Alberta Food Safety for

Meat Processors

by Environmental Public Health

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Alberta Food Safety for Meat Processors

Environmental Public Health developed this course to help meat processors prepare a

final product that is safe for their customers to eat. The goal of the course is to inform

meat processors about the impacts of foodborne illness, the potential hazards

associated with meat products, and the control measures that are necessary to reduce

or eliminate the risk to customers.

Study the course booklet at your own pace, watch the linked online videos and then

complete the online exam. The exam has a total of 25 multiple-choice questions. The

passing mark is 80%. Upon passing the exam, an Alberta Food Safety for Meat

Processors Certificate will be awarded to you, which is valid for three years.

This course is intended for all meat processors as additional training, but not as a

replacement to the food safety training described under Section 31 of the Food

Regulation. Our website has further information on Section 31 Food Safety Classes:

http://www.albertahealthservices.ca/eph/Page3151.aspx

You can get a copy online of the Alberta Food Regulation ( http://www.qp.albe

rta.ca/documents/Regs/2006_031.pdf ) and Food Retail and Food Services Code

( http://www.health.alberta.ca/documents/Food-Code-Alberta-2003.pdf ).

Our website has a map with contact information for all Environmental Public Health

office locations: https://www.google.com/maps/d/edit?mid=1iwOXE4dGqJ-b-HZr-

n_7hJaoC-Q&msa=0

Feel free to contact your local Public Health Inspector to talk about food safety practices

and facility requirements for your own food establishment.

Contents

ACKNOWLEDGMENTS ....................................................................................................................................................................... 4

1. HISTORY OF MEAT PROCESSING ............................................................................................................................................... 5

2. FOOD SAFETY VERSUS FOOD QUALITY ..................................................................................................................................... 5

3. WHAT IS A FOODBORNE ILLNESS? ............................................................................................................................................ 6

4. GENERAL FOOD SAFETY PRACTICES ........................................................................................................................................ 10

#1: IF YOU ARE SICK, DO NOT WORK WITH FOOD ........................................................................................................................................ 11

#2 WASH YOUR HANDS PROPERLY .............................................................................................................................................................. 12

#3 PRACTICE GOOD PERSONAL HYGIENE ...................................................................................................................................................... 14

#4 KEEP POTENTIALLY HAZARDOUS FOODS OUT OF THE DANGER ZONE .............................................................................................................. 15

#5 PREVENT CROSS CONTAMINATION .......................................................................................................................................................... 17

#6 CLEAN AND SANITIZE ............................................................................................................................................................................ 18

#7 FACILITY DESIGN ................................................................................................................................................................................. 25

#8 PEST CONTROL.................................................................................................................................................................................... 27

5. MEAT PROCESSING STEPS ...................................................................................................................................................... 28

IMPORTANT TERMS AND CONCEPTS FOR MEAT PROCESSORS ............................................................................................................................ 28

#1 KEY FOOD SAFETY STEPS DURING SLAUGHTER .......................................................................................................................................... 32

#2 ANTIMICROBIAL SPRAY TREATMENT ........................................................................................................................................................ 33

#3 SAUSAGE MAKING TECHNIQUES AND PROCESSED MEAT TYPES .................................................................................................................... 34

a) Curing .................................................................................................................................................................................... 34

b) Fermentation ........................................................................................................................................................................ 37

c) Dehydration .......................................................................................................................................................................... 42

d) Cooking ................................................................................................................................................................................. 43

e) Cold Smoking ........................................................................................................................................................................ 44

#4 USE OF SPICES ..................................................................................................................................................................................... 45

#5 PACKAGING ........................................................................................................................................................................................ 45

#6 LABELLING FOOD PRODUCTS .................................................................................................................................................................. 47

#7 FOOD SAFETY PLAN – TYING IT ALL TOGETHER .......................................................................................................................................... 48

SUMMARY ....................................................................................................................................................................................... 49

APPENDIX 1 – PROCESSED MEAT PRODUCTS QUICK FACTS ............................................................................................................. 52

APPENDIX 2 - THE SEVEN PRINCIPLES OF HACCP ............................................................................................................................. 57

Acknowledgments

Alberta Health Services, Environmental Public Health would like to acknowledge the

collaborative efforts of Alberta Agriculture and Forestry, and Alberta Health.

Some information in this course was retrieved from the following various websites:

Alberta Health Services Environmental Public Health

iwww.ahs.ca/eph

Alberta Agriculture and Forestry

http://www1.agric.gov.ab.ca/$Department/deptdocs.nsf/All/fs14754

Alberta Food Processors Association http://www.afpa.com/

Canadian Food Inspection Agency http://www.inspection.gc.ca/food/meat-and-

poultry-products/eng/1300124955992/1300125034322

The American Meat Institute Foundation. 1997. Good manufacturing practices for

fermented dry and semi dry sausage products

http://meathaccp.wisc.edu/validation/fermentation.html

Picture source: Local Food Heroes http://www.localfoodheroes.co.uk/?o=15

Picture source: Wayne Hunter, SAIT

E-16-001 Created: Sep/16

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1. Introduction to Meat Processing

Meat can be processed into a wide variety of

products, such as bacon, ham, sausage,

prosciutto, salami, bologna, etc. Meat processing

techniques have developed over the centuries as a

way of keeping raw meats from spoiling,

particularly at a time when refrigeration was not yet

available. Preservation was done through methods

such as salting, smoking, drying, fermenting or

cooking the meat.

In the early years, food related illnesses and diseases caused by improperly processed

meats were common. Since then, meat processors have had to change methods in an

effort to reduce foodborne illness and to

meet government regulations for protecting

public health. Over time, meat processors

have adopted best practices through trial

and error with new processes and new

products. Today meat processing is

considered an art and science, with an

emphasis on trying new recipes and

discovering new flavours and textures.

2. Food Safety versus Food Quality

Food safety and food quality are two important aspects in the meat processing industry.

The aim for food safety is to prevent health hazards. Examples of health hazards

include disease-causing microorganisms (known as pathogens), allergens, chemical

cleaning agents, or broken glass ending up in the food. Food quality refers to properties

such as the colour, flavour, texture, taste, and freshness of the food product. The focus

of this course is on food safety of meat processing, rather than on food quality.

Photo

: John P

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: A

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3. What is a Foodborne Illness?

Foodborne illness, also known as food poisoning, is any

illness caused by eating or drinking food contaminated

with a biological, chemical, or physical hazard.

Common symptoms of foodborne illness include:

diarrhea nausea

vomiting stomach cramps

fever headache

dizziness body ache

A person who is suffering from a foodborne illness may have only one of these

symptoms or may have a combination of the above symptoms. The symptoms may take

just a few hours or several days to develop.

The severity of the illness, and the

time it takes to make someone sick,

can depend on the health of the

individual, the type of pathogen or

contamination eaten, and the

amount of contamination eaten.

Complications from severe cases of

foodborne illness include arthritis,

paralysis, tissue damage, organ

failure, miscarriage, coma, and

death.

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Who is most at risk of foodborne illness?

Certain groups of people are more likely to get sick

from contaminated food or beverages. They may

develop life threatening or long term medical

complications from food borne hazards. These

groups include:

children pregnant women

the elderly people with weakened immune systems

Salmonella can grow with or without oxygen.

It grows well in the range of temperatures from

5°C to 47°C.

A pH of less than 4.6 prevents Salmonella growth;

pH values of 6.5 to 7.5 are ideal for growth.

Sausage fermentation must decrease pH and

water activity, while increasing numbers of

desirable bacteria (through starter cultures) to

compete with Salmonella.

If the fermentation process proceeds properly,

Salmonella growth is more likely to be inhibited.

Pathogen Spotlight: Salmonella

There are several strains of Salmonella that cause infections in people. Salmonella is carried in the intestinal

tracts of sheep, cattle, swine, poultry, and humans. Salmonella infections are not often detected in animals,

so contamination is spread as animals move between feedlots, holding pens, and slaughter plants.

A person may become sick with salmonellosis 6 to 48 hours after consuming food contaminated with

Salmonella. Symptoms last 2 – 3 days and may include diarrhea, abdominal cramps, fever, nausea, vomiting,

chills, dehydration and headache.

