Food Security Plans for the Meat Industry Food Security & Recall Plan Development for the Meat Industry March 6, 2010 Myrtle Beach, SC Lynn Knipe The Ohio State University

Food Defense n n Alias, Food Security n n Food safety procedures protect your products from unintentional contamination. n n Food defense procedures protect your products from intentional contamination.

Food Defense n n Having measures in place to reduce the chances of someone intentionally contaminating the food supply in order to: hurt or kill someone disrupt our economy ruin your business

Food Defense Plans n n Voluntary, at this time. n n Self-assessment of operation n n Develop plan n n Monitor plan. n n Review and revise annually.

Benefits of Implementing Food Defense Plans n n Reduce the risk of unsafe product and economic loss. n n Reduce theft. n n Reduce the need for additional mandatory regulations. n n Reduce company liability.

Key Areas of Food Defense n n Outside Security n n Inside Security n n Personnel Security n n Emergency Response Procedures

Outside Security n n Prevent unauthorized access or entry of unapproved materials into facility

Outside Security: Physical Facilities n n Entrances (doors, windows, vents, gates, smokehouses) Door locking policies. Routine checks for signs of tampering? n n Who has access to…? Loading docks Parking lots Livestock pens Outside storage facilities Keys (Key log)

Outside Security: Shipping & Receiving n n Deliveries checked against shipping documents. n n Deliveries supervised. n n Inspect incoming products for evidence of tampering. n n Truck seals. inspected, verified & # recorded.

Outside Security: Mail Handling n n Mail handled away from food. n n Mail handlers are aware of proper handling of suspicious mail and U.S. Postal Service guidelines.

Inside Security n n Prevent intentional contamination throughout the entire production process.

Inside Security: Slaughter and Processing n n Employee traffic patterns. n n Access to large mixers, combo bins, grinderhoppers, brine mixing tanks, scalding tanks, chill tanks, carcass rinses n n Regular inspection of equipment?

Inside Security: Storage Rooms n n Maintain inventories of restricted ingredients, cleaning and sanitizing products n n Raw and Finished Products Coolers & freezers n n Packaging Materials & Labels Controlled to prevent theft n n Who has access?

Inside Security: Water/Ice Supply n n Who has access to…? water lines, wells, ice makers? n n Lines, tanks and/or ice makers regularly inspected for signs of tampering?

Inside Security: Information n n Sensitive information site plans, flow charts n n Paper & computer records security checked backed up regularly n n Who has access?

Personnel Security n n To ensure that only authorized personnel are in the facility at any time.

Personnel Security: Employees n n Background checks on new & temporary employees Verify that sanitation, maintenance, construction & repair personnel are properly identified and authorized to perform such activities, & restricted access to areas that they don’t work in.

Personnel Security: Employees n n Proper supervision of employees. n n Restrictions on what employees can bring in or take out. n n Method to ID or recognize employees Uniforms & footwear Picture IDs

Personnel Security: Non-Employees n n Visitors, drivers, construction or repair workers. n n Restrict access to sensitive areas Accompanied by plant personnel n n Restrict what they bring in and take out. n n Visitor ID

Personnel Security: Security Training n n Awareness training for new hires observe and report suspicious activity n n Refresher training periodically.

Emergency Response Procedures n n To respond quickly to a product contamination threat or event using planned measures.

Emergency Response: Contacts & Plan n n Emergency plan n n Up-to-date plant personnel contact information n n Up-to-date emergency contact information Inspection admin., customers, media, etc.

Emergency Response: Recall Plans n n Product recall plan developed, and periodically tested and reviewed.

