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Module 3 Bacon & Gammon

Last Updated: 17 Jul 2023.

1.1 Compliance with the Quality Pork Charter rules

The Charter participant shall be compliant with the requirements of the BMPA Quality Pork Charter Rules. The BMPA Quality Pork Charter underpins the Red Tractor Assurance or Quality Meat Scotland standards for pork and pork meat products, therefore as pork is used as the raw material for all products produced in the whole Charter it is a requirement to hold certification for module 2 – BMPA Quality Assured Pork and also the products you produce are made with pork that is BQAP. Red Tractor Assurance are the license holders of the RTA logo

Participants in the manufacturing modules (3, 4 & 5) are not required to be certified against BQAP (Module 2) unless they are also operating as a cutting plant. However, they are required to use BQAP raw material.

Guidance

The Charter participant shall be aware that where specific Charter rules have been highlighted that these are auditable points within the scope of this pork module against which compliance shall be assessed by the service provider.

Evidence

Compliance with the specific auditable points of the BMPA Quality Pork Charter Rules.

1.1 Minimum standards for all products

The following minimum standards shall apply to all BMPA Quality Assured Bacon and Gammon products: 

  • The surface of the product shall be clean and free from extraneous matter including tar.
  • Rind, where present, shall be clean, free of bruises, hair and stubble.
  • The lean shall be of a good colour, free of bruising, mis-cure, bone fragments, and excessive levels of blood spots.
  • The fat shall be firm and white and no evidence of bruising, separation, softness or discolouration.
  • The product shall show no signs of spoilage e.g. odour, colour or taste
  • The product shall be virtually free of jelly pockets, excessive moisture and separation of lean and fatty tissues.
  • Where rind or rind plus back fat have been added to the product, this shall adhere securely to the meat.
  • Bacon shall be free of bone splinters, bone-dust and loose debris.
  • In moulded products, the lean meat shall retain its intrinsic muscle structure.

Guidance

The mis-curing of product can adversely affect the appearance of product. This may be caused by poor distribution of cure, insufficient curing time, or by blocked injection needles that can cause a problem referred to as “tiger stripping” where the needle pattern is clearly visible in the lean muscle of the product being produced”.

Refer to the BMPA/PTF Bacon Code of Practice for further information and guidance.

Evidence

Visual inspection of product.

1.2 When producing component packs

Where a bacon site is producing component packs e.g. pigs in blankets it shall be certified against the bacon and gammon module which may include the use of pancetta rather than bacon wrapped around the sausage.

1.2 Whole, three-quarter and Spencer’s sides

Whole bone-in sides, three-quarter sides (sides less the fore-end) and Spencer’s sides less the gammon, the bacon shall comply, as a minimum, with the following specification listed in clauses 1.3 to 1.7:

Evidence

Verify carcase classification records. Visual inspection of product.

1.3 Primal cuts of bacon: Fore-ends

1.3.1 For cured fore-ends the product shall comply with the following specification:

  • Visual lean at cut face minimum 70% VL

1.3.2 For fore-end joints, steaks and rashers, products derived from bacon fore-ends in their natural form, or from fore-ends or fore-end meat which has been formed by pressing into moulds or casings and possibly heat-treated or smoked, shall comply with the following specification:

  • The product shall retain its integral muscle structure. 
  • The product shall comply with the following minimum standards for leanness (Minimum, % VL):
Joints
Neck-end45%
Bacon75%
Shoulder75%
Picnic75%
Fore-hock75%
Collar70%
Rashers
Top back70%
Collar70%
Cooked rashers50%
Steaks
Bacon75%
Shoulder75%
Picnic75%
Fore-hock75%
Collar75%
  • The lean meat may be encased in an added covering of back fat and or rind.

Evidence

Visual inspection of product.

1.4 Primal cuts of bacon: Middles

1.4.1 For middles, the product shall comply with the following specification:

  • Visual lean (overall) minimum 70% VL
  • Visual lean (in streak) minimum 55% VL
  • Eye muscle depth at deepest point minimum 50mm
  • Fat depth over eye-muscle maximum 10mm (Maximum 12mm including rind)

For air dried and dry cured product, due to significant shrinkage during maturation, an exemption from the above allowances for eye muscle depth has been granted. Therefore: Eye muscle depth at deepest point: minimum 40mm. The middle may be rind-on.

1.4.2 The middle may be separated into back and streak by a straight cut parallel to the dorsal (loin) edge, to yield a back of approximate 20cm width.

1.4.3 For lardons/pancetta, the product shall comply with the following specification:

  • Visual lean minimum 55% VL
  • The quality attribute specification (QAS) shall specify dice dimensions, the agreed level of variance, and state the quantity of allowable fines which shall not exceed 10% of the pack by weight.