People may be exposed to Salmonella by eating undercooked or raw animal products, or by cross

contamination between raw meat and other foods. Salmonella is usually present in an infected person’s stool,

therefore good personal hygiene is critical to help keep the disease from spreading to others.

Salmonellosis can be prevented by proper cooking of food, avoiding recontamination of cooked or ready to

eat food, maintaining low storage temperatures, proper hygienic practices by food handlers, excluding sick

employees from handling food, and avoiding contamination of food and water from animal feces.

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What are the potential hazards associated with meat processing?

Biological hazards

Microorganisms or microbes are living organisms.

They are so small that they can only be seen by

looking through a microscope. Microorganisms

are found everywhere in our natural environment,

like dirt, water, dust, ice, air and moisture. Many

microorganisms are beneficial and can be useful

in food processing, such as fermenting meats.

Helpful microorganisms, such as those found in

starter cultures, can also be used to slow or stop

the growth of pathogens by competing for

nutrients necessary for growth.

About 1% of known microorganisms are potentially dangerous and are responsible for

serious illness and death. As defined earlier, disease-causing microorganisms are

called pathogens. Pathogens are found throughout the environment. They are

commonly found in the digestive tract of animals, and therefore in animal feces, and on

raw meat, poultry and fish. Food handlers themselves can be the most common source

of pathogens in a food establishment.

Another biological hazard is toxins. Toxins are poisonous substances naturally

produced by some bacteria, such as Staphylococcus aureus, and also by some molds.

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Chemical hazards

Foodborne illness can also be caused by contamination of food by chemical agents.

This contamination may occur by accident (e.g a spill or leak), by not understanding

how to use a chemical properly, or by using the wrong chemical.

Heating or cooking the food is not going to destroy the chemical contamination. Some

chemicals may have a strong smell or taste that can be detected in the food, but other

chemicals may not. Symptoms usually occur quickly after exposure. Symptoms will

depend on the chemical that was consumed, but usually include nausea and vomiting.

Some people are very sensitive to chemicals; they can get sick from just a small

amount of chemical contamination.

Some chemicals that may be found in the food establishment that can be sources of

contamination include:

Pesticides

Cleaning and sanitizing materials

Toxic metals, such as copper

Food additives and preservatives

Physical hazards

Physical foodborne illness refers to contamination of food by physical objects which

may cause illness or injury.

Some common examples of physical contamination are items from:

surfaces or equipment in the food

establishment

- glass, metal, plastic, wood

a food handler

- hair, artificial nail, band-aid,

jewelry

miscellaneous sources

- thumbtacks, staples, toothpick,

bag clip, etc

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4. General Food Safety Practices

Food safety practices work best when they are treated as an important part of the food

establishment’s goal of providing safe and wholesome products to the customer.

Consider food safety a best business practice and not simply a legal obligation to

comply with the Food Regulation or simple a response to the Public Health Inspector’s

instructions.

The public expects to be served clean and safe food. For your operation to remain in

business, you must ensure public confidence.

Safe food handling practices are important for many reasons:

Customers deserve and expect it

They affect the establishment’s reputation

They impact the efficiency of the establishment’s operation

They reduce the risk of closure by health departments

They reduce legal liability and chance of prosecution

Unsafe food does not always have an altered appearance, odour, or taste. So, if you

ever doubt the safety of the food you have prepared, do not use it; someone’s health

may be at risk. When in doubt - throw it out.

The following sections will describe important safe food handling practices that should

be followed in all meat processing facilities.

Photo

: jojo

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#1: If You Are Sick, Do Not Work With Food

The Communicable Disease Regulation prohibits a

person from working with food if they have symptoms of

foodborne illness. The person in charge of a meat

processing operation shall not allow an employee to

handle food if they are aware that the employee is ill

with vomiting and/or diarrhea. The sick employee should

consult with a doctor before returning to food related

duties.

The fecal-oral route is a common way of transferring

pathogens from one person to another. When someone is

sick with vomiting and diarrhea caused by an infection, the

pathogens causing their symptoms can be shed by the

millions in the vomit and feces.

To make matters worse, a person is still contagious and can continue to shed

pathogens for many days even after the vomiting and diarrhea stop. When an infected

employee goes to the toilet, they will likely contaminate their hands with these

pathogens. Even with good handwashing, some pathogens can remain on the hands. If

the meat processor then prepares food, the food or equipment they touch could become

contaminated with those pathogens. Customers who eat this food would be exposed to

the pathogens and may become sick.

In the case of an employee that does or may have a foodborne illness themselves,

handwashing is not enough – they must be excluded from working with food.

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It is important to practice the following:

• Do not work with food while you are ill with vomiting and/or diarrhea.

• Do not prepare food for others until at least 48 hours after symptoms of the

illness stops.

• Do not work with food if you have yellowing of the skin or your urine is dark

brown in colour as this indicates jaundice. Jaundice is a symptom of a very

contagious food-borne pathogen called Hepatitis A virus.

• You can take precautions if experiencing other types of symptoms, such as

sneezing, coughing, or a runny nose. Precautions include more frequent

handwashing, proper glove use, or wearing a mask.

• Infected cuts, boils or burns on the skin can be properly protected with a bandage

and glove to prevent the spread of pathogens.

#2 Wash Your Hands Properly

Think of your hands and fingernails as always dirty. Just because they look clean does

not mean they are clean. If you do not wash your hands properly or keep your

fingernails trimmed short, your hands can easily spread pathogens.

If you take the time to wash all parts of your hands properly, at least 20 seconds

should have passed. Fingertips and nails are usually the dirtiest part of the hand. A

thorough handwashing includes fronts, backs, in between fingers on both sides, the

wrists, the thumbs, and fingertips.

Watch the following Handwashing Video (https://www.youtube.com/watch?

v=Vl05XB9q6nw) for a demonstration.

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Handwashing procedure:

1. Wet hands with warm running water.

2. Add soap and lather well.

3. Rub hands together (not under the running

water).

4. Use a nylon nail brush and scrub under the

fingernails, between the fingers and backs of

the hands.

5. Rinse thoroughly.

6. Dry hands with a paper towel.

7. Use paper towel to turn off the taps. The hand

sink taps are one of the most contaminated

surfaces in your facility.

Wash your hands OFTEN

• Before preparing food

• After using the bathroom

• After touching raw meat, fish or

poultry

• After smoking, eating, or

coming back from a break

• After using chemicals for

cleaning, processing, etc.

• When your hands become soiled

e.g. after handling dirty

equipment or garbage

• Anytime your hands become

dirty

• Anytime you need to touch

finished product (e.g. food

or clean utensils).

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The use of gloves does not replace handwashing.

Gloves can also spread microorganisms so care must

be taken to use gloves properly. Wash and dry hands

before putting on the gloves, change the gloves often

and between tasks, and wash your hands every time

you change your gloves.

Disposable plastic wear such as gloves, aprons, and

sleeves should be used when handling ready-to-eat

foods (e.g. sandwiches, meat platters, cheese and

cracker platter) and during activities which require

frequent handwashing/rinsing (e.g. skinning,

eviscerating or any abattoir or sanitation activities).

The only time you are required to wear a glove, or finger cot, is to cover a bandaged part

of your hand due to a cut or sore.

The use of hand sanitizer does not replace handwashing. Hand sanitizer will not work on

hands that are dirty. It can be used as an extra step after handwashing.

#3 Practice Good Personal Hygiene

• Wear clean clothing and footwear. Change uniforms and aprons daily, or

more often when needed, and when leaving ready-to-eat areas.

• Keep hair under control. This may be done with a hat, hair net, pulling hair back

into a pony tail or any other approved method.

• Keep fingernails short and clean. Do not wear nail polish or fake fingernails.

• Avoid wearing jewelry.

• Do not smoke in a food area.

• Cover coughs and sneezes with your sleeve, instead of your hands or a tissue.

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#4 Keep Potentially Hazardous Foods out of the Danger Zone

Potentially hazardous foods are foods that are moist and rich in protein, such as meats

and poultry. Disease causing bacteria can easily grow, multiply and some bacteria may

produce toxins in these types of foods. The time it takes bacteria to grow in foods

depends on temperature. Under ideal temperatures, bacteria can double their number

every 20 minutes.

