Survey Questions and Frequency of Responses for Meat Slaughter and
Processing Plants
These
are the responses to the questionnaire
answered by 861 meat slaughter and processing plant respondents about
HACCP costs and food safety technologies.
Questions and responses are grouped by topic in the following order:
The following list of tables is also available in Excel
format.
Effects of the PR/HACCP Rule on Plant Operations
and Costs
(Question # Q1): In your opinion, since the Pathogen Reduction/HACCP
Rule has been implemented, how costly has each aspect of it been to this
plant? (Please circle ONE number for each.)
Q1 |
Response Category
(Percentage of Respondents) |
Responded "Don't
know" or no response (Number) |
No Cost To Plant |
Slight Cost |
Somewhat Costly |
Very Costly |
Writing, maintaining, and complying with Standard Sanitation
Operating Procedures (SSOPs) |
2.01 |
35.11 |
42.08 |
20.80 |
15 |
Writing, maintaining, and complying with HACCP product
plans |
1.18 |
21.37 |
43.33 |
34.12 |
14 |
E. coli and other testing |
19.98 |
21.09 |
34.99 |
23.95 |
55 |
Zero fecal matter standard |
52.09 |
17.97 |
14.90 |
15.04 |
143 |
Salmonella standard |
33.51 |
29.20 |
24.64 |
12.65 |
94 |
Preshipment review requirements |
10.49 |
45.65 |
35.16 |
8.70 |
22 |
Other (please specify) |
37.58 |
8.72 |
16.11 |
37.58 |
712 |
(Question # Q2): In your opinion, of the Pathogen Reduction/HACCP Rule
identified in Q1, which one has been most effective for pathogen reduction
up to now?
Most effective HACCP component for path reduction |
Q2 |
Frequency |
Percent |
Writing/complying with SSOPs |
284 |
32.98 |
Writing/complying with HACCP plan |
211 |
24.51 |
E. coli testing |
76 |
8.83 |
Salmonella standard |
15 |
1.74 |
Preshipment review |
16 |
1.86 |
Other |
10 |
1.16 |
Missing |
33 |
3.83 |
No benefit |
136 |
15.80 |
Zero fecal matter standard |
80 |
9.29 |
(Question # Q3): In your opinion, of the Pathogen Reduction/HACCP Rule
identified in Q1, which one has been most costly for pathogen reduction
up to now?
Most costly HACCP component for path reduction |
Q3 |
Frequency |
Percent |
Writing/complying with SSOPs |
101 |
11.73 |
Writing/complying with HACCP plan |
400 |
46.46 |
E. coli testing |
188 |
21.84 |
Salmonella standard |
46 |
5.34 |
Preshipment review |
9 |
1.05 |
Other |
21 |
2.44 |
Missing |
36 |
4.18 |
No benefit |
4 |
0.46 |
Zero fecal matter standard |
56 |
6.50 |
(Question # Q4): How much change has this plant made to each of the following
operational areas since 1996?
Q4 |
Response Category
(Percentage of Respondents) |
Responded "Don't
know"
or no response (Number) |
No Change |
Slight Change |
Some Change |
Great Deal of Change |
Suppliers or producers |
23.18 |
28.43 |
34.89 |
13.50 |
24 |
Raw and finished prod flows |
18.39 |
23.84 |
36.77 |
21.00 |
18 |
Product rework |
26.87 |
26.75 |
25.03 |
21.35 |
46 |
Frequency of cleaning/sanitizing |
30.08 |
25.38 |
30.20 |
14.34 |
10 |
Purchase/installation of equipment for pathogen control |
23.60 |
21.22 |
30.63 |
24.55 |
22 |
Plant facilities for better pathogen control |
26.34 |
23.84 |
26.58 |
23.24 |
22 |
Other (specify) |
47.22 |
2.78 |
10.19 |
39.81 |
753 |
(Question # Q5): In your opinion, which one of the six operational areas
in Q4 has had the greatest impact on pathogen control?
Operational change with greatest impact on pathogen
control |
Q5 |
Frequency |
Percent |
Requirements for meat suppliers |
86 |
9.99 |
Raw and finished product flows |
168 |
19.51 |
Product rework |
29 |
3.37 |
Don't know |
3 |
0.35 |
Purchase and installation of equipment |
146 |
16.96 |
Plant facilities for better pathogen |
101 |
11.73 |
Other pathogen control |
16 |
1.86 |
Missing |
14 |
1.63 |
No impact |
108 |
12.54 |
Frequency with operations |
190 |
22.07 |
(Question # Q6): In your opinion, which one of the six operational areas
in Q4 has been the most costly for pathogen control?
