Karoo Meat of Origin standard: Abattoir

Transcription

1 Karoo Meat of Origin standard: Abattoir

2 Karoo Meat of Origin Standard: Abattoir 1. Origin of animals a. Farm declaration of origin b. Accredited producers only 2. Carcass specification 3. General a. HAS point compliance b. Management Responsibility 4. Animal welfare a. Unloading b. Lairage (at Abattoir) 5. Killing and slaughtering 6. Carcass chilling 7. Facilities & premises 8. Personnel hygiene and Protective clothing 9. Quality management a. ph report b. Certificate of Conformance c. Micro Records d. Calibration of equipment 10. Traceability 11. Cleaning and sanitation 12. Maintenance 13. Pest control 14. Storage 15. Transport 16. Document and record control 17. Audits 18. Non-conformance to specifications Approved by: Johann Kirsten Owner: KDF Page 2 of 16

3 1. Origin of animals a. Farm declaration of compliance to KAROO MEAT OF ORIGIN standards The following options are allowable: Option 1 i. The farmer delivers the animals and signs the verwyderings sertifikaat / ontvangsbewys or something similar where it states that the animals are free range and conforms to the rest of the specs for free range and Karoo animals. ii. Keep a copy of this document on file for auditing purposes. Option 2 i. Animals, ready for slaughter, may only be removed from the farm if accompanied by a DECLARATION OF COMPLIANCE TO KAROO MEAT OF ORIGIN STANDARDS (Addendum 1). ii. This form must be completed and signed by the producer (or an authorized person). iii. The producer will keep a copy of the DECLARATION OF COMPLIANCE TO KAROO MEAT OF ORIGIN STANDARDS, while the other copy will accompany the specific truck to the dedicated abattoir. The abattoir will only accept animals for slaughter that are accompanied by a Declaration of Compliance. iv. Keep this copy on file for auditing purposes. b. Accredited/ certified producers only i. Check the KMOO database to confirm that the producer/ farmer are certified and that their certification is still valid. Approved by: Johann Kirsten Owner: KDF Page 3 of 16

4 2. Carcass specification Lamb and mutton Only carcasses falling in the following categories of the South African meat classification system (as specified in Meat Classification Regulations No R863 published in the RSA Government Gazette of 1 September 2006) qualify for certification as Karoo sheep meat of origin: Breed Preferably meat breed types with good bone: muscle ratio with an even fat distribution. Carcass mass A-grades >14 but < 25kg AB-grade >14 but <29kg B-grades >14 but <31kg C-grades >14 but <31kg Classification Age classes A, AB, B and C Fat classes 1 to 6 Conformation 3, 4 and 5 Damage Only F1 damage allowed In particular, the following classes of carcasses do not qualify for certification: Age classes: AB, BBB, CCC stamped MD indicating rams or carcasses showing signs of late castration in those age groups Carcasses with code 2 and 3 damage 3. General a. HAS point compliance i. A minimum of 75% average score to be obtained during HAS audit as conducted by the Department of Agriculture. ii. It will be expected of the abattoir to supply the summary page of the HAS audit report to the auditor. This will be forwarded to KMOO with the KMOO audit report. b. Management Responsibility i. Management will ensure that all relevant staff have sufficient knowledge and training in meat hygiene principles and practices ii. Management will ensure that hygiene standards are understood and complied with by all personnel, visitors and contractors before entering the premises. Approved by: Johann Kirsten Owner: KDF Page 4 of 16

5 iii. Management will ensure that there is a documented customer complaint system and/or procedure in place. iv. There shall be periodic review and verification of the food safety system onsite which covers the entire process. The review process shall include customer complaints, audits and corrective actions, etc. v. Management will ensure that meat is only sold to certified KMOO clients. This can be checked on the database that is send through on a regular basis by the MOOK office. 4. Animal welfare a. Unloading i. Injury free. ii. Non slip floor. iii. Correct slope <30. iv. No delay in unloading. v. Good lighting. b. Lairage (at Abattoir) i. Clean drinking water to be available freely. ii. Shade to be provided. iii. Lairage to be cleaned between each batch. iv. Non slip floor. v. Not to be overcrowded : 0.56 m² per animal vi. Animals should not be transported more than 250km to an abattoir. Any distance further than 250km needs to be approved by KMOO first. vii. Animals to be rested before slaughter as follows: a. Transport distance <100km: resting period 1 hour minimum b. Transport distance 100km to 250km: resting period 2 hours minimum viii. Adequate ventilation is required. ix. Feeding of animals when required. x. Lairages equipped with notices specifying the number and type of species permitted. 5. Killing and slaughtering a. Humane procedures must be in place. b. Veterinary inspector to inspect animals before killing (Act 87 of 1967). c. Animals heavily contaminated with faeces and/ mud should be excluded. d. Congestion and excitement to be prevented from lairage to stunning area. Approved by: Johann Kirsten Owner: KDF Page 5 of 16

