HAZARDS IN MEAT PROCESSING

Contents
1. PHYSICAL HAZARDS......................................................................................................................2
1.1 DEFINITION....................................................................................................................................2
1.2 CONTROL MEASURES OF PHYSICAL HAZARDS IN MEAT...................................................2
1.3 POSSIBLE PHYSICAL HAZARDS ENCOUNTERED DURING MEAT PROCESSING
OPERATIONS........................................................................................................................................3
2.0 CHEMICAL HAZARDS.......................................................................................................................4
2.1 DEFINITION....................................................................................................................................4
2.2 CONTROL MEASURES OF CHEMICAL HAZARDS IN MEAT PROCESSING.........................4
2.3 POSSIBLE CHEMICAL HAZARDS ENCOUNTERED DURING MEAT PROCESSING............5
3.0 BIOLOGICAL HAZARDS...................................................................................................................6
3.1 DEFINITION....................................................................................................................................6
3.2 CONTROL MEASURES OF BIOLOGICAL HAZARDS IN MEAT PROCESSING.....................6
3.3 POSSIBLE BIOLOGICAL HAZARDS ENCOUNTERED DURING MEAT PROCESSING.........7
4.0 CRITICAL COTROL POINTS (CCPs).........................................................................................11
5.0 GOOD HYGIENIC PRACTICES (GHP) IN MEAT PROCESSING.................................................11
5.1 Personal hygiene..............................................................................................................................11
5.2 Basic hygiene of meat processing....................................................................................................12
5.3 Hygiene of meat processing premises..............................................................................................12
5.4 Hygiene of meat processing equipment...........................................................................................13

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1. PHYSICAL HAZARDS
1.1 DEFINITION
 A physical hazard is any extraneous object or foreign matter in a food item
which can cause illness or injury to a person consuming the product.
 These foreign objects include but not limited to bone or bone chips, metal
flakes or fragments, injection needles, shotgun pellets, pieces of product
packaging, stones, glass or wood fragments, insect parts or other filth,
personal items or any other foreign material not normally found in food
products.
 Sources for such contaminants include
o raw materials,
o badly maintained facilities and equipment,
o improper production procedures and
o poor employee practices.

1.2 CONTROL MEASURES OF PHYSICAL HAZARDS IN MEAT

o Raw material inspection and specification.
o Vendor certification and letters of guarantees.
o Metal detectors to detect pieces of metal in the meat.
o X-ray technology to detect bone fragments.
o Effective pest control in the facility.
o Preventative equipment maintenance and proper sanitation procedures.
o Proper maintenance and calibration of detection equipment.
o Appropriate handling of packaging material.
o Proper shipping, receiving and storage practices.
o Tamper-evident packaging.
o Employee education on personal related hazards e.g. personal effects.
o Protected light fixtures.
o Controlling contact between pieces of machinery.

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 1.3 POSSIBLE PHYSICAL HAZARDS ENCOUNTERED DURING MEAT
PROCESSING OPERATIONS.

The table below indicates some possible physical hazards that may be found in meat
processing operations, their injury potential to consumers and their sources.

SN PHYSICAL INJURY POTENTIAL COMMON SOURCES

HAZARD TO CONSUMER
1. GLASS Cuts, bleeding; may require Bottles, jars, light fixtures,
surgery to find or remove utensils, gauge covers
2. WOOD Cuts, infections, choking; Fields, pallets, boxes,
may require surgery to buildings
remove
3. STONES Choking, broken teeth Fields, buildings
4. BULLET/ BB Cuts, infections; may Animals shot in field,
SHOT/ require surgery to remove hypodermic needles used for
NEEDLES injections
4. JEWELRY Cuts, infections; may Pens/ pencils, buttons,
require surgery to remove careless employee practices
5. METAL Cuts, infections; may Machinery, wire, fields,
require surgery to remove employees
6. INSECT PARTS Illness, trauma, choking Fields, plant-post process
& OTHER entry
FILTH
7. INSULATION Choking; long-term effect if Building materials
asbestos
8. BONE Choking, trauma Fields, improper plant
processing
9. PLASTIC Choking, cuts, infections; Fields, plant packaging
may require surgery to materials, pallets, employees
remove
10. PERSONAL Choking, cuts, broken teeth; Employees
EFFECTS may require surgery to
remove

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 2.0 CHEMICAL HAZARDS
2.1 DEFINITION
 A chemical hazard is any substance that can cause a health problem when
ingested in food or inhaled.
 Chemicals are divided in two primary categories: prohibited substances and
unavoidable poisonous or deleterious substances.
 Each company should make certain that none of prohibited substances are
present in ingredients or supplies.
 Unavoidable poisonous or deleterious substances have FDA tolerance levels
or action levels in the event that exposure or introduction is unavoidable.
Those products without tolerance levels must not be present in any amount.
 Products that fall into these categories include pesticides, herbicides, growth
hormones and antibiotics, additives and processing aids, lubricants, paints,
cleaners and sanitizers.
 Chemical hazards should be addressed in steps in production process:
o storage,
o during use (cleaning agents, sanitizers),
o prior to receipt (in ingredients and packaging materials),
o upon receipt of materials,
o during processing and
o prior to shipment of product.
 Chemicals which should be considered include color additives, indirect food
additives, direct food additives, prior-sanctioned substances generally
recognized as safe.
 All chemicals used in and around manufactured product should have
specifications developed, as well as a letter of guarantee from the
manufacturer.