Operational change most costly for pathogen control |
Q6 |
Frequency |
Percent |
Requirements for meat suppliers |
38 |
4.41 |
Raw and finished product flows |
71 |
8.25 |
Product rework |
46 |
5.34 |
Don't know |
5 |
0.58 |
Purchase and installation of equipment |
251 |
29.15 |
Plant facilities for better pathogen |
215 |
24.97 |
Other pathogen control |
24 |
2.79 |
Missing |
38 |
4.41 |
No impact |
41 |
4.76 |
Frequency with operations |
132 |
15.33 |
(Question # Q7): How many additional employees has this plant hired due
to the Pathogen Reduction/HACCP Rule enacted in 1996? (Answer ZERO if
this plant hired no one. New employees should include additional quality
control personnel as well as production workers. Each part-time worker
should be counted as one-half of a worker.
Q7 |
Mean number of workers from reporting
plants |
Number of plants reporting |
Number of plants not reporting |
Number of production workers |
3.69 |
827 |
34 |
Number of lab and other nonproduction workers |
1.54 |
782 |
79 |
(Question # Q8):In your opinion, how costly have additional labor and
other operating requirements and additional capital expenditures been
to this plant due to the following components of the Pathogen Reduction/HACCP
Rule.
Q8 |
Response Category
(Percentage of Respondents) |
Responded
"Don't know" or no response (Number) |
No Cost To Plant
|
Slight Cost |
Somewhat Costly
|
Very Costly |
Writing, maintaining, and complying w/SSOPs |
5.18 |
36.00 |
40.00 |
18.82 |
11 |
Writing, maintaining, and complying w/HACCP plans |
3.16 |
24.21 |
43.51 |
29.12 |
6 |
Zero fecal matter standard |
53.90 |
19.02 |
14.91 |
12.18 |
130 |
Salmonella standard |
39.71 |
31.72 |
19.53 |
9.04 |
98 |
(Question # Q9): In your opinion: how much of a change has there been
to the annual downtime of this plant due to the following components of
the Pathogen Reduction/HACCP Rule?
Q9 |
Response Category
(Percentage of Respondents) |
Responded "Don't know" or no response (Number) |
Reduced |
No Change |
Small increase
(less than 8 hours) |
Some increase
(less than 24 hours) |
Great deal of
increase (more than 24 hour) |
Writing, maintaining, complying with SSOPs |
5.17 |
41.25 |
28.79 |
14.81 |
9.99 |
10 |
Writing, maintaining, and complying w/HACCP plans |
4.59 |
37.65 |
30.24 |
15.18 |
12.35 |
11 |
Zero fecal matter standard |
20.50 |
49.31 |
16.76 |
8.17 |
5.26 |
139 |
Salmonella standard |
16.58 |
61.46 |
15.36 |
3.77 |
2.83 |
119 |
(Question # Q10): How has the Pathogen Reduction/HACCP Rule affected
finished product yields from incoming raw meat or animals?
Impact of HACCP on yield of incoming
raw meat or animals |
Q10 |
Frequency |
Percent |
Yield reduced |
208 |
24.85 |
Yield not changed |
612 |
73.12 |
Yield increased |
17 |
2.03 |
Frequency Missing = 24 |
(Question # Q11): Please estimate the amount this plant has spent on
fixed capital expenditures for the reconfiguration of production lines
and other factory modifications, and for the installation and purchase/construction
of steam vacuum units, organic/antimicrobial spray washers, equipment
that raises raw product surface temperature over 160 degrees, or other
equipment in order to comply with the Pathogen Reduction/HACCP Rule of
1996.
Q11 |
Mean value of fixed capital expenditures |
Number of plants reporting |
Number of plants not reporting |
Mean value of fixed capital expenditures per plant. |
$469,800 |
745 |
116 |
(Question # Q12): Over and above that which was required under the Pathogen
Reduction/HACCP Rule, has this plant...
