e.g. when E. coli persists in the water despite successive corrective actions, including disinfection. Local councils should inform processors in the event of a boil water notice. This action is taken only when other forms of disinfection have not been effective. Refer to the Drinking Water Standards for New Zealand (DWSNZ). In the event of a boil water notice or non-compliance, contact your verifier and advise them of the actions you have taken. Refer to Figure 1 and Figure 2 in Appendix 3 for the actions that lead to an issue of a boil water notice. Ministry for Primary Industries Page 63 of 148

65 Handling and Disposition of Contaminated Materials (1) If contamination with non-potable water occurs: a) affected poultry product and material must not be used for human consumption [HC Spec 3.2 (2)]; b) affected product contact surfaces must be cleaned and sanitised prior to reuse [AP Reg 11]; and c) affected packaging materials and containers that cannot be effectively cleaned and sanitised must not be used for packing of any poultry product and material [HC Spec 7.2 (4)]. (2) The operator should also comply with the requirements and procedures for non-complying products procedures of their RMP. Refer to Part 6.8 Non-Complying Product and Recall for further guidance Records (1) Keep records to demonstrate compliance with the requirements [RMP Spec 20(2)]. (2) Examples of Potable Water records to keep; a) water assessment records; b) completed Water Supply Assessment Checklist (for operator supplied water); c) water management plan, if applicable; d) checks of the reticulation system; e) water testing results; f) any non-compliances identified and preventative and corrective actions taken; and g) results of any analysis undertaken. Ministry for Primary Industries Page 64 of 148

66 Part 4: Repairs and Maintenance 4.1 Scope (1) To ensure that the premises, facilities and equipment are maintained in good working order and meet the requirements. 4.2 Requirements and Procedures (1) The operator must document and implement a repairs and maintenance programme to ensure that the premises, facilities and equipment are maintained in good working order and hygienic conditions [AP Reg 11]. (2) Repairs and maintenance work should be undertaken in a manner that minimises contamination of poultry material, ingredients, products, packaging, equipment and the processing environment. (3) Product, ingredients and packaging must be protected from contamination or removed from the affected area while repairs or maintenance work is conducted [AP Reg 11]. (4) Product, ingredients or packaging that cannot be protected or removed from the affected area during repairs and maintenance work should: a) be identified; b) have its condition assessed by a suitably skilled person; and c) have an appropriate disposition applied, if necessary. (5) Equipment and the surrounding area affected by repairs and maintenance activities should be returned to a hygienic and sanitary condition before processing resumes. (6) The repairs and maintenance programme should include the following: a) scope of the repairs and maintenance programme (it should include buildings, facilities and equipment that will affect the ability to produce safe and suitable product); b) responsibilities of personnel implementing the programme (including any competencies required for specific tasks where appropriate); c) a maintenance schedule identifying the maintenance requirements and frequencies of items covered by the programme; d) the type of system(s) used on the premises for identifying and tracking required, open, and overdue repairs and maintenance work (e.g. list, register or computerised system); e) maintenance procedures for both programmed (e.g. routine) and non-programmed (e.g. facility or equipment breakdowns) maintenance tasks; f) restoring appropriate hygienic conditions to the affected area and/or equipment (e.g. hygiene checks); and g) procedures for re-commissioning or returning equipment to use. Product exposed during maintenance may be at risk from contamination. Maintenance may disturb dust, dirt and harbourage sites for microorganisms, all of which can present a food safety risk. If the temperature of raw poultry product and material is raised for a significant length of time due to maintenance activities, it may provide ideal conditions for the growth of microorganisms. Before commencing repairs and maintenance activities, consider the following: type and extent of the repairs and maintenance work e.g.; is it a major or minor repair; could it cause dust, swarf, airborne contamination or splashes; Ministry for Primary Industries Page 65 of 148

67 could it affect items or equipment around or below where the work is taking place; exposure of ingredients, products, packaging, or equipment to contamination, and implementing controls for protecting them (e.g. removing them from the affected area or covering them); type of product and processing area affected (e.g. primary or secondary processing areas); movement of maintenance workers; maintenance equipment, tools and materials to be used (i.e. could they be a source of contamination); and physical location of repair e.g. high traffic area. The operator should document how they will manage the above considerations when conducting major construction or renovation work. For example, fit-outs, relocating product lines, extensions, re-surfacing etc. in processing or support areas. MPI does not expect operators to develop procedures for each repair and maintenance activity. Operators should develop generic procedures for programmed and non-programmed maintenance to ensure product safety and suitability is maintained. Operators should consider the following when developing maintenance procedures: planning required (scheduling, approval to access affected equipment or areas); specific personnel and equipment (including tools) required; and hygiene requirements (personnel, tools, removing or protecting product). A non-programmed maintenance procedure should ensure a suitably skilled person: assesses the work s potential to contaminate product, ingredients, packaging, equipment and the processing environment; and implements appropriate controls to protect these items where possible and/or minimise contamination before maintenance work begins. In addition, operators may wish to document procedures for specific non-programmed maintenance tasks such as equipment breakdown, glass breakages etc. 4.3 Hygiene Practices Associated with Repairs and Maintenance (1) Operators must ensure chemicals used for repairs and maintenance comply, refer to Part 6.10 Control of Maintenance Compounds [HC Spec 3.4 (1)]. (2) Product, ingredients and packaging must be protected from contamination or removed from the affected area while repairs or maintenance is made [AP Reg 10 and 11]. (3) The operator must take corrective actions when repairs that cannot be carried out in a sanitary manner are required during processing (such as during equipment breakdown) [RMP Spec 11 (2)]. (4) Maintenance personnel should comply with the operator s requirements for hygienic practices appropriate to the area they are operating in. (5) Tools used for repairs and maintenance should: a) not come in contact with, or compromise the hygienic status of, any product, ingredient or packaging material; and b) be cleaned and sanitised to meet the hygienic requirements of a contact surface. (6) Tools should be removed and/or returned to storage once maintenance or repair work is completed, unless required for frequent use. If required for frequent use, tools should have a designated storage place and be maintained in a hygienic manner. (7) After any repairs or maintenance, affected contact surfaces must be cleaned and sanitised. A preoperative hygiene check must occur before processing recommences [AP Reg 11 (1)]. Ministry for Primary Industries Page 66 of 148

68 Repair actions may include: removing the defective equipment from the processing area to be repaired whilst processing continues. Products, ingredients and packaging that could potentially be contaminated while repairs are made are protected from contamination or removed from the affected area; or ceasing processing in the area affected by the breakdown. In extenuating circumstances, production may continue whilst maintenance is being carried out, but the affected product should be: separated; retained and assessed for safety and suitability; and managed appropriately. Normal in-process adjustments to machinery or equipment (e.g. replacing injector needles, etc.) are not considered a maintenance activity. When making in-process adjustments, care is still needed to ensure: that product is protected from contamination; and appropriate cleaning and sanitation occurs afterwards if necessary. The person in charge of processing should be notified prior to any repairs and maintenance during processing. Extenuating circumstances would be where animal welfare requirements require processing to continue, or where food safety would be more at risk if processing did not continue. Tools should be cleaned (and sanitised depending on the hygienic status of the area) before entering processing areas, especially when working on product contact surfaces. Where practical it is recommended operators have maintenance tools that are dedicated for use in specific areas of their operation to avoid cross contamination. 4.4 Maintenance Programmed Maintenance (1) The operator must routinely and systematically inspect the buildings, facilities and equipment to identify and correct items that require preventative repair and maintenance [AP Reg 11(1)]. (2) The inspection should include known sources of physical contaminants. (3) The operator should ensure programmed maintenance is conducted at a time and in a manner that will not affect product safety and suitability. (4) Programmed maintenance should only occur during processing if the impact on product safety and suitability is managed appropriately. (5) The frequency of programmed maintenance should ensure that buildings, facilities and equipment remain suitable for producing safe and suitable product. (6) The operator should consider how frequently maintenance checks need to be conducted (e.g. daily, weekly, or less frequently). Repetitive problems or breakdowns may indicate that the maintenance frequency needs to be increased, or equipment/facilities need replacing. See Table 5 below. (7) The operator should consider and appropriately manage any risk to product safety and suitability that construction and renovation activities may cause. Table 5: Examples of maintenance check by frequency Ministry for Primary Industries Page 67 of 148

69 Daily maintenance checks on Weekly maintenance checks Less frequent maintenance checks Equipment used for critical measurements, e.g. weigh lines Key equipment will operate in a manner that does not compromise product safety and suitability Equipment such as blades, injector needles, plucker fingers to ensure equipment integrity Building maintenance (e.g. flaking paint, light covers, rust on overheads, pipework) Checks on equipment and parts which may not be inspected on a daily basis, e.g. conveyors, mechanical separators, chiller systems etc. Roofs, guttering Pumps, motors Hot water steam, water reticulation systems Known sources of physical contaminants should include items that have been known to, or are reasonably likely to, pose a physical hazard in product. Sources may include: glass items (including covered glass); nuts and bolts known to require frequent tightening; needles; blades; and moving parts prone to wear and tear or breakage, etc. Maintenance should occur at the end of processing. If this is not practicable, it should take place at a time that reduces the opportunity of contaminating exposed ingredients, packaging and product. This could be at a normal work break during processing. A delay in completing programmed maintenance is acceptable in some situations (e.g. when parts are not available due to factors outside the operator s control) provided it does not affect product safety and suitability. Operators should consider the impact of construction and renovation activities on product safety during the planning phase of these activities. They should implement appropriate measures to prevent product contamination. During construction or renovation, operators should increase the amount of contaminant monitoring in surrounding processing areas. Processing should not occur in areas directly affected by construction and renovations Non-Programmed Maintenance (including Emergency Maintenance) (1) The operator should take all practical steps to ensure there is no adverse effect on product safety or suitability from non-programmed maintenance. (2) The supervisor should be notified immediately of any situation which requires non-programmed maintenance. (3) Before any non-programmed maintenance work begins, a suitably skilled person should: a) assess the potential of the work and associated activities to contaminate: i) product; ii) ingredients; iii) packaging; iv) equipment; and Ministry for Primary Industries Page 68 of 148

70 v) the processing environment; b) put in place appropriate controls to protect these items where possible and minimise contamination. (4) The operator should consider the impact of the defect on product safety and suitability and assign it to one of three categories: critical, major or minor. (5) The operator should determine the urgency of which non-programmed maintenance should be undertaken when defects (e.g. breakdowns) occur: a) critical defects operators should take all practical steps to ensure they are repaired immediately; b) major defects should be repaired at the earliest opportunity (i.e. at the end of the processing period); and c) minor defects should be repaired as the opportunity arises. The operator should set a date for correction of the defect. It is common practice to categorise defects as: critical - a defect that would have a direct or immediate effect on product safety (e.g. damage to, or severe deterioration of a product contact surface, processing equipment failure etc.); major - a defect that may result in a direct effect on product safety by introducing a conflicting hygiene status; and minor - a defect which is not expected to have any direct effect on product safety. When determining the urgency of non-programmed maintenance, operators should consider the stage in processing, including: the effect of the defect breakdown on the entire processing line (e.g. animal welfare issues with live poultry in the hanging bay); and the processing environment conditions. Repairing a minor defect should be scheduled as part of programmed maintenance and corrected within 6 months of being raised, or sooner where possible Temporary Repairs (1) Temporary repairs should: a) not affect the hygienic status of equipment, processing areas or the safety or suitability of product; and b) be recorded on the maintenance system to be permanently repaired within an allocated time, as determined by the repair s impact on product safety and suitability. A temporary repair is acceptable to resolve an issue whilst allowing processing to continue in the shortterm, when a permanent or complete repair cannot be made Lighting Replacement (1) The replacement of glass lighting (e.g. fluorescent tubes and bulbs) in processing areas, support areas, or amenities should not occur until processing in the affected room has ended. (2) If replacement is essential to allow processing to continue (but the glass is not broken), nonprogrammed maintenance procedures should be followed. Ministry for Primary Industries Page 69 of 148

71 4.4.5 Breakages (Glass and Other Physical Hazards) (1) The operator should take all practicable corrective actions in the event of a breakage during processing, e.g.; a) isolate the affected area; b) notify the supervisor in charge of area of the incident; c) ensure any affected personal protective equipment is changed; d) use appropriate equipment to remove the breakage and clean the area; e) identify and isolate any affected product and apply appropriate disposition; or f) assess the hygienic status of the affected area and confirm as acceptable prior to resuming processing Approved Maintenance Compounds (1) Using maintenance compounds within processing and support areas must be in accordance with manufacturer s directions and the conditions approved by MPI, this includes compounds where there is potential for incidental product contact (e.g. oil, lubricants and surface treatment compounds) [HC Spec 3.4 (1)]. Refer to Part 6.10 Control of Maintenance Compounds Building Maintenance (1) The condition of buildings must not be a source of contamination [AP Reg 11]. Roofs, gutters and drains should be maintained to prevent build-up of debris that may lead to pooling, flooding, leaks and the attraction and harbourage of pests. Coverings over windows, doors, vents and openings should be maintained to minimise the entry of pests External Environment (1) External areas within the RMP boundary must be maintained in a tidy condition to minimise potential sources of contaminants and harbourages for pests [AP Reg 11]. Roadways and car parks should be tar sealed or concreted. Landscaped areas, e.g. shrubs, trees, grass should not be in close proximity to buildings where product is processed. Unused equipment should be covered and stored on hard standings away from buildings where product is processed or stored. Storage on grassed areas may increase the likelihood of pest harbourage due to the difficulties of maintaining the grass height Essential Services (1) The operator should maintain the on-site services that affect the production of safe and suitable product. This includes water reticulation systems, waste water and sewerage systems, and electricity supply (where appropriate). (2) Essential service maintenance should be part of the programmed maintenance schedule. Ministry for Primary Industries Page 70 of 148

72 Processing Areas, Food Support Areas and Amenities (1) The operator must maintain processing areas, support areas and amenities to: a) allow for appropriate cleaning and sanitation to take place; and b) ensure the integrity of the hygienic envelope [AP Reg 9 and 11]. Examples of items that may affect product safety if poorly maintained include: exposed wood; openings to the outside environment such as windows, doors, and vents; and fixtures and fittings (e.g. cracks and crevices in ceilings, walls, floors, flaking paint, overhead leaks from pipes, equipment attachments) Engineering Workshops, Equipment and Tools (1) Debris from engineering workshops (such as swarf and other unwanted materials) should be prevented from entering processing or support areas. (2) Equipment, tools and parts used for repairs and maintenance in processing and support areas must not be a source of contamination [AP Reg 11]. (3) The operator should implement a tools and parts reconciliation system to ensure all tools taken into processing or support areas are accounted for once maintenance is complete. (4) Tools should be removed and/or returned to storage or a designated area (e.g. a shadow board) once maintenance or repair work is complete. This may be achieved by keeping doors closed, the use of swarf mats, boot washes etc. Tools, tool kit and equipment parts should be assessed for their suitability for use in the intended environment. Where necessary they should be cleaned and sanitised before being taken into processing and/or support areas. A reconciliation system could include tool kit monitoring, shadow boards, counting and recording the number in and out, verification and sign-off by engineers once maintenance is complete via a work order Records (1) Refer to Part 4.6 Records. 4.5 Equipment Maintenance (1) The operator must maintain equipment to ensure it is not a source of contamination to product [HC Spec 2.3 (4)]. (2) The operator should determine the frequency of equipment maintenance based on: a) the type of equipment; b) its intended use; c) frequency of use; and d) manufacturer s recommendations (where available). (3) The operator must regularly update the maintenance schedule to ensure the maintenance requirements for new or re-commissioned equipment is included [RMP Spec 19 (2)]. Ministry for Primary Industries Page 71 of 148

73 Where manufacturer s recommendations are not available, maintenance frequencies should be based on the operator s knowledge of equipment performance, reliability and consistency. Equipment maintenance checks should also include an assessment of: the equipment s overall condition and integrity (e.g. is it working properly); sources of physical contaminants (e.g. damaged, lost or worn parts, rust, loose flaking paint, loose parts on equipment prone to vibration, broken parts such as needles and blades etc.,); and microorganism harbourage sites (e.g. worn or frayed hoses, gaskets or belts, porous welds, product contact surfaces). Repetitive equipment problems or breakdowns may indicate that the maintenance frequency should be reviewed and increased, or that the equipment needs to be replaced Damaged, Decommissioned or Idle Equipment (1) Damaged, decommissioned or idle equipment should be stored in an appropriate way to ensure it does not become a source of contaminants or harbours pests. (2) Equipment that could be a source of contamination should be: a) physically isolated from processing lines and product; or b) removed from processing areas. (3) Damaged or decommissioned equipment that remains in processing areas should be clearly identified. Where possible, damaged or decommissioned equipment should be removed from processing areas. Decommissioned equipment may be stored outdoors, but should be placed on a hard standing (e.g. concrete, sealed or paved area) and covered. It is recommended to operators that they document why equipment is decommissioned or damaged as these details can be helpful when determining the equipment's suitability for repair or re-commissioning Returning Equipment to Use (Including Re-Commissioning Equipment) (1) The operator should have a procedure to ensure that equipment returned to use (i.e. after repairs and maintenance, re-commissioning or having previously been idle) is not a source of contamination to the product. (2) The procedure should include steps to ensure that: a) equipment is thoroughly cleaned and sanitised before being returned into a processing or support area; b) validated equipment is revalidated if the repairs and maintenance activity may affect its validated status (e.g. replacing temperature probes sensors in ovens freezers); and c) equipment is subject to a pre-operational check before processing re-commences Maintenance of Calibration of Equipment (1) The operator must implement procedures to prevent unauthorised adjustments to calibrated equipment during maintenance [HC Spec 6.2 (3)]. (2) Calibrated equipment that is non-conforming (e.g. broken, expired calibration period) must be identified as non-conforming, and not used for critical measurements until it is recalibrated, repaired or replaced. Ministry for Primary Industries Page 72 of 148

74 Refer to Part 6.9 Calibration of Measuring Equipment Maintenance Personnel and Contractors (1) The operator should ensure that maintenance workers, including contractors are: a) competent to perform the required tasks; b) trained to do their job without contaminating product (or if contamination occurs, able to follow appropriate product disposition procedures); c) where possible, to minimise contamination of the surrounding environment; and d) trained in, and adhere to hygienic requirements. Refer to Part 4.3 Hygienic Practices Associated with Repairs and Maintenance for further guidance. Examples of minimising contamination of surrounding environment include: adequate clean-up upon completion of the work; and the use of dedicated tools for the raw or ready-to-eat product areas, or at least a sanitation step to minimise cross contamination. The operator needs to ensure that contractors are trained and competent. This can be achieved in several ways, including: providing contractor inductions or refresher training; use of approved supplier databases; and having identification and supervision (where appropriate) whilst on site Records (1) Refer to Part 4.6 Records. 4.6 Records (1) Keep records to demonstrate compliance with the requirements [RMP Spec 20(2)]. (2) Examples of Repairs and Maintenance records to keep; a) repair and maintenance activities and systems; b) repairs and maintenance register; c) site plan with the RMP boundary; and d) verification activities. Records should include the following: a maintenance schedule; maintenance records or job sheets including: when and how the defect breakdown was repaired; who conducted the work; who has signed-off that it was completed; and that returning equipment to use procedure was followed; corrective action records (including details of affected product if applicable); and verification records. Ministry for Primary Industries Page 73 of 148

