Identifying production facility characteristics in small and very small meat processing plants with reference to FSIS Salmonella test results

Salmonella spp. is one of the leading microbial causes of foodborne illness in the United States with over 43,000 reported cases in 2007. This has shown an increase over the past several years, while many of the other pathogens most often linked to animal products have decreased. To address this trend, in 2006, the Food Safety and Inspection Service (FSIS) implemented a categorical system to encourage processors to make improvements to their processing conditions. This system was designed to assist plants that were in danger of failing initial Salmonella test sets.;Production facilities with less than 500 employees face unique challenges, such as lack of technical support, financial and physical flexibility. These processors make a wide array of products. These unique challenges necessitate identifying processing conditions and sanitation protocols that correlate with reduced Salmonella contamination.;Using the results from the FSIS 2005 Salmonella test sets, a case-control study was designed to address this need. The small and very small plants that failed test set A were selected as cases (n=32) and controls were matched to the case plants by inspection district and size, 4:1. Control plants had completed and passed the A set tests. The survey instrument was created in 3 parts: General Hazard Analysis and Critical Control Points (HACCP), Slaughter, and Raw Product Processing. The slaughter survey contained additional questions regarding livestock species-specific practices. Surveys were completed by phone with company representatives familiar with the establishments' HACCP plans and sanitation practices. The response rates were 40% and 38% for case and control plants, respectively. Other than variables representing plant size, such as numbers of employees and volume of production, there were few significant differences between small and very small respondents. Differences between cases and controls were found in animal washing before slaughter, type of poultry evisceration and percentage of raw product from in-house slaughter. Most of the plants (71%), operate under 2 or 3 processing categories; with the majority of the plants processing 10 or more products (60%). Seventy-six percent process raw products daily. Only 34% of the respondents slaughter red meat with 57% of those slaughtering daily. Gloves are worn during processing in 88% of the plants that process raw products; however, almost a quarter of those reported no policy requiring glove use. Ninety-five percent of plants reporting woven glove use have policies to launder or dispose of gloves. About 36% of the plants had Sanitation Standard Operating Procedures or Good Manufacturing Practices in place to specifically address Salmonella. Almost 28% have determined Salmonella contamination as a hazard likely to occur in their processes. Consistent use and knowledge of sanitation protocols were lacking in many cases. Additional details from these plants could provide more useful information for Salmonella control in smaller processing facilities. Results from this research will help focus and expand specific Extension programs for small and very small meat processors.