Q12 |
Response Category
(Percentage of Respondents) |
Responded "Don't know" or no response (Number) |
No |
Yes |
Exceeded HACCP Rule requirements in making factory
modifications to better control pathogens since 1996 |
34.34 |
65.66 |
63 |
Exceeded HACCP Rule requirements in the purchase
of equipment to better control pathogens since 1996 |
52.18 |
47.82 |
60 |
(Question # Q13): Do you think capital expenditures for the factory modifications
and equipment purchases and installations described in Q12 exceeded the
fixed capital expenditures that this plant incurred in order to comply
with the Pathogen Reduction/HACCP Rule?
The number of plants with private investments
in food safety exceeding expenditures due to HACCP |
Q13 |
Frequency |
Percent |
No |
387 |
47.90 |
Yes |
258 |
31.93 |
Don't Know |
163 |
20.17 |
Frequency Missing = 53 |
(Question # Q14: Please estimate how much water sanitizer, electricity,
maintenance, and other nonlabor variable costs increased per year due
to the Pathogen Reduction/HACCP Rule of 1996?
Q14 |
Mean expenditures on nonlabor costs
per year |
Number of plants reporting |
Number of plants not reporting |
Mean nonlabor cost increase per plants |
$268,900 |
658 |
194 |
(Question # Q15A: How many persons in this plant were involved in developing
SSOPs, HACCP plans, and other operating plans required by the Pathogen
Reduction/HACCP Rule of 1996?
Q15A |
Mean number of workers |
Number of plants reporting |
Number of plants not reporting |
Mean number of workers developing plans |
3.56 |
835 |
26 |
(Question # Q15B: How many days were spent by individuals, in total in
your plant, in developing SSOPs, HACCP plans, and other operating plans
required by the Pathogen Reduction/HACCP Rule of 1996?
Q15B |
Mean number of days |
Number of plants reporting |
Number of plants not reporting |
Mean number of days developing SSOPs and HACCP plans. |
52 |
835 |
26 |
(Question # Q18): Which ONE answer best describes how the shelf lives
of products sold by this plant have changed since 1996?
Change in shelf life of products sold since 1996 |
Q18 |
Frequency |
Percent |
Shelf life decreased |
10 |
1.20 |
Shelf life not changed |
513 |
61.81 |
Shelf life increased 1-2 days |
60 |
7.23 |
Shelf life increased by more than 2 days |
85 |
10.24 |
Shelf life increased by more than 7 days |
75 |
9.04 |
Don't Know |
87 |
10.48 |
Frequency Missing = 31 |
Characteristics of the Surveyed Plants
(Question # Q41: How many pounds of beef and pork products did this plant
sell under its own name or other names last year in 2000?
Q41 |
Mean pounds of output produced in 2000
in millions |
Number of plants reporting |
Number of plants not reporting |
Output sold |
40.25 |
725 |
127 |
(Question # Q42): Does this plant export products outside of the
United States?
Plants that export products outside of the United
States |
Q42 |
Frequency |
Percent |
No |
521 |
61.22 |
Yes |
324 |
38.07 |
Don't Know |
6 |
0.71 |
Frequency Missing = 10 |
(Question # Q43: Is more than 75% of the product from this plant sold
within the same state and/or adjacent states?
Majority of product sold within or to adjacent
states |
Q43 |
Frequency |
Percent |
No |
297 |
34.94 |
Yes |
532 |
62.59 |
Don't Know |
21 |
2.47 |
Frequency Missing = 11 |
(Question # Q44): Do some major customers of this plant test your products
for pathogens or harmful bacteria or require sanitation and product handling
practices that are more stringent than those demanded by FSIS?
Do major customers have more stringent requirements
than FSIS |
Q44 |
Frequency |
Percent |
No |
349 |
41.45 |
Yes |
367 |
43.59 |
Don't Know |
126 |
14.96 |
Frequency Missing = 19 |
(Question # Q45): Does this plant produce products under its own brand?
Plants producing products under their own brand |
Q45 |
Frequency |
Percent |
No |
98 |
11.61 |
Yes |
743 |
88.03 |
Don't Know |
3 |
0.36 |
Frequency Missing = 17 |
(Question # Q46): Does this plant produce cooked or otherwise further
processed products?
Plant producing cooked or otherwise further processed
products |
Q46 |
Frequency |
Percent |
No |
291 |
34.81 |
Yes |
532 |
63.64 |
Answered no, but also answered Q47 |
13 |
1.56 |
Frequency Missing = 25 |
(Question # Q47): What percentage of total production in 2000 was accounted
for by each of the following further processed products?