2.2 CONTROL MEASURES OF CHEMICAL HAZARDS IN MEAT

PROCESSING
o Proper storage and handling practices; chemicals should be stored separately
from food products and packaging materials to avoid contamination.

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 o Special care should be taken to thoroughly rinse cleaning products and
sanitizers from the equipment during clean-up, especially in areas where
liquid tends to accumulate.
o Only USDA approved chemicals should be used during cleaning and
sanitizing.
o Pest control should be performed by professionals and chemical residues in
incoming food products should be controlled.
o Keeping of an inventory of all chemicals, colorings and additives.
o Frequent review of current procedures and formulations, as well as audits of
chemical use.
o Adequate employee training.
o In-house testing.
o Keeping up with new regulations.

2.3 POSSIBLE CHEMICAL HAZARDS ENCOUNTERED DURING MEAT

PROCESSING
The table below shows chemical hazards that may be found in meat processing.

S ACTIVITY/ STEP/ CHEMICAL HAZARDS

N MATERIAL
1. RAW MATERIALS Pesticides, antibiotics, hormones, toxins,
fertilizers, fungicides, heavy metals, PCBs.
2. PROCESSING Direct food additives- preservatives (nitrite),
flavor enhancers, color additives.
Indirect food additives- boiler water additives,
peeling aids, defoaming agents.
3. BUILDING & EQUIPMENT Lubricants, paints, coatings.
MAINTENANCE
4. SANITATION Pesticides, cleaners, sanitizers.
5. STORAGE & SHIPPING All types of chemicals, cross-contamination.

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 3.0 BIOLOGICAL HAZARDS
3.1 DEFINITION
 Biological hazards include micro-organisms such as bacteria, viruses, yeasts,
molds and parasites whose ingestion in food leads to illnesses (food infection
or food intoxication)
 Foodborne infection is caused by the ingestion of food containing live bacteria
which grow and establish themselves in the human intestinal tract for
example; Salmonella, Campylobacter, E. coli and Listeria monocytogenes.
 Foodborne intoxication is caused by ingesting food containing toxins formed
by bacteria which resulted from the bacterial growth in the food item for
example; Staphylococcus aureus, Clostridium botulinum and Clostridium
perfringens.
 Toxins are released in the gut when large of vegetative cells are eaten. Toxins
may not alter the appearance, odour or flavor of food.
 Most micro-organisms thrive well in meat products due to favourable
conditions such as being high in nutrients, high in water activity; provide an
excellent ‘food’ for micro-organisms.
 Apart from food poisoning (infection and intoxication), these micro-
organisms (bacteria) also result in meat spoilage such as putrefaction
(breakdown of proteins), slime formation, sourness (production of lactic acid),
discoloration and rancidity (breakdown of fats).
 Meat spoilage bacteria will grow if temperatures are not kept in the cooling (-
1oC to +4oC) or freezing (below -1oC) range.
 Not all bacteria which contaminate meat will behave in same way. Some may
multiply already at temperatures of 10oC, others at higher temperatures for
example 30oC. Most bacteria will optimally grow in the range between 30 to
37oC.

3.2 CONTROL MEASURES OF BIOLOGICAL HAZARDS IN MEAT

PROCESSING
 Proper inspection of raw meat from vendors.
 Proper meat processing temperatures (cooking, chilling, freezing, thawing,
packaging, storage)
 Hand washing; to prevent contamination.

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  Hand sanitation; to prevent human contamination of food.
 Drain sanitation; drains are sources of many biological contaminants.
 Cross-contamination/ food contact utensils; should be eliminated by use of
color-coded and controlled food grade utensils and tools including sanitary
storage.
 Cross-contamination/ maintenance tools and parts; process for cleaning and
sanitizing tools and parts must be in place for food use and tools and parts
need to be protected in storage or when staged for use.
 Doorway sanitation between food plant zones including outside-in doors via
sanitary mats, fountains, shoe covers, changing from street shoes to
designated work boots and sanitation stations can eliminate contamination.
 Environmental testing for biological contaminant levels on food plant surfaces
(non-direct surfaces of floors, walls and equipment). Additional areas to be
tested include door handles, hoods light switches, storage units, fork trucks,
transport or any other non-food contact surfaces that could be source of
biological contamination.
 Biofilms/ hard-to-reach areas; use of dry steam to remove Biofilms.