75 Comprehensive maintenance records will assist the operator to verify that the repairs and maintenance programme is working correctly. It may also be useful in the event of a food safety incident or trace back situation and may help to reduce the risk to the business. Ministry for Primary Industries Page 74 of 148

76 Part 5: Cleaning and Sanitation 5.1 Scope (1) To ensure that all areas within the premise, facilities and equipment are maintained in a hygienic condition and procedures for cleaning and sanitation are in place that meet the requirements. 5.2 Requirements and Procedures (1) The operator must ensure that all areas of their site (e.g. within the physical boundaries) of the RMP, including the facilities, support areas and equipment, are maintained in a clean and sanitary condition appropriate to the use of the area [AP Reg 11 (1) and HC Spec 2.2 (2)] Documented Cleaning and Sanitation Programme (1) The operator must develop and implement a written cleaning programme for all of the following: a) processing areas; b) storage areas; c) freezers and chillers; d) equipment; e) amenities; and f) external areas of the premises [AP Reg 11]. (2) The cleaning programme should include the following information: a) areas/equipment to be cleaned; b) procedures for all cleaning and sanitising operations, including the cleaning method, frequency of cleaning and sequence of cleaning; c) detergents/sanitisers to be used, their concentration, application method and contact time required; d) the identity or positon of person(s) responsible for the cleaning activity; e) methods and frequencies of monitoring and verification of effectiveness of the cleaning and sanitation procedures; and f) cleaning records forms or check sheets. 5.3 General Cleaning Procedures (1) Cleaning activities must be carried out in a way that will minimise contamination of: a) poultry product or material; b) ingredients; c) product contact materials (e.g. packaging); and d) previously cleaned areas, structures facilities or equipment [AP Reg 10 and 11]. (2) Workers should be adequately trained in the handling of cleaning chemicals and the implementation of the cleaning programme. (3) Cleaning compounds should be used in accordance with procedures given in Part 6.10 Control of Maintenance Compounds. (4) The cleaning method should be appropriate to: a) the product and the operation; b) the type of surface to be cleaned; and c) the type and characteristics of the residual material or dirt to be cleaned off the surface. Ministry for Primary Industries Page 75 of 148

77 Food processing areas, facilities and equipment should be cleaned in accordance to the cleaning programme. Frequency should be often enough to minimise or prevent cross contamination of poultry product and material. Care is required to avoid re-contamination. Cleaning from clean areas towards dirty areas can help minimise the spread of contamination, e.g. walls should be washed before floors. However when hosing floors, high-pressure hoses can re-contaminate previously cleaned surfaces with waste water Most processing areas will require a wet cleaning routine. Dry cleaning is recommended for areas where dry materials are handled and stored; ingredient and packaging stores; preparation areas for dry ingredients; and outer packaging areas. Dry cleaning in areas with exposed ingredients or product is only appropriate where moisture levels in products are below levels sufficient to support microbial growth. Water and steam should be contained within the immediate area that is being wet cleaned to prevent wetting dry ingredients, packaging, products and dry product areas. If product is not removed from the area, the amount of water used should be limited to that necessary to complete the cleaning procedure. A mixture of wet and dry cleaning may be suitable in some circumstances (e.g. support areas, packing areas that require occasional wet cleaning). Operators may choose to incorporate existing documented information into their cleaning and sanitation programme by reference Wet Cleaning of Processing Areas (1) Processing areas and equipment (except dry areas/equipment) should be wet cleaned using effective cleaning and sanitising procedures. (2) Poultry products or material, ingredients, packaging and other material that may be contaminated during cleaning should be: a) removed from the area and stored in an appropriate location; or b) protected from moisture, before wet cleaning is started. (3) Clean water should be used for wet cleaning of facilities and equipment. (4) Product contact surfaces, including processing and conveying equipment should be cleaned (and sanitised if appropriate): a) at least at the end of each production day, unless an alternative cleaning frequency has been validated by the operator and approved by MPI; b) whenever surfaces become contaminated or come into contact with waste; and c) whenever necessary to prevent cross contamination between products of different hygiene status (e.g. offals for animal consumption and product for rendering). (5) All surfaces within rooms (e.g. ceilings, walls and floors), equipment and contact surfaces that are wet cleaned should be dry before processing of dry product restarts. (6) When footbaths are used, they should be maintained properly with effective concentrations of sanitiser so that they do not become a source of contamination. Ministry for Primary Industries Page 76 of 148

78 Cleaning should commence without delay after finishing the day s operation, because the more the residues age, the more difficult it is to remove from equipment surfaces. Cleaning of facilities and equipment which are no longer in use should not be started if there: is still exposed product and packaging within the area; and is potential for exposed product and packaging to be contaminated from splashes and aerosols created during cleaning. A basic cleaning and sanitising system usually involves the following steps: removal of gross contamination (e.g. removing scraps); rinsing the area with cold or warm water (60 C or cooler to prevent coagulation of protein, which makes it extremely difficult to remove); applying a detergent solution or foam and leaving it on all surfaces for the time specified by the manufacturer; scrubbing surfaces to loosen and remove dirt; rinsing with water and draining; if scale has to be removed, an acid detergent is used at this stage, followed by rinsing and draining; applying a chemical sanitiser and leaving it on all surfaces for the time specified by the manufacturer; rinsing off the chemical sanitiser with water and draining (not needed if a no-rinse sanitiser is used); and allowing surfaces and equipment to dry. Equipment and machinery that require disassembly should: be disassembled in accordance with manufacturer s instructions; and have all parts cleaned and sanitised, including hard-to-reach areas where residue can build up. Areas that are wet cleaned should be as dry as possible before restarting processing Dry Cleaning of Dry Processing and Storage Areas (1) Dry processing, storage areas and stores should: a) have adequate space to allow for effective cleaning; b) be kept dry and tidy; and c) be cleaned regularly by appropriate dry cleaning methods. (2) Products, dry ingredients, packaging and other materials should be stacked and stored in an appropriate manner. Dry cleaning methods include brushing, sweeping, scraping, vacuuming and blowing with compressed air. The cleaning method should minimise the creation of dust and airborne contamination, particularly to prevent cross contamination of allergens from dry ingredients. When vacuum cleaning systems are used, filters should be changed regularly and dust bags should be removed and replaced in a way that will not result in the contamination of any product or product contact surface Sterilising Surfaces or Equipment (1) Sterilising may be required to meet certain OMARs and has been included here for completeness. Ministry for Primary Industries Page 77 of 148

79 Surfaces or equipment intended to be sterilised should be clean prior to sterilising. The operator should regularly monitor steriliser water temperatures when in use. Temperatures should be checked in continuous flow systems if sterilising water stops flowing for more than 15 minutes. Sterilisers should be: emptied and cleaned at least once every processing period; and kept in such a condition that sterilisation is effective. The presence of contaminants (e.g. fat) in the steriliser should be minimised to ensure sterilisation effectiveness is not compromised. Equipment (such as knives, steels etc.) should not be stored in steriliser drains. If the sterilising water temperature is less than 82ºC, then: cease production immediately; an approved sanitising maintenance compound can be used in place of sterilising water provided it can achieve an equivalent microbial outcome; or production may continue for up to 30 minutes from when the sterilising water temperature is first noted to be below 82ºC, provided: the discrepancy at the point of use is the first to occur during the processing period; the premises do not have a history of non-compliance for sterilising water temperature control; and continued processing is unlikely to result in an adverse food safety outcome. Surfaces and equipment should be exposed to sterilising water for sufficient time to reduce microbial contamination to below the expected mean log 10 count of organism(s) found on product Cleaning and Sanitising During the Processing Day (1) Operators should ensure personnel maintain a clean work area by completing the following during breaks or once every three hours, whichever is earliest: a) removing process scraps, waste from floors, and emptying waste/rubbish bins where practical; b) cleaning and sanitising/sterilising knives, utensils, pouches and chopping boards; c) cleaning and sanitising product contact clothing before re-use; d) gloves must be cleaned (if reusable) or replaced. Protective cut-resistant gloves must be cleaned and sanitised unless they are covered with an impervious glove; and e) ensuring footbaths contain an effective concentration of sanitiser. (2) Surfaces should be clean before sanitising. Sanitiser should be used in accordance with the manufacturer s instructions and MPI s conditions of approval. (3) Processing equipment or contact surfaces that have been used and remain idle for longer than 4 hours, should be cleaned and sanitised prior to reuse. Sanitiser are most effective on clean surfaces. More frequent cleaning may be required if the equipment is in a non-refrigerated area. Operators should not combine cleaning compounds with sanitisers in an attempt to reduce cleaning times, without seeking professional advice. Incorrectly combining cleaning compounds and sanitisers may reduce their effectiveness. Ministry for Primary Industries Page 78 of 148

80 All reasonable attempts should be made to remove process scraps. It is accepted that accessing some parts of equipment is difficult and small amounts of process scraps may remain after cleaning during breaks. Microbiological contamination on contact surfaces can build-up during the processing period. Operators should determine an appropriate cleaning frequency based on their knowledge of the process and product. Raw poultry processing areas operating at ambient temperatures are likely to require more frequent cleaning than areas operating at 12 C or below Cleaning-in-Place systems (1) CIP systems should not be a source of cross contamination. (2) Cleaning instructions on the CIP system should be provided by the manufacturer and should include: a) cleaning solutions; b) temperature of cleaning solutions; c) inspection points; d) the quality of hot water reviewed; e) contact times and flow rates; f) any special cleaning requirements; and g) wash line injector settings Changing to Products that Require a Higher Hygienic Status (1) When in the same area or using the same equipment to process products that require a higher hygiene status than the previous product, the operator should ensure: a) personnel clean and sanitise the product contact surfaces, equipment and areas to be used for processing; and b) a pre-operative hygiene check of the area and equipment is completed before processing the product requiring the higher hygienic status; This includes dismantling moving parts of equipment that come into contact with product (e.g. conveyor belts etc.). Cleaning and sanitising is intended to reduce microbial loads and to prevent cross contamination between different product types that have a different hygienic status, e.g.: from offal to other products (where not included in the final product); and between products of different allergenic status. It is not expected that operators specifically test the different poultry cuts/types to determine whether a certain batch has higher levels of contamination and needs to be processed separately. Operators should use any previous data, along with their general knowledge of microbial levels within their product, to assist with production planning. Refer to Part Hygienic Practices and Part 2.4 Operator Verification for further guidance. 5.4 Cleaning of Areas and Facilities Processing Areas (1) All wet processing areas should be cleaned and sanitised at the end of each processing period. See Table 6 below for suggested cleaning frequencies. Ministry for Primary Industries Page 79 of 148

81 (2) All other facilities should be cleaned, and where appropriate sanitised, at: a) the end of each processing period; or b) a frequency specified in the cleaning and sanitation programme. (3) Floors should be cleaned and sanitised at the end of each processing period. Drain covers should be emptied and cleaned at the end of each processing period. (4) Walls should be cleaned and sanitised, to the ceiling, weekly or at a frequency defined in the cleaning and sanitation programme. Walls should be visibly clean at pre-operational hygiene checks. Table 6: Suggested cleaning method and frequency for various facilities Facility/area Cleaning Method Cleaning Frequency Wet processing areas Cleaned and sanitised End of each processing period Amenities Cleaned Daily Dry stores Dry cleaned At least weekly or at a frequency specified in the cleaning and sanitation programme Other facilities Cleaned, and where appropriate sanitised End of each processing period or at a frequency specified in the cleaning and sanitation programme Floors Cleaned and sanitised End of each processing period Walls, ceilings Sanitised Weekly or at a frequency defined in the cleaning and sanitation programme Drain covers/sieves Emptied and cleaned End of each processing period Overhead Structures (including ceilings) (1) All overhead structures should: a) not be a source of contamination; and b) be inspected, cleaned and sanitised at a frequency: i) defined in the cleaning and sanitation programme; and ii) when not visibly clean Chillers and Freezers (1) Chillers and freezers should be: a) emptied, cleaned and sanitised at a frequency specified in the cleaning and sanitation programme; and b) maintained in a clean and tidy condition. Chillers containing: unprotected product should be cleaned and sanitised weekly; and protected product should be cleaned and sanitised at least monthly Fans and Evaporators (1) Fans and evaporators should be cleaned on a regular basis and after substantial maintenance work. (2) Fans and evaporators in processing areas should be cleaned at least once every 6 months or whenever necessary. (3) Air circulating systems, filters and air socks should be cleaned in accordance with: Ministry for Primary Industries Page 80 of 148

82 a) the manufacturer s instructions where available; or b) the cleaning and sanitation programme. The frequency of cleaning should be determined by visual inspection, and where appropriate, microbial monitoring. Cleaning procedures may include, or require, fumigation Footbaths (1) Footbaths should: a) be cleaned and sanitised at the end of each processing period; b) have an effective concentration of sanitiser maintained during processing; and c) be emptied and refilled with fresh sanitiser at regular intervals during the processing period. 5.5 Cleaning of Equipment Processing Equipment (1) Processing equipment, including conveying equipment and trolleys, should be cleaned and sanitised at the end of each processing period or more frequently depending on use. (2) Product contact equipment should be cleaned inside and out, including areas where product waste and contamination may accumulate, but are difficult to access (e.g. areas caged for safety reasons during operation, blade covers etc.). (3) Alternative cleaning and sanitation frequencies can be used for non-contact surfaces on processing equipment, provided they: a) are stated in the cleaning and sanitation programme; and b) comply with the hygienic requirements and that this can be demonstrated by ongoing monitoring and operator verification. (4) Portable equipment should be checked to ensure it is in a clean and sanitary condition before entering a processing area Conveyors (1) Product contact conveyors, including the supporting structure and underneath the belt, should be cleaned and sanitised at the end of each processing period. (2) All other conveyors should be cleaned at a frequency specified in the cleaning and sanitation programme Equipment Used in Live Bird Handling/Reception Areas (1) Crates and modules should be washed and dried, or washed and sanitised, before re-use. (2) The operator should ensure automated washing systems are operating correctly and achieving the required state of cleanliness. All reasonable attempts should be made to remove visible contamination to minimise the presence of Campylobacter. Some crates and modules may need washing more than once to achieve this. Washing activities should be conducted away from processing areas (including hanging and slaughtering areas) where possible. It is common for washing to occur in lairage areas and this is acceptable. Ministry for Primary Industries Page 81 of 148

83 Aerosols from washing activities (such as water blasting) may cause cross contamination from crates/modules into processing areas. Operators could separate washing activities from processing activities by using physical barriers or washing once processing is complete Trucks and Forklifts for Handling Live Poultry (1) Trucks and forklifts should be cleaned and sanitised at a frequency specified in the cleaning and sanitation programme. Truck trays and decks should be visibly clean prior to use/re-use to minimise cross contamination. Forklift wheels and forks should be visibly clean at the beginning of each processing period. See the Broiler Growing Bio-security Manual for more details regarding cleaning vehicles, available on the PIANZ website at: Equipment Used in Primary Processing Areas (1) At the end of each processing period: a) hanging bays and lairage areas should be cleaned; and b) all primary processing equipment (including shackles on kill lines, evisceration lines, weigh lines) and primary processing areas should be cleaned and sanitised. Operators must comply with the requirements of Part 8: Primary Processing of Poultry. During processing, shackles should be rinsed before re-use. This may be achieved with on-line continuous spray rinses. These rinses should be checked to ensure they are working correctly. Table 7: on cleaning methods and frequency for processing equipment. Processing Equipment Scald Tanks Batch scalders Waxing equipment Cleaning Method (a) Drain (b) Clean and sanitise (a) Remove organic waste material between processing batches (b) Drain (c) Clean and sanitise (a) Waxing equipment including feather removal pluckers, should be cleaned and sanitised at regular intervals (b) Feather separation sieves included in wax dipping machines should be removed and cleaned once daily Cleaning Frequency Additional As specified cleaning and sanitation programme. As specified cleaning and sanitation programme. As specified cleaning and sanitation programme. Pluckers (a) Clean rubber finger mounts When rubber fingers are replaced. The scald tank water should be completely changed between batches. Operator should remove visible contamination such as feathers from the Ministry for Primary Industries Page 82 of 148

84 Processing Equipment Flaying equipment Cleaning Method (a) Clean and sanitise Cleaning Frequency Additional Prior to use and at regular intervals during operation. Eviscerators (a) Clean As specified cleaning and sanitation programme. Immersion Chillers (a) Drain (b) Clean and sanitise Equipment Used in Secondary Processing Areas As specified cleaning and sanitation programme. pluckers. It is accepted that due to difficulties in removing all feathers, some may remain after cleaning. Remove any fat deposits, protein, blood or other organic matter. (1) All secondary processing equipment should be cleaned and sanitised at the end of each processing period. (2) Cut-up machines, mincers, comminution equipment, tumblers, injectors and coaters should be dismantled, cleaned and sanitised at the end of each processing period. This includes equipment such as trolleys, waste containers, plastic pallets, pallet jacks etc Product Contact Containers (1) Product contact containers (e.g. dixies, tubs, trays and crates) should be: a) used in a manner that minimises contamination of product and product contact surfaces; b) cleaned and sanitised at a frequency specified in the cleaning and sanitation programme; c) not placed directly on the floor or other contaminated surfaces, unless they are designed and designated for this purpose (e.g. floor dixies); and d) dry when returned to dry processing areas. The cleaning and sanitation frequency should take into account the areas in which the containers are used and whether or not product comes into direct contact with them. Containers that have been in contact with the floor or other contaminated surface should not be stacked, tipped or handled in a manner that could contaminate products. 5.6 Cleaning Inspection (1) Cleanings checks or inspections should be undertaken on a regular basis to: a) ensure compliance to the cleaning and sanitation programme; and b) check the effectiveness of cleaning by assigned personnel. (2) Pre-operational check of facilities and equipment should be conducted by a suitably skilled person to ensure that operations begin only after sanitation requirements have been met. Ministry for Primary Industries Page 83 of 148