Q47 |
Response Category
(Percentage of Respondents) |
Missing or skipped
(Number) |
Items Not Produced
0% |
Very Little 1
to 20% |
Some 21 to 40%
|
About Half 41
to 60% |
Most 61 to 80%
|
Almost All 81
to 99% |
All 100% |
Bologna, frankfurters, other luncheon meats |
53.00 |
20.91 |
9.73 |
7.87 |
4.76 |
2.07 |
1.66 |
378 |
Pepperoni, other fermented, aged dry or semi-dried products |
73.15 |
12.47 |
6.13 |
1.48 |
2.11 |
2.75 |
1.90 |
388 |
Roast beef, oven-cooked ham, or other cooked beef or pork products |
49.68 |
25.81 |
12.69 |
3.87 |
2.37 |
3.01 |
2.58 |
396 |
Smoked ham, bacon, or other smoked products |
34.49 |
22.04 |
15.51 |
9.80 |
6.33 |
6.73 |
5.10 |
371 |
Other cooked or processed product |
30.19 |
34.05 |
13.70 |
8.57 |
3.64 |
3.85 |
6.00 |
394 |
(Question # Q48): Does this plant produce raw products?
Plants producing raw products |
Q48 |
Frequency |
Percent |
No |
156 |
18.98 |
Yes |
656 |
79.81 |
Answered no, but answered Q49 |
10 |
1.22 |
Frequency Missing = 39 |
(Question # Q49): What percentage of total annual production in 2000
was accounted for by each of the following raw products?
Q49 |
Response Category
(Percentage of Respondents) |
Responded
"Don't know" or no response (Number) |
Items Not Produced
0% |
Very Little 1
to 20% |
Some 21 to 40%
|
About Half 41
to 60% |
Most 61 to 80%
|
Almost All 81
to 99% |
All 100% |
Carcasses and primals |
50.62 |
14.76 |
7.38 |
6.15 |
5.10 |
8.61 |
7.38 |
292 |
Course or fine ground beef or pork |
31.28 |
26.50 |
15.90 |
9.74 |
5.13 |
7.52 |
3.93 |
276 |
Trim and other boneless beef or pork |
31.37 |
32.26 |
16.40 |
9.27 |
4.46 |
4.10 |
2.14 |
300 |
Subprimal and fabricated cuts |
39.24 |
26.40 |
14.10 |
7.78 |
6.69 |
3.44 |
2.35 |
308 |
Other raw products |
30.77 |
43.22 |
10.62 |
4.76 |
1.47 |
3.85 |
5.31 |
315 |
(Question # Q50): Does this plant slaughter cattle or hogs?
Plants slaughtering cattle or hogs |
Q50 |
Frequency |
Percent |
No |
371 |
55.21 |
Yes |
283 |
42.11 |
Answered no, but answered Q50-Q65 |
18 |
2.68 |
Frequency Missing = 189 |
(Question # Q57): Does this plant dehide cattle or hogs in a slaughtering
operation?
Plants that dehide cattle or hogs in a slaughtering |
Q57 |
Frequency |
Percent |
No |
53 |
16.99 |
Yes |
243 |
77.88 |
Answered no, but answered Q58-Q65 |
16 |
5.13 |
Frequency Missing = 549 |
Miscellaneous Survey Questions
(Question # Q16): Did this plant use schematics or flow diagrams to identify
critical pathogen control points before the Pathogen Reduction/HACCP Rule
of 1996?
Usage of schematics or flow diagrams prior to
PR/HACCP |
Q16 |
Frequency |
Percent |
No |
499 |
59.90 |
Yes |
301 |
36.13 |
Don't Know |
33 |
3.96 |
Frequency Missing = 28 |
(Question # Q17): Did this plant routinely review operations and make
adjustments to operations for better pathogen control before the Pathogen
Reduction/HACCP Rule of 1996?
Number of plants reviewing operations for better
pathogen control prior to PR/HACCP rule |
Q17 |
Frequency |
Percent |
No |
191 |
22.93 |
Yes |
592 |
71.07 |
Don't Know |
50 |
6.00 |
Frequency Missing = 28 |
(Question # Q29): Assuming that irradiation is permitted, do you think
this plant will irradiate SOME of its finished products within the next
three years?