3.3 POSSIBLE BIOLOGICAL HAZARDS ENCOUNTERED DURING

MEAT PROCESSING

The table below shows common micro-organisms that are found in meat and meat
products, their sources, effects and control measures.

SN MICRO- EFFECTS SOURCES CONTROL

ORGANISM
1. Staphylococcus Food intoxication; Poor personal Good personal
aureus pathogen must grow in hygiene, food hygiene, keep
food and produce kept in room food out of
toxins. Toxin causes temperature. temperature
illnesses and is heat danger zone.
stable. Live cells do not
have to be consumed.
2. Clostridium Level of contamination Soil, untreated Proper chilling
botulinum is very low. Produces water, poorly of cooked
toxins. Toxin is among preserved/ food, use of
most toxic of all canned food. preservatives
naturally occurring such as salt
substances. It is spore and nitrites,
forming bacteria. ensuring low
Survives heating/ PH, retorting
cooking process. Toxin (canned

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 is not heat stable. products)
Using safe
water and raw
materials.
Keeping food
at safe
temperatures.
3. Clostridium Common in poultry Normal flora of Spore will
perfringens products. Vegetative intestinal tract survive cooked
cells of the bacteria of man and product.
have to be consumed. animals Proper chilling
Toxin produced in the of cooked
intestines. It is spore product.
forming bacteria.
Resistance to heat,
survives cooking, rapid
outgrowth
4. Salmonella Food infection. Live Common in Proper
cells must be consumed poultry. Some cooking, avoid
to cause illness. humans are cross-
carriers. contamination
Intestinal tract after cooking,
of animal. good personal
Cross- hygiene.
contamination.
5. Campylobacter Causes food-borne Harbored in the Very sensitive
jejuni infections. Live cells intestinal tract to
must be consumed to of animals. environment.
cause illnesses. Proper
cooking.
Drying.
Vacuum
packaging.
6. Escherichia coli Food infection. Does Harbored in Cooking at
0157:H7 not have to grow in intestinal tract 160oF for 15
food to cause illness. of animals. seconds.
Low infectious dose. Human faeces. Temperature
control that is
40-45oF; fewer
cells are less
likely to cause
illness,
Personal
hygiene.
7. Listeria Food infection. Live Harbored in Proper
monocytogenes cells have to be intestinal tract cooking.

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 consumed to cause of animals and Proper
illness. the sanitation.
environment. Low PH.
Cross- Low water
contamination activity.
from plant Freezing.
environment.
Grows at
refrigeration
temperature.
8. Yersinia Food infection. Only Found in wide Proper
enterocolitica certain bioserotypes are variety of cooking.
pathogenic. animals, food Separation of
and water. Pigs raw from
are principal cooked.
reservoir of Reheating of
bioserotypes cooked foods.
pathogenic to Capable of
humans. growth at low
temperatures
that is
minimum
growth
temperature
30oF. Salt will
inhibit growth
at low
temperature.
9. Trichinella Parasite. Causes Ingestion of raw Proper cooking
spiralis infection. or poorly of meat that is
cooked pork or 140 F instant
meat from other or 130 F for 30
mammals minutes.
containing Freezing meat
viable, infective at 20 F for 12
larvae. days or at 5 F
for 30 days.
Drying; for dry
sausage,
drying time
depends on the
diameter of
sausage.
Irradiation.
10. Norwalk-like Foodborne infections. Spreads Infected
virus Rarely diagnosed. primarily from workers should

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 one infected not be allowed
person to to come into
another. contact with
Infected kitchen meat or
workers can processing
contaminate a equipment.
food item
during
processing or
preparation.
11. Shigella spp Causes food infections. Found in water Proper
and food employee.
polluted with Portable water.
human feces. Avoiding
Unsanitary cross-
handling by contamination
food handlers. of RTE.
12. Cryptosporidiu Severe watery diarrhea, Intestinal tract Heat sensitive
m parvum cramps, low grade of cattle. at 161 F for 5
fever. Contaminated seconds.
water Killed by
contaminated freezing at 29
food by food F for 24 hours.
handlers. Use of
portable water
and proper
employee
hygiene.
13. Hepatitis A Acute liver disease. Ingestion of Proper
faecal matter, employee
even in hygiene.
microscopic Heat
amount. treatment.
Ingestion of Harvest
contaminated shellfish from
meat. approved
growing water.