6 e. Sticks should not be used on moving animals. The animals should be moving in single file. f. No animal should be left in the stunning area during breaks. g. Emergency slaughter facility and SOP in place. h. Stunning must be effective and done according to the manufacturers specifications. Recommended to be done for 3 seconds at 90 Volts (0.8 Ampere). i. The animal should be shackled, hoisted and neck slit open within 30 seconds. j. Electrical stimulation should once again be done according to the specifications of the manufacturer. Recommended to be done for seconds/ Volts/0, 6 Amp. It is critical that the ph of the loin muscle is lower than 6.0 about 1 hour after kill. k. A system should be in place to ensure knifes are sharp. l. A 2 knife system should be in place. No mixing of clean and dirty knifes. m. No dressing started before the completion of the bleeding. Minimum of 6 minutes for sheep. n. Inspect carcass and offal for diseases. o. SOP in place for contaminated and/or dropped carcasses. p. No signs of hair, blood, faeces, soil, etc. may be present on the carcass before cooling. q. If allowed, wash the carcass with cold water with 2ppm available chlorine. r. All sterilisers should be 82 C with proper overflow to ensure clean water. s. Carcass correctly tagged with Lot no/ tracking number on KMOO tag. If the specific abattoir s process does not allow for the carcass to be tagged as per requirement above, it should be discussed with a MOOK representative. The MOOK rep needs to give permission in writing. t. Carcasses need to be clearly and correctly marked/ stamped for KMOO. i. The lamb needs to be roller marked with the following: CERT KMOO ii. The lamb also needs to be marked with a KMOO stamp on the upper leg. Example: Approved by: Johann Kirsten Owner: KDF Page 6 of 16

7 iii. The issuing of stamps and roller marks will be strictly controlled and the abattoir will be expected to sign for it. iv. The stamp/roller marks needs to be returned to MOOK if not slaughtering certified KMOO lamb anymore. v. When stamp/ roller mark is not in use it should be cleaned and kept in secure place on the abattoir premises. u. Only ink approved for use on foodstuffs should be used. 6. Carcass chilling a. Cold room to operate between 0 and 2 C, RH 85-90% and air speed 0.75m/sec. b. Deep leg muscle temperature to be below 10 C within 16 hours after slaughtering. Temperature to be below 5 C before carcasses can be dispatched. c. No mixing of hot and cold carcasses. d. No non-food item or product other than meat stored in carcass chillers. e. Floors to be rinsed daily. All floors, doors, walls and rails to be cleaned and sanitised after each cycle. f. Meat should not to be in direct contact with floor and walls. g. Sufficient spacing to be left between carcasses for optimum air circulation. h. Cold room to be free from bad smells and odors. Approved by: Johann Kirsten Owner: KDF Page 7 of 16

8 7. Facilities & premises Covered in HAS audit. Refer where necessary. a. Design and facilities b. Personnel facilities, toilets and hand washing facilities (R962 of 23 November 2012) c. Site and premises 8. Personnel hygiene and Protective clothing Covered in HAS audit. Refer where necessary. 9. Quality management a. ph-report (spec is less than 6) i. The ph of at least one carcass per every second cradle (5 or 6 per cradle) must be checked before entering the chiller. The ph should be lower than 6 about 1 hour after kill. Reject carcasses with ph>6. Record these ph's. ii. Keep these records on file for auditing purposes. b. Certificate of Conformance i. It is expected that each load of carcasses (per customer) must be accompanied by a Certificate of Conformance. The COC must be completed as follows: a) Option 1 Complete the COC in full. OR b) Option 2 The temperatures and ph s of every 20 th carcass should be filled in. This is only allowed if/ when a Serial Number Tracking Invoice per customer is also attached. The batch numbers of each farmer needs to be linked to the certification numbers of the farmers. This can be Approved by: Johann Kirsten Owner: KDF Page 8 of 16