The temperature range between 4°C and 60°C is known as the temperature “Danger

Zone”. Bacteria multiply rapidly in food stored in the Danger Zone. Below 4°C (normal

refrigeration temperature), most bacteria grow slowly but are not killed. Storing foods

above 60°C (acceptable hot holding temperatures) can slow or stop bacterial growth.

Keep potentially hazardous foods out of the Danger Zone as much as possible, by

keeping hot foods hot (≥ 60°C), and cold foods cold (≤ 4°C). Limit the amount of time

that potentially hazardous foods spend in the Danger Zone to two hours or less.

Because dangerous bacteria may still grow at 4°C, refrigerated fresh meat should not

be stored for extended periods of time. Freezing the meat to -18°C can increase the

shelf life up to one year or longer.

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Pathogen Spotlight: Staphyloccocus aureus

Staphyloccocus aureus, or “Staph” is a bacteria that produces a toxin as it grows in food. Although the

bacteria can be killed with high heat, the toxin is not destroyed by cooking temperatures. As early as 30

minutes after eating the toxin, a person may experience nausea, vomiting, abdominal cramping,

sweating, chills, weak pulse, and shock. The illness is rarely fatal, and recovery usually occurs within

24-48 hours.

S. aureus is commonly found in the nose, throat, skin and hair of healthy people, or their infected

scrapes, cuts, and burns, and the hides of animals. S. aureus does not compete very well with other

bacteria in foods. When the other competitive bacteria are destroyed by cooking or inhibited by salt,

S. aureus, that is reintroduced by contaminated food handlers, will grow more easily. S. aureus can

also grow in curing solutions if conditions are favorable.

To prevent growth of S. aureus and its toxin in food:

Keep potentially hazardous foods ≤ 4°C or ≥

60°C

Rapidly drop pH to less than 5.3 in fermented foods

Keep the water activity of the food below 0.85

When thawing frozen meat, maintain strict temperature control. Do not thaw frozen

meat in the temperature danger zone (i.e. at room temperature) as the surface of the

meat will quickly thaw out, while the centre will remain frozen for quite some time. This

means the surface of the meat will be in the temperature danger zone for long periods

of time as the centre of the meat continues to thaw. Practicing temperature control

during the thaw means no part of the meat was warmer than 4°C. Thaw frozen meat in

the refrigerator at 4°C or less. If you plan on cooking the meat immediately, you can

thaw it under cold running water, or in the microwave. Never thaw frozen meat in

standing warm water – warm water from the tap mixed with frozen food can create

temperature conditions where dangerous bacteria can grow very well.

S. aureus will grow in foods with:

Water activity ≥ 0.86 under aerobic

conditions or 0.90 under anaerobic

condition

High concentrations of salt or sugar

Low to moderate amounts of nitrite

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#5 Prevent Cross Contamination

Pathogens do not move around by themselves. They are spread by hands, pieces of

clothing, sneezes and coughs, mice, insects, dust, and anything else that moves or is

moved. Raw and processed meats can easily become contaminated with pathogens

that are transferred from contaminated hands, equipment and surfaces.

Pathogens can be transferred from raw foods (particularly

raw meats and poultry) to cooked and ready-to-eat foods,

by hands, utensils, containers and work surfaces in the

food processing area. Pathogens can also be spread from

one type of raw meat to another. The transfer of bacteria

from one item to another is known as cross contamination.

To prevent cross contamination:

• Regularly wash and sanitize all equipment and food

contact surfaces, such as knives, cutting boards,

countertops and sinks that have been in contact with

raw meats, fish and poultry.

• Handle raw meats and poultry separately from other foods by using different

equipment or kitchen spaces. For example, using color coded equipment and

surfaces. You can also separate food handling tasks in time, for example,

preparing a salad before you bring raw meat into the food preparation space.

• Store raw meats on the lowest shelf in the refrigerator, with nothing stored

underneath it. Ideally, store raw meats in a separate fridge all together.

These precautions must also be used to prevent the spread of pathogens between

different kinds of raw meat. For example, a band saw used to cut up chicken should be

cleaned and sanitized before it is used again for raw beef. In storage, best practice

would be to have nothing stored under raw poultry, except more raw poultry.

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#6 Clean and Sanitize

The longer a surface remains contaminated with

pathogens, the more likely those pathogens will

end up contaminating food. Everything in a food

preparation space must be kept clean. Anything

that touches food must be regularly cleaned and

sanitized.

When using surfaces and equipment continuously at

room temperature to prepare food, it should be

cleaned and sanitized as often as necessary - but at

least every four hours.

Cleaning is using soap and water to remove dirt and food debris. Soap removes some,

but not all of the germs on a surface. Soap does not kill microorganisms - there can

still be an unacceptable level of pathogens left on a surface after cleaning with soap.

Sanitizing is using heat or chemicals to destroy microorganisms that were left

behind after cleaning. Sanitizing may not destroy all microorganisms either – it will

only reduce the number of microorganisms to a reasonably acceptable level.

An approved sanitizer must be available on-site at all times for sanitizing surfaces

and utensils. There are limited chemical sanitizers approved for use in Alberta food

establishments.

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Chemical sanitizers

It is important to mix sanitizer

concentrations correctly.

When using chemical sanitizers,

use test strips to make sure the

concentration is correct. Test strips

or kits can be purchased from a

chemical supplier. Be aware of the

expiry date and manufacturer’s

instructions.

1) Chlorine

Regular chlorine bleach (no perfumes or fibre guard) is relatively inexpensive, and is

effective at destroying germs. One disadvantage of chlorine is that it is inactivated in

the presence of organic matter and its strength weakens over time. Chlorine

sanitizers should be mixed up fresh on a daily basis.

In a food establishment, chlorine sanitizers should contain at least 100 – 200 parts

per million of chlorine. Parts per million (ppm), is a unit of concentration and is equal

to mg/L (milligrams per Litre).

To get 100 ppm chlorine in your sanitizer, add chlorine to clean water:

• one tablespoon of chlorine per gallon of water, or

• ½ ounce of chlorine per gallon of water, or

• ½ teaspoon of chlorine per Litre of water, or

• 2 millilitres of chlorine per Litre of water.

The above amounts are based on 5% available chlorine. Some commercial bleach

products have more or less chlorine content. Bleach products will also lose strength

over time, even in a closed container. Check your product and adjust the amounts

added (or use your test strips), to get a sanitizer that is 100 ppm.

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2) Quaternary Ammonium Compound

A quaternary ammonium compound (quat) is another approved sanitizer. To mix a

quat sanitizer solution, dilute the concentrated product with water to a concentration

of 200 ppm. The concentration of the quat sanitizer solutions will vary based on the

manufacturer, so always follow manufacturer’s instructions for proper mixing and use.

3) Iodine

Iodine is approved for use as a sanitizer. An iodine solution should contain 12.5 ppm -

25 ppm available iodine. Iodine is unstable at temperatures above 120°F (48°C), so it

should not be mixed with hot water to make the sanitizer solution.

What affects how well the chemical sanitizer will work?

The surface - Make sure equipment and food contact surfaces are maintained to be

smooth and easy to clean. Cracks, pits, or crevices in a surface that you are trying to

sanitize, can protect germs from the action of the chemical sanitizer.

Presence of organic matter - Surfaces

should be visibly clean and free of soap, for

effective sanitization. The presence of dirt,

food debris and soap reduces the

effectiveness of sanitizers to the point where

it may not work at all.

Contact time – to do an effective job of

killing pathogens, surfaces should stay wet

with sanitizer for a minimum of 2 minutes.

Temperature – In general, you can use

warm water temperatures (around 45°C) to

mix sanitizers of chlorine and quats. Iodine

Chemical sanitizer will not be effective on this

cutting board.

solutions should be mixed at cooler temperatures (but no colder than 24°C).

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Heat as a sanitizer

Usually hot water is used to sanitize dishes in a high-

temperature dishwashing machine. Use the

dishwasher’s temperature gauge to make sure the

sanitizing cycle reaches 82°C for at least 10 seconds.

