Poultry Grading Monitoring Manual. Prepared by: Canadian Poultry and Egg Processors Council

Transcription

1 Poultry Grading Monitoring Manual Prepared by: Canadian Poultry and Egg Processors Council

2 1.0 Table of Contents Page 1.0 Table of Contents Introduction Definitions Product Sampling Plan Switching Rules Decision Tree Sampling Tables for Normal, Tightened and Reduced Table A. ISO Single Sampling Plan for Normal Inspection 5 Table B. ISO Single Sampling Plan for Tightened Inspection 6 Table C. ISO Single Sampling Plan for Reduced Inspection Monitoring Procedures Reporting Carcass Grade Factors and Specification Tables 9 1

3 2.0 Introduction In 2011, CFIA announced to the membership of the Canadian Poultry and Egg Processors Council (CPEPC) their intention to reduce their involvement in poultry carcass grading from the current monitoring role to a less frequent auditing role, thus leaving the grading and monitoring solely to industry. This document is designed by member companies of CPEPC as guidance for industry to monitor their company-specific grading program which has been developed to market graded poultry in accordance with the grade names and requirements established under the Livestock and Poultry Carcass Grading Regulations. 3.0 Definitions AQL Acceptable Quality Level. The Acceptable Quality Level (AQL) is a designated value of percent defectives (nonconforming) or defects (nonconformities) per hundred carcasses that will be accepted most of the time by the acceptance sampling procedure to be used. Determination of acceptability of a lot The number of carcasses inspected shall be equal to the sample size given by the plan. If the number of defective (nonconforming) units found in the sample is equal to or less than the acceptance number (Ac) for the appropriate sample size, the lot shall be considered acceptable upon removal of the defective birds found. If the number of defective (nonconforming) units is equal to or greater than the rejection number (Re), the lot shall be considered non-acceptable. Drawing random samples Identify 1, count 5 and select. The process will be repeated for each carcass or once the fifth carcass is identified, consecutive carcasses will be selected. Levels of Sampling Tightened (2 x Daily)-For those establishments which have a low or unacceptable quality standard of production for graded poultry. Normal (Daily)-For those establishments which have an average quality standard of production for graded poultry. Reduced (Weekly) -For those establishments which have a high quality standard of production for graded poultry. Further Reduced (1 in 20 consecutive lots)-if an additional 10 samples are accepted under Reduced inspection, the sampling frequency may be reduced further to one sample per 20 consecutive lots. Lot carcasses per hour, or carcasses per shift, or per shipment as defined by the processor in their sampling plan. 2

4 Sampling Plan composed of three numbers: the sample size, the acceptance number and the rejection number. The plan consists of drawing from the lot, at random the designated number of units of product required to make up the sample size, as per the sampling level, described in Monitoring, Table D. The units of product drawn are then known individually as "units" and collectively as "a sample". The sample is inspected and the number of defective units recorded, upon which the entire lot is accepted or rejected according to the acceptance and rejection number criteria described in 5.0 Monitoring, Table D. Tolerance Limits per Level of Inspection. Switching Rules Normal to Reduced - Five consecutive lots inspected at normal level are accepted. Reduced to Further Reduced- 10 consecutive lots are accepted under Reduced Inspection Reduced to Normal - One inspected lot is not accepted. Further Reduced to Normal One inspected lot is not accepted. Normal to Tightened - Two out of five consecutive lots inspected at normal level are not accepted. Tightened to Normal - Three consecutive lots inspected at tightened level are accepted. Unit One carcass. 4.0 Product Sampling Plan The sampling plan can be followed at origin and destination. General inspection level I (one) is considered appropriate for poultry sampling. Carcasses are selected after the grader, before packaging. Four levels of sampling severity inspection will be used: tightened, normal, reduced and further reduced. Note: To implement the sampling plan, all establishments will start inspection at the Normal level. 3

5 4.1 Switching Rules Decision Tree 5 consecutive lots are acceptable, go to REDUCED 2 out of 5 consecutive lots are unacceptable, Go to TIGHTENED FURTHER REDUCED 1 in 20 consecutive lots REDUCED Once Weekly, (or every 5 shifts) NORMAL Once Daily for 2 wks or10 shifts TIGHTENED 2X Daily 10 additional acceptable lots 1 unacceptable lot or the number of defective units exceeds the (Ac) limit but not the (Re) limit, go to NORMAL 3 consecutive lots are acceptable, go to NORMAL *5 consecutive unacceptable lots on tightened level results in the review of the establishment status. 4

6 4.2 Sampling tables for Normal, Tightened and Reduced, (reflect the current ISO :1999(E)) Table A. ISO Single Sampling Plan for Normal Inspection 5