85 (3) If a pre-operational hygiene check shows a problem: a) the source of the contamination should be fixed (immediately if there is a food safety risk); or b) the frequency of cleaning is increased sufficiently to manage the problem. (4) A pre-operative hygiene check of the area and equipment to be used should be completed before the product requiring the higher hygienic status is processed. For further guidance on pre-operative hygiene and visual checks, refer to Part 2.4 Operator Verification. 5.7 Cleaning and Sanitation Monitoring (1) The operator should document and implement a monitoring programme to verify that an adequate state of hygiene is achieved after cleaning and sanitising, and maintained during processing. (2) The monitoring programme should include the following: a) person(s) responsible for conducting testing; b) frequency of testing; c) areas to be tested, including processing environment and contact surfaces; d) test methods (e.g. Aerobic Plate Count (APC) or ATP swabs); e) standards/limits to be met; and f) a clear description of when and what corrective action should be taken. The effectiveness of cleaning and sanitation should be verified by direct or indirect microbiological testing (e.g. using contact slides/plates, swabs or ATP) of the relevant environment and contact surfaces. MPI only expects that such testing will be carried out when microbiological problems are indicated by: failures to meet product microbiological limits for pathogens or indicator organisms; findings of visual inspections; findings of internal audits; or other relevant information. For poultry processing, microbiological loading of commercially clean contact surfaces has been found over time to normally be (APC at 30 C) <10 2 cfu/cm 2. One-off counts could be in the cfu/cm 2 range but would not be standard. During operations the mean log 10 count of microorganism(s) found on contact surfaces should not exceed the expected mean log 10 count of organism(s) found on product, i.e. contacting the surface should not increase the microbiological loading. Rapid tests for hygiene evaluation (e.g. ATP bioluminescence) may be routinely used provided the operator has set maximum allowable limits, and justified how these have been set. 5.8 Records (1) Keep records to demonstrate compliance with the requirements [RMP Spec 20(2)]. (1) Examples of Cleaning records to keep: a) cleaning records; b) pre-operational check sheets; c) any environmental test results, and Ministry for Primary Industries Page 84 of 148

86 d) monitoring and corrective action records. Ministry for Primary Industries Page 85 of 148

87 Part 6: Supporting Systems 6.1 Incoming Materials Scope (1) To ensure that all incoming materials, ingredients and raw materials used in poultry processing are fit for intended purpose and meet the requirements. Note: packaging is an input and the requirements are described separately in Part 6.3 Packaging Requirements and Procedures (1) The operator should develop and implement written procedures for the sourcing and purchase of incoming materials to ensure they comply with agreed specifications. (2) All process incoming materials, including ingredients, additives and processing aids, must be stored, handled and transported to minimise any potential contamination or deterioration [HC Spec 14.8]. (3) Incoming materials should be checked, on arrival or prior to use to ensure they are: a) clearly labelled and are fit for purpose; and b) obtained from suppliers who are trading under appropriate legalisation (e.g. Food Act, APA). (4) All imported foods (including ingredients and additives) should be safe and suitable and meet all relevant NZ food legislation, including the FSC. (5) Where raw unprocessed vegetables are used as an ingredient they should be prepared separately (e.g. not in areas where there is exposed finished product). Further guidance on importing products into New Zealand can be found on MPI s website at The operator should have an appropriate supporting system for inputs (ingredients, additives and processing aids). The following points should be considered, as appropriate to the input: develop specifications for the input that are appropriate to the hazards that are reasonably likely to occur and considering how the input will be used; develop a list of approved suppliers; on receipt of the input, check the information provided by the supplier e.g. certificates of analysis or supplier guarantees; check samples of the input periodically against the input specifications; where possible, periodically audit the approved suppliers premises. Audits performed by other parties may be used to provide the necessary confidence in their systems; and ensure that the supplier informs the operator if there is a change or problem to the input specification. In this Code, raw unprocessed vegetables refer to those that are received in an unwashed and/or unpeeled state. Raw unprocessed vegetables can bring a range of contaminants such as dirt and microorganisms into the processing areas. It is important that they are prepared using GOP in manner that does not contaminate other inputs or products Handling and Storage (1) Incoming material must be stored: Ministry for Primary Industries Page 86 of 148

88 a) away from inappropriate or potentially harmful chemicals; b) in an area that is clean, tidy and free from pests; c) at the appropriate temperature as per manufacturer s instructions, e.g. ambient, chilled or frozen; d) off the floor in closed containers or packs when not in use; and e) with clear identification [HC Spec 14.8]. (2) Raw materials and ingredients should be: a) moved to appropriate storage rooms as soon as possible after delivery; b) held at appropriate temperatures to maintain their safety and suitability for their intended purpose; c) protected against contamination or damage during storage; d) stored on racks, shelves or pallets to ensure no contact with the floor; e) kept separate from maintenance compounds and other hazardous materials; and f) properly labelled or identified. When dealing with the use and storage of part containers the operator should: ensure that clean and/or dedicated utensils are used for dispensing inputs; store the opened container in accordance with any manufacturer s instructions; ensure that the incoming material is used within any shelf life provided for opened products; and dispose of any incoming material that is no longer suitable for processing or if information that should be available with the incoming material is lost (e.g. identity, storage instructions, shelf life) Records (1) Keep records to demonstrate compliance with the requirements [RMP Spec 20(2)]. (2) Examples of Incoming Material records to keep; a) list of suppliers; b) raw material, inputs and ingredient specifications; c) any supplier guarantees or certificates of analysis; d) any supplier audit reports; e) incoming goods checks and delivery documentation; and f) any corrective action taken. 6.2 Allergen Management Scope (1) This section applies to operators who process products containing allergens and who also process products that are labelled allergen free. Allergens refer to those substances in FSC Standard Some operators elect to have the same allergen status for all products, in which case the management of separation is less of an issue. However, the operator would still need to ensure that: the labelling complies with the requirements of the FSC at all times; and an accurate and up-to date knowledge of all inputs, including new or substitute inputs is maintained. VITAL decision making tool is a tool that can be used to assist in allergen labelling. This tool and other useful information are available on the Allergen Bureau website at: Ministry for Primary Industries Page 87 of 148

89 6.2.2 Procedures (1) Where appropriate, the operator should document procedures to manage allergens throughout the process from reception to load out. (2) The operator should have documented cleaning procedures to minimise the possibility of cross contamination of allergens to products that are not intended to contain that substance. (3) Cleaning procedures should include, as appropriate: a) the cleaning of all surfaces, equipment, utensils, clothing and hands (personnel) that may have come in contact with products that contain allergens; b) management and clean-up of spills; c) cleaning of hidden or static areas and dismantling of equipment to remove residues; and d) evidence that the cleaning procedures are effective in removing the allergens. (4) The operator should ensure that all relevant personnel have knowledge of: a) the consequences of consumption of allergens by susceptible consumers; and b) GOP in the management of allergens specific to: i) their premises; ii) types of products processed; and iii) their roles and responsibilities. (5) The operator should document all formulations including ingredients, compound ingredients, substitute ingredients, additives and processing aids, and should have knowledge of: a) the presence of any allergens; b) those that are derived from allergens; and c) those that have a high likelihood of having been cross contaminated with allergens (i.e. may contain traces of allergens). (6) The operator should have a system of notification from the supplier if the allergen status of an ingredient, additive or processing aid changes. (7) Production and/or cleaning schedules should be managed to ensure that cross contamination of allergens does not occur. (8) If a product does not contain the same allergen as a previously processed product then a full clean down should occur, including the changing of personal protective equipment that may contaminate the product. (9) The operator should provide separation, by partition, location or other effective means to minimise the opportunity for cross contamination of allergens to non-allergenic products. (10) The nature of the separation should be based on a thorough investigation of the products, processes, premises and equipment design and construction. (11) The operator should ensure that re-worked products that contains allergens is not included in products that would not normally contain that ingredient (allergen). An example of where the good knowledge of ingredients is necessary is preservatives. For example sulphites as a preservative are labelled as an allergen if it is present at 10 ppm or greater. Products that do not contain allergens should be processed first, followed by products with an increasing allergen status (for example soy, then soy and dairy, then soy, dairy and gluten). Cross contamination during storage and processing should to be considered. Where possible inputs and products containing allergens should be stored separately. Where this is not possible, it should be stored segregated, in sealed packaging or air tight containers etc. Ministry for Primary Industries Page 88 of 148

90 For further guidance on managing cross contamination, Part Cross Contamination Records (1) Keep records to demonstrate compliance with the requirements [RMP Spec 20 (2)]. (2) Examples of Allergen Management records to keep; a) the name and address of suppliers of raw materials and ingredients; b) details about the supplied item, including the batch number, quantity, delivery date and allergen status; c) the supplier status of any approved suppliers; d) production records indicating the type, formulation and quantity of the finished products manufactured, the production or manufacturing dates and batch numbers, the use of any reworked products, and any repacking done; e) an inventory system either electronic or hard copy that allows finished products to be traced; f) the name and address of the person or company to which the batch of products are delivered to; g) load in and load out checks; and h) any corrective action taken. 6.3 Packaging Scope (1) To ensure packaging used for poultry material is fit for intended purpose and meets the requirements Requirements and Procedures (1) Packaging materials, including outer packaging (e.g. transportation outers and wraps), must be stored and handled in a manner that minimises contamination of the packaging or poultry products [HC Spec 14.8]. (2) Product contact packaging should be: a) checked on arrival to ensure it is intact, clean, clearly labelled, and matches the order; b) stored in a clean dry area, away from chemicals; c) protected from contamination when not in use; d) free from contaminating substances and objectionable odours; and e) clean, unused and undamaged at point of use. (3) Outer packaging materials (e.g. transportation outers and wraps) that product contact packaging is delivered or stored in, should not be taken into food processing areas. (4) Ongoing compliance to documented procedures should be regularly checked by the responsible person. It is recommended that cardboard packaging for bulk packs is designed so the sides overlap, providing extra strength to the edges of the box. Some packaging materials such as cardboard cartons are often re-used for other purposes e.g. for readyto eat foods (sandwiches, cakes, etc.). Operators who become aware that this is occurring with their packaging should advise against it Packaging Process (1) Packing operations and equipment should: Ministry for Primary Industries Page 89 of 148

91 a) not be a source of contamination; and b) minimises contact of the product with the outside of the packaging. (2) Products with damaged packaging must be handled in manner that will minimise: a) the exposure or spillage of the product (e.g. products can be wrapped and sealed); b) contamination or deterioration of the product; and c) contamination of other products and the storage area [HC Spec 7.2 (4)]. (3) Repacking of product with damaged packaging should occur in a manner that minimises contamination. (4) Any product that has been detrimentally affected as a result of the packaging damage should be dealt with in accordance with the requirements of Part 6.8 Non-Complying Product and Recall. Exposed poultry packed in retail trays ready for wrapping should not be stacked on top of each other unless cross contamination between the product and the bottom of the next tray is prevented. Crevices and gaps within packaging equipment have been shown to be a source of contamination in the past. The use of packaging that is fully sealed is recommended to prevent liquids from leaking out. Where leak proof (or similar) packaging integrity is claimed, the integrity of the pack seals should be confirmed. The frequency of checks should be based on performance. Evidence of good seal formation can result in fewer checks. If there is a trend of increasing seal failures, the frequency should be increased until the problem is resolved Packaging Specifications (1) The composition and, where appropriate, the conditions of use of packaging must: a) comply with the requirements specified in the current US Code of Federal Regulations, Title 21, Parts , which applies equally to coatings, linings and cartons where these are the direct product contact surface; b) comply with the requirements specified in the current Australian Standard: Plastics materials for food contact use, AS ; or c) be determined by the operator to be suitable for use, based on an analysis of hazards and other risk factors from the packaging [HC Spec 7.2 (1)]. (2) The type and composition of the packaging must be appropriate for the intended use [HC Spec 7.2 (2)]. (3) The packaging materials should be of sufficient strength and durability to protect the products from exposure to contaminants that may be encountered during normal operations and in the distribution chain. (4) Operators must retain records (e.g. supplier guarantees) that the composition of the packaging material complies with relevant legislation [HC Spec 9.2 (1)]. FSC does not specify details of materials permitted to be added to or used to produce food packaging materials. However, packaging when used should not cause food to be unsafe or tainted. Therefore, it is the responsibility of food manufacturers and sellers to ensure their products are safe and that they comply with relevant legislation. In practice, packaging suppliers will need to ensure their products are suitable for the intended use. Compliance with recognised international food standards such as those of the European Union (EU) or the United States Food and Drug Administration (FDA) would be reasonable evidence that materials are suitable for food use. Ministry for Primary Industries Page 90 of 148

92 The packaging materials should be of sufficient strength and durability to protect the products from exposure to contaminants that may be encountered during normal operations and in the distribution chain. Operators should discuss with their supplier how the packaging is to be used, e.g. whether it is to be used for frozen or chilled products or whether it needs to be microwavable etc.. This will need to be taken into consideration by the supplier when the supplier guarantee is given Reusable Packaging (1) Reused and recycled packaging must not be a source of contamination to products [HC Spec 7.2 (5)]. (2) Labels present on reusable packaging must be up-to-date [HC Spec 8.4 (1)]. (3) Reusable packaging (e.g. plastic dixies, bins etc.) which have been in direct contact with poultry should be cleaned and sanitised, dried and cooled to at least room temperature (25 C) by the operator before use. (4) The operator should ensure that the reusable packaging is not damaged (e.g. no sharp edges that may rip packaging) and remains suitable for re-use Records (1) Keep records to demonstrate compliance with the requirements [RMP Spec 20 (2)]. (2) Examples of Packaging records to keep; a) a register of packaging and/or packaging supplier contact details; b) any supplier statements or guarantees for product contact packaging and containers; c) incoming packaging documentation; and d) records of any problems detected and any corrective action taken (including restoration of control, product disposition and prevention of recurrence). 6.4 Inventory Control and Traceability Scope (1) To ensure that poultry product and material can be traced and an inventory system is maintained that meets the requirements Inventory Control (1) An inventory control programme must be documented for poultry material and product and records maintained [HC Spec 9.2 (3)]. (2) Inventories must be maintained for all inputs (e.g. poultry, ingredients) and finished products, including any non-compliant materials and products [HC Spec 9.2 (3)]. (3) Non-complying products and the reasons for non-compliance should be clearly identified in the inventory. (4) There must be a system in place for the identification of raw materials and products, and documentation that will allow any finished product to be traced: a) back to the supplier that the poultry product and material was sourced from; and b) to the next person or company that the product is transferred to for further processing, packing, or storage; distributed to; or sold to [AP Reg 18 (1)]. (5) The operator must have procedures to track inputs through processing so that products can be quickly and effectively identified and isolated in the event that a problem arises [HC Spec 9.2 (3)]. Ministry for Primary Industries Page 91 of 148

93 6.4.3 Traceability (1) The operator must document and implement a traceability system that: a) allows for the identification of all raw materials, ingredients and products throughout the entire production chain (i.e. from reception of incoming materials, through to processing or manufacturing, to dispatch of products); b) enables the movement of raw materials and ingredients to be traced from the supplier; and c) enables the next person or company that any product is transferred to for processing, packing, storage, distribution or sale to be traced [AP Reg 18 (1)]. (2) Traceability between all parts of the poultry material, or group of materials in the case of batch processing, must be maintained until the post-mortem examination is completed (e.g. carcass and viscera should be examined at the same time) [HC Spec 13.7 (1)]. (3) Re-work should be clearly identified and tracked to finished product. (4) All outgoing products must be clearly labelled and accompanied by appropriate documentation to ensure traceability of the batch [HC Spec 8.2 (3) and 8.3 (1)]. It is recommended that the operator maintain a one step forward, one step backward traceability system. This will allows the identification of where inputs and other materials have been received from and where the products have been dispatched to. The operator should record the identification of all inputs (e.g. batch code or lot identification) released to processing each day. The more precisely an input can be traced to a specific product, the less product will be affected in the event that it needs to be held or recalled. Operators intending to export with an official assurance should check the requirements for inventory control, transport conditions etc., which may include needing to undertake load out checks. Refer to OMARs and OAS for guidance on load out checks Records (1) Keep records to demonstrate compliance with the requirements [RMP Spec 20 (2)]. (2) Examples of Inventory Control and Traceability records to keep; a) the name and address of suppliers of raw materials and ingredients; b) details about the supplied item, including the batch number, quantity and delivery date; c) the supplier status of any approved suppliers; d) production records indicating the type, formulation and quantity of the finished products manufactured, the production or manufacturing dates and batch numbers, the use of any reworked products, and any repacking done; e) an inventory system either electronic or hard copy that allows finished products to be traced; f) the name and address of the person or company to which the batch of products are delivered to; g) load in and load out checks; and h) any corrective action taken. 6.5 Labelling and Identification of Product Scope (1) To ensure that poultry product and material is correctly identified and labelled and meets the requirements. Ministry for Primary Industries Page 92 of 148

94 6.5.2 Requirements and Procedures (1) Poultry material and product must be labelled or identified in accordance with any relevant specifications [AP Reg 19 (1)]. (2) Any labelling or identification required by specifications must: a) clearly relate to the poultry material or product to which it applies; and b) contain information that accurately describes or differentiates so as to identify the poultry material or product to which it applies [AP Reg 19 (2)]. (3) The operator should develop and implement written procedures to ensure that: a) labels are designed to meet regulatory requirements; b) all information on labels or packaging are correct and accurate; c) labels contain storage directions where necessary to maintain the poultry material as suitable for processing or fit for intended purpose; d) any claims on product labels are accurate and evidence is available to support the claims; e) labels are stored in a manner that maintains them in good condition; and f) damaged or obsolete labels are disposed of appropriately. (4) Products must be labelled in a manner that enables traceability to be maintained [HC Spec 8.2 (2)] Labelling of Transportation Outers (1) Provided the operator has documented systems to ensure that traceability is maintained, this clause does not apply to: a) poultry material and product that is transferred within New Zealand between sites of a single company or subsidiaries of a parent company; or b) between subsidiaries of a parent company and the parent company, prior to the completion of processing [HC Spec 8.2 (2)]. (2) All transportation outers of poultry material and products leaving the premises must have a label that clearly identifies: a) product name or description; b) instructions for storage and use where necessary to maintain safety and suitability of product; and c) lot identification [HC Spec 8.2 (3)]. (3) Poultry material or product that is not intended for human consumption must have clear labels indicating the product is not for human consumption [HC Spec 8.2(4)] Identification of Poultry Material or Product in Bulk Transportation Units (1) Transport units used for the transportation of unpackaged bulk poultry material or product that cannot be practicably labelled, must have the information specified in clause 8.2(3) of the HC Spec (Part (2)) provided: a) with the poultry material or product; or b) on the accompanying documentation [HC Spec 8.3 (1)] Labelling and Accompanying Documentation Changes (1) If the status of the poultry material s suitability or fitness for purpose changes, labelling must be changed or replaced to reflect this [HC Spec 8.4 (1)]. (2) If poultry material or product is downgraded and is no longer intended to be traded for human consumption, any labelling must be removed or defaced at the consigning premises on: a) the transportation outer; b) accompanying documentation; Ministry for Primary Industries Page 93 of 148

