DUTCH VALLEY VEAL / BROWN PACKING COMPANY, INC.
Case-Ready Veal Standard Operating Procedures (SOP)
Introduction: This advanced packaging machine is intended to provide superior shelf life and utility for marketing Brown Packing Company, Inc. veal products. To insure that this machine performs its intended function only products of the highest quality can be used in this machine . Use of lower quality or microbially challenged product will defeat the purpose of this system and reduce its effectiveness in extending the product shelf life of the veal it protects.
CVP Machine Parameters: Prior to initial set up, the machine and all other equipment that is used in the production of Case-Ready products must be inspected as per Brown Packing Company's pre-operational SOP for proper sanitation and cleanliness. Once checked and signed off as per pre-operational SOP procedures, the machine can be set up. Following the manufacturer's instructions, the machine must be set up and tested for proper operation prior to packing product. All gas flows and vacuum parameters must be operating properly, as the proper mix of gases in the machine is what provides the extended shelf life by retarding the growth of spoilage microorganisms (germs). Once the machine is set up and shown to be operating properly, the operator will check and initial the Case-Ready production daily operations log for that day. Additionally, each hour during production the machine operator will check and sign off on the machine operational parameters including vacuum levels and gas mixture levels on the daily operation log for this machine.
Supplemental Equipment: When preparing knife-cut product for the Case-Ready machine, knives should be thoroughly cleaned and sanitized before breaking or cutting the meat. This will prevent contamination from product that is acceptable for other processes but does not meet the strict Case-Ready process quality standards.
If the product is a bone-in product that must be sawed prior to Case-Ready packaging, a dedicated saw must be used and must have been inspected and passed as per the pre-operational SOP for that equipment. Using a dedicated saw for Case-Ready product will prevent cross contamination with other acceptable product that might not meet the stringent quality level that is required for this packaging process.
The "Precision Cut" slicing machine, tables, trays and lugs should be cleaned and sanitized prior to processing product for the Case-Ready package.
Product/Processing Parameters: Because of the cost of packaging with this machine and our intent to insure the longest possible shelf life, it is essential that the product going into the package be of the highest possible quality and have the least instance of allowing for microbial exposure or growth. In order to insure that the Case-Ready machine is operated on a "just-in-time" basis the product to be packaged in the machine will not be cut for more than one hour prior to packaging. Product that is packaged in the Case-Ready machine should be taken from carcasses that ideally have a internal temperature of 33ºF, but in no case, be warmer than 39ºF. To extend shelf life by limiting cross-contamination, product used for this packaging should not be taken from meat that was stored in combos or lugs. Product for Case-Ready packaging should be taken directly from hanging carcasses or from special storage that prevents or limits the potential for cross-contamination (individual product on proper shelving, trees, or racking would be ideal).
Product for the Case-Ready package should be taken from carcasses that are within 24-48 hours of slaughter, and never should product be taken from carcasses that are more than 72 hours of slaughter. Product for Case-Ready packaging should generally be taken from smaller carcasses, ideally weighing 190 - 210 pounds. In addition, product for the Case-Ready package should never be cut from previously frozen or tempered meat.
Product that is ready to be packaged in the Case-Ready machine should be placed in clean trays or lugs and be kept near the loading area while awaiting insertion into the package. Product should not be held for more than one hour in this manner. Product that is held for more than one hour in this manner because of machine problems or excess production should be diverted to other packaging such as vacuum packaged or frozen product. Controlling production so that it is delivered "just-in-time" will insure that the product is packaged in a timely manner and that there is little time for environmental or microbial contamination to occur.
Personnel: Production employees actually packing product into the Case-Ready package should have sterile disposable gloves worn over cotton gloves, hair nets and, if applicable, beard nets. If processors touch anything besides the intended Case-Ready product or package, then the disposal sterile gloves should be replaced promptly. Additionally, to prevent contamination from clothing that may have been worn elsewhere in the plant, disposable protective aprons must be donned at the machine site. These aprons must be removed at the machine site when breaks are taken and/or disposed of at the end of the day. The Case-Ready processing foreman is responsible for insuring that the employees are dressed properly and are following the proper procedures.
Environment and Production Area: The Case-Ready production area must be kept clean and clear of product that is intended for other production. Since wooden pallets are a significant known source for contamination they must be kept out of the production area. Inedible product must regularly removed from the area or stored in a manner to prevent contamination of product that is intended for the Case-Ready package. Only Case-Ready personnel should be in the work area. Lines on the floor shall indicate the Case-Ready area and designated a "No Other Meat OR Employee Zone". The temperature of the Case-Ready processing area must be as cold as practical for optimal processing conditions -- ideally under 40ºF, and never above 45ºF. A temperature recorder shall be placed in the Case-Ready area and the temperature shall be recorded hourly to insure that the meat in process is maintained at proper temperature during the packaging process.
Finished Product Handling: Once veal product is packaged, the product should be quickly removed from the Case-Ready processing area to the cold storage area. During breaks that are more than 15 minutes in length, product in process and packaged product should be moved to a cold storage room until processing can resume. This will insure that product that is, or is about to be packaged using the Case-Ready process will not suffer from temperature abuse. The Case-Ready packaged product must be handled in a gentle manner. Every effort must be made to deliver the Case-Ready product to the customer quickly and under proper refrigeration. Trucks must be chilled to under 45º F before loading the Case-Ready product. The product should never be transported in vehicles that are under 32º F. The use of temperature recorders may be required if product temperature abuse is suspected.
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