You can also use hot water to sanitize in a sink, if you

can maintain the water temperature in the sink at 77°C

for at least 2 minutes.

Dishwashing methods

When washing equipment by hand in a sink (manual dishwashing), follow the four-step

dishwashing method:

1) Wash equipment in warm soapy water. Change wash water often, or at least

before the suds disappear.

2) Rinse equipment with clean warm water. Change rinse water frequently, before it

becomes soapy.

3) Sanitize, either by fully submerging in hot water (77°C) or in an approved

chemical sanitizer at the right concentration for the 2 minute contact time.

4) Air Dry equipment on a drain board made of non-corroding and non-absorbent

material. Do not towel dry as this can re-contaminate the equipment you just

cleaned and sanitized.

Whether you are using a 2 compartment sink or a 3 compartment sink, the steps will be

the same. Check with your Public Health Inspector about minimum sink requirements

for your facility.

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The same steps apply when using a dishwashing machine, except much of it is

automated. You can make sure the machine’s sanitizing cycle is working properly by

checking the temperature gauge (hi-temp machine) or checking the dishes with a test

strip while they are still wet with sanitizer.

Items too big to fit in the sink or dishwasher, such as

large equipment or a countertop, must be cleaned in

place following the same basic procedure as above. If

using bleach to sanitize while cleaning in place, use a

100 to 200 ppm chlorine solution.

Pieces of equipment must be completely taken apart

to prevent food debris build-up and allow effective

cleaning and sanitizing.

Always examine the equipment for cleanliness and

damage. Re-wash any unclean equipment, and

throw out any damaged equipment.

Store clean and sanitized items in a manner and

location where they are not likely to get dirty again.

Use disposable rags / wipes with spray sanitizer, or keep reusable rags in a container of

sanitizer solution between uses. Used rags are moist and contaminated and will grow

bacteria when they are left hanging around.

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Required: written sanitation procedures

Section 29 of the Alberta Food Regulation requires commercial food establishments to

have written procedures designed to ensure its safe and sanitary operation and

maintenance. The procedures must include the cleaning and sanitizing requirements for

all equipment and utensils in it, if any, that are not normally washed in a dishwasher,

and a list of all cleaning and sanitizing agents used in the commercial food

establishment, including their concentrations and their uses.

How do I write my sanitation procedure?

• Identify what needs to be cleaned.

• Identify how often it needs to be cleaned

(demand, daily, weekly, etc).

• Describe any precautions that must be

taken prior to cleaning.

• Describe the method of cleaning, and

sanitizing if required.

• List the chemical and concentrations used for that cleaning task.

• Identify the person responsible for carrying out the cleaning task.

• Identify the person responsible for making sure the cleaning task has been

carried out effectively.

All of these details can be

captured and recorded in a

table format.

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Environmental Public Health has both a table template online

(http://www.albertahealthservices.ca/assets/wf/eph/wf-eh-cleaning-schedule-

template.pdf) and a more comprehensive sanitation program plan with tools to help

build your procedures (http://www.albertahealthservices.ca/assets/wf/eph/wf-eh-

sanitation-ssfa.pdf).

Things to consider when building a cleaning and sanitation plan:

• Identify all food contact surfaces: such as conveyors, peelers, walls, floors,

overhead fixtures, rails, refrigeration units, collators, belts, gloves, slicers,

and tables, which can all be sources of product contamination.

• Include refrigeration and freezer units in the cleaning and sanitizing schedule.

• Floors and floor drains can become important sources of Listeria. For this reason,

floors should be sanitized after they are cleaned. The frequency (e.g., daily,

weekly) of cleaning depends upon the type of operation and whether the floor

can be kept clean and dry.

• Include drain maintenance in your cleaning and sanitizing schedule to prevent

backups and pest problems. Never use a high pressure hose to free a

blocked drain because this may spread contamination.

• Remove standing water from floors after cleanup. Wet/dry vacuums and

squeegees are effective.

• Be mindful that excessive spray and splashing while cleaning floors and walls

may re-contaminate equipment in that area.

• Outer protective clothing of cleaning crew should be properly washed, sanitized,

and dried after use.

• Wash and sanitize mops, squeegees, wet/dry vacuums, and condensate removal

equipment after use.

• Only use cleaning equipment that can be easily cleaned and sanitized

themselves. For example, plastic broom handles and bristles, instead of

absorbent natural materials, are best.

25

• Remove hoses from production area after cleanup. Clean, sanitize, and store

on hooks off the floor.

• Keep blowers and ducts free of dust and debris.

• Keep washrooms, locker rooms, and lunch rooms clean and orderly.

#7 Facility Design

Good design of a meat processing area is important to help prevent cross

contamination. Properly maintained facilities and equipment, well trained-employees,

and well-designed process flow are necessary for safe food handling.

• All processing should have separate areas for the handling of raw meats

and those that are ready-to-eat.

• Employees, meat containers, meat, ingredients, pallets, and refuse

containers should not move between raw foods and ready-to-eat work

areas.

• If employees work in multiple areas, they must change outer clothing, wash

hands, change gloves, clean and sanitize footwear, equipment and utensils

before entering ready-to-eat product areas. Distinguish employees in raw and

ready-to-eat areas by color of hat or frock.

• Hallways common to raw and ready-to-eat areas must be kept clean and

dry. Frequent use of vacuum scrubbers is recommended.

• Outside air infiltration must be controlled, intake air must be conditioned, and

adequate insulation must be provided for maintaining dry environment.

Consider the location of air supply intakes in relation to sources of

contamination or dirty air (e.g. not located near garbage disposal or areas with

a lot of vehicle exhaust). Air supply should go through a well-maintained

filtration system.

26

• Place food equipment and sinks in such a way as to prevent splashing or

dripping from the equipment onto food products.

• Refrigeration and freezer spaces must be large enough and have good air

circulation to maintain proper temperature and humidity control.

• Overhead rails and conveyors must be accessible, cleanable, and free of

condensate.

• Seams, gaps, protruding ledges, inside threads, inside shoulders, exposed bolts

and rivets of equipment and food contact surfaces should be assessed for

potential problems with cleaning and sanitizing.

• Keep pallets in good repair, clean and dry.

• Keep protective covers over control panels, motors and equipment.

• Keep ceiling, walls, and floors smooth, sealed, and non-absorbent.

• Keep drains working properly, clean, with no standing water.

• Keep pipes and insulation dry and in good repair.

• Keep doors and windows tight fitting to keep pests out.

#8 Pest Control

Pests are a concern because they carry and spread pathogens to food items,

equipment, and the general environment. Pest control should be ongoing and

routine, as mice, flies and cockroaches will always be attracted to food

establishments. Pests will try to get inside your facility for

shelter, water, and food. Pest animals have one thing in

common: they multiply quickly. Once inside, if pests are not

controlled they can quickly become an infestation.

27

Don’t attract them – control garbage storage areas; have garbage removed as often

as needed; remove clutter and junk inside and outside your facility.

Don’t let them in – look for and seal up any possible

entry points for pests such as small spaces under

exterior doors, tears in door and window screens,

holes in walls. Inspect incoming food ingredients.

Don’t feed them – the most important preventative

step is to deny pests a source of food. Practice

excellent housekeeping by cleaning up food debris

often, and protect foods with tight-fitting container lids

and covers.

Don’t let them get comfortable – it is easy for pests to establish themselves in

cluttered areas that no one ever disturbs. Make a point of regularly inspecting your own

facility, behind and under equipment or checking unused rooms, for signs of pests.

Keep storage areas organized and practice good stock rotation. Required: Written pest control records

Section 21 of the Alberta Food Regulation has specific requirements concerning pests

and control measures, which food establishment operators must follow:

21(1) The commercial food establishment and any surrounding area, premises or

facilities supporting the commercial food establishment must be kept free of pests and

of conditions that lead to the harbouring or breeding of pests.

21(2) A written record of all pest control measures used in the commercial food

establishment and surrounding area, premises and facilities referred to in section (1)

must be maintained.