95 c) inspection legends; and d) any other identification of the product as being suitable for processing for human consumption [HC Spec 8.4 (2)]. (3) Any false or misleading labelling on reused or recycled packaging resulting from previous uses must be removed or defaced at the consigning premises [HC Spec 8.4 (3)] Poultry Material and Products Packaged for Retail Sale (1) Poultry material and products packaged for retail sale should be labelled in accordance with the requirements of the FSC and Weights and Measures Act For further information and guidance: go to the MPI website and search using Labelling ; refer to food labelling requirements in the FSC or refer to the MPI Food Labelling Guide at: The MPI and FSANZ labelling guides provide detailed information on what a food label needs to include. The Weights and Measures Act is administered by the Ministry for Business, Innovation and Employment (MBIE) and applies to all products sold by weight or by a measure, e.g. kilograms. MBIEs Trading Standard team enforces these rules. Further information can be found at the website and using the search term: Trade Measurement. Refer to country specific OMARs for labelling requirements for export product Records (1) Keep records to demonstrate compliance with the requirements [RMP Spec 20 (2)]. (2) Examples of Labelling and Identification of Product records to keep; a) label checklists; b) verified translations of labels; and c) copies of the labels. 6.6 Storage Scope (1) To ensure that poultry products are stored correctly so that they will maintain their intended state of preservation, prevent contamination and remain fit for purpose Requirements and Procedures (1) Operators must establish and carry out effective procedures to: a) ensure appropriate and adequate maintenance, cleaning and sanitation; b) manage waste; and c) control pests [AP Reg 11 (1)]. (2) Should be able to identify products and materials at all times. (3) Operators should store products and materials to: a) minimise deterioration; b) minimise damage to packaging; Ministry for Primary Industries Page 94 of 148

96 c) facilitate effective cleaning; and d) facilitate effective inventory control. (4) Storage areas used to store or contain poultry products that are not suitable for processing or not fit for human consumption but is suitable or fit for some other purpose must: a) be kept under controlled conditions so it is clearly identified in a manner that will ensure that it will not be mistakenly or fraudulently released; and b) not be sources of contamination to other product that is intended for human consumption [HC Spec 3.2 (1) and (2)]. (5) The operator should discard any stored raw material or ingredient when: a) it is no longer safe (e.g. contaminated with rodent droppings, chemicals) or suitable for use (e.g. it has signs of spoilage, it is past its use-by date); or b) important information needed for its safe use is lost (e.g. identity). (6) Products must be transferred without unnecessary delay to appropriate chiller, freezer or cold storage: a) to ensure that required product temperatures are achieved and maintained; and b) in a manner that minimises any potential microbial proliferation and contamination or damage to products [HC Spec 13.9 (1)] Refrigerated Storage (1) The refrigeration equipment and/or facilities must be used within their design capabilities and capacity [AP Reg 10]. (2) The type of packaging, filling of packages, method of stacking product and loading of the chiller, freezer or cold store, should ensure that the temperature of product is reduced without unnecessary delay. (3) Equipment for the control and monitoring of temperatures and other parameters (e.g. airflow) should be operating at all times while refrigeration facilities are in use. (4) Products that may taint or contaminate other products should be kept separate or be prevented from contaminating other products. (5) Where product is, or likely to be exposed, pallets and other storage equipment must be made of impervious materials [HC Spec 2.2 (1)] Freezing and Cold Storage (1) Product that is to be frozen must be reduced to: a) a temperature of -12 C or colder in a freezer prior to transfer to cold storage; or b) an alternative temperature and subsequent freezing parameters documented in the RMP [HC Spec 13.9 (2)]. (2) As a minimum, the product temperature at the thermal centre of a carton should be colder than the latent heat phase of raw meat, i.e. below -2 C prior to removal from the freezer. Where the product temperature is not reduced to -12 C or colder in a freezer prior to transfer to cold storage, an alternative regime should be developed in accordance with the principles of temperature equilibration. Temperature equilibration is theoretical and assumes uniform freezing temperatures. The equilibrated temperature is the arithmetic mean of the temperature of product at the thermal centre and product at the surface of a carton. If the thermal centre is -4 C and the surface -26 C on leaving the freezer, the equilibrated temperature will be close to the mean of -4 C and -26 C, i.e. -15 C. Ministry for Primary Industries Page 95 of 148

97 When applying temperature equilibration for temperature reduction: the temperature at the thermal centre of the carton must be colder than the latent heat phase of raw meat, i.e. below -2 C prior to removal from the freezer; and temperature measurements must be made shortly after product is removed from the freezer. Any product that is out of the freezer for greater than one hour should not be eligible for entry into cold store on the basis of equilibration Load Out (1) Refrigerated and frozen products should be dispatched and loaded into refrigerated vehicles without unnecessary delay after removal from the cold store to ensure that required product temperatures are maintained. (2) Products should be adequately protected from the elements and environmental contaminants prior to and during loading. (3) All documentation accompanying outgoing products must be complete and accurate, and provide the necessary information for the effective identification and traceability of the products [HC Spec 9.2 (1)] Records (1) Keep records to demonstrate compliance with the requirements [RMP Spec 20 (2)]. (2) Examples of Storage records to keep; a) inventory records; b) load in and load out checks; c) records of cleaning and maintenance of stores; d) any refrigeration/temperature records; and e) any corrective action. 6.7 Transportation Scope (1) To ensure that poultry product or material that is transported; a) during primary processing; or b) between premises operating under an RMP maintains its status as suitable for processing and is fit for intended purpose, to minimise hazards and other risk factors, and meets the requirements. (2) It does not apply to transport operators transporting live poultry to primary processors Design and Construction of Transportation units (1) Transportation units and loading equipment must be designed, constructed, equipped and operated to: a) maintain the status of poultry material as suitable for processing and as fit for intended purpose; and b) minimise hazards and other risk factors [HC Spec 16.2 (1) and (2)]. (2) Refrigerated transport units must be designed, constructed and equipped to ensure that the specified temperatures are achieved and maintained throughout transportation [HC Spec 16.2 (3)]. (3) Temperature-measuring devices used to measure critical temperatures must be calibrated and located to measure the internal temperature of a transportation unit at the warmest point [HC Spec 16.2 (4)]. Ministry for Primary Industries Page 96 of 148

98 6.7.3 Hygiene and Maintenance (1) Transportation units and loading equipment must be kept clean and maintained in good working condition [HC Spec 16.3 (1)]. (2) The operator must ensure that: a) hygienic handling practices are followed by persons involved in the transportation of poultry material or product; and b) any exposed poultry material or product (e.g. carcasses) is not handled by any person with any condition or illness [HC Spec 16.3 (2) and (3)]. Refer to Part Health of Personnel for further guidance on conditions or illness that could affect the safety or suitability of poultry Operation (1) Transportation units must be: a) operated so that the required product temperature is maintained throughout transportation; and b) loaded within the designed refrigeration capacity [HC Spec 16.2 (1)]. (2) Poultry materials or products must be maintained at their preservation temperatures, or alternative temperature or cooling condition specified in the RMP during transportation [HC Spec 16.4 (2)]. (3) Records demonstrating the maintenance of the preservation temperature or condition during transportation must be kept [HC Spec 16.4 (2)]. (4) Poultry material or product that is conveyed together with any other animal material or product or any other thing that may be a source of contamination must be adequately: a) separated from the source of contamination; or b) protected in a manner that prevents cross contamination [HC Spec 16.4 (1)]. (5) The determination of poultry material or product temperature and the taking of any samples must be carried out in such a manner that contamination of that poultry material or product is minimised [HC Spec 16.4 (3)]. (6) Refrigerated poultry material or product must not be accepted from the primary processor for transportation until the preservation temperature has been met as specified in either: a) the APA or the Food Act 2014; or b) the registered RMP [HC Spec 16.4 (4)]. (7) The transport operator must have a documented contingency plan to deal with any failure to maintain preservation temperatures during transportation, including: a) immediate notification to the person who has responsibility for the poultry material or product; and b) corrective actions to prevent recurrence [HC Spec 16.4 (5)]. (8) The transport operator must ensure that persons transporting animal material or product are aware of the relevant specifications and are adequately trained [HC Spec 16.4 (6)]. (9) Poultry material and product that are preserved primarily by refrigeration must be reduced to the maximum chilled (7 C) or frozen temperature (-12 C), validated at the thermal centre of the animal material or product, prior to release from any primary processing premises [HC Spec 13.9 (2)]. Refer to Part 6.9 Calibration of Measuring Equipment for thermometers and CATRs. Ministry for Primary Industries Page 97 of 148

99 Transporting poultry products for export that require an official assurance must operate under an RMP or Regulated Control Scheme (RCS). Further requirements and guidance for transport are specified in the following: MPI transport webpage: Developing RMP for transport operators: Record (1) Keep records to demonstrate compliance with the requirements [RMP Spec 20 (2)]. (2) Examples of Transportation records to keep; a) delivery records; b) records of cleaning and maintenance of transportation units; c) temperature records during transport; d) load in and load out checks; and e) any corrective action taken. 6.8 Non-Complying Product and Recall Scope (1) To ensure that non-complying products are handled and stored acceptably and that a product recall products procedure is in place that meets the requirements Non-Complying products (1) The RMP operator must notify the recognised RMP verifier in writing, without unnecessary delay, when there is any significant concern about the safety or suitability of any of their products [RMP Spec 13 (3)(a)]. (2) The operator should ensure that non-complying product is appropriately managed. (3) The operator should document procedures for the identification, handling, storage and disposition of any non-complying product. The procedures should facilitate the traceability and inventory of any noncomplying products. (4) This should include determining whether any other product has been detrimentally affected as a result of the non-compliance and taking appropriate actions to manage this. (5) Non-complying products should be handled and stored in a manner that prevents: a) contamination and deterioration of other products; and b) contamination of the storage environment. (6) Non-complying products should be: a) clearly identified; b) separated from other products; and c) held within the premises until disposition is determined by a suitably skilled person or, in certain cases, by MPI. (7) The disposition of any non-complying product should be determined by a suitably skilled person considering various factors, such as: a) product safety and suitability; b) the amount of product affected; c) whether the products have been released for distribution or not; d) whether the products can be reprocessed; and e) any instructions from MPI or the RMP verifier. Ministry for Primary Industries Page 98 of 148

100 Appropriate actions of any non-complying products may involve one or a combination of the following, depending on the nature and extent of the problem: restricted release of products; regrading of products for an alternative use (e.g. for down grading or rendering); reworking; reprocessing to ensure that the product complies to the requirements; rejection (disposition); and withdrawal or recall of products which have been distributed for sale Recall (1) Where, due to the nature of the poultry material or products it is possible to recall it from trade, distribution or consumers. The operator must document a recall procedure, including: a) the criteria for deciding when a recall will be initiated; and b) how retrieval and disposition of the relevant poultry material or product will be managed [RMP Spec 14 (1)]. (2) The operator must document a system for notifying MPI and the recognised RMP verifier, as soon as possible, when product is recalled from trade, distribution or from consumers [RMP Spec 14 (2)]. (3) A product recall procedure should be periodically tested using a trial run or mock recall exercise. This can be considered as a validation of the product recall procedure. The findings of this validation should be documented and held as part of the product recall procedure. It is recommended that product recall procedures are validated annually, or more frequently if appropriate and the effectiveness reviewed. In a recall, the removal of the product from consumers should be seen as the initial corrective action. Once this is achieved, the prevention of a recurrence can be addressed. For further information refer to MPI s Recall Material for guidance on recall procedures, or go to the MPI website and search on recall Records (1) Keep records to demonstrate compliance with the requirements [RMP Spec 20 (2)]. (2) Examples of Non-Complying Product and recall records to keep; a) inventory or register of non-complying products; b) records of assessment and disposition of non-complying products; c) records of all recall activities, including mock recalls; d) any correspondence with the RMP verifier or MPI; and e) any corrective action taken. 6.9 Calibration of Measuring Equipment Scope (1) To ensure that measuring equipment that is used to carry out measurements is calibrated and functions as intended and meet the requirements. (2) Measuring equipment include the following: Ministry for Primary Industries Page 99 of 148

101 a) temperature measuring/recording devices; b) timing devices; c) scales; d) metal detectors; e) water activity meters; f) ph meters; g) flow meters; h) other instruments. (3) It is recommended that calibration is also applied to equipment used in monitoring GOP parameters (e.g. refrigeration temperatures) and product parameters (e.g. product weight) Requirements and Procedures (1) Measuring equipment such as scales, thermometers, ph meters and flow meters (whether stand-alone or integrated) that is used to provide measurements identified as critical in the operator s risk management programme must: a) be properly calibrated and functions as intended; b) have the accuracy, precision and conditions of use appropriate to the task performed; c) be calibrated: i) against a reference standard (shows traceability of calibration to a national or international standard of measurement); or ii) (if no such standard exists) be calibrated on a basis that is documented in, or incorporated by reference into, the RMP; and d) be uniquely identified (e.g. by using serial numbers, indelible tags or other permanent means of identification) to enable traceability of the calibrations and to identify the calibration status [AP Reg 14 (1) and HC Spec 6.2 (1)] Calibration Programme (1) The operator must document a calibration programme that includes minimum frequencies of calibration for each piece of measuring equipment used to provide critical measurements, or used as reference standards, taking into consideration the following (as appropriate): a) the stability of the piece of equipment; b) the nature of the measurement; and c) the manufacturer s instructions [HC Spec 6.2 (2)]. (2) Safeguards must be in place to prevent unauthorised adjustments to the calibration of the measuring equipment, including movement of the equipment where this may invalidate the calibration [HC Spec 6.2 (3)]. (3) Reference standards (e.g. reference thermometer or reference weights) should have a current calibration certificate before they can be used. The certificate should be issued by a recognised person or agency. (4) Equipment used for making critical measurements (i.e. for monitoring critical limits), including reference thermometers, metal detectors and scales, should: a) be calibrated by a recognised agency; or b) have an assurance or guarantee of the instrument s accuracy provided by the equipment manufacturer. Ministry for Primary Industries Page 100 of 148

102 The calibration programme should also: identify whether the measuring equipment is used for taking critical measurements or not; identify the person or agency who will perform the calibration; indicate the maximum error allowed before corrective action is taken (e.g. ±1 C, ±1g); indicate how the calibration date and any correction factor will be affixed to the measuring device; include the corrective actions to be taken when a measuring device: is damaged or provides inconsistent or inaccurate readings; and identification and disposition of any product produced when the device was out of order. Aside from a calibration certificate or certificate of accuracy, newly purchased measuring devices should be provided with written calibration instructions, including methods and frequencies. The Weights and Measures Act is administered by the Ministry for Business, Innovation and Employment (MBIE) and applies to all products sold by weight or by a measure, e.g. kilograms. MBIEs Trading Standard team enforces these rules. Further information can be found at the website and using the search term: Trade Measurement. The reference thermometer should only be used for checking working thermometers and should not be used for routine measurements. (5) Any in-house routine checks of measuring equipment should be carried out against reference standards at regular and established frequencies by suitably skilled personnel. Refer to Table 7 below. Table 7: Calibration methods and frequencies for various measuring equipment Measuring equipment Calibration Method Calibration Frequency Person/agency responsible Reference thermometer Working thermometers Continuous temperature reading devices used in refrigeration rooms Thermocouples and data loggers Weighing scales (ingredient and product scales, platform scales) Weighing scales (e.g. final product scales) Test weights Standardised against a national or international standard Calibrated against a reference thermometer Ice point and/or boiling point method, as appropriate (Refer to the guidance box below for methods Calibrated against a reference thermometer Refer to guidance box below for methods Check against test weights Certify for accuracy as per the Weights and Measurement Act 1987 Standardised against a national standard Once every 1-5 years Annually Weekly or Fortnightly - if used daily for monitoring critical limits Monthly - for other working thermometers - Annually Daily Annually Annually Recognised/approved laboratory Recognised person or agency Suitably skilled person Recognised person or agency Suitably skilled person Recognised person or agency Recognised/approved laboratory Ministry for Primary Industries Page 101 of 148

103 Measuring equipment Calibration Method Calibration Frequency Person/agency responsible ph meter Metal detector Check against standard solutions; follow manufacturer s instructions Test against metal test pieces Before each day s use, or as recommended by manufacturer At least daily Suitably skilled person Suitably skilled person Servicing and calibration Annually Instrument specialist Ice point and boiling point calibration methods Hot point calibration is used when monitoring temperatures higher than room temperature (e.g. cooking temperatures). A combination of the ice point and hot point methods is recommended for a more accurate calibration of thermometers used to monitor a wide range of temperatures. Ice point method: i) use enough crushed ice in a container to allow immersion of most of the probe stem. Add just enough water to remove the air around the ice particles and to form a slush. Wait for the ice to appear clear; ii) stir the mixture (do not use the probe for mixing), tip off excess water, insert the probe and leave it for about 2 minutes. Ensure that the tip of the probe is in good contact with the slush ice at the centre of the container; iii) stir the mixture again and check the reading on the thermometer. Accept if the deviation from 0 C is within the declared limits of accuracy; and iv) if the deviation from 0 C is greater than the limit of accuracy adjust the thermometer accordingly or discard and replace the thermometer. Boiling point method: i) place the probe in a container with boiling water for about 2-3 minutes until the thermometer reading stabilises. The probe should be at the centre of the container; ii) accept if the deviation from 100 C, or appropriate temperature according to elevation, is within the declared limits of accuracy; and iii) if the deviation from 100 C is greater than the limit of accuracy, or greater than ± 1.0 C, adjust the thermometer accordingly or discard and replace the thermometer. Calibration of thermocouples and data loggers Seek technical advice or calibration service for guidance on how to calibrate thermocouples and data loggers Records (1) Keep records to demonstrate compliance with the requirements [RMP Spec 20 (2)]. (2) Examples of Calibration of Measuring Equipment records to keep; a) identification, location and calibration status of equipment; b) calibration schedules; c) certificates of accuracy or calibration; and d) in-house calibration records; and e) any corrective action taken. Ministry for Primary Industries Page 102 of 148

104 6.10 Control of Maintenance Compounds Scope (1) To ensure the proper use and storage of maintenance compounds to prevent or minimise the contamination of poultry material or products, packaging, equipment, or processing environment. (2) Chemicals include maintenance compounds used for cleaning, sanitation, fumigation, pest control and the repairs and maintenance of equipment Requirements and Procedures (1) Operators must develop written procedures for handling, storage and use of maintenance compounds [AP Reg 11(3)]. (2) Operators must only use approved non-dairy maintenance compounds during processing operations and in the maintenance of processing areas, facilities and equipment [HC Spec 3.4 (1)]. (3) Any maintenance compounds used during processing operations must be approved for that purpose before use [AP Reg 11 (4)]. (4) Product and packaging contaminated by a maintenance compound, which adversely affects its fitness for intended purpose, must not be used for human or animal consumption [HC Spec 3.4 (1)]. (5) The operator must label all decanted containers of approved maintenance compounds with the name(s) of the maintenance compound as approved or as they appear in the list of approved maintenance compounds contained in specifications [HC Spec 3.4 (2)]. (6) Maintenance compounds (e.g. cleaners, sanitisers and pesticides) must be stored, managed and handled in a way that prevents contamination by the maintenance compound of poultry material and products, facilities and equipment [AP Reg 11 (3)] Approved Maintenance Compounds (1) The operator must maintain a current register (list) of maintenance compounds on the premises [HC Spec 9.2 (3)]. (2) The use of maintenance compounds within processing and support areas must be in accordance with the manufacturer s directions and the conditions approved by MPI. This includes compounds where there is the potential for incidental product contact (e.g. sanitiser, lubricants, and surface treatment compounds) [AP Reg 11(3)]. MPI approval of a maintenance compound, and the associated conditions, only relate to minimising the risk of contamination of animal material or product. The approval does not relate to the efficacy of the compound. For this information the operator should approach their supplier. Refer to the MPI Approved Maintenance Compounds (Non-Dairy) Register for a list of MPI approved maintenance compounds. Search using the terms approved maintenance compound on the MPI website. The register of maintenance compounds should contain any rodent control compounds Storage of Maintenance Compounds (1) Chemicals should be stored in a designated area (e.g. shelf, cupboard or room) and kept separate from poultry products, ingredients, and packaging and any unapproved maintenance compounds. (2) Chemicals should be kept in sealed clearly labelled containers when not in use. (3) All containers and implements used for measuring or pouring of chemicals should be clearly identified (e.g. labelled as For Chemicals Only ) to ensure no secondary use of these containers. Ministry for Primary Industries Page 103 of 148