Sample Defense Plan: Buckeye Meat Company 1) Description of Facility Type of Facility (meat, poultry, slaughter, processing, etc.) Size of Facility (very small, small, etc.) Where Facility is Located Number of Employees Other Pertinent Information

Buckeye Meat Company Sample Defense Plan: Buckeye Meat Company 2) Description of Plan Development Flow Diagram of Operation Food Defense & Assessment Slaughter Processing Storage Packaging and Storage Incoming Live Animals

Sample Defense Plan: Buckeye Meat Company 3) List of Identified Vulnerabilities and Proposed Solutions Need to have a solution for every identified vulnerability on the food defense assessment Need to address all 4 key areas (Outside Security, Inside Security, Personnel Security & Emergency Response Procedures)

Identified Vulnerabilities & Proposed Solutions (Cont’d) AreaIdentified VulnerabilityProposed Solutions Outside Security 1) No lighting installed over delivery area 1) Install adequate lighting above delivery area with motion sensor. 2) Back and side door not always locked. 2) Install locks on back and side doors that automatically lock when doors are closed. 3) Deliveries made unaccompanied by company employee. 3) Establish new policy that delivery people must be accompanied by company employee. 4) Trucks shipping products are not inspected before loading 3) Begin regular inspections of trucks used to ship products looking for presence of liquids, solids, or other suspicious materials before loading.

Identified Vulnerabilities & Proposed Solutions (Cont’d) AreaIdentified Vulnerability Proposed Solution to Counter Vulnerability Inside Security 1) Access to computer used for record- keeping not restricted 1) 1) Password protect computer and provide password to only essential personnel. Install virus software and firewall. Periodically back-up records and store copies at owner’s house. 2) Access to cold storage areas not controlled 2) Install locks on storage room and refrigerator/freezer doors. Increase lighting around storage areas.

Identified Vulnerabilities & Proposed Solutions (Cont’d) AreaIdentified VulnerabilityProposed Solution to Counter Vulnerability Inside Security 3) Access to managerial office not restricted 3) Lock door to managerial office when unoccupied. 4) Access between slaughter and processing areas not restricted so that slaughter employees can easily cross over to the processing area 4) Install door with combination lock between two areas. Require color- coded garb to distinguish between workers in the two areas. 5) Arrangements have not been made with local health officials for notification of compromised water supply. 5) Contact local health officials to make arrangements to be notified within 1 hour of any compromise to water supply.

Personnel Security 1) Lax visitor access control during normal business hours 1) Lock entry way from main entrance reception area to plant floor. Install buzzer to alert staff of visitor presence when reception area is not staffed 2) Background checks are not performed on new or seasonal employees 2) Perform background checks on all new hires or seasonal employees before allowing access to plant. Identified Vulnerabilities & Proposed Solutions (Cont’d)

AreaIdentified Vulnerability Proposed Solution Personnel Security 3) Employees are allowed to bring personal items (water bottles, keys, wallets) into slaughter/processing areas 3) Prohibit bringing any personal items into slaughter/processing areas. Provide employees with storage lockers/containers to store personal items. 4) Employees are allowed to wear street clothing on slaughter floor 4) Require employees to change into company- provided uniform & footwear before entering slaughter/processing areas. Identified Vulnerabilities & Proposed Solutions (Cont’d)

Sample Defense Plan: Buckeye Meat Company 4) Contact List List all important plant and agency contacts

Sample Defense Plan: Buckeye Meat Company 5) Product Recall Procedures May be taken from HACCP plan 6) Defense Assessment Record Updated at least annually Updated after mock exercises 7) Plan Revision Record

Step 3: Implement n n Assign responsibility for annual defense assessments. n n Train employees in regard to food defense and the establishment’s plan. n n Conduct mock exercises to assess effectiveness of the plan. n n Revise as necessary.

Summary n n Food Defense and Bio- Security Plan is a living document - - Continuous assessment and revision - - May periodically change

Summary n n Food Defense and Bio- Security involves the entire establishment - - Strong support from management & involvement from all employees - - Training and preparation (mock exercises) for all

Food Defense = Strong Offense n n Be on the lookout for breakdowns in security. n n Be on the lookout for suspicious activity. n n Be on the lookout for new ways to secure your establishment.

Food Defense Resources n n For help with writing Food Defense and Bio-Security Plans and employee training, please visit the following: Food-Defense-Plan %20_2_.pdf Food-Defense-Plan %20_2_.pdf Emergency_Response/index.asphttp://origin- Emergency_Response/index.asp

Lynn Knipe, Ph.D. Processed Meats Extension Specialist Ohio State University (614)