Plants planning to irradiate SOME finished
products within 3 years |
Q29 |
Frequency |
Percent |
No |
517 |
61.26 |
Yes |
79 |
9.36 |
Not Applicable |
57 |
6.75 |
Don't Know |
191 |
22.63 |
Frequency Missing = 17 |
(Question # Q56): Did this plant use a hot water pasteurizer, steam vacuum
units, organic antimicrobial spray washes, or other equipment to better
control pathogens prior to 1996?
Plants that used equipment for pathogen control
prior to 1996 |
Q56 |
Frequency |
Percent |
No |
215 |
68.47 |
Yes |
91 |
28.98 |
Don't Know |
8 |
2.55 |
Frequency Missing = 547 |
(Question # Q67): Did you need to consult others within the plant to
answer all the questions in this questionnaire?
Consult others to complete the questionnaire |
Q67 |
Frequency |
Percent |
No |
410 |
70.09 |
Yes |
175 |
29.91 |
Frequency Missing = 276 |
Food Safety Technology Questions Dealing
with Plant Operations
(Question # Q21):Which ONE answer best describes how this plant cleans
and sanitizes the unprocessed, raw, and finished product conveyors?
Method of cleaning and sanitizing raw, unprocessed,
and finished product conveyors |
Q21 |
Frequency |
Percent |
Conveyors are not run while cleaned |
66 |
7.99 |
Only unprocessed raw product conveyors are run while cleaned |
27 |
3.27 |
Only finished product conveyors are run while cleaned |
26 |
3.15 |
Both unprocessed raw product and finished product conveyors
are run while cleaned |
382 |
46.25 |
Plant has automatic self-sanitizing conveyors |
11 |
1.33 |
Don't Know |
19 |
2.30 |
Not Applicable, No conveyor |
295 |
35.71 |
Frequency Missing = 35 |
(Question # Q24): Which ONE answer best describes what this plant does
with product that needs to be reworked?
Method of handling product that needs to be reworked |
Q24 |
Frequency |
Percent |
Use in next and subsequent lots |
322 |
38.70 |
Use in next and subsequent lots, rework remaining at the end
of the day is sold or transferred to another plant |
51 |
6.13 |
Hold until end of the day before using |
89 |
10.70 |
Sell to a further processor or transfer to another plant for
cooking only |
35 |
4.21 |
Discard, sell, or transfer to another plant for uses other than
human consumption |
137 |
16.47 |
Don't Know |
36 |
4.33 |
Other |
162 |
19.47 |
Frequency Missing = 29 |
(Question # Q25): If you responded OTHER in Q24, please specify.
Other (please specify) |
Q25 |
Frequency |
Percent |
Comments |
163 |
88.59 |
No |
21 |
11.41 |
Frequency Missing = 677 |
(Question # Q30): Which ONE answer best describes the instructional training
programs on safe food handling practices for new and experienced workers
of this plant?
Nature of the plant’s instructional training
program on safe food handling |
Q30 |
Frequency |
Percent |
On-the-job training only |
253 |
29.98 |
Instructional training for new workers only |
34 |
4.03 |
Instructional training for experienced workers only |
2 |
0.24 |
Specific instructional training for both |
551 |
65.28 |
Don't Know |
4 |
0.47 |
Frequency Missing = 17 |
(Question # Q31): Does this plant offer worker incentives, such as gifts
or compensation, for detecting and reporting possible sources of contamination
or unsanitary conditions?
Plant provision of worker incentives for reporting
contamination |
Q31 |
Frequency |
Percent |
No |
733 |
86.24 |
Yes |
107 |
12.59 |
Don't Know |
10 |
1.18 |
Frequency Missing = 11 |
(Question # Q32): For each situation described, please tell us what
production workers do if they detect feces, condensation, or other contamination
on the meat, or some other unsanitary condition near the meat.
Q32 |
Response Category
(Percentage of Respondents) |
Responded "Don't know" or no response (Number) |
No |
Yes |
Take corrective actions on their own initiative if in their
personal work area |
16.26 |
83.74 |
86 |
Notify the production worker responsible for work area if outside
worker’s personal area. |
17.97 |
82.03 |
121 |
Notify the supervisor for all unsanitary conditions |
3.96 |
96.04 |
53 |
(Question # Q33): Has this plant required growers or meat suppliers to
make changes to their management practices that have had a measurable
impact on reducing pathogens?