105 (4) Storage areas should be kept clean and tidy. Maintenance compounds that are in-use or for immediate use may be stored in processing and support areas, but only in quantities necessary for immediate use Handling and Use of Maintenance Compounds (1) Maintenance compounds must be used in accordance with manufacturer s directions and, if applicable, any conditions of the MPI approval [AP Reg 11 (3)]. (1) Personnel should be trained and suitably skilled in the correct access, handling and use of maintenance compounds and have access to documented directions. (2) All containers or tools (e.g. measuring cylinders, jugs, scoops, funnels) used for measuring or pouring of maintenance compounds should: a) be used for that purpose only (e.g. labelled for chemical use only ); and b) not be used for measuring food or ingredients. (3) Maintenance compounds should only be handled or used by or under the supervision of suitably trained or experienced personnel. (4) Documented directions for use should be available, either: a) at the point where the compound is used (i.e. on the container label); or b) on information data sheets available to personnel using the compound. (5) Poultry material, ingredients, products and exposed packaging should be removed from the area or kept protected (e.g. covered) prior to the use of any maintenance compound that may result in their contamination. (6) Processing areas or equipment contaminated by a maintenance compound should be corrected according to the maintenance compound s properties and its effect on the product s fitness for intended purpose. This includes compounds used where there is potential for incidental product contact (e.g. sanitiser, lubricants and surface treatment compounds) Non-Approved Maintenance Compounds (1) Non-approved maintenance compounds may be used in offices, staff rooms, staff kitchens, etc. with appropriate controls. (2) Non-approved maintenance compounds should be controlled by: a) maintaining an inventory (register); b) stored separately from approved maintenance compounds; c) their use managed appropriately; and d) clearly identified as not to be used in processing areas or amenities. Non-approved chemicals within an RMP boundary may not be permissible for export premises. Check OMARs for each individual country you export to Disposition of Contaminated Material (1) Empty chemical containers should be disposed of or returned to the manufacturer: Ministry for Primary Industries Page 104 of 148

106 a) in a manner that will not contaminate any product or product contact surfaces; b) in line with good environmental management; and c) in accordance with manufacturer s instructions. (2) Empty chemical containers should not be re-used for any other purpose within the premises. (3) When chemical contamination occurs, the operator should take the following actions: a) affected poultry material and products should be considered to be non-complying and could be unfit for human or animal consumption and should be held until a final disposition can be determined [HC Spec 3.2 (2)]; b) the procedures for non-complying product should be followed; c) affected food contact surfaces should be cleaned and sanitised prior to reuse [AP Reg 11]; and d) affected packaging materials that cannot be effectively cleaned and sanitised should not be used for packing of any poultry product and material [HC Spec 7.2 (4)] Records (1) Keep records to demonstrate compliance with the requirements [RMP Spec 20 (2)]. (2) Examples of Maintenance Compounds records to keep; a) register of current chemicals used and held in the premises; b) any chemical information sheets provided by the supplier, including instructions for handling and use; c) personnel training records; d) material safety data (MSD) sheets for each compound; and e) any corrective action taken Pest Control Scope (1) To ensure that pests are effectively excluded from the premises to prevent contamination or minimise contamination of poultry products, packaging, other inputs, equipment, and the processing environment. (2) Pests include rodents, birds, insects, dogs and cats Requirements and Procedures (1) The operator must develop and implement a written pest control programme to minimise the exposure of poultry material, ingredients, products, packaging, equipment and the processing environment to hazards associated with pests [AP Reg 11 (1) to (3)]. (2) The programme should include, but is not restricted to: a) who is responsible for the pest management activities; b) how buildings within the RMP boundary are pest-proofed, (e.g. self-closing doors, fly screens, drain traps); c) how pests are killed and prevented from breeding; d) how pesticides and pest management equipment (including rodent bait stations, electric insect killers, traps, insect sticky boards etc.) are used in the control of pests; e) the methods used to monitor the presence of pests and the effectiveness of pest control; and f) the corrective actions to be taken when pests are detected, including disposing of any contaminated items, including dead pests. (3) Pesticides must be used by suitably skilled personnel and only in accordance with Part 6.10 Control of Maintenance Compounds [AP Reg 11 (3)]. Ministry for Primary Industries Page 105 of 148

107 Prevention of Infestation and Access of Pests into Buildings and Facilities (1) Buildings and storage facilities (including water storage tanks) should be kept in good repair and condition to prevent pest access and to eliminate potential breeding sites. (2) Places where pests are likely to gain access (such as holes and drains) should be sealed, or provided with screens or similar materials that prevent the entry of pests. (3) External doors that are not screened should be kept closed at all times when not in use. (4) The facilities, support areas and external environment should be kept clean and tidy. (5) The external environment should be checked regularly for evidence of pest activity. It should be kept free of food sources and breeding sites (e.g. long grass, bird s nest, food waste, etc.). (6) Dogs, cats and other mammalian pests should not be permitted to enter processing, packaging and storage areas (i.e. buildings and external areas within the RMP boundary). (7) Waste materials should be kept in covered pest-proof containers, and regularly collected and disposed of. Areas that are likely to attract flies and other insects should be sprayed, as necessary. Mesh screens should be used on windows, doors, ventilators and other openings in the processing and packing areas that may be kept open during operations, to prevent the entry of insects, birds, and other pests. Roadways and car parks should be tar sealed or concreted. Landscaped areas, e.g. shrubs, trees, grass should not be in close proximity to buildings where product is processed. Unused equipment should be covered and stored on hard standings away from buildings where product is processed or stored. Storage on grassed areas may increase the likelihood of pest harbourage due to the difficulties of maintaining the grass height Use of Pest Traps (1) Pest traps (e.g. bait stations, rodent boxes, electric insect traps) should be located where they do not present a risk of contamination to any product. (2) The operator should: a) identify the location of pest management equipment (including marked rodent bait stations and electric insect traps) on a site or building plan, or other suitable record; and b) document changes to equipment locations. (3) Rodenticides should only be used in bait stations. (4) Bait stations should be regularly checked for the following: a) correct location as indicated in the plan or record; b) presence of bait; c) evidence of pest activity (e.g. nibbled bait, bait missing, droppings); and d) boxes are in good working condition and with legible identification. (5) The frequency for monitoring of traps should be determined relative to the type of trap and the degree of pest activity observed. Increased monitoring and appropriate corrective actions should be implemented when increased activity is observed. Ministry for Primary Industries Page 106 of 148

108 Numbering bait stations may make identifying them on a site or building plan easier Use of Pesticides (1) Pest control chemicals (rodenticides and insecticides) should be handled, used and stored according to the procedures given in Part 6.10 Control of Maintenance Compounds. (2) Insecticides that have any residual activity or are dispensed as continuous aerosols or contain perfumes should not be used in processing areas or other areas in a manner that would cause contamination of live poultry, products or product contact surfaces (e.g. Type B insecticides). (3) Insect traps, which include ultra-violet lamps, sticky boards, pheromone traps and any form of attractant device, should be constructed so they catch and secure insects in a way that makes disposal easy (e.g. a suitable drawer, tray or adhesive mat) Handling and Disposition of Contaminated Material (1) Where there is evidence of contamination by pests or any pest activity in product, ingredients or packaging, the affected product or ingredients should be declared unfit for human consumption. (2) Affected packaging materials should not be used for packing product, or in situations where it may come into contact with product. (3) Affected contact surfaces should be cleaned and sanitised prior to reuse Records (1) Keep records to demonstrate compliance with the requirements [RMP Spec 20 (2)]. (2) Examples of Pest Control records to keep; a) details of the contracted pest control person or agency, if applicable; b) observations from monitoring, including any evidence of pests; c) location of bait stations or other traps (e.g. a site plan); d) list of approved chemicals used; e) name, amount and point of use of any pesticide used; f) pesticide and insecticide handling training records; g) weed spraying records; and h) any corrective action taken Waste Materials Scope (1) To ensure that waste materials are effectively managed and are not a source of contamination to products, processing areas, equipment or personnel, and that the requirements are met Requirements and Procedures (1) The operator must effectively manage waste material to minimise pest activity, offensive odours and contamination of product, processing areas, equipment or personnel [AP Reg 11 (1)]. (2) Waste material must be: a) conveyed to a waste area in a timely manner; b) kept under controlled conditions to ensure that it will not be mistakenly or fraudulently released as suitable for processing or fit for human consumption; c) kept in covered pest-proof containers (if receptacles are kept outside or are not in continuous use inside); and Ministry for Primary Industries Page 107 of 148

109 d) regularly collected and disposed of in a manner that ensures that it will not become a source of contamination to other poultry material or product [HC Spec 3.2 and 3.3]. Waste management applies to all areas within the physical boundaries of the RMP site, including facilities, support areas and the external environment Waste Containers and Equipment (1) Waste containers should be clearly identifiable and suitable for use. (2) Waste containers and associated equipment such as trolleys should not be a source of contamination to product, ingredients, contact surfaces, or processing or support areas. (3) Waste containers, in processing or support areas, should be emptied and cleaned: a) at a frequency specified in the cleaning and sanitation programme; and b) as a minimum at the end of each processing period. (4) The underneath of waste containers should be sanitised before re-entering a processing area or area of higher hygienic status if they have been taken outside or moved through an area of lower hygienic status. (5) Waste containers and associated equipment returned to dry processing areas should be dry. (6) Waste containers present in processing areas during processing should only be those required by necessity Records (1) Keep records to demonstrate compliance with the requirements [RMP Spec 20 (2)]. (2) Examples of Waste Materials records to keep; a) general hygiene check of processing areas, facilities and external environment; b) site plan with bait stations; c) monitoring records of bait stations and pest activity; and d) any corrective action taken. Ministry for Primary Industries Page 108 of 148

110 Part 7: Procurement of Poultry Material To be developed Ministry for Primary Industries Page 109 of 148

111 Part 8: Primary Processing of Poultry 8.1 Scope (1) To ensure that poultry material and products are fit for intended purpose after it has been slaughtered and dressed, and meets the requirements. 8.2 Requirements and Procedures (1) The operator must document procedures within their RMP covering their slaughter and dressing process(es) [HC Spec 9.2 (1)]. (2) Slaughtering practices must comply with any minimum standards issued under the Animal Welfare Act Non-Product Contact Surfaces (Dropped Product) (1) Contact between poultry material and products with non-product contact surfaces should be minimised. (2) Where product does contact non-product contact surfaces the following corrective action should be taken without delay: a) restoration of control; b) disposition of affected product; and c) prevent re-occurrence of the problem. (3) Any design or operational fault causing the problem should be fixed in a timely manner. (4) Product unfit for human consumption product should be: a) dealt with immediately; and b) down-graded to animal consumption or rendering or condemned or, where permitted, decontaminated to make it fit for intended purpose. (5) The following unwrapped products are considered waste material and should be appropriately disposed of: a) any offal falling onto the floor; b) any product falling into a drain in any area; c) any coated product, product with a non-meat component (e.g. stuffing bullets) or partially cooked or fully cooked product that contacts the floor; d) any product that comes into contact with the floor outside of normal processing areas; and e) any product falling onto a high traffic area (heavy foot traffic or handling equipment). (6) Affected product should be decontaminated to make it fit for intended purpose or downgraded. Equipment should be designed and operated to avoid product contacting any non-product contact surfaces. Operators should consider it to be unacceptable for product to be dropped on the floor and every attempt should be made to prevent this from happening. Decontamination may be achieved by rinsing or trimming to remove all contamination. It is not appropriate to place birds or any part straight back onto the processing line without such decontamination, even if there are effective rinses after that point in the process. For more information, refer to Part 6.8 Non-Complying Product and Recall. Ministry for Primary Industries Page 110 of 148

112 Affected product may be rinsed or trimmed to remove all contamination according to procedures below Decontamination by Trimming or Skinning and Continuous Rinsing (1) Dedicated wash sink(s) in both primary and secondary processing, with attached trimming table and knife sanitiser should: a) be set up and the lighting at the level required for product examination; and b) have a sink with running water with an antimicrobial processing aid. (2) Contaminated product should be kept separate from product that has been decontaminated. (3) Heavily soiled product should be trimmed or skinned before rinsing. (4) If the product is trimmed, it should have the contaminated parts removed without contacting or penetrating the area of contamination. (5) Trimming should be carried out in areas where it will not cross contaminate other poultry or product contact surfaces (unless these surfaces are cleaned and sanitised prior to next use). (6) Contaminated product should be rinsed: a) as soon as possible until all visible contamination has been removed; and b) with continuously flowing water, so that contamination is rinsed away immediately to the drain. Contaminated product may include whole bird or portion and sealed packaged product that has been dropped. Alternative control measures may be permitted if operators document them in their RMP and submit them to MPI for approval as part of the registered programme Removal of Contamination by Dipping (1) Operators using dipping to remove contamination should document all parameters that could affect decontamination efficacy including: a) name of processing aid; b) concentration of processing aid; c) contact time on product; and d) monitoring of critical parameters at sufficient frequency to ensure that the processing aid continues to remain effective. (2) Validation data should be provided to MPI to show that approved processing aids are used in accordance with the FSC requirements Removal of Contamination from Unsealed Packaged Products (1) If any raw material or ingredient is damaged or contaminated, the operator must: a) check and ensure that the contents have not been contaminated or deteriorated; b) correct the problem (e.g. repack or repair the damage), if appropriate; and c) dispose of any affected product, raw material or ingredient that is no longer suitable for processing [HC Spec 7.2 (4)]. (2) Contaminated packaging of unsealed packaged products should be hygienically removed and replaced. Ministry for Primary Industries Page 111 of 148

113 Refer to Part 6.3 Packaging for guidance. 8.3 Status of Poultry for Slaughter (1) An operator must not accept any poultry for processing if a supplier statement has not been supplied or is incomplete [HC Spec 13.3 (1)]. (2) An operator may hold poultry pending the supply of a completed or replacement supplier statement [HC Spec 13.3 (2)]. (3) If any poultry that is submitted for processing is accompanied by a poison use statement, the operator must confirm that the animal material is suitable for processing before processing [HC Spec 13.3 (3)]. (4) An operator must not accept poultry for processing if the operator reasonably suspects that the information in the accompanying supplier statement is fraudulent, and must inform MPI within one day [HC Spec 13.3 (4)]. (5) An operator may accept farmed poultry if: a) the supplier is a specified supplier within the operator s supplier guarantee programme; b) the supplier has provided information in accordance with the supplier guarantee programme at least 6 monthly; and c) the animal material is of the type that is described in the supplier guarantee programme [HC Spec 13.3 (5)]. (6) The operator must document procedures to deal with situations where the supplier statement does not confirm the status of the animal material as suitable for processing [HC Spec 13.3 (7)] (7) The operator must keep a copy of every supplier statement for 4 years [HC Spec 13.3 (8)]. Further guidance and information to be given in Part 7 Procurement of Poultry Material (to be developed). 8.4 Hanging and Ante-Mortem Examination (1) Poultry must be examined in accordance with any relevant ante-mortem regulations and specifications prior to their slaughter [HC Spec 13.4]. (2) Operators must set a limit for acceptable numbers of Dead On Arrivals which if exceeded will result in corrective action [AM PM Spec 11 (1)]. (3) The operator of a processing premises must ensure that: a) poultry found dead on arrival are recorded, and appropriately disposed of, e.g. destroyed or rendered, and b) moribund, unhealthy or rejected birds are not processed but are killed humanely and appropriately disposed of, e.g. destroyed or rendered [AM PM Spec 11 (2)]. Ministry for Primary Industries Page 112 of 148

114 If the observations made at ante-mortem examination suggest that poultry display symptoms of a notifiable or exotic disease, the operator must contact the MPI Pest and Disease hotline ( ) as soon as possible. The affected poultry should be withheld from slaughter. Stress has been shown to increase the shedding of enteric pathogens. Operators should provide conditions and handle live birds in a manner that minimises stress. Full gastro-intestinal tracts are associated with increased spillage and faecal contamination during processing. Withholding of feed (but not water) for 4-10 hours prior to slaughter (including catching and transportation time) has been shown to reduce contamination. Operators processing birds with pendulous full crops should slow down the line so there is sufficient time for effective crop-removal. 8.5 Primary Processing of Poultry Material Handling and Processing (1) Traceability between all parts of the poultry material, or group of animal material in the case of batch processing, must be maintained until the post-mortem examination is completed (e.g. carcass and viscera must be examined at the same time) [HC Spec 13.7 (1)]. (2) Cross-contamination between carcasses or within a single carcass must be managed [HC Spec 13.7 (3)]. (3) Evisceration must be performed in a manner that manages the contamination of the carcass and viscera. The technique used must take into account the consistency of the faecal material. [HC Spec 13.7 (4)]. (4) Dressing must be carried out hygienically and in a way that manages the actual and potential distribution and proliferation of contaminants [HC Spec 13.7 (5)] Slaughter (1) Slaughtering practices must comply with any relevant Code of Welfare or codes of recommendations and minimum standards issued under the Animal Welfare Act (2) Slaughter must be carried out without unnecessary delay and in a way that manages the distribution and proliferation of contaminants [HC Spec 13.5 (1)]. (3) Slaughter must only be performed at a rate at which bodies of animals can be accepted for dressing [HC Spec 13.5 (2)] Bleeding (1) Bleeding should be effectively completed before scalding in order to reduce the organic matter entering the scalder and the number of red birds. The presence of high levels of organic material (e.g. blood, faecal matter on feathers) in the scald tank may reduce the efficiency of this intervention to minimise contamination present on the carcass Scalding (1) There should be at least 750 ml of water added to the scald tank per carcass. Ministry for Primary Industries Page 113 of 148