9 incorporated with the SNTI (or similar) or the batch numbers can be forwarded by to the MOOK office for further distribution. ii. The abattoir must be able to proof full traceability throughout this process. iii. Duplicates should be kept on record for auditing purposes. iv. See Addendum 2 c. Micro records i. Carcass: Total count <50 000/g E.Coli Coliforms Staph. aureus Salmonella Clostridium perfringens Listeria monocytogenes <10/g <100/g Absent/20g Absent/25g Absent/g Absent/g ii. Water: Total count Coliforms E coli <1000/ml <10/ml Absent/ml d. Calibration of equipment i. Calibration and verification of measuring equipment: 1. All scales and thermometers shall be calibrated annually and calibration certificates shall be kept on file. 2. Mass pieces used for the verification of scales shall be calibrated every two years and calibration certificates obtained. The mass pieces used for the verification of scales shall be a mass that is similar to the final mass of the product being weighed. 3. Equipment shall be labelled with the calibration details. Approved by: Johann Kirsten Owner: KDF Page 9 of 16

10 4. Monthly verification of the equipment is to be done on site and records kept. ii. Scale verification: 1. Once a month the scales must be verified to ensure they are accurate. 2. Calibrated mass pieces must be put on the scale and the weight recorded. All readings must be recorded. Any readings that are more than one division out must be reported to Management. All nonconformances must be recorded on the corrective action form, and the necessary action and follow up recorded. 3. Management should get the scales to be calibrated by the company servicing the scales. The scale company is to supply a calibration certificate for each scale calibrated. iii. Thermometer verification: 1. The verification of the thermometer should be done monthly by using the ice point method. 2. Ice Point Method: Fill a glass with crushed ice. Add clean cold tap water until the glass is half full and stir well. 3. Put the probe of the thermometer into the glass. Ensure the sensing area of the thermometer is submerged in the ice water and stir the water and ice with the probe. 4. Wait at least 30 seconds or until the indicator stops moving. 5. Record the temperature on the indicator on a verification sheet. 6. If the thermometer does not read between +1 C and 1 C it must be reported to Management. All non-conformances must be recorded on a corrective action form, and the necessary action and follow up recorded. Management should send the thermometer to a SANAS accredited supplier in order to be fixed and calibrated. The company repairing the thermometer must supply a calibration certificate when returning it. Approved by: Johann Kirsten Owner: KDF Page 10 of 16

11 iv. Fridge, freezer and truck gauges: 1. Once a month the fridge, freezer and truck gauges must be verified by placing the already verified thermometer inside the fridge, freezer or truck and leaving it there for a few minutes until the indicator stops moving. 2. The reading on the dial and that of the thermometer must be recorded on the verification sheet. Should the readings be more than 1 C apart it must be reported to management. All non-conformances must be recorded on the corrective action form, and the necessary action and follow up recorded. 3. When the gauges are not accurate, an accredited company must calibrate the gauges and supply a calibration certificate. 10. Traceability a. Only animals from Certified KMOO farmers may be used for KMOO. b. The abattoir will only accept Karoo Meat of Origin animals if a Declaration of Origin and/or a verwyderings sertifikaat / ontvangsbewys accompanies the specific truck. c. Karoo Meat of Origin animals should be kept separately in a dedicated pen. d. Tracking number: The animals should each receive a unique carcass number (tracking number), which must ensure full traceability to the live animal and the farmer. e. The identification mark must be visible at all times. f. All relevant information must be documented and recorded. g. At the point of carcass classification and weighing, a specific Karoo Meat of Origin mark must be stamped on as well as rolled onto the specific carcasses. h. All Karoo Meat of Origin carcasses must be easily identifiable in the chiller as well as in the truck delivering the carcasses. 11. Cleaning and sanitation Covered in HAS audit. Refer where necessary. Approved by: Johann Kirsten Owner: KDF Page 11 of 16

12 12. Maintenance a. An effective maintenance program shall be implemented to ensure the proper functioning of equipment, buildings and vehicles. b. Any equipment that is critical to food safety shall be identified and a planned maintenance program set up. The planned maintenance program shall stipulate the equipment to be maintained; work to be carried out on equipment, frequency of maintenance. c. Only food grade lubricants may be used on equipment within the butchery. Material safety data sheets (MSDS) shall be kept on file for the lubricants used on site. d. Whenever any maintenance is carried out in the abattoir a job card is to be completed. The equipment and area is to be properly cleaned after maintenance has been completed and this is to be signed off on the job card. e. Planned maintenance should be done as far as possible outside of production hours. SOP (to prevent contamination of product) to be in place when maintenance needs to be done in production area while production is taking place. 13. Pest control a. Effective measures shall be taken to eliminate flies, other insects, rodents or other pests in the abattoir. b. Fly electrocuters shall be of the design with glue boards to catch the flying insects and shall be serviced at least monthly. The unit shall be positioned in the abattoir where is will not be over or close to any meat and away from natural light. The ultraviolet tubes shall be replaced annually and it should be protected against shattering. c. The facility shall be properly proofed at the bottom of the external doors and at windows to prevent the entry of pests. d. The facility shall be kept clean to prevent the attraction of pests to the facility. 14. Storage Covered in HAS audit. Refer where necessary. Approved by: Johann Kirsten Owner: KDF Page 12 of 16