A pest control checklist template is available from Environmental Public Health for you

to use to manage pest control in your meat processing facility:

http://www.albertahealthservices.ca/assets/wf/eph/wf-eh-pest-control-checklist.pdf

28

A licensed pest control operator can provide routine inspection and control services. An

experienced pest control professional will know best what methods will work for each

situation, to effectively manage and get rid of pests in your establishment.

5. Meat Processing Steps

In this section, the booklet covers practices and food preparation steps that are

specific to meat processing. There are several measures you can take before, during,

and after processing to eliminate or control pathogens in your food products.

The more measures you take, the more likely your food products will be safe.

Also see Appendix 1 “Processed Meat Products Quick Facts” for a summary of

criteria for specific meat products.

Important Terms and Concepts for Meat Processors

Acidity – will describe how much acid is in a food product. Higher acid increases the

tangy or sour taste of food. Many pathogenic bacteria cannot grow in foods with high

level of acid, specifically with a pH of 4.6 or lower (See “Shelf Stable”).

Acidulants or Acidifiers – ingredients added to food products to lower the pH, and

therefore limit or control the growth of pathogenic bacteria. Examples of acidifiers are

Gluconolactone, also called Glucono delta-lactone (GDL) or Citric Acid.

Aerobic – refers to conditions where oxygen is present or an environment that contains

air. Some bacteria require oxygen to grow and are called aerobic. Many spoilage

bacteria are aerobic bacteria.

Anaerobic – refers to conditions where oxygen is absent or an environment that is

closed off from the air. Some pathogenic bacteria can grow in the absence of air, such

as in vacuum-packed meats or closed sausage casings. Botulism is a serious food

borne illness that is caused by a toxin from anaerobic bacteria.

29

Aw, or Water activity - the amount of available moisture in a food that

microorganisms can use to grow and multiply. If you control the amount of moisture in

food, you can limit and control the growth of pathogenic bacteria.

Curing – describes various meat preservation and flavoring processes that involve

adding combinations of salt, nitrates, nitrites, and/or sugar. Curing can reduce the

water activity of meat, and adding nitrate/nitrite salts prevents bacterial growth.

Fermentation - a process in which lactic acid-producing bacteria increase the acidity of

a food by converting sugars, such as dextrose or sucrose in the meat mixture, to lactic

acid. By lowering the pH, you can limit or control growth of pathogenic bacteria.

Heat treatment – Heat can be used as a kill step (i.e. cooking) to make a ready-to-eat

meat product. Heat treatment can also refer to a process that uses heat to change the

look and taste of a meat product, but does not guarantee the safety of the food product

(e.g. cold smoking). The times and temperatures used will vary depending on the

purpose of the heat treatment.

Modified Atmosphere Packaging (MAP) or Controlled Atmosphere Packaging

(CAP) - Modified Atmosphere Packaging (MAP) involves replacing air and oxygen

inside a sealed package with an inert gas, such nitrogen, carbon dioxide, or carbon

monoxide. Controlled Atmosphere Packaging (CAP) is using a MAP process, and

including a packet of oxygen-absorbing material inside the package.

Nitrate/Nitrite –chemical compounds added to meat through the curing process. Nitrite

prevents the growth of pathogenic bacteria and spoilage organisms, as well as giving

the meat product a desirable pink-red 'fresh' color. In meat, nitrate will convert to nitrite

as time passes. Adding nitrate to meat is useful where a long release of nitrite is

needed.

pH – A measure of acidity (pH <7) or alkalinity (pH >7) of a food.

30

Shelf stable – means a meat product that does not require refrigeration. To be shelf

stable, a meat product must meet one of the following:

pH of 4.6 or less regardless of aw

aw of 0.85 or less regardless of pH

pH of 5.3 or less AND aw of 0.90 or less.

Smoking - is exposing meat to smoke, or addition of flavoring agents, mainly to

change the flavor, smell, color and appearance of meat products. This is not a food

safety step.

Starter Culture - a product made up of microorganisms that perform the fermentation

of food products. Starters usually consist of nutrient liquids or powdered cultivation

medium, that have been colonized by specific bacteria, yeast and molds.

31

It is also important to distinguish between Ready-to-Eat (RTE) meat products, and

Non-Ready-to-Eat (NRTE) meat products.

NRTE products must be fully cooked before consumption and include:

1) Products that have been heat treated or smoked to improve their appearance

or flavor, for example, Farmer Sausage. The heat or smoking process does

not destroy pathogens.

2) Raw fermented products, such as

Teewurst and Mettwurst, that have

been processed with salt, sugar,

culture and cure. These controls

work during the fermentation to

prevent the growth of pathogenic

bacteria and the production of their

toxins, such as with

Staphylococcus. However, these

kinds of products have typically not

undergone a treatment to

adequately destroy

the bacteria themselves.

Raw fermented sausage is cooked before eaten.

3) Fresh raw meat products like breakfast sausage, ham, and bacon.

RTE products may be eaten without additional cooking and include products that have been cured, dried, fermented, heat treated, or a combination of these processes to sufficiently control pathogens to an acceptable level.

Examples of RTE are cold cuts or sandwich meats such as bologna, salami, cappicola, prosciutto, corned beef, and pimento loaf.

32

#1 Key Food Safety Steps During Slaughter

Clean and sanitize the facility and equipment thoroughly and consistently.

Wear clean clothing and follow strict personal hygiene requirements.

Take care not to spread fecal contamination during carcass dressing activities

such as during hide removal and evisceration steps.

Visible contamination on a

carcass while skinning, must

be trimmed with a knife and

not sprayed off with water.

The water spray will not

effectively remove the

contamination from the meat,

but will also spread the

contamination further.

Washing the carcasses with potable warm water is optional. If a carcass has

been carefully skinned and dressed, there is no benefit from total surface

washing.

Apply an antimicrobial spray on the carcass surface to reduce harmful bacteria.

Chill the carcass as quickly as possible.

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#2 Antimicrobial Spray Treatment

Antimicrobial spray is approved for

use by Health Canada as a

processing aid to control harmful

bacteria on meat surfaces after

slaughter. Antimicrobial sprays are

safe, easy to use and can extend shelf

life of the meat by several days.

Studies show up to a 99% reduction of

bacteria on treated beef carcasses,

internal organs and meat parts.

These sprays are a dilute solution of an organic acid (lactic, acetic, citric, and

peroxyacetic acid), or sodium hypochlorite (bleach). In small abattoirs, the solution is

usually applied with a hand sprayer or automatic pump. It usually takes from 30

seconds to 2 minutes to treat a carcass. An automatic pump can deliver a large volume

of antimicrobial spray on carcasses in a short time.

Automatic pump Hand sprayer

Alberta Agriculture and Forestry has produced a video titled “Antimicrobial Spray

Intervention,” which can be viewed on YouTube at http://youtu.be/tbyYW4YjUEg

34

Monitoring of antimicrobial spray solutions is required. Inexpensive test kits to verify

solution concentration are available from industry suppliers.

Testing the spray solutions and

record keeping is important:

to check that the correct concentration

of solution is being used

to adjust the solution concentration as

necessary

to keep written records of the test

results

Antimicrobial spray test kit

#3 Sausage Making Techniques and Processed Meat Types

RTE processed meats can be achieved through cooking, curing, fermentation, drying or

a combination of any and all of these processes. The development of these techniques

to preserve meat has led to products we are familiar with today, such as salami, corned

beef, and jerky. Generally, we can describe a processed meat as one of the following

types:

Cured

Fermented, dry-processed

Fermented, semi-dry processed

Air-dried / dehydrated

Cooked

Cold-smoked

a) Curing

Cure is a common industry term for the addition of concentrated salts into either a

sausage, ham or bacon product. The curing salts will contain various amounts of nitrate

and/or nitrite. The addition of nitrate/nitrite salts into meat prevents bacterial growth.

Without the curing salts, the meat would more readily spoil or allow the growth of

dangerous bacteria.

35

Curing salts have different trade names such as “Prague Powder” and “All Purpose

Cure”. It is important to be aware that there is no set industry standard for the

percentage of nitrate/nitrites in a

pre-mixed curing salt.

Concentrations can range from

0.5% to 25% and higher. The

concentration of nitrate/nitrites in

the product you choose must be

confirmed.