115 (2) Where a wetting agent is added to scald water it should be an approved processing aid used according to the manufacturer s instructions. (3) All scald tanks should be emptied and cleaned at the end of each day s operations. (4) Operators should document the scald temperature that they use to achieve effective feather removal and minimise pathogen proliferation. (5) Where batch scalding is performed, the scald water tank must be emptied and cleaned at every break. Scalding tanks should be set up so that water is counterflow (in the opposite direction to bird movement) and so that there is an overflow of water out of the scalder. Water should be agitated to prevent build-up of sediment, scum and to improve penetration of the water to the feather follicles. Temperature control of the scald tank is important as: low temperatures result in inadequate removal of feathers and increased survival of bacteria; and high temperatures damage the epidermis and may result in undesirable appearance. Sufficient contact time is also important for good feather removal. When scalding sprays or steam jets are used, they should be sufficient in number and type to maintain an adequate scalding operation. There are two commonly-used scalding procedures: Hard scald (sub-scald) 55 to 60 C: cuticle (epidermis) is removed loses colour; excellent for further processing i.e. adhesion of batter and breading; easy picking damage from pickers limited & few residual feathers; and increases drying and discolouration of skin. Soft scald (semi-scald) 50 to 54.5 C: cuticle (epidermis) intact; harder to defeather extra pickers required may increase skin damage; and more desirable colour. Temperatures above 55 C provide a significant log reduction in Campylobacter; the log reduction is reduced at temperatures below 55 C Defeathering (1) Collection and removal of feathers from the defeathering and scalding areas should be carried out at a frequency and in a manner that minimises: a) build-up of feathers; and b) contamination of the product or processing area. Defeathering may be achieved by plucking, waxing or flaying. Defeathering is considered a dirty activity and should be physically separated as much as possible from later primary processing activities Pluckers (1) Defeathering equipment should be adjusted to suit the particular size or type of carcass being plucked. (2) Broken plucker fingers should be replaced prior to the next day s processing. (3) Drum pluckers should be emptied of feathers at least at every break and more often where practicable. Ministry for Primary Industries Page 114 of 148

116 Continuous rinsing of equipment may be beneficial at minimising microbe contamination. It is recommended that an approved antimicrobial processing aid is used in at least the last half of the plucker to rinse the carcass during plucking Waxing (1) Where feathers are removed by waxing, the principles of hygienic dressing apply. (2) Only clean plucking wax of edible grade which has been stored under hygienic conditions should be used for wax dipping. (3) The wax peeler should be designed, maintained and operated in a manner that will not be a source of contamination. (4) Collection and removal of feathers and wax should be carried out at a frequency and in a manner that minimises: a) build-up of feathers; and b) contamination of the product or processing area. (5) Feather separation sieves included in wax dipping machines should be removed and cleaned once daily. (6) Reclaimed wax should be held at a temperature of not less than 80 C for: a) a period of not less than 20 minutes; or b) a time and temperature equivalent to ensure adequate pasteurisation. (7) Following heat treatment the wax should be skimmed, washed and filtered or passed through a centrifugal cleaning machine before re-entering the process. Refer to Part 6.10 Control of Maintenance Compounds and Food Standards Code Standard Processing Aids and Schedule 18. Where wax is used in the removal of secondary feathers, carcasses should be handled so that all wax and removed feathers fall into containers Flaying (skinning) (1) Where poultry are intended to be skinned pre-evisceration, the principles of hygienic dressing apply. (2) Hygienic techniques should be used during flaying. If multiple operations are carried out on the same carcass by the same operator, the operations posing the least risk of contamination should be performed first. (3) Flaying equipment should be designed, maintained and operated to not damage or be a source of contamination to the birds Post Defeathering (1) All birds should be rinsed by a constant spray of potable water before any incision is made Head-Pulling (1) Head pulling equipment should be designed and adjusted to minimise blockage through build-up of heads and head contact with the rest of the carcass after removal. Ministry for Primary Industries Page 115 of 148

117 Head pulling should be carried out in such a manner that leakage from the crop is prevented. Heads should be pulled downwards to reduce contamination due to crop rupture Hock Cutting Wherever possible hock cutting should occur before evisceration Transfer to Evisceration Line (1) The rehanging operator (also in automated systems) should rinse hands and aprons at least every break and when visibly soiled. Feet are usually cut as part of this process. This is a good first location for post-mortem examination Feet Recovery (1) Feet for human consumption should be rinsed with an approved processing aid which is antimicrobial. (2) Feet for human or animal consumption should be visually clean and be chilled to 10 C within 4 hours of removal Automatic Vent Cutting and Drilling (1) There should be continuous sprays to rinse the equipment, vent area and the rear of the bird. An approved antimicrobial processing aid should be added to the rinse water Manual Vent Cutting (1) A knife or implement used in a venting operation should not be used to cut any other part of a poultry carcass unless it is first cleaned and sanitised. (2) For manual operations, facilities should be provided for rinsing of hands and implements Evisceration (1) Evisceration must be performed in a manner that manages the contamination of the carcass and viscera. The technique used must take into account the consistency of the faecal material [HC Spec 13.7 (4)]. (2) Poultry should be eviscerated within one hour of being slaughtered. (3) The alimentary tract and other internal organs should be removed in a manner that minimises contamination to the rest of the carcass. (4) Operators must: a) document the level of faecal contamination that will result in a corrective action; b) monitor and record the actual level of faecal contamination; and c) take corrective action when the defined levels are exceeded [AM PM Spec 15]. (5) Every reasonable attempt must be made to remove visible contamination. If the defined limit is exceeded then: a) the line should be adjusted as soon as possible; Ministry for Primary Industries Page 116 of 148

118 b) line speed reduced to enable better decontamination practices; or c) other suitable corrective action such as retraining of operators that eviscerate by hand [AM PM Spec 15 (4)]. (6) There should be continuous sprays to rinse equipment and the carcass. Any antimicrobial agent added to the rinse water should be an approved processing aid Automatic Evisceration (1) Mechanical evisceration equipment should be adjusted to suit the particular size or type of carcass being eviscerated in order to minimise: a) damage to carcasses; b) damage to the alimentary tract and other internal organs; c) incomplete removal of the alimentary tract and other internal organs; and d) spillage from the alimentary tract and other internal organs onto the carcass. (2) Mechanical evisceration equipment should be rinsed continuously. (3) If the operator requires a manual back-up for a mechanical venting operation, facilities for the rinsing of hands and implements should be provided. The most important factor for reducing damage to the intestine is the way that the equipment is maintained and configured for a particular size or type of carcass Manual Evisceration (1) Operators should ensure that facilities are available so that rinsing of hands and evisceration tools can occur to minimise cross contamination during manual evisceration. (2) During a manual evisceration process all utensils, hands, benches and other product contact surfaces should be rinsed in potable water regularly or when contaminated and rinsed and sanitised at every break. (3) Where rinsing is not possible between every carcass, the contaminants and contaminated rinse water should be directed away from all other carcasses as far as practicable. (4) Each set of viscera should be removed from the bench surface immediately after evisceration. (5) As much waste as practicable should be ducted to drains. When carcasses are contaminated by faecal, ova or other contamination, rinsing should occur before further carcasses are processed Post-Mortem Examination (1) Only poultry material that has been examined in accordance with the ante-mortem and post-mortem regulations and specifications may be released from the final primary processor [HC Spec 13.8 (1)]. (2) Traceability between all parts of the poultry material, or group of animal material in the case of batch processing, must be maintained until the post-mortem examination is completed (e.g. carcass and viscera must be examined at the same time) [HC Spec 13.7 (1)]. Ministry for Primary Industries Page 117 of 148

119 Post-mortem examination can be conducted along the chain at different points, however it must be completed at the end of primary processing, as per clause (1) above, e.g. the completion of primary chilling. In practice most operators conduct post-mortem examination at the following points: post plucking - the external carcass; and after evisceration - the internal cavity and viscera Post Evisceration Decontamination (1) All carcasses post-evisceration should be rinsed by a constant spray of potable water. The resulting carcass should be visibly clean. The position of this rinse will vary depending on the set up of the operation Cropping (1) The brush used to clean the probe at the bottom of its movement should be kept clean and in good condition Neck Flap Removal Neck flaps may be trimmed to remove contamination Inside/Outside Wash (Final Carcass Rinse) (1) After evisceration, all carcasses should be rinsed with: a) running potable water with at least 0.5 litres per bird; and/or b) an approved processing aid to remove any remaining visible contamination before undergoing any chilling regime. (2) Carcases that are still visually contaminated after rinsing should, where practicable, be immediately removed from the process line and be decontaminated prior to being placed back on the processing line. Sprays used for poultry rinsing should ensure thorough rinsing inside and outside the carcass. The water volume/pressure should be sufficient to cover the whole carcass and to remove visual contamination Offal Recovery for Human Consumption (1) Poultry offal for human consumption must be: a) removed, collected and handled in a way that minimises contamination of the offal; and b) rinsed using potable water with an approved antimicrobial processing aid before or during chilling, with continuous cooling to 7 C or colder within four hours removal [HC Spec 13.9 (2)]. (2) Offal should not be placed within a dressed poultry carcass unless the offal is enclosed in a sealed pack or securely wrapped to prevent cross contamination between offal and carcass. (3) Where water is used to chill the offal, the water should be maintained in a sanitary condition by using sufficient overflow, water replacement or other appropriate mechanisms. Ministry for Primary Industries Page 118 of 148

120 (4) Ice and water retention should be minimised. The generally accepted preservation temperature for chilled meat is 7 C or cooler and for frozen meat it is -12 C or cooler. Meat and poultry are usually dispatched and transported from slaughter and dressing facilities at these temperatures. A chilled or cooled poultry material may be transported to and received at poultry processing premises at 7 C or warmer provided that: continuous cooling occurs during holding and transport of the poultry material (i.e. product temperature should not go up); the cooling procedures and transport conditions are documented in the RMP of the operator either supplying or receiving the poultry material; and the operator is able to demonstrate the effectiveness of any alternative cooling method and conditions in maintaining the safety and quality of the poultry material, considering its intended use. An example of an alternative cooling method is the continuous cooling of offal by packing them in bulk bins with ice and transporting them in this state. In this case, the following should be written in the RMP: the cooling procedures (e.g. method of packing in bins, proportion of ice to product, maximum period for holding); transport conditions (e.g. delivery time); the criteria for accepting the product (e.g. product temperature, amount of ice left in the bin, signs of spoilage or quality deterioration). Frozen poultry materials may be transported to and received at poultry processing premises at -12 C or cooler provided that they remain in the frozen state (i.e. frozen hard) with no signs of tempering or thawing Offal Recovery for Animal Consumption (1) Offal for animal consumption should be: a) removed, collected and handled in a way that minimises contamination of the offal; b) rinsed under potable water; and c) continuously chilled to 10 C or cooler within four hours after removal Primary Chilling (1) Carcasses should be chilled using immersion and/or air chilling systems to minimise microbial proliferation and handled in a manner to minimise microbial contaminants. (2) Immersion and air chilling systems should deliver product at 10 C or less before the product leaves primary processing. (3) The final product must have no more than 1.0 mg/kg free available chlorine when chlorine is used as a washing agent [FSC Standard 1.3.3]. (4) Condensation should be minimised throughout primary processing areas as it can be a source of contamination. (5) Where condensation is avoidable through better premises and/or equipment design, modifications must be made to minimise the accumulation of condensation [HC Spec 2.2 (1)]. (6) Where condensation is unavoidable, it is expected that corrective action is taken to demonstrate that cleaning is effective, including: a) cleaning and sanitising any ceilings or overhead structures; and b) subjecting any ceilings or overhead structures to pre-operational inspection and microbiological monitoring. Ministry for Primary Industries Page 119 of 148

121 A pre-chill tank using ph corrected water with a maximum of 200 ppm total chlorine is sometimes used. Water vapour will only condense onto another surface when that surface is cooler than the temperature of the water vapour, or when the water vapour equilibrate in air, i.e. saturation humidity, has been exceeded. In buildings the internal air can have a high level of relative humidity due to the activity inside it. When warmer air comes into contact with colder surfaces such as cold walls it condenses. Check OMARs as several countries have very strict condensation control requirements Immersion Chilling (1) Any immersion chillers should be operated to minimise microbial cross contamination from one carcass to another via the chiller water. (2) Operators should document the operating conditions that they set to ensure that: a) water and ice are potable on entry to the chilling system; b) build-up of organic matter is minimised (as determined through appropriate monitoring, e.g. visual and/or turbidity); c) approved processing aids are used as per manufacturer s recommendations including ph control where necessary; d) the water temperature and flow rate, carcass throughput and dwell time are adequate to achieve an internal carcass temperature of 10 C or less when exiting from the immersion chiller (refer to Table 8 below for suggested water flow rates); and e) the water is of a volume consistent with good operating practice as described below, or changed at a frequency that ensures that the water meets standards set under (b) above. (3) Where chlorine is used, there should be a residual amount of free available chlorine at the point where water exits the final tank. (4) Excess water and/or ice should be removed from the carcass directly after immersion chilling to minimise the amount of fluid that could lead to cross contamination later in the food chain. Table 8: The following water flow rates are consistent with good manufacturing practice Carcass weight (kg) Minimum flow (litres/carcass) 1 Minimum Flow (litres/carcass) < > Operators should aim for 3-5 ppm free available chlorine where the water exits the final tank. Operators may use a pre or post-spin chill dip with an antimicrobial processing aid to further reduce contamination. It is recommended that any water that flows from one immersion tank to another is filtered to remove organic material before entering the later tank. 1 Recommended minimum flow through the final tank when multiple immersion tanks are used. The minimum flow rates (litres/carcase) given above do not include the initial volume required to fill the tank at the start of processing or at any other time the tank is being filled. Ministry for Primary Industries Page 120 of 148

122 Alternative Chilling Processes (1) Alternative chilling processes for carcasses, including air chilling and spray chilling, should be operated to achieve an internal carcass temperature of 10 C or less when exiting from the chiller. (2) The operator should document the following relevant operating conditions to achieve an internal carcass temperature of 10 C or less when exiting from the chiller : a) air flow rates; b) air temperature; c) humidity; d) maximum capacity; e) product layout; and f) dwell time. (3) Air chillers should be cleaned and sanitised as per the frequency specified in the cleaning schedule. Alternative chilling processes may be done on a continuous chain and/or as static batch chilling (before or after packing) Drainage (1) Where carcass washing is carried out during processing, carcass wash areas should be constructed to confine wash water to that area and direct it to the drainage system. (2) Excess water and/or ice should be removed from birds directly after carcass wash or immersion chilling to minimise drip that could lead to cross contamination. 8.6 National Microbiological Database Whole Carcass Rinse Sampling (1) Whole poultry carcass rinse samples must be taken as per the Animal Products Notice for the National Microbiological Database Programme Specification [NMD Spec 4.2]. (2) Corrective actions must be taken in the event of non-compliance with any of the Salmonella and Campylobacter regulatory limits for poultry [NMD Spec ]. Appendix 3 provides guidance on troubleshooting for problems associated with Campylobacter during the poultry processing chain. Ministry for Primary Industries Page 121 of 148

123 Part 9: Secondary Processing of Poultry 9.1 Scope (1) To ensure that poultry material and products that is secondary processed is fit for intended purpose, and meets the requirements. 9.2 Requirements and Procedures (1) The operator must document procedures covering their processing activities [HC Spec 9.2 (1)]. (2) Visibly contaminated or dropped product should be handled in accordance with Part Non-Product Contact Surfaces (Dropped Products). (3) Controls should be documented to address the presence of unexpected extraneous material such as bones (in boneless product), feathers and cartilage in the product. (4) Product should be downgraded if its status becomes unknown (e.g. due to failure in the method of identification used, such as labels being lost or becoming unreadable) or its status changes due to contamination. The degree to which product is downgraded (e.g. petfood, waste) will depend on the nature of the failure and the operator must ensure that there is no risk to the intended consumer of the downgraded product [HC Spec 3.2 (2)]. (5) Condensation should be managed to prevent it being a source of contamination by: a) removing condensation before or during processing; and b) keeping surfaces that are subject to condensation clean. The capacity and capability of secondary processing operations should be aligned with throughput such that product accumulation in processing areas is minimised. The presence of extraneous material would be considered a wholesomeness risk factor as defined in the APA; something that is unexpected or unusual in the product. Condensation from pre-production should be removed before processing commences in the area. Where condensation sources can be minimised or eliminated through better facility and/or equipment, modifications should be made to achieve this. Condensation that forms during processing should be removed by the use of an absorbent medium to minimise the risk of dripping onto product Minimising Cross Contamination (1) The build-up of scraps and waste material on equipment should be removed during breaks or earlier if necessary to minimise contamination. (2) Unless the final product includes a mixture of different meat types (e.g. offal and diced chicken), the following should be processed separately: a) unpackaged poultry meat types with relatively high microbial counts (e.g. offal) and poultry meat with relatively low microbial counts (e.g. whole birds); or b) different species of meat (e.g. red meat, fish). (3) If different meat types or species are processed at the same time but need to be kept separate, each operation should be separated by distance, physical barriers or other effective means. Ministry for Primary Industries Page 122 of 148

124 (4) Different personnel should attend to each type or species unless procedures are in place to ensure that no cross contamination occurs. (5) Product contact surfaces and equipment used for one meat type or species should be cleaned and sanitised before processing meat from any other type or species. (6) Water movement should be controlled in the processing areas, except where the operator can demonstrate that any uncontrolled water cannot contaminate product or product contact surfaces. (7) Containers used for product intended for human consumption should: a) not be placed directly on the floor; and b) be distinguishable from containers that are permitted to be placed directly on the floor. Build-up of scraps and waste material can be a source of contamination to product. It is acceptable to process poultry meat types with relatively low microbial counts (e.g. whole birds) before processing meats with relatively high microbial counts (e.g. poultry offals) without the need to clean and sanitise in between. The operator should use any previous validation, along with their general knowledge of microbial levels within their products, to assist with production planning. It is not expected that the operator specifically test the different meat types to determine whether a certain batch has higher levels of contamination and as such needs to be processed separately. Key reasons for requiring separation between meat types or species is the varying microbial loadings and consumer expectations. Separation can be achieved by physical barrier, distance or time If your intended consumer would consider a lack of separation to be a risk to wholesomeness (i.e. objectionable or offensive) procedures will need to be put in place to ensure that this risk factor is controlled. It is recommended that colour be used to differentiate between containers that are used for different purposes e.g. human consumption, animal consumption, waste. Where labels are used, care should be taken to ensure that they cannot detach and drop into product. Once product is no longer exposed (e.g. is packaged), separation to minimise contamination is no longer necessary through the remainder of the process (e.g. weighing, labelling, strapping etc.) Temperature Control during Processing (1) Product should be brought into the processing room progressively as needed, and removed to the chiller or freezer immediately after processing, to maintain chill product temperatures. (2) If the temperature of the raw poultry exceeds 10 C (e.g. processing is delayed), poultry should be processed immediately or immediate action should be taken to reduce this temperature. (3) If the raw meat processing area is operating at ambient temperatures the poultry should be held in the processing area for no more than one hour. If a processing area is operating at ambient temperatures, the growth rate of spoilage and pathogenic microorganisms increases as the temperatures increase. Ministry for Primary Industries Page 123 of 148