Number of plants imposing food safety requirements
on growers or meat supplier |
Q33 |
Frequency |
Percent |
No |
507 |
59.58 |
Yes |
216 |
25.38 |
Not Applicable |
64 |
7.52 |
Don't Know |
64 |
7.52 |
Frequency Missing = 10 |
(Question # Q34): Does this plant have a color-code or other system to
ensure that unprocessed and finished products are not mixed and supplies
and equipment are not shared between unprocessed and finished product
areas?
Plants using a color-code or other system to
ensure no mixing of unprocessed/ finished products |
Q34 |
Frequency |
Percent |
No |
281 |
33.61 |
Yes |
540 |
64.59 |
Don't Know |
15 |
1.79 |
Frequency Missing = 25 |
(Question # Q35): For each type of product, what is the common practice
for maintaining product temperature in the chiller?
Q35 |
Response Category
(Percentage of Respondents) |
Responded "Don't
know," "Not Applicable," or no response (Number) |
Chiller at FSIS standard
for temperature |
Chiller slightly below FSIS
below FSIS standard |
Chiller 5 or more degrees
below temperature standard |
Unprocessed raw product |
25.20 |
37.73 |
37.07 |
111 |
Processed raw product |
25.86 |
37.36 |
36.78 |
165 |
Cooked product |
26.52 |
37.02 |
36.46 |
318 |
(Question # Q51): Does this plant require that purchased animals be removed
from feed or have an empty gut prior to shipment to the plant?
Plants requiring animals to be removed from
feed prior to shipment |
Q51 |
Frequency |
Percent |
No |
228 |
75.25 |
Yes |
64 |
21.12 |
Don't Know |
11 |
3.63 |
Frequency Missing = 558 |
Food Safety Technology Questions Dealing
with Sanitation
(Question # Q36: Does this plant issue cleaned and sanitized smocks or
uniforms to employees at the beginning of the shift?
Plants that issue cleaned and sanitized uniforms
for each shift |
Q36 |
Frequency |
Percent |
No |
29 |
3.40 |
Yes |
821 |
96.36 |
Don't Know |
2 |
0.23 |
Frequency Missing = 9 |
(Question # Q37): Outside of direct contamination, which ONE statement
best describes the routine practice in this plant for sanitizing hands
or gloves that contact raw or cooked product in the finished product processing
area?
Description of routine practice for sanitizing
hands or gloves |
Q37 |
Frequency |
Percent |
No routine, sanitize when contaminated |
184 |
21.78 |
Sanitize one or more times per shift, less than once per hour |
368 |
43.55 |
Sanitize one or more times per hour, less than each unit |
180 |
21.30 |
Sanitize after each unit of product |
94 |
11.12 |
Don't know |
19 |
2.25 |
Frequency Missing = 16 |
(Question # Q38): Outside of direct contamination, which ONE statement
best describes the routine practice in this plant for sanitizing worker
cut-up knives that contact raw or cooked product in the finished product
processing area?
Routine practice of the plant for sanitizing
cutup knives |
Q38 |
Frequency |
Percent |
No routine-when contaminated |
201 |
24.57 |
Sanitize one or more times per shift but less than once per
hour |
276 |
33.74 |
Sanitize one or more times per hour but less than after each
unit |
127 |
15.53 |
Sanitize after each unit of product |
162 |
19.80 |
Sanitize two knives in rotation |
21 |
2.57 |
Don't know |
31 |
3.79 |
Frequency Missing = 43 |
(Question # Q39): Which ONE statement best describes how often drains
are sanitized?
Frequency that plant sanitizes drains |
Q39 |
Frequency |
Percent |
Less than once per week |
99 |
11.63 |
More than once per week, less than once daily |
237 |
27.85 |
More than once daily, less than once per shift |
329 |
38.66 |
One or more times per shift |
143 |
16.80 |
Don't Know |
43 |
5.05 |
Frequency Missing = 10 |
(Question # Q40): Does this plant have a mid-shift clean-up in which
workers clean all product contact surfaces?