13 15. Transport a. Deep bone muscle temperature of carcasses transported by truck should be less than 5 C maximum and should be delivered at 5 C maximum. b. Trucks should be pre-cooled to 2 C at least before loading carcasses. c. Trucks need to be clean, free of taints or smells. d. Loading area temperature must be a maximum of 12 C when in use. e. Carcass should be transported in hanging position. Meat not to be in direct contact with the floor of the vehicle. f. Sufficient spacing to be left between carcasses for optimum air circulation. g. Personal clothing as well as protective clothing should be clean. 16. Document and record control a. All documents and records developed for the food quality and safety program shall be written in a similar format and approved before use to ensure that the correct and most updated version is available for use. b. All documentation must be written in a standard format and must include the following: Page number Revision/ Version number Effective date Approved by and designation Documentation number c. Controlled documentation must be readily available for use by employees conducting tasks described in the applicable documents. No hand written changes are permitted. d. When documents and records need to be updated the date and the revision number is to be updated and the document then re-issued. e. Documentation Distribution Register This document is to be used every time a new or revised document is issued for use. The person issued to, document title; page number, version number and date issued must be recorded. Where the documentation is replacing existing documentation the old documentation shall be recalled from the responsible person. The person receiving the documentation must sign the document. f. Amendment Register: Whenever a document is amended this document must be completed. The Doc. No., page no., version, a brief description of the amendment and effective date must be recorded. The assigned person amending the documentation must sign the document. When amending the documents the version number and effective date must be changed. Approved by: Johann Kirsten Owner: KDF Page 13 of 16

14 g. Examples of forms that may be used are available on request from KMOO. 17. Audits In order to ensure full compliance to above-mentioned specifications, the Karoo Meat of Origin scheme will be conducting annual (unless otherwise specified) audits. This will be conducted by an independent auditing body (e.g. SAMIC), as appointed by the KDF and will be done at the abattoirs cost. This audit will include a paper audit to cross check figures with farmer s capacity/ animals received by abattoir/ animals received from abattoir, etc. It will also include a full traceability audit from the start to the final paperwork. 18. Non-conformance to specifications a. Carcasses which do not comply with the above-mentioned specifications will not be eligible to be used as Certified Karoo Meat of Origin carcasses. b. The right to use the certification mark will be terminated immediately if an abattoir is found, at any stage, not to be adhering to the specifications. c. We also ask that any person who is aware of malpractices anywhere in the chain to report it to KMOO via our Website Contact Us at Approved by: Johann Kirsten Owner: KDF Page 14 of 16

15 Addendum 1 DECLARATION OF COMPLIANCE TO KAROO MEAT OF ORIGIN STANDARDS Verklaring dat die eienaar van die diere gelewer (aan die slagpale) voldoen aan die Karoo Meat of Origin standaarde. Declaration that the owner of animals delivered to the abattoir complies with the Karoo Meat of Origin standards. Ek / I, (volle name) (full name) van die plaas/plase of the farm(s) (plaas se naam) (farm name/s) en gesertifiseer as n Karoo Meat of Origin verskaffer met nommer and accredited as a Karoo Meat of Origin supplier with number verklaar hiermee / hereby declare: dat die diere gelewer deur my aan that the animals delivered by me to (Slagpale Naam) (Name of Abattoir) aan al die Karoo Meat of Origin spesifikasies voldoen. comply with all the Karoo Meat of Origin specifications. Geteken / Signed: Datum/Date: Approved by: Johann Kirsten Owner: KDF Page 15 of 16

16 Addendum 3 CERTIFICATE OF CONFORMANCE Date: It is hereby confirmed that this batch of meat has been inspected by the meat inspector and is fit for human consumption. It has been sourced and slaughtered in accordance to the Meat Safety Act 40/2000. All measures have been taken to ensure the meat is free of physical, chemical and microbiological contamination. All meat complies with the Certified Karoo Meat of Origin standard and has been marked as such. Tracking number As per traceability documentation Batch number From farmer certification no As per traceability documentation Temperature (Every 20 th carcass to be measured) ph Abattoir: Certification number Signed: Designation: Approved by: Johann Kirsten Owner: KDF Page 16 of 16