125 To minimise the growth of bacteria on product contact surfaces during processing and to assist in maintaining chill product temperatures, it is strongly recommended that raw meat processing areas are operated at 12 C or less. New businesses should consider the following when designing their facilities: Target: <7 C ideal chilled product temperatures; 7 C 10 C acceptable working range for handling poultry; and Over 10 C take immediate action to reduce temperature. Corrective actions to reduce product temperatures may include using ice to reduce the product temperature or transferring the poultry to a chiller or freezer. 9.3 Whole Birds Where possible, whole birds should be received after the completion of primary chilling at a temperature of 10 C or less. Where this is not the case, the operator must complete the chilling process as quickly as possible. It is recommended that bins containing product awaiting packing are completely emptied prior to refilling. 9.4 Maturing or Ageing (1) The temperature of the maturing room and product should minimise the growth of pathogenic and spoilage organisms throughout the maturing process. Maturing is typically achieved by chilling product for a period of time, usually 4 to 6 hours at 4 C or less. To increase the rate of maturation, electrical stimulation may be used. Processes such as marinating may also be used to mature product. 9.5 Boning and Size Reduction (1) The control of physical hazards that are reasonably likely to occur such as blades, knives, needles and equipment parts, should be demonstrated and recorded. (2) As a minimum, checks on blades, knives and needles should occur at the end of each production day to ensure no breaks, chips or missing items. (3) The presence of bone in boneless product should be minimised. (4) Product intended for further processing requiring specified weight ranges or dimensions to ensure food safety (e.g. product to be cooked), should be checked to ensure that it falls within that range. This may also include customer requirements for specific size ranges or dimensions. The more frequent the checks, the less product that will be affected in the event that a problem occurs. Checks for bone in boneless product should be conducted at a frequency sufficient to accurately monitor their occurrence. In the event that the levels found exceed the documented process capability, actions should be taken, such as: Ministry for Primary Industries Page 124 of 148

126 providing staff with additional training; and increasing the frequency of inspection until the cause of the problem is rectified. Corrective actions in the event of a problem should include holding and inspecting all affected product since the last compliant result. 9.6 Comminution (1) Comminution should be conducted in a manner that minimises contamination and growth of microorganisms. (2) The temperature of meat should be reduced to the preservation temperature immediately after comminution unless it is immediately subject to further processing. When undergoing comminution, the following points should be considered: temperature of the product can increase, often as high as 10 C, as a result of the energy required during comminution, which can then allow for more rapid bacterial growth; reducing the product temperature prior to comminution should ensure that cooling time after comminution minimises the opportunity for microbial growth; the cooling rate at the slowest cooling point within the product, particularly if product is collected into large containers or bins; product should remain in the processing area for the shortest time possible; trimmings are often subject to high levels of handling and possibly temperature fluctuation, and as such, will be more highly contaminated; raw material should be checked before comminution to prevent contamination by extraneous material; any accumulated product should be periodically removed from the equipment; and the processing environment and hygiene of product contact surfaces should be maintained according to the requirements of Part 5 Cleaning and Sanitation. 9.7 Mechanically Separated Meat (MSM) (1) The temperatures of bones, carcasses or portions that are intended to be processed using mechanical separation methods must be: a) chilled to or maintained below 10 C and mechanically separated within 5 hours of boning; b) chilled to 4 C and mechanically separated within 72 hours of boning; c) chilled to -2 C and mechanically separated within 120 hours of boning; or d) immediately placed in a freezer and frozen within 48 hours of boning [HC Spec 14.6 (2)]. (2) The calcium content of mechanically separated animal product, calculated and stated on a dry matter basis, must not exceed 1.5 percent [HC Spec 14.6 (3)]. (3) Mechanically separated animal product must be: a) used as an ingredient directly after the separation process; b) immediately cooled to a maximum temperature of 4 C and used for further processing within 48 hours; or c) immediately frozen [HC Spec 14.6 (4)]. (4) The operator must document an operator-defined limit, including actions to be taken if the limit is exceeded, for aerobic plate count and Escherichia coli for the purpose of microbiological process control for mechanically separated poultry product and material [HC Spec 14.6 (5)]. Ministry for Primary Industries Page 125 of 148

127 (5) Records must be kept to show that MSM has been processed in accordance with the requirements [HC Spec 9.2 (1)]. When higher than normal microbial levels are detected, the operator should investigate the cause and take appropriate actions. When producing frozen MSM, care should be taken to ensure that packaging does not become trapped within the product, as this could be inadvertently included in further processed products. Alternative packaging materials such as wax lined boxes could be used to avoid this. 9.8 Formulated Products Marinades or Brining Solutions (1) Marinades or brines should be kept at 10 C or lower. (2) If product contains an additive which has a maximum permitted level specified in legislation (e.g. nitrite), the operator must have evidence to demonstrate that the product does not exceed those levels at the point of sale [FSC Standard 1.3.1]. Unused marinade or brine that has been prepared and stored under appropriate conditions, may continue to be used within its shelf life. Equipment such as injectors and tumblers are not able to deliver a consistent, accurate pick up on every individual piece of meat (there are many variables which can affect this). A range is often provided in quality control checks, for example 10 ± 2% is typical for injected whole birds. This variability needs to be considered when ensuring compliance for additives. If a company produces a range of nitrite containing products, representative or worst case samples only may be tested rather than every product in the range. Where the operator has not tested all products, they should be able to justify how the tested samples are representative of those not tested. Some natural ingredients such as celery salt contain nitrites and the inclusion of this ingredient should be taken into consideration when determining compliance with the FSC Injection (1) At a minimum, the operator should inspect the injection equipment (e.g. needles) at the end of each processing day to ensure no breaks, chips or missing parts. (2) The operator must take appropriate corrective action if a problem is identified [RMP Spec 11 (2)]. It is recommended that operators should: periodically check the microbiological levels of the brine or marinade during a complete processing run; investigate causes when higher than normal microbial levels are detected; and take appropriate actions depending on the levels detected. Actions should include holding and inspecting all affected product since the last compliant result, until the item is located. A metal detector may be used for this purpose. Ministry for Primary Industries Page 126 of 148

128 The inspection of the needles is sometimes identified as a CCP. Some equipment is able to identify needle damage or breakage automatically, which can reduce the amount of affected product in the event of damage or breakage Tumbling (1) Chilled temperatures should be maintained during tumbling or massaging operations to minimise microbial growth. (2) If the temperature has risen to 10 C or above during processing, this should be reduced as soon as possible. 9.9 Assembly, Wraps, Kebabs and Other Value Added Products (1) Product inclusions such as wooden kebab sticks must be managed to ensure that they do not become a physical hazard to other products [HC Spec 7.2 (1) c)]. (2) The finished product should be reduced to its preservation temperature as soon as possible after processing. (3) If combining raw and ready-to-eat product components (e.g. providing ready-to-eat sauce sachets with raw product), the operator should ensure that the product is presented in a manner that would minimise the likelihood that the consumer could cross contaminate between the two components during preparation. An important consideration when making many different product varieties (e.g. types, flavours) is the control of cross contamination of products with a different allergen status (see Part 6.2 Allergen Management for guidance). The additional handling required during mixing and assembly of value added products could lead to higher bacterial counts. This may be minimised by: ensuring that the raw poultry and other refrigerated components are at as low a temperature as possible and limiting the time that they are out of the chiller or freezer; limiting, as much as possible, the amount of product handling; ensuring that all equipment is thoroughly cleaned and sanitised before use; ensuring that personal protective equipment (e.g. gloves, sleeves, aprons etc.) that may contact the product is clean and sanitised or changed as often as necessary to minimise contamination; and processing in chilled rooms Coatings (Battering and Breading) (1) Temperature of batters and egg or milk wash should be kept at 10 C or less whenever practical. (2) Re-circulated coating components (e.g. egg or milk wash, batter, pre-dust, crumb, flour etc.) should be discarded at the end of the production run unless re-use has been validated Rework (1) Rework should be clearly identified and traceable to the final product. (2) If the addition of rework changes a final product formulation, this should be reflected in the product labelling. Ministry for Primary Industries Page 127 of 148

129 The operator should set an operator-defined limit for rework, considering how the addition of rework impacts on: the shelf life of the product; and nutritional information labelling. It is strongly recommended that rework only be incorporated into other products with a compatible formulation (e.g. same allergen status, formulation etc.). Refer to Parts 6.4 Inventory Control and Traceability and 6.5 Labelling and Identification of Product for further procedures relating to rework Metal Detection (1) Metal detectors should be calibrated at appropriate frequencies using test metals that are similar to those found in the premises, and calibration records must be kept [HC Spec 6.2 (1) and 9.2 (1)]. (2) Operators should have a procedure in place should a metal fragment contamination occur. Procedures should include holding and checking affected product until the operator is sure the item is not in the product. Metal detectors should be used in accordance with manufacturer s instructions Secondary Chilling The operator should continue to cool the product to ensure that it reaches 7 C or lower without unnecessary delay Thawing (1) To minimise deterioration and contamination of poultry product or poultry material, the operator should establish, validate and comply with process criteria for thawing poultry (including air and water thawing), such as: a) air temperature; b) water temperature; c) time of thawing; and d) temperature of the poultry at the completion of thawing. (2) Poultry meat should be thawed at: a) a maximum air temperature of 10 C for up to 72 hours; b) a maximum air temperature of 7 C for up to 96 hours; or c) a maximum air temperature of 15 C, where no part of the product exceeds 10 C (3) The product temperature should be constantly monitored under an automatic control system. (4) The temperature of product at the top leading corner of the carton, i.e. the corner that first intercepts the air flow, at the warmest location in the chiller should be used as the reference to monitor and control the temperature. Ministry for Primary Industries Page 128 of 148

130 (5) Adequate controls to ensure that the maximum meat surface and water temperature are not exceeded should be documented and where necessary, validated. (6) Thawed meat which is not processed directly after thawing should be reduced to less than 4 C and the maximum holding time prior to use should be validated. (7) All product must be identified with a lot number and the lot must be tracked throughout the thawing process [HC Spec 8.2 (3)]. (8) The lot number must be maintained with the temperature records [HC Spec 9.2 (1)]. (9) If poultry meat is thawed in a water tank: a) a continuous flow of potable water sufficient to keep the water clean should be provided; and b) the temperature of the water after equilibration should not exceed 10 C. (10) If poultry meat is thawed by potable water sprays, the temperature of the water should not exceed 10 C. Where only partial water thawing of the meat surface is required (e.g. to assist in the removal of entrapped plastic), Part 9.12 Thawing still applies Tempering The principles of thawing product apply also to tempering, with the restriction that the end point temperature remains colder than the freezing point of the product Shelf life (1) The operator must validate the shelf life of products and keep records detailing how the shelf-life was determined, including test results [HC Spec 9.2 (1)]. (2) The operator must comply with the validated shelf life [FSC Standard 1.2.5]. on shelf life testing can be found in the MPI booklet How to Determine the Shelf Life of Food available at: Shelf-life validation trials should be conducted at temperatures that can be reasonably achieved in the distribution and retail system, and in the customer s home. Operators should verify the shelf-life of each product on an ongoing basis e.g. by implementing a rolling testing scheme that includes all products types. Ministry for Primary Industries Page 129 of 148

131 Appendix 1 Schedule 1 Specification for Potable Water Supplied by Operator Reproduced from the Animal Products Notice: Specifications for Human Consumption signed 1 st March Application Part 1 (1) This Schedule applies to each potable water source that is supplied by an operator solely for the use of that operator at poultry material or poultry product processing facilities. This Schedule does not apply to operators using an independent water supply such as a town supply. 2 Definitions (1) In this Schedule: secure means the water has been assessed as secure using the Water Supply Assessment Checklist not secure means the water has been assessed as not secure using the Water Supply Assessment Checklist. 3 Initial assessment of water supply (1) Operators must complete one Water Supply Assessment Checklist for each applicable water source used to supply water to the processing operation. (2) If the water source is found to be not satisfactory, the operator must apply corrective actions, including treatment where necessary. (3) The operator may choose to conduct the required water testing at any stage during the completion of the Water Supply Assessment Checklist. (4) However, the operator must have evidence that the water source meets the criteria in Table 1 at the completion of the assessment process; and for example, if initial tests indicate that the water is not satisfactory and corrective action is taken to ensure compliance, further testing will be required. (5) If the Water Supply Assessment Checklist indicates that there may be a particular chemical hazard associated with a water supply, the operator must also arrange for chemical analyses to confirm that the water meets the relevant Maximum Acceptable Value (MAV) in the current edition of the Drinkingwater Standards for New Zealand (DWSNZ) issued by the Ministry of Health. (6) If MAVs are exceeded, the operator must treat the water so that DWSNZ is complied with. (7) The operator must keep the completed Water Supply Assessment Checklist and any associated records as part of the risk management programme. 4 Reassessment of water supply (1) The operator must reassess each applicable potable water source that he or she supplies by completing the Water Supply Assessment Checklist: a) at least once every three years; and b) prior to using a new operator source of potable water (that is, the source changes or a new source is added); and c) within one month of any changes to the environment in or around the water source that may affect the potable water quality. 5 Ongoing water testing Ministry for Primary Industries Page 130 of 148

132 (1) Each applicable potable water source supplied by the operator must be subject to ongoing monitoring according to the following requirements: a) potable water must meet the criteria at the point of use set out in Table 1 according to the testing frequency set out in Table 2; b) microbiological testing must be performed by a recognised laboratory with the required tests in the laboratory s scope of accreditation; c) the operator must ensure that the training of water samplers is undertaken by a laboratory referred to in paragraph b); d) if chemical hazards are identified, the operator must arrange for relevant chemical analyses of the water and test for compliance with the relevant MAV in the DWSNZ. 6 Expected corrective actions (1) If the operator identifies that there is a problem with the potable water source the following actions must be taken: a) where possible remove the source of contamination; and b) if necessary, set up controls to prevent recontamination; and c) treat water, if the above controls do not completely fix the problem; and d) confirm that the corrective action is effective through relevant microbiological and chemical testing. Table 1: Quality of Potable Water Measurement Escherichia coli or faecal coliforms Turbidity Criteria ph (when chlorinated) 6.5 to 8 Chlorine (when chlorinated) Table 2: Frequency of testing Daily water use¹ Using <100 m 3 /day and product packaged at all times Using m 3 /day and product packaged at all times Must not be detectable in any 100 millilitre sample Should not routinely exceed 1 NTU, must not exceed 5 NTUs Not less than 0.2 mg/l (ppm) free available chlorine with a minimum contact time of 20 minutes Microbiology (Escherichia coli or faecal coliforms) 1 per 6 months 1 per 6 months 1 per 3 months 1 per 3 months Turbidity 2 ph 3 Chlorine 3 1 per 6 months 1 per 3 months Using <2000 m 3 /day 1 per month 1 per month 1 per month Using m 3 /day 1 per 2 weeks 1 per 2 weeks 1 per 2 weeks Using > m 3 /day 1 per week 1 per week 1 per week Daily Daily Daily Daily Daily Ministry for Primary Industries Page 131 of 148

133 Part 2 Water Supply Assessment Checklist Complete one Checklist for each water source being assessed. A: SUPPLIER DETAILS RMP number Person who completed checklist B: WATER SOURCE Tick the box representing your water source and then go to the appropriate part of the Checklist as indicated. Deep bore water (i.e. bore more than 10 m deep) Go to B1 Surface water (e.g. bore less than 10 m deep, spring, well, river, stream, dam, lake, reservoir) Go to B2 Roof water Go to B3 B1: DEEP BORE WATER (i.e. bore more than 10 m deep) Tick the appropriate boxes in the table below and then move on to the relevant parts of the Checklist as appropriate to the responses given. Yes No Question Is the bore less than 10 m deep? Is the soil/rock type such that contaminants could flow into the groundwater? Is surface water able to drain into the bore, due to the bore-head being inadequately sealed? Is the bore-head in an area prone to ponding and flooding? Do farmed poultry have access to the bore-head? Is there any specific tank/long-drop toilet outlet within 100 m of the bore-head? Do any of the following water characteristics change after rain? (You will need records of these to confirm these statements) Colour Temperature Turbidity ph Escherichia coli or faecal coliform count If all responses are NO, the water is secure; go to C, Water Storage If any responses are YES, the water is not secure. Record details of the problem(s) in row B1 of Table D. If the problem(s) can be eliminated from the water supply permanently, eliminate the problem(s) and go to C, Water Storage. If the problem(s) cannot be eliminated permanently, go to B2 and answer the questions for surface water If all responses are YES, the water is not secure go to B2 and answer the questions for surface water. Ministry for Primary Industries Page 132 of 148

134 B2: SURFACE WATER e.g. shallow bore (less than 10 m), deep bore not secure, spring, dam, lake, reservoir, stream. Tick the appropriate boxes in the table below and then move on to the relevant parts of the Checklist as appropriate to the responses given. Describe the water source (including name where appropriate) Shallow bore... Dam... Deep bore not secure.... Lake... Spring... Reservoir Stream... River Other (specify)... Yes No Question Are any of the following within 50 m of the water source? Offal pit/soak hole Animal effluent to pasture Sumps, stock-yards or feed pads not connected to an approved effluent system Fuel tanks Timber treatment facility Abandoned or decommissioned wells Septic tank/long-drop toilet Land disposal site/refuse pit Silage stack Chemical preparation/storage Pesticide residues Do you have any of the following water problems? (You will need records of these to confirm these statements) Bacterial contamination Turbidity Sediment Colour Smell Taste Do any of the following factors present risks to the water? Spray drift Nearby factories Mining operations Material from effluent ponds or surface impoundments (waste ponds or lagoons) either treated discharge or leakage Contaminants washed into source during irrigation Geothermal contaminants (e.g. arsenic, boron, lithium) Saline water Possible flooding (consider council land information/lim reports) Other (specify): If all responses are NO, continue with B2 If any responses are YES, record details of the problem(s) in row B2 of Table D then continue with B2 Ministry for Primary Industries Page 133 of 148

135 B2: SURFACE WATER (Continued) Tick the appropriate boxes in the tables below and then move on to the relevant parts of the Checklist as appropriate to the responses given. Describe the surface water type Flowing water (e.g. unsecure bores, rivers, streams, springs) Go to B2(i) Confined water (e.g. dams, lakes, reservoirs) Go to B2(ii) B2(i): FLOWING SURFACE WATER Yes No Question Is effluent discharged less than 2 km upstream of the water intake and if yes, is effluent discharged less than 4 hours before water is taken from that source? If Yes to both statements, state the water source: Do farmed animals have access to within 10 m of the water intake? Is industrial or urban storm water discharged to the source water upstream of the intake? If all responses are NO, go to C, Water Storage If any response is YES, record details of the problem(s) in row B2(i) of Table D and then go to C, Water Storage B2(ii): CONFINED SURFACE WATER Yes No Question Is the water accessible to farmed animals? Is effluent discharged into the dam/lake/reservoir? Is industrial or urban storm water discharged into the dam/ lake/ reservoir? If all responses are NO, go to C, Water Storage If any response is YES, record details of the problem(s) in row B2(ii) of Table D and then go to C, Water Storage Ministry for Primary Industries Page 134 of 148