Plants with mid-shift clean-up for cleaning
product contact surfaces |
Q40 |
Frequency |
Percent |
No |
479 |
56.75 |
Yes |
360 |
42.65 |
Don't Know |
5 |
0.59 |
Frequency Missing = 17 |
Food Safety Technology Questions Dealing
with Equipment
(Question # Q19):Which ONE answer best describes the type of conveyor
belts used for unpackaged, raw and finished product in this plant?
Type of conveyor belts used for raw and finished
product |
Q19 |
Frequency |
Percent |
Mainly cloth-backed belts |
39 |
4.70 |
Mainly plastic or stainless steel belts |
339 |
40.84 |
A mixture of cloth-backed/plastic/stainless steel belts |
126 |
15.18 |
Don't Know |
5 |
0.60 |
Not Applicable |
291 |
35.06 |
Other |
30 |
3.61 |
Frequency Missing = 31 |
(Question # Q20): If other, please specify the belt used.
Type of conveyor belt used for raw and finished
product |
Q20 |
Frequency |
Percent |
Comments |
33 |
54.10 |
No |
28 |
45.90 |
Frequency Missing = 800 |
(Question # Q22): For new equipment purchases, does this plant specify
surfaces that minimize biofilm build-up?
Plants imposing equipment specifications that
minimize biofilm build-up |
Q22 |
Frequency |
Percent |
No |
220 |
27.06 |
Yes |
452 |
55.60 |
Don't Know |
141 |
17.34 |
Frequency Missing = 48 |
(Question # Q23): Does this plant maintain positive air pressure in the
final product (raw or cooked) processing areas?
Does plant have positive air pressure in the
final product areas |
Q23 |
Frequency |
Percent |
No |
257 |
30.63 |
Yes, in some of the final product areas |
156 |
18.59 |
Yes, in all of the final product areas |
184 |
21.93 |
Don't Know |
93 |
11.08 |
Not Applicable |
149 |
17.76 |
Frequency Missing = 22 |
(Question # Q52): Does this plant use a hot water pasteurizer or other
heat treating process that raises carcass surface temperature over 160
degrees that is during the decontamination procedure but prior to carcass
processing storage (missing includes plants for which equipment is not
applicable, such as further processors)?
Plants using a hot water pasteurizer or other
heat treating method on carcass surface |
Q52 |
Frequency |
Percent |
No |
213 |
70.07 |
Yes |
85 |
27.96 |
Don't Know |
6 |
1.97 |
Frequency Missing = 557 |
(Question # Q53): Does this plant use a steam carcass pasteurizer, such
as a Frigoscandia, to pasteurize carcasses?
Plants using a steam carcass pasteurizer on
carcass surface |
Q53 |
Frequency |
Percent |
No |
282 |
92.76 |
Yes |
21 |
6.91 |
Don't Know |
1 |
0.33 |
Frequency Missing = 557 |
(Question # Q54): Does this plant use organic acid sprays on carcasses?
Plants using organic acid sprays on carcasses |
Q54 |
Frequency |
Percent |
No |
194 |
64.03 |
Yes |
107 |
35.31 |
Don't Know |
2 |
0.66 |
Frequency Missing = 558 |
(Question # Q55): Does this plant use steam vacuuming equipment for spot
removal of fecal matter?
Plants using steam vacuuming equipment for
spot removal of fecal matter |
Q55 |
Frequency |
Percent |
No |
234 |
74.05 |
Yes |
80 |
25.32 |
Don't Know |
2 |
0.63 |
Frequency Missing = 545 |
Food Safety Technology Questions Dealing
with Product and Environmental Testing
(Question # Q26): Over and above that which is required under the Pathogen
Reduction/HACCP Rule, does this plant test raw or cooked product with...
Q26 |
Response Category
(Percentage of Respondents) |
Responded "Don't know" or no response (Number) |
No |
Yes |
Aerobic plate counts (APC) tests |
49.53 |
50.47 |
116 |
Tests for Salmonella or generic E. coli |
39.25 |
60.75 |
66 |
Tests for E. coli O157 or Listeria |
40.15 |
59.85 |
54 |
(Question # Q27) Over and above that which is required under the Pathogen
Reduction/HACCP Rule, does this plant test environmental cleanliness in
the production area or production equipment with...