Processors must also follow

instructions on the product

package and be capable of

calculating ppm content in their

formulas/recipes. You want

Example of a calculation formula spreadsheet.

enough nitrate/nitrite in your product to be effective at controlling bacterial growth, but

not so much that it may be a concern for consumers.

Pure potassium nitrate and sodium nitrite are also available for processors who wish to

formulate their own cure solutions. When using undiluted nitrate/nitrites, processors

must be capable of weighing these ingredients with accuracy.

There are also regulations that limit the amount of nitrate/nitrites. Typically processed

meat products that use cure must have at least 100 ppm nitrate/nitrite, but not more

than 200 ppm. Some processed meats are different (bacon is minimum 100 ppm,

maximum 120 ppm). The processor needs to follow recipes carefully. This means well-

calibrated scales and precise calculations for the curing formula.

There are typically two curing methods used: whole muscle curing (e.g. pork leg, ham,

beef brisket, corned beef pastrami) and meat emulsion curing (such as in sausage

making).

36

Whole Muscle Dry Curing is massaging a cure mixture onto the meat. Some

processors apply the mixture every 2-4 days over a forty day period. Others may apply

the dry mixture once, seal the product, and allow it to sit for several days or weeks. It

takes time for the cure mixture to penetrate the meat from the surface.

Whole Muscle Wet curing methods use a brine solution that contains the cure

ingredients (e.g. salt, sugar, nitrate/nitrites, water).

Wet curing may be done by:

Osmosis - the meat is immersed and kept in a brine solution for a period of time.

Brine typically penetrates the meat at a rate of approximately 2.5 cm / day.

Stitching – brine is injected into the product with single or multiple needles. This

speeds the curing process as the brine is evenly distributed throughout the

product.

Artery pump – commonly used for pork legs, the brine is distributed throughout

the meat by using the animal’s arteries. This method also speeds up the curing.

You can tell how well the meat has been

cured by checking the color of the

product in a cross section. Meat that is

thoroughly cured will be pink. Meat tissue

that hasn’t been penetrated by the cure

will have a distinctly different color, such

as grey. This uncured tissue has not

been properly preserved and will spoil

more rapidly. It will also support the

growth of dangerous bacteria. This

uncured tissue is not considered RTE,

unless the product undergoes additional

processing or cooking to make it RTE.

The flesh in the centre of this cross cut is greyish, and

towards the surface it is pink. The cure has not

penetrated the meat to the centre.

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37

b) Fermentation

Fermentation is a process of using lactic acid-producing bacteria to lower the pH of

meat emulsion product. Fermentation relies on good control over complex and precise

combinations of time, temperature, nitrite concentration, salt concentration (minimum

2.5% of the formulation), pH and aw factors. When done correctly, the process allows

the growth of lactic acid-producing bacteria, while preventing the growth of pathogenic

bacteria and the production of bacterial toxins.

Use a commercially prepared culture of lactic acid forming bacteria to add to the

chopped or ground meat. Follow manufacturer instructions for proper use of the culture.

See a list of approved cultures on the Canadian Food Inspection Agency (CFIA) website

(http://www.inspection.gc.ca/food/meat-and-poultry-products/manual-of-

procedures/chapter-4/annex-g/eng/1370536922521/1370537138760).

An alternative to commercial starter cultures for reducing pH in meat emulsions is direct

acidulation with acidulants or acidifiers. These ingredients should be incorporated into

sausage batter following procedures recommended by the manufacturer.

When the stuffed sausage pH reaches 5.3 or less, the environment for pathogenic

bacteria growth is effectively controlled.

pH monitoring

A pH meter is required to determine if the product has in fact reached a pH of 5.3 by the

end of the degree hours limit. Use the pH meter frequently and consistently throughout

the fermentation process.

Monitoring pH will tell you if a product is not acidifying as expected, and if not, it may

help to determine why. For example, if you notice changes in pH have slowed or

stopped, you may have to add more sugar (e.g. dextrose) to meet lactic acid bacteria

38

growth needs, or add more acidulant. You can monitor pH to ensure the product also

stays within desired palatability (lower pH will mean increased sourness or tanginess).

It is important to record all pH measurements:

throughout the fermentation process to determine when a pH of 5.3 has been

reached (i.e. important to know to calculate the degree hours limit).

before the product surface temperature reaches 43°C, or

before starting any final heat treatment

Degree hours

Fermented and acidulated sausages must reach a pH of 5.3 or lower within the

acceptable degree hours timeframe. Degree hours is the time, in hours, that a

fermenting or drying meat item has spent at a particular temperature, multiplied by the

temperature in degrees Celsius, up until it reached a pH of at least 5.3.

You can use degree hours to determine if the food has spent too long a time, at too

warm a temperature, to reach the target pH. If fermentation has taken too long to drop

the pH, there is a risk that unacceptable levels of pathogenic bacteria or their toxins are

now in the meat.

You only calculate degree hours for the time the meat product has been at

temperatures ≥ 15.6°C. Use the highest temperature of the product, in the fermentation

room, over the entire length of time it takes for the pH to reach 5.3. Temperatures for

degree hour calculations should be taken at the product’s surface. If this is not possible,

fermentation room temperatures may be used.

Where the room temperature, or product surface never reaches 33°C, the

degree hours limit is 665.

Between 33°C and 37°C, the degree hours limit is 555.

Exceeding 37°C, the degree hours limit is 500.

39

Calculations must be made for each amount of time that a temperature is within the

above listed temperature ranges and each sum must be added together to achieve the

degree hours calculation. It is necessary to record and calculate the degree hours

during fermentation and meat-drying processes.

Here is an example of how to use the calculation method when the room temperature

changes over time:

It takes 35 hours for product to reach a pH of 5.3 or less. Fermentation room

temperature is 24°C for the first 10 hours, 30°C for second 10 hours and 35°C for the

final 15 hours.

Step 1

Degrees above 15.6°C: 24°C - 15.6°C = 8.4°C

Hours to reach pH of 5.3: 10

Degree hours calculation: (8.4°C) x (10) = 84 degree hours

Step 2

Degrees above 15.6°C: 30°C - 15.6°C = 14.4°C

Hours to reach pH of 5.3: 10

Degree hours calculation: (14.4°C) x (10) = 144 degree hours

Step 3

Degrees above 15.6°C: 35°C - 15.6°C = 19.4°C

Hours to reach pH of 5.3: 15

Degree hours calculation: (19.4°C) x (15) = 291 degree hours

Degree hours calculation for the entire fermentation process = 84+144+291=519

The highest temperature reached = 35°C

The corresponding degree-hour limit = 555 (between 33°C and 37°C)

This example meets the guideline because its degree hours are less than the limit.

40

When fermentation is done at a constant temperature, operators can either use the

following table or the calculation method for determining degree hours limits and

maximum time for fermentation at a given room temperature.

Fermentation Done at a Constant Temperature (Constant Temperature Process)

Degree hours limit for corresponding temperature

Fermentation room temperature (°C)

Maximum allowed hours to achieve a pH of 5.3

665 20 150

665 22 103.4

665 24 78.9

665 26 63.8

665 28 53.6

665 30 46.2

665 32 40.5

555 33 31.8

555 34 30.1

555 35 28.6

555 36 27.2

555 37 25.9

500 38 22.3

500 40 20.5

500 42 18.9

500 44 17.6

500 46 16.4

500 48 15.4

500 50 14.5

Here’s an example of how to use the calculation method for constant temperature

processes:

Fermentation room temperature is a constant 35°C. It takes 40 hours for the pH to reach

5.3.

Degrees above 15.6°C: 35°C - 15.6°C = 19.4°C

Hours to reach pH of 5.3: 40

Degree hours calculation: (19.4°C) x (40) = 776 degree hours

The corresponding degree hours limit (between 33 and 37°C) is 555 degree hours. This

example does not meet the guideline because it exceeds the degree hours limit.

41

If beef is an ingredient in the fermented sausage product, you must perform a heat

treatment step (see Cooking section below) in the sausage making process to destroy

E. coli O157:H7. Even if there is no beef in the product, but you have raw beef onsite,

consider using a heat treatment to eliminate the risk of E. coli in other products, from

cross contamination.