136 B3: ROOF WATER Tick the appropriate boxes in the table below and then move on to the relevant parts of the Checklist as appropriate to the responses given. Yes No Question Roofing materials: Are any of the following materials used on the water collection surfaces? Galvanised iron Lead materials (lead nails, flashings, paint) Asbestos materials Paint or other surface treatment in poor condition Roof environment Is the roof overhung by trees? Are there any other factors that could encourage birds or other pests to move about or settle on the roof? Atmospheric fall-out Are there industrial (including agricultural chemicals) or natural sources of atmospheric fall-out? Is there any ash/soot deposit on the roof? Roof maintenance Are the gutterings left for more than a month before being cleaned out? If all responses are NO, go to C, Water Storage If any responses are YES, record details of the problem(s) in row B3 of Table D and then go to C, Water Storage C: WATER STORAGE Describe water storage facilities Do not have holding tanks Go to Table D if problems have been identified in the previous parts, and E if no problems have been identified in the previous parts Have holding tanks Go to C1 C1: HOLDING TANKS If there is more than one storage facility, copy and fill out this part for each storage facility. Yes No Question Is the outlet of the holding tank below or level with the base of the tank, allowing any debris that has settled to be sucked out with the water? Is the water in holding tanks prone to stagnation that results in deterioration of water quality? Are holding tanks inspected and maintained less than once per year? Are holding tanks dirty and not cleaned when necessary? Are holding tanks uncovered, allowing access by animals or other debris or other contaminants to the tanks? If all responses are NO, the water STORAGE is satisfactory. Go to Table D and check that any other problems identified in the Checklist are followed up. If any response is YES, the water STORAGE is not satisfactory. Record details of the problem(s) in row C1 of Table D and then fill out the rest of Table D. Ministry for Primary Industries Page 135 of 148

137 Table D: CORRECTIVE ACTION Wherever there was a YES answer in the part of the Checklist referred to, write the details of the problem(s) identified in the correct row of this table. Fill out the rest of the table to show whether or not the problem(s) is a source of contamination, and where possible what you have done to eliminate the problem(s) and permanently prevent the contamination from occurring (for example, preventing animal access, no longer using chemicals in the vicinity of the collection area, resurfacing roof). Problem Ref Problem(s) identified Biological hazard, chemical hazard or turbidity issue caused by the problem(s) Action taken to address the problem(s) Eliminated ( ) Still remains ( ) B1 Deep bore water B2 Surface water B2(i) Flowing surface water B2(ii) Confined surface water B3 Roof water C1 Holding tanks E Initial water testing If the problem(s) has been permanently eliminated, a water management plan is not needed. Go to E If the problem(s) still exists, record the problem(s) in the first row of D1 and then fill out the rest of D1 with how the problem(s) will be managed on an ongoing basis Ministry for Primary Industries Page 136 of 148

138 D1: WATER MANAGEMENT PLAN A water management plan is required where there are any problems that are not managed with your water supply. This water management plan covers the routine, ongoing water treatment undertaken or actions to ensure that the water is potable, and it may include routine testing conducted to demonstrate that a problem (that cannot be permanently eliminated) is being controlled on an ongoing basis such that treatment is not needed. A separate D1 should be completed for each problem that needs to be managed from Table D Document and implement a water management plan Remaining problem from Table D: Method to manage the identified problem Filtration Chlorination Ultraviolet light Ozone Routine ongoing testing to demonstrate control Other (specify): The treatment is done in accordance with the procedures: provided by the manufacturer / supplier of the water treatment system (attach); or given below: (enter details where relevant, e.g.: equipment type; equipment maintenance [frequency, activity and method, e.g. for replacement of cleaning filters or replacement of UV lights]; other control measures e.g. addition of chorine or ozone, frequency, method, any limits [e.g. concentration of chlorine, monitoring frequency], what is checked [e.g. chlorine level, turbidity] and method, corrective action to be taken when limits exceeded or not met): Or Details of routine testing to demonstrate that the problem is being controlled on an ongoing basis (test, frequency). Other ongoing control measures (frequency, activity and method, e.g. for routine cleaning of roof or tanks): Once table is completed, go to E Ministry for Primary Industries Page 137 of 148

139 E: INITIAL WATER TESTING Yes No Question Has a microbiological test for Escherichia coli or faecal coliforms been done on this source within the past month? If a particular chemical hazard was identified as likely to occur during the completion of this Checklist, has a relevant chemical test been done on this within the past month? If all responses are YES If any response is NO, get the relevant tests done, then Name the laboratory that did each test Yes No Question Does the water satisfy the microbiological criteria in Table 1: Quality of Potable Water? For any additional chemical tests done, does the water satisfy the requirements of the current DWSNZ? If any response is NO, go to Table D and review/improve the corrective actions taken. Repeat the testing and corrective action process until the water is satisfactory If all responses are YES The water is satisfactory. No further action is needed until a reassessment of the water supply is required (see clause 4, reassessment of water supply) or further water testing is required in accordance with the requirements of Table 2: Frequency of Ongoing Testing. Ministry for Primary Industries Page 138 of 148

140 Appendix 2 Responses to a Water Quality Transgression Reproduced from Drinking-water Standards for New Zealand 2005 (Revised 2008) Figure 1: Response to a transgression in a drinking-water supply distribution zone Ministry for Primary Industries Page 139 of 148

141 Figure 2: Response to a turbidity transgression in water after treatment Ministry for Primary Industries Page 140 of 148

142 Appendix 3 Campylobacter Troubleshooting Purpose (1) This Campylobacter Troubleshooting Appendix is intended to provide a framework and guidance to assist a poultry primary processing premises review current processing procedures and operation of specific control measures for Campylobacter. The guidance may be applied by either a standard throughput or very low throughput operator unless otherwise stated: a) at start-up of a new or significantly amended poultry processing operation that is subject to National Microbiological Database testing requirements: or b) in response to any first non-compliant window (Enumeration Failure or Detection Failure) against the Campylobacter performance target; or c) for a standard throughput premises in the event that the prevalence performance target is exceeded to inform the written initial report and the implementation plan that is submitted to the MPI verifier. (2) The guidance document can be used where processing practices have changed or have differed, or where further investigation could result in improvements. It is intended to assist the operator to investigate and review the processing practices and identify actions that can improve any process step or specific control measures for Campylobacter. The possible investigation and resulting actions to control Campylobacter at any particular point are not limited to those outlined in this document. Background (1) The guidance document is intended to assist poultry operators to identify control measures for Campylobacter during primary processing of chickens. For example, in the event of exceeding the Campylobacter Performance Target or the Prevalence Performance Target or for new primary poultry processors specified in the Animal Products (National Microbiological Database Specifications) Notices. It has been developed in consultation with the Poultry Industry of New Zealand (PIANZ) to support the implementation of the Prevalence Performance Target introduced into the National Microbiological Database (NMD) poultry programme. (2) The guidance document is divided into two key areas the: a) first provides a framework that a primary processor of poultry can use to review production and processing procedures and the operation of control measures specific for Campylobacter spp. This is not an exhaustive list but is intended to provide assistance to the operator. b) second area addresses those process steps that the poultry industry has identified as being the key process steps to review first in the event of breaching either the: i) component of the Campylobacter Performance Target (Enumeration Failure or Detection Failure); or ii) Prevalence Performance Target. Ministry for Primary Industries Page 141 of 148

143 Review of production and processing procedures (1) The following table provides a series of prompts and questions to assist the operator to review the production and processing procedures and the operation of control measures specific for Campylobacter spp. No. Process step 1 Poultry supply: Has there been an increase in the number of free-range and/or organic flocks? Are the birds dirtier than normal on receipt? If there is an increase in the percentage of chickens that are first cut positives: o take into account the season and recent weather; and o compare the results with those from the corresponding period from the previous 2 years to determine whether similar results have occurred previously. 2 Feed withdrawal: Feed withdrawal practices should be adequately investigated e.g. has the company feed withdrawal times been verified? Consider whether the intestines were ribbon-like when examined after evisceration. Was there any feed present in the crop? Investigate environmental management practices that impact on feed withdrawal e.g. water / light and are company procedures being followed? What is the steady state feeding prior to slaughter? Are any non-conformances identified with the feeding regime followed up with the farming division/growers? 3 Catching: Consider: Whether the scheduling of the catching of birds between different farms and sheds enables the sheds with first cut birds to be caught before other sheds with older birds (second and later cuts)? How biosecurity is managed when catchers operate at different farms each day? Whether the equipment, including personal equipment, going into sheds is clean? Investigating biosecurity routines on farm including personal hygiene (i.e. personnel and equipment including of catchers). 4 Transport: Consider the: Cleanliness of crates and modules Dryness of crates and modules Cleanliness of truck beds. 5 Stress management of birds during: Consider: Lairage (including temperature control) Hanging (including dim lighting, gentle handling) Slaughter (including proper stunning). 6 Kill line: Is the line speed appropriate for the size / weight of birds? Consider the weight range of the live birds and the line speed. Is the line running at a speed within the design capacity of the equipment? Are the weights within the design range of the equipment? Do the birds finish bleeding out before reaching the scald tank? 7 Scalding: Are the scalding tanks are emptied of water completely daily? Does the water in the scalding tank move by counter flow to the direction of the birds and overflow? Is the organic material in water is minimized by the water replacement rate? Scald temperature is: C Scald time is: seconds Has an additional antimicrobial intervention (e.g. high ph) been considered? 8 Bird washing (at every stage): Ministry for Primary Industries Page 142 of 148

144 No. Process step Are the washers achieving full coverage of birds and appropriate volume of water? Are there washers located at all relevant points along the chain to address potential contamination? 9 Plucking set up: Investigate plucker efficiency (birds should not be either excessively plucked or have feathers remaining) Consider the type of plucker and whether it is being operated according to the manufacturer s instructions or limit cross contamination Consider whether the plucker fingers are damaged (micro cracks) or worn due to age and are working effectively. 10 Post-pluck bird rinse(s): Full coverage Sufficient pressure Antimicrobial type (if any) Antimicrobial concentration (if any) 11 Plucker equipment rinse (during operation): Does the rinse provide full coverage of the equipment? Does the water operate under sufficient pressure? Antimicrobial type (if any) Antimicrobial concentration (if any) Is the rinse sufficient to avoid buildup of gunge? 12 Manual processing is hygienic (may be multiple locations to consider): Are hand rinse/wash stations close to all manual handling points? Is the frequency of hand rinsing / washing acceptable? Are knife rinsing / washing / sanitising stations close to manual handling points? Is the frequency of knife rinsing / washing / sanitising acceptable? 13 Evisceration equipment set up: Is each piece of equipment set up to the manufacturer s operating specifications at all times? Is the equipment adjusted appropriate to the bird size? How old is the equipment? Consider whether the equipment is damaged or worn and is not working effectively Is there a servicing and maintenance programme for the evisceration equipment? When was equipment last serviced / maintained? Is the equipment capable of operating to the required standard? Has the advice of an independent equipment specialist been sought and if so, have all recommendations been followed? 14 Vent cut: Is the vent drill and opener operating correctly? Has the vent opener been set up in line the manufacturer s instructions? Is the knife breaking guts? Breakage of guts after vent cut: % (Is there an increase of gut breakage from the norm?) Is there a maintenance schedule? Is this aligned with the manufacturer s guidance for the frequency of maintenance and servicing? 15 Evisceration (including manual): Are the guts undamaged and removed cleanly from the birds? Investigate gut breakage to assess equipment performance? Is the proportion of missed or burst gut packs exceeding the norm? 16 Post evisceration bird rinse(s) after each flock: Is there full coverage of each carcass? Is the water at a sufficient pressure? Antimicrobial type (if any) Antimicrobial concentration (if any) 17 Evisceration equipment rinse(s) on each flock: Is there full coverage of the evisceration equipment? Is the wash of sufficient pressure? Antimicrobial type (if any) Ministry for Primary Industries Page 143 of 148

145 No. Process step Antimicrobial concentration (if any) 18 Gut removal: Effectiveness Hygienic handling Monitor and investigate any incomplete / faecal contamination when this is above the norm? 19 Post mortem examination: Ensure that the levels of contamination, or damage to the viscera, are not above the industry norm and investigate if not acceptable: Faecal contamination: % Damage to the viscera % Other issues: 20 Extremities: Where head and/or feet are left on ensure that these are rinsed to the extent practicable. 21 Inside-outside wash: Does the inside-outside wash achieve a full coverage of the carcass? Is the wash at a sufficient pressure? Is any antimicrobial added to the inside-outside wash? What concentration of antimicrobial (if any) is applied 22 Pre-immersion chill with addition of antimicrobial (wash/spray with the application of an antimicrobial): Contact time: ph: Antimicrobial type (if any) Antimicrobial concentration (if any) 23 Immersion chill (NB: If using air chill refer to line 25): Check that the immersion chillers are not overloaded Check that the water is flowing counter to the direction of the birds Water volume per bird is at least to the Processing of Poultry Code of Practice, approx. 2L per bird requirement: Have the measuring equipment for ph, water temperature and antimicrobial concentration been maintained and calibrated according to the manufacturer s instructions? Retention time and water replacement rate has been investigated and is appropriate and effective: Antimicrobial type (if any) Is the ph monitored and appropriate for maximum effectiveness of antimicrobial: Confirm that the antimicrobial concentration is monitored and within the correct parameters (if any) Is the anti-microbial concentration activity uniformly distributed throughout the tank? Are sufficient checks been done to provide good process assurance? Is the antimicrobial dosing system working as intended? Are the birds sufficiently agitated in the tank to ensure that they are well dispersed and have adequate exposure to the chilled water and antimicrobial (where used)? Temperature of birds at exit: C How often are checks done Is the ratio of birds to water known and in line with the manufacturer s recommendations? Check that the immersion chiller is not overloaded Where the active ingredient is chlorine, the residual chlorine should be in free available form. What is the retention time of the birds in the immersion chiller? Can this be increased? 24 Post-chill antimicrobial: Contact time: ph: Antimicrobial type (if any) Antimicrobial concentration (if any) 25 Air chilling Are the air chillers operating according to the manufacturer s instructions? Has any measuring equipment been maintained and calibrated according to the manufacturer s Ministry for Primary Industries Page 144 of 148

146 No. Process step instructions? What is the temperature of the birds on exit? 26 Process capability: Have any additional samples been taken to establish process capability and effectiveness of control measures along the process? Have these results been analysed and actions implemented? What has occurred results from this implementation of these actions have these been incorporated into the RMP / HACCP? 27 Changes: Have those results that have fallen outside the limits of the Campylobacter performance target (CPT) and Performance Prevalence Target (PPT) been investigated and followed-up? For example, investigate whether failed results tend to occur at the same time of day, on birds from certain growers, on a particular processing line, etc. If so what? When? Has anything changed since the last period of good performance (e.g. supervision, operators, equipment, speed of processing, volumes of water, concentration or supplier of chemicals)? 28 Other: It is strongly recommended that each premises conducts a longitudinal study incorporating each major processing step (e.g. pre-scald, post scald, post pluck, post eviseration, post cropper, pre spin chill, post spin chill, after post chill intervention). This study provides a benchmark to use at different times of the year to understand the loading of Campylobacter entering the plant and the impact of processing interventions through the process. This information may provide some insight at times of CPT and/or PPT non-compliance. Ministry for Primary Industries Page 145 of 148

147 Responding when the Campylobacter limits in the NMD are exceeded General actions (1) Initial actions to consider in the event of a non-compliance with the National Microbiological Database programme for poultry Campylobacter Targets (Campylobacter Performance Target and/or Prevalence Performance Target) (Figure 1). Figure 1: Initial actions in the event that the NMD Campylobacter limits are exceeded Non-compliant moving window and/or Prevalence Performance Target Check effectiveness of eviseration Look at the conditions in the spin-chill (immersion chiller) Look at equipment set up and performance Investigate feed withdrawal Specific Actions (1) Consider more specific targeted actions in the event that either the Campylobacter Performance Target (Enumeration Failure and Detection Failure) and/or Prevalence Performance Target is exceeded. Enumeration Failure Look at the detection of bile and/or faecal contents on the carcass post-eviseration wash (1) Be on alert for an enumeration failure. This occurs where there is a non-compliant moving window due to the exceedance of the Enumeration Limit. The enumeration limit is defined as when the Campylobacter colony count is great than log cfu/whole carcass. (2) Figure 2 provides actions that could be considered when responding to an enumeration failure. Ministry for Primary Industries Page 146 of 148

148 Figure 2: Actions to consider at specific process steps in the event that an enumeration failure occurs Process step Vent drill and opener Vent opener and evisceration equipment Specific actions to consider when responding to an enumeration failure 1 Investigate whether the equipment is operating correctly 1 Is the equipment set according to the manufacturer s requirements? Note: The number of broken guts can help to indicate whether the problem is severe 2 Is the cropper working effectively? 3 Is the maintenance and servicing in line or more frequent than the manufacturer s guidance? 4 Is the eviscerator set up and operating correctly? Does the number of missed or burst gut packs exceed the norm? Detection Failure or Prevalence Performance Target (1) Be on alert for a detection failure. This occurs when there is a non-compliant moving window due to the exceedance of the detection limit. The detection limit is defined as a Campylobacter colony count > log cfu/carcass. The performance prevalence target applies at the close of a quarter to operators of a standard throughput premises that processes broiler chickens if Campylobacter is detected in more than 30% of samples from broiler chickens. (2) Figure 3 provides examples of the process steps and questions to address following a detection failure or exceeding the prevalence performance target. Ministry for Primary Industries Page 147 of 148

149 Figure 3: Processing steps to review in the event of failing to meet the detection limit of prevalence performance target Are the incoming birds dirtier than normal? Compare the results for corresponding periods from the previous 2 years. In the event of either a Detection Limit or Prevalence Performance Target failure: Is the line speed appropriate for the size of bird? Immersion chiller checks Check that this is not overloaded Check the rate of water flow, at least 2L per bird Check that the ph is between (or ph 6.5 where there are potential OSH concerns) Where chlorine is the active intervention check the free available chlorine (FAC) (preferably >3ppm) at water overflow at bird entry*. Check that the agitation system keeps a good water flow over the surface of the birds Check the retention time of the birds. Is this unchanged since the last good performance period (recommend at least 70 minutes)? Is all the measuring equipment calibrated? Is the antimicrobial dosing system** working as intended? Check the antimicrobial e.g. ASC, system retention time seconds. Consider what changes have occurred since the last period of good performance to: Supervision Operators Equipment Speed of processing Volumes of water Chemical concentration Chemical supplier, etc.? *Consider adding more chlorine to bring the concentration at the water overflow to 5ppm **Where acidified sodium chlorite (ASC) is used. Check both the ph 2.5 ±0.05 and the ASC concentration in the tank. Consider increasing the concentration of ASC to reduce levels of Campylobacter detected. For example, increase to 800 ppm in tank (c. 900 ppm at generator). Ministry for Primary Industries Page 148 of 148