Q27 |
Response Category
(Percentage of Respondents) |
Responded "Don't know" or no response (Number) |
No |
Yes |
Microbial swab tests |
38.61 |
61.39 |
58 |
Tests for Salmonella or generic E. coli |
57.66 |
42.34 |
84 |
Tests for E. coli O157 or Listeria |
49.05 |
50.95 |
68 |
(Question # Q28): Over and above that which may be required under the
Pathogen Reduction/HACCP Rule, for each type of test how has the frequency
of bacterial testing changed since 1996?
Q28 |
Response Category
(Percentage of Respondents) |
Missing
(Number) |
Decreased |
No Change |
No testing in
1996, but test now |
Increased but
not doubled |
Doubled or more
than doubled |
Test for Listeria, E coli, Salmonella |
1.70 |
35.48 |
19.08 |
23.21 |
20.53 |
38 |
Generic tests or microbial swab of environment |
1.72 |
43.01 |
14.95 |
20.34 |
19.98 |
45 |
Food Safety Technology Questions Dealing
with Dehiding
(Question # Q58): Which method best describes how this plant removes
the hide from the carcass?
Method that removes the hide from the carcass |
Q58 |
Frequency |
Percent |
Manual hide removal with skinning knife |
119 |
47.98 |
Hide pulled up mechanically |
46 |
18.55 |
Hide pulled down mechanically |
38 |
15.32 |
Air dehiding |
1 |
0.40 |
Other |
39 |
15.73 |
Don't Know |
5 |
2.02 |
Frequency Missing = 613 |
(Question # Q59): If responded OTHER in Q58, please specify method of
hide removal?
Other (please specify method) |
Q59 |
Frequency |
Percent |
Comments |
42 |
58.33 |
No |
30 |
41.67 |
Frequency Missing = 789 |
(Question # Q60): Which method best describes how this plant prevents
the hide exterior from touching the carcass?
Method for preventing the hide exterior from
touching carcass |
Q60 |
Frequency |
Percent |
Worker precaution |
185 |
74.60 |
Reusable paper or plastic shield |
1 |
0.40 |
Fresh or sanitized paper or plastic shield |
9 |
3.63 |
All of the above |
23 |
9.27 |
Other |
23 |
9.27 |
Don't Know |
7 |
2.82 |
Frequency Missing = 613 |
(Question # Q61): If response was OTHER in Q60, please describe the method
of hide removal used in your plant?
Other (please specify) |
Q61 |
Frequency |
Percent |
Comments |
25 |
44.64 |
No |
31 |
55.36 |
Frequency Missing = 805 |
(Question # Q62): Does this plant use an air exhaust system vacuum or
other system that creates a negative pressure around the carcass in the
dehiding area?
Plants using negative air pressure around the
carcass |
Q62 |
Frequency |
Percent |
No |
203 |
78.68 |
Yes |
47 |
18.22 |
Don't Know |
8 |
3.10 |
Frequency Missing = 603 |
(Question # Q63): Does this plant use a plastic bag or a similar device
to prevent fecal contamination from the bung?
Plants using plastic bag to prevent fecal contamination
from reaching bung |
Q63 |
Frequency |
Percent |
No |
106 |
40.93 |
Yes |
147 |
56.76 |
Don't Know |
6 |
2.32 |
Frequency Missing = 602 |
(Question # Q64): On the kill floor, outside of direct contamination,
how often are hands washed or gloves that contact carcasses on the kill
floor cleaned and sanitized?
Frequency of sanitizing hands or gloves contacting
carcasses |
Q64 |
Frequency |
Percent |
Sanitized only when contaminated |
33 |
13.69 |
Sanitized one or more times per shift, less than 1 per hour |
17 |
7.05 |
Sanitized one or more times per hour, less than each carcass |
65 |
26.97 |
Sanitized after each carcass |
115 |
47.72 |
Don't know |
11 |
4.56 |
Frequency Missing = 620 |
(Question # Q65): How often are cut-up knives that contact carcasses
on the kill floor cleaned and sanitized?
Frequency of cleaning and sanitizing cut-up knives
that contact carcasses |
Q65 |
Frequency |
Percent |
Sanitized only when contaminated |
27 |
11.11 |
Sanitized one or more times per shift, less than once per hour |
11 |
4.53 |
Sanitized one or more times per hour, less than after each carcass |
44 |
18.11 |
Sanitized after each carcass |
135 |
55.56 |
Sanitized in rotation |
19 |
7.82 |
Don't know |
7 |
2.88 |
Frequency Missing = 618 |
|