There is no evidence at this time that pH, brine

concentrations, competitive exclusion, or drying

is sufficient to destroy E. coli O157:H7.

E. coli O157:H7 may be present in a fermented

product because it is able to survive in a pH

as low as 3.6 for long periods of time.

Any RTE product that contains beef as an

ingredient, must be processed with heat that is

sufficient to destroy E. coli O157:H7.

Processors must prevent recontamination of

finished products, with cross contamination

control and good sanitation practices

Pathogen Spotlight: Escherichia coli O157:H7

This bacteria is found in the intestinal tract of animals. E. coli O157:H7 commonly gets into foods through

the contamination of meat with animal feces during slaughter or from cross-contamination between raw

animal products and other foods. Infected meat processors can also spread E. coli O157:H7 through the

fecal oral route. A person may need to swallow as few as ten bacterial cells of E. coli to become sick.

When a person becomes infected, the E. coli O157:H7 bacteria growing in their intestines release a toxin

which causes bleeding and can be very destructive to the person’s bodily tissues. While most people

recover, complications from an E. coli O157:H7 infection include organ failure, coma, stroke, paralysis,

brain damage and death. Most common symptoms are abdominal pain, fever, and diarrhea which is

sometimes bloody.

A meat processor is not allowed to work in the facility if they have symptoms common to an intestinal

infection, such as diarrhea.

Controlling fecal contamination of raw products and eliminating E. coli O157:H7 in processed foods is

critical.

Strongly consider using a heat treatment to destroy E. coli O157:H7, as a regular

part of your process for meat products that contain pork as well. Recently, pork has

been identified as the source of E. coli O157:H7 in multiple outbreaks in Alberta. This

may indicate that pork will also become commonly associated with E. coli O157:H7,

and will require the same processing as beef products.

42

c) Dehydration

Air drying will reduce water activity in the meat, which inhibits the growth of dangerous

bacteria. A designated space, or drying room is needed, where temperature, humidity

and air circulation can be controlled during the drying process. This is important to

prevent any fluctuations that could impact on the safety of the final product.

Uncooked, air-dried products produced as RTE must meet shelf stable criteria as

detailed for fermented dried products. Air drying must be compliant with degree hour

calculations.

Beef products must undergo a heat treatment to control E. coli O157:H7 prior to any

drying process. Consider the same heat treatment for products containing pork as well.

Pork products must undergo Trichinella control measures.

CFIA provides directions for these control processes

(http://www.inspection.gc.ca/food/meat-and-poultry-products/manual-of-

procedures/chapter-4/annex-b/eng/1370459846651/1370459906560).

Trichinosis has occurred when uncooked or

undercooked pork products have been

eaten.

These include dry and semi-dry fermented

sausage products that contain pork.

Trichinella can be destroyed by curing, by heat,

or by freezing.

There are requirements for cure

concentrations, and for time and temperature

limits, that must be closely followed during

these Trichinella control steps.

Pathogen Spotlight: Trichinella spiralis

This parasitic worm causes an infection called trichinosis. When a person eats undercooked meat that

contains T. spiralis worms, the worms burrow from the person’s gut to different parts of the body,

causing swelling, muscle pain, fever and weakness. The majority of infections have no symptoms, as

usually only a small number of worms are eaten. If a large number of T. spiralis worms are eaten, the

person could die from damage to the brain, heart or lungs as the worms travel through these tissues.

All products containing pork must undergo a process to control Trichinella spiralis.

43

d) Cooking

Sausage products may be cooked or otherwise processed with heat (for example in a

smokehouse or water bath) to meet ready to eat requirements. Cooked sausage

products require a minimum nitrate/nitrite content of 100 ppm, but no greater than 200

ppm.

If you are cooking the sausage product to make it RTE, it should be fully cooked to an

internal temperature of 71°C for 15 seconds. There are alternative temperature and time

combinations that you can use. CFIA provides a table of time and temperature

combinations to effectively destroy pathogens and make the product RTE

(http://www.inspection.gc.ca/food/meat-and-poultry-products/manual-of-

procedures/chapter-4/annex-d/eng/1370527526866/1370527574493).

If beef is an ingredient you will need a heat treatment step in the sausage making

process to destroy E. coli O157:H7. Consider the same heat treatment for products

containing pork as well.

Cooked products must be kept refrigerated, unless there has been additional

processing to make the product shelf stable.

Rapid cooling of cooked products

After cooking, products must be properly cooled. The cooling must be continuous and

begins immediately after the heating process is completed.

Rapid cooling will drop the product’s internal temperature through the danger zone

quickly, so that pathogenic bacteria have minimal time at the optimal growth

temperatures to multiply and potentially produce toxins.

A two-stage cooling process is preferred, whereby dropping the product from cooking

temperatures to 20 °C within the first two hours. Then cool the product to 4 °C within 4

hours.

If an alternative cooling process and criteria is used, such as slow cooling, please refer

to other resources such as CFIA.

44

e) Cold Smoking

“Cold smoked” meats are products that have been cured and have been heat treated,

but are not fully cooked. Therefore they are not-ready-to-eat.

Smoking is used mainly to change the flavor, smell, color and appearance of meat

products. This is not a food safety step, as cold smoking temperatures are generally

less than 30 °C.

A product will typically spend time at danger zone temperatures during a cold smoking

process. The time that a product is above 4 °C and below 60°C must be carefully

controlled to limit growth of pathogenic bacteria and their toxins.

Ham and bacon are examples

of cold smoked products, which

are not fully cooked. This

means they are not ready to

eat. Customers may mistakenly

think that a smoking process

makes the meat safe to eat

without further cooking. It is

important that the packaging

label indicates that the product

needs to be cooked before

being eaten. Because cold

smoked meat requires

refrigeration, this should also be

indicated on the label.

Time and Temperature Requirements for Smoked Meat Products

Cold smoked products can meet RTE criteria, if they have undergone other processing

to control E. coli O157:H7 (if containing beef), or Trichinella (if containing pork). A

process to control E. coli O157:H7 is also recommended for products containing pork.

45

#4 Use of spices

Use caution when adding spices to processed meat. Spices have increasingly been

linked to foodborne illness outbreaks. There is an increased risk when adding spice

paste as a final step to a RTE product (e.g. Basturma). Spices should come from an

approved, reputable supplier. The spice product should be labelled or confirmed as

treated or pathogen-free. If the spices are not confirmed as pathogen free, then:

- Perform a cooking step to

destroy pathogens before it

is applied to the RTE meat.

- Perform a cooking step to

destroy pathogens after it

is applied to the RTE meat.

#5 Packaging

Packaging prevents contamination of the finished product and increases shelf life,

preventing the growth of mold and other spoilage organisms. Because there are

anaerobic pathogens that can grow in the absence of oxygen, many packaged

processed meats still require refrigeration.

For processed meat, common forms of packaging are:

Vacuum Packaging – vacuums the air from the package while sealing.

Modified Atmosphere Packaging (MAP)

Controlled Atmosphere Packaging (CAP)

Basturma with spice paste applied to the outside.

46

Only use packaging materials that are food grade

quality. Package meat products in a sanitary

manner, and away from the meat processing areas.

When not in use, store packaging materials and

equipment in a location where they are not likely to

become contaminated.

In spore form, C. botulinum is protected from

normal cooking temperatures.

Common methods of heat pasteurization, such as

those used in some meat processing, is not

enough to kill bacterial spores, or to destroy the

toxins.

The risk from C. botulinum in your meat

products requires strict control of temperature,

salt content and acidic conditions during

processes such as fermentation and smoking.

It also means a vacuum or MAP packaged meat

product, that is not shelf stable, must be kept

refrigerated or frozen.

Pathogen Spotlight: Clostridium botulinum

Clostridium botulinum is a spore-forming bacteria that produces dangerous toxins under anaerobic or

low oxygen conditions. Botulinum toxins are one of the most lethal substances known.

Foodborne botulism is often caused by eating improperly processed food, like homemade canned food,

fermented meats or smoked meats and fish. The botulinum toxins affect the nervous system and early

symptoms include muscle weakness, blurred vision, dry mouth and difficulty swallowing and speaking.