7 Table B. ISO Single Sampling Plan for Tightened Inspection 6

8 Table C. ISO Single Sampling Plan for Reduced Inspection 7

9 5.0 Monitoring Procedure Monitoring is conducted by company graders, trained and certified by CFIA (or an industry trainer who has been trained by CFIA) Graders randomly select units at origin or destination locations as per the sampling tables and visually inspect carcasses for defects as described in 7.0 Grade Factors and Specification Tables herein. Limits are defined by the following table as per the ISO sampling plans. (AQL = 10) Table D. Tolerance Limits per Level of Sampling Lot size Sample size code letter Level of Sampling Tightened Normal Reduced Further Reduced Ac Re Ac Re Ac Re Ac Re G H J Ac: acceptance number = maximum number of defective units allowed in the sample for an acceptable lot. Re: rejection number = minimum number of defective units in the sample requiring the lot to be rejected. *If, at the end of a lot inspection, the acceptance number has been exceeded but the rejected number has not been reached, accept the lot but reinstate the normal level. *If sample size exceeds lot size, do 100% lot inspection and still utilize the acceptance and rejection numbers corresponding to the lot size. Corrective Action if the grade is not met the processor must take corrective action, which may include but is not limited to: retraining of graders, assign carcasses the lower grade, resample the lot and rework if required, etc. 6.0 Reporting Industry monitors will record at least the following information: -Type of graded poultry -Number of carcasses drawn -Weight range -Grading - explanation of the specific defects -Grade designation -Total defective carcasses 8

10 7.0 Carcass Grade Factors and Specification Tables Canadian Poultry Grade Standards - Conformation Factors and Sub-factors Canada A Canada Utility Skeletal Structure Normal Slightly crooked keel - no meat interference Slightly crooked keel - may have meat interference Curvature of Back Moderate Allowed Knobby Knees Nil Allowed Cysts Nil Weights < 2kg: 18 mm (dime size) Weights of 2-4.5kg: 25 cent piece Deformed Backs Nil Nil Weights > 4.5kg: 27 mm (dollar coin) Blisters Max. length 2.5 cm Max. length 2.5 cm Canadian Poultry Grade Standards - Flesh Factors and Sub-factors Canada A Canada Utility Breast: Moderately plump; moderate taper. Keel: Maximum projection anterior end 3.0 mm Breast: Sufficient to prevent sharp falling away from keel. Keel: Maximum projection 3.0 mm beyond the flesh. Canadian Poultry Grade Standards Fat and Flabbiness Factors and Sub-factors Canada A Canada Utility Fat Chicken, Capon, Rock Cornish Hen, mature chicken, old rooster, Duck, Geese: Breast, thighs and back show evidence of fat cover. Turkey: Deposits main feather tract on breast, evidence by pronounced thickening at center. Sufficient to prevent flesh from appearing prominently through the skin. 9

11 Flabbiness Breast: slight Allowed Canadian Poultry Grade Standards - Dressing Factors and Sub-factors Canada A Canada Utility Skin Tears Discolouration Parts Missing Breast (< 5.5kg): Aggregate length of 6 mm Elsewhere (< 5.5kg): Aggregate length of 2.5 cm Breast (= 5.5 kg): Aggregate length of 1.2 cm Elsewhere(= 5.5 kg): Aggregate length of 3.5 cm Breast: Total area 1.6 cm 2 Elsewhere: Total area 6.5 cm 2 Wing Tips and Tail - may be removed. Breast bone - may be removed for poultry weighting less than 900g. Wing tips and flat wings - may be removed for Ducks and Geese. Flesh Exposure: Maximum 3.0 cm of exposed flesh at posterior end of the keel. Areas of skin removed not more than 1/2 of the area of the breast. Tears and cuts half the length of keel. Breast: Total area 6.5 cm 2 Elsewhere: Total area 8.0 cm 2 Wings - May be removed Legs - One leg including thigh or both drumsticks removed Tail - May be removed Limbs - Removed at a joint only Flesh - Small area of flesh Skin - Not more than 1/2 of the area of the breast may be removed Back Portion - Young and mature turkey < 7 kg = 4 cm maximum; and Young and mature turkey = 7 kg = 6 cm maximum Note: parts must be removed at the joint Freezer Burn Surface desiccation maximum area of 14.5 cm 2 Surface desiccation maximum area of 14.5 cm 2 Dried Out Areas Not allowed Not allowed Broken Bones and Dislocated Bones Minor dislocation of the vertebra column not affecting the shape and the rigidity. Wing and leg bones may be dislocated - no broken bones 10