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 4.0 CRITICAL COTROL POINTS (CCPs)
 Some points where controls can be applied in meat processing include:
 Chilling to temperatures that minimize microbial growth;
 Thermal processing at a specific temperature for an exact period of time in order
to destroy microbial pathogens;
 Product formulations control, such as the addition of cultures or adjustment of pH
or water activity.
 Inspection of raw meat and packaging materials for physical hazards such as
stones, wood, bone chips and other foreign materials.
 Testing ingredients for chemical residues.
 Testing product for metal contamination.
 Processing procedures, such as filling and sealing cans; and,
 Slaughter procedures such as evisceration or anti-microbial interventions.

5.0 GOOD HYGIENIC PRACTICES (GHP) IN MEAT

PROCESSING
5.1 Personal hygiene
 Wear clean protective clothes.
 Washing hands before starting work.
 Repeatedly washing hands during work.
 No finger rings, watches and bracelets.
 Access to production areas with working clothes only.
 Cleaning/ disinfection of hands/ tools/ clothes if there was contact
between highly contaminated subjects or abnormal animal parts likely
to contain pathogens.
 Fresh wounds through knifes etc. must be covered by a water tight
bandage. Workers with purulent wounds are not allowed to work with
meat (risk of spread of staphylococcus aureus).
 Strict toilet hygiene must be observed (removal of aprons, hand
washing and hand disinfection). Toilets must be kept clean and must

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 not have direct access to production areas (risk of spread of
Salmonella)
 Periodic medical examination of staff.

5.2 Basic hygiene of meat processing

 Ideally meat cutting/ deboning should be carried out in climatized
rooms (approx. 10oC) with low air humidity. Meat should be brought
in progressively and not accumulate on work tables.
 If visual contamination of manufacturing meat occurred, do not try to
wash it off but remove it with knives by cutting off superficial meat
parts in case of minor contamination. Discard meat in case of heavy
contamination.
 Do not hose down floor and wall areas or equipment next to meat
processing operations or final products with power hose (risk of
contamination by aerosol/ droplets).
 Never take meat pieces which accidentally had contact with the floor
or other contaminated surfaces, back onto working tables or into meat
processing machines.
 Containers for meat, fat or semi-or fully processed meat products must
not be placed directly on the floor but on hygienic stands, pallets.

5.3 Hygiene of meat processing premises

 Adequate room for personnel must be available including sections for
changing clothes and for personal hygiene.
 Wall windows must be positioned at a sufficient height from the floors
in order to allow profound washing and disinfection of floors and
walls. Wall windows for processing plants must be at their lowest part
at least 2m high over floor level. Window frame should be of non-
corrosive metals e.g. aluminium and must not be painted.
 Walls in all rooms where meat and by-products are handled, must have
smooth and easily washable surfaces up to a minimum height of 2m in
processing plants. Walls should be preferably covered with wall tiles
or at least wall paint.
 Floors in the mentioned sections must be impermeable to water and
reasonably smooth for good cleaning but anti-slip for workers safety.
They are usually made of fat resistant concrete and additional covering
by epoxy or floor ceramics.
 In order to facilitate proper cleaning, the junctions between walls and
floors must be rounded.

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  All wet rooms must have floor drains which be covered with non-
corrosive metal plates or grills. Covers should be easily removable for
proper cleaning of drains.
 Provisions must be made to channel water form hand-wash facilities,
cool room evaporators, tool sterilizers etc. by means of water pipes or
directly into effluent drains without contaminating the floor.
 Rooms for meat processing should have sufficient ventilations. Air
conditioning is only required in meat cutting/ deboning rooms (10-
12oC).
 Supply systems for electrical wiring and pipes for hot and cold water
as well as for compressed air should not hamper cleaning operations
and be out of possible dirt contamination. Insulation for hot water
pipes must have smooth surfaces and be washable.
 Opening for ventilation must be bird-and insect-proof.

5.4 Hygiene of meat processing equipment

 Tools and surfaces in contact with meat should be made of food grade
stainless steel or synthetic material. Stainless steel must be used for
working tables, meat hooks, blades of knives, saws, cleavers, and axes.
 All parts of machinery in contact with meat, fat, sausage mixes and
meat ingredients must be of stainless steel such as frozen meat cutter,
grinder, meat mixer and tumbler, meat emulsifier, sausage stuffer,
brine injector etc.
 Stainless steel parts must be smooth, easily accessible for cleaning and
without hidden spaces, where particles of meat materials may
accumulate.
 Galvanized steel or food grade aluminium are useful materials in
industries as they are non-corrosive but however should not come into
contact with meat because are not sufficiently smooth and may release
unwanted substances. Suitable for overheated rails, supporting
structures, working platforms and frames for tables and machinery.
 Food grade synthetic materials are used for many types of meat
containers and for handles of knives and other hand tools, for cutting
boards and some internal parts of meat processing equipment such as
washers, parts of valves etc.

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