Vomiting, diarrhea, constipation and abdominal swelling may also occur. The disease can progress to

paralysis of muscles, including those used for breathing. People sick with botulism are sometimes

paralyzed for weeks, and have to be put on a respirator until the body can get rid of the toxins.

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#6 Labelling Food Products

Meat processors must ensure their packaged product is labelled, and meets the

requirements of the Federal Consumer Packaging and Labelling Act. Before creating a

label for a food product please check CFIA’s Industry Labelling Tool

(http://www.inspection.gc.ca/food/labelling/food-labelling-for-

industry/eng/1383607266489/1383607344939).

Why is it important to properly label processed meat products?

A list of ingredients lets customers know if they need to avoid certain foods because of

an allergy or intolerance. Some people also may avoid foods due to a cultural practice,

such as not eating pork.

The name of the product and the producer’s

contact information is important so that the

product can be recalled if there is a safety or

quality concern.

A best before date is important so that the

product is eaten within a reasonable time after

production. This will help in maintaining the

quality and the safety of the product.

Directions for the customer, on how to store the

food product is important for maintaining its

safety and quality. For example, “refrigeration

required”, or “keep in cool, dry conditions”.

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If any meat product is a NRTE meat product but has the appearance of or could be

mistaken for a RTE meat product, the meat product must have the following information

on its label:

The words "must be cooked", "raw product", "uncooked" or any equivalent words

or word as part of the common name of the product to indicate that the product

requires cooking before consumption; and

Comprehensive cooking instructions such as an internal temperature-time

relationship that, if followed, will result in a RTE meat product.

#7 Food Safety Plan – Tying it all Together

A food safety plan or program ensures the meat processing steps are done correctly,

each and every time. Meat processors use food safety programs to reduce the

likelihood that unsafe products reach customers. In the past, food safety programs

depended largely on final product inspections and testing (e.g. test 1 sandwich out of

every 1000 sandwiches prepared to see if quality is acceptable). This approach was

discontinued, because it was found to be expensive, and not effective at protecting

customers.

An example of a proven food safety model is HACCP. HACCP, which stands for Hazard

Analysis Critical Control Point, is now widely used by the food industry. HACCP is a

system that takes a preventative approach to food safety at all the stages of food

handling, from “farm to fork”.

All Federally registered food processing facilities are required to have a HACCP plan

or a Preventive Control Plan. Provincially permitted businesses are not, but many

have chosen to develop and practice a food safety plan based on HACCP principles.

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See Appendix 2 for “The Seven Principles of HACCP”.

Take a look at CFIA’s Food Safety Enhancement Plan

(http://www.inspection.gc.ca/food/safe-food-production-systems/food-safety-

enhancement-program/eng/1299855874288/1299859914238 ) for a detailed

explanation on how to develop a HACCP plan for your meat processing facility. Alberta

Agriculture and Forestry also has the Alberta HACCP Advantage Food Safety

Guidebook (http://www1.agric.gov.ab.ca/$Department/deptdocs.nsf/all/afs12301).

Summary

Foodborne illness has costs to individuals, to society and to food establishments. There

are consequences that may be mild and brief, or severe and long-lasting. At its worst,

foodborne illness destroys lives and businesses.

The cost of foodborne illness to society is estimated around $12 to $14 billion each

year. Impacts on the community include loss of jobs and loss of dollars into the local

economy.

Take some time to think about what you have learned from this booklet, and how you

will adopt food safety into your work routines. You have a responsibility to your

customers to meet necessary food safety practices. It is a responsible practice to

develop food safety policies, records, and checklists for your facility.

Examples of policies include:

Employee illness policy

Handwashing and glove use policy

Personal hygiene policy

Temperature control logs

Food processing records, e.g. degree hours, cooking logs, cooling logs, etc.

Cleaning and maintenance schedules

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Chemical use policy and log sheets

Pest control checklist

Ingredient records (a record of where you purchased your ingredients)

Distribution records ( a record of to whom you sold product)

Recall policy (what to do in the event a recall is required)

You can find food safety policies, templates and tools on Environmental Public Health’s

website at: http://www.albertahealthservices.ca/eph/Page8302.aspx

It is critical that every meat processor be aware of food safety risks, understand control

measures, and put a food safety plan into action. It is equally important to adopt a

positive food safety culture within an establishment. Meat processors must demonstrate

serious attitudes to food safety: proper knowledge, equipment, and policies will make

little to no difference if food handling staff do not care enough to practice what they

know is right.

A positive food safety culture is created by:

Clearly communicated expectations from supervisors to staff.

Formal food safety training for all staff.

Encouraging staff to speak about and report food safety issues to supervisors.

Most importantly, supervisors lead by example - be a model for the behavior

you wish to see in your staff.

If you encounter a situation in your

own facility that concerns you, or if you

are unsure about a food safety

procedure or requirement, it is in your

best interest to contact Environmental

Public Health, and speak with your

local Public Health Inspector.

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Our website has a map with contact information for all Environmental Public Health

office locations: https://www.google.com/maps/d/edit?mid=1iwOXE4dGqJ-b-HZr-

n_7hJaoC-Q&msa=0

About us

The Environmental Public Health Department of Alberta Health Services helps to

provide, protect and promote a healthy environment.

We inspect public places like restaurants, swimming pools, rental houses, day

cares and tattooing/ piercing shops to help keep people and the environment

safe and healthy.

Teach people how to keep places safe.

Make sure that laws like the Public Health Act are being followed.

Follow-up complaints about the safety of public places.

Investigate when someone gets sick from unsafe food, drinking water, swimming

pools or other places

For more information visit www.ahs.ca/eph

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Appendix 1 – Processed Meat Products Quick Facts

(From Alberta Agriculture and Forestry)

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Appendix 2 - The Seven Principles of HACCP

Principle 1: Conduct a hazard analysis.

A food safety hazard is any biological, chemical, or physical property that may cause a

food to be unsafe for human consumption. Look at product items, their ingredient list

and recipes to identify food safety hazards and what measures are in place, or can be

put in place to control these hazards. For example, in a recipe for cooking a whole

turkey, the raw turkey meat would contain the biological hazards of pathogens.

Principle 2: Identify critical control points

A critical control point is a point, step, or procedure in a food handling process where a

loss of control could result in a food safety hazard. A critical step is usually the last

opportunity for the food handler to prevent, eliminate, or reduce a hazard to an

acceptable level before the food reaches the customer. In the recipe for turkey, a critical

control point would be the step where the raw turkey meat is cooked.

Principle 3: Establish critical limits for each critical control point.

A critical limit is the maximum or minimum value to which a physical, biological, or

chemical hazard must be controlled at a critical control point to prevent, eliminate, or

reduce that hazard to an acceptable level. In the turkey example, the critical limit would

be the minimum internal cooking temperature to ensure the turkey was thoroughly

cooked – Health Canada recommends 85 °C for a whole turkey, so that is the critical

limit in this example.

Principle 4: Establish critical control point monitoring requirements.

Monitoring activities at the critical control points are necessary to ensure that critical

limits are met and that the food handling process is under control. Usually managers or

supervisors have the responsibility for monitoring critical control points or other quality

control measures. For example, using a probe thermometer to ensure the turkey had

reached the minimum internal cooking temperature of 85°C.

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Principle 5: Establish corrective actions.

Corrective actions instruct the food handlers on the appropriate response when the

monitoring step indicates a loss of control at a critical control point. Corrective actions

are intended to make sure that no unsafe foods reach the customer. If the turkey had

not reached the minimum internal cooking temperature, corrective action is: continue

cooking until the turkey reaches 85°C.

Principle 6: Establish record keeping procedures.

Effective HACCP programs require certain documents and maintained, including the

hazard analysis, written HACCP plan, and records documenting the monitoring of

critical control points, critical limits, verification activities, and details of when corrective

actions were performed.

Principle 7: Establish procedures to ensure HACCP plan is working as intended.

Validation of the HACCP plan means periodically reviewing the plan and checking that it

still does what it was intended to do: production of a safe food product. Sometimes the

plan needs to be checked when a meat facility gets new equipment, new products, new

ingredients, or new recipes.