Evidence

Visual inspection of product

1.5 Primal cuts of bacon: Backs

1.5.1 Product shall comply with the following specification:

  • Visual lean (overall) minimum 75% VL
  • Visual lean (in prime) minimum 80% VL
  • Eye Muscle depth at deepest point minimum 50mm
  • Fat depth over eye muscle maximum 10mm (maximum 12mm including rind)

1.5.2 For rashers from the back, product shall comply with the following specification:

  • Eye muscle depth at deepest point minimum 50mm
  • Fat depth over eye muscle maximum 10mm (maximum 12mm including rind)

1.6 Primal cuts of bacon: Streaky/Pancetta

1.6.1 The product shall comply with the following specification:

  • Visual lean (overall) minimum 55% VL

1.6.2 The flank may have been removed and the belly edge trimmed back.

Evidence

Visual inspection of product

1.7 Primal cuts of bacon: Gammon

1.7.1 The product shall comply with the following specification:

  • Visual lean at cut face minimum 75% VL

1.7.2 For gammon joints, steaks and rashers, products derived from boneless gammons in their natural shape or from gammons or gammon meat which has been formed by pressing into moulds or casings and possibly heat-set shall comply with the following specification:

  • The product shall have retained its integral muscle structure.
  • Joints (excluding hock) Minimum 85% VL
  • Steaks Minimum 85% VL
  • Rashers Minimum 85% VL

The product may have been encased in an added covering of rind and/or back fat.

Evidence

Visual inspection of product.

1.8 Bacon Chops

1.8.1 Bacon chops shall be derived from bone-in or boneless primal backs of bacon. 

1.8.2 The product shall comply with the following specification: 

  • Length of chop Maximum 20cm
  • Visual Lean Minimum 80% (excluding bone if present)
  • Eye Muscle depth Minimum 50mm at deepest point
  • Fat depth over eye-muscle Maximum 10mm (or maximum 12mm if rind included)

Evidence

Visual inspection of product.

2.1 Sourcing, traceability and proving assurance

2.1.1 Pork raw material to be used in the manufacture of BMPA Quality Assured Bacon shall be sourced from supplying sites that are certified against the BMPA Quality Assured Pork module (BQAP). Refer to the Charter Rules.

2.1.2 To maintain traceability all pork raw material purchased by the Charter participant shall be accompanied by clearly marked delivery documentation and labelling which confirms its assured status and country of birth, rearing and slaughter or statement of pigs’ origin. Where pigs are born, reared and slaughtered in one country, a single statement of origin is sufficient for the traceability declaration.

Guidance

The site shall hold copies of all assured pork suppliers’ BMPA Quality Pork Charter certification.

It is not sufficient for a single header/logo to be the sole indicator of assured status on the delivery document. Where there is doubt regarding the status of the supply chain, verification shall be sought. 

Evidence

Copies of suppliers’ certificates of conformity against the BMPA pork module shall be held by the site and these shall be valid for the period under review. For each consignment of BQAP material delivered there shall be a warranty that clearly confirms the materials’ assured status and origin information of the pork.

2.2 Sourcing bacon

Bacon, gammon or sausage feedstock brought in from a different site shall be sourced from a participant of the BMPA Quality Assured Bacon and Gammon or BMPA Quality Assured Pork Sausage module and the product shall be certified against that module. Refer to the Charter Rules.

Guidance

Where the site is only slicing and packing bacon/gammon, or is only assembling component packs e.g. pigs in blankets, and the pre-requisites of the site being BRC GFS certified (minimum Grade B), compliant with BMPA Quality Pork Charter Rules, and that each product type being packed are certified against one of the relevant Charter modules and traceable to an approved participating site, then only the clauses contained within BMPA Quality Assured Bacon and Gammon module appropriate to the process being undertaken shall apply e.g. slicing and packing bacon packs or packing pigs in blankets.

Evidence

Copy of supplier’s certificate of conformity against the BMPA Bacon and Gammon or BMPA Quality Assured Pork Sausage module. 

2.3 Transporting raw materials

2.3.1 The site shall have standard operating procedures and inspection records for the reception, assessment, temperature monitoring, and the action to be taken if requirements are not meet for all pork and bacon deliveries to the site.

2.3.2 When placed in the transport vehicles, pork and bacon raw material shall be either hung on clean well-maintained stands/hooks or supplied in covered, clean, intact containers, cartons or trays that pose no risk of contamination to the contents.

2.3.3 Each consignment of pork and bacon raw material shall be examined on arrival to ensure that it is compliant with specification, free from contamination and indications of spoilage.

Guidance

If incoming pork or bacon material is not being received at the time of the audit, verification shall be sought by talking to key personnel to confirm the system for the transport of product. Verification of the cleanliness and temperature compliance may be taken by sampling/examining the most recent deliveries in the intake chill or associated areas.

Packaging shall be appropriate to the product being delivered. E.g. naked product delivered in dolavs/shrouded (liners). Vacuum packed product in boxes or containers. 

Evidence

Documented procedure. Visual inspection of the incoming material. Checks on the integrity of packaging. Examples of intake records.

2.4 Temperature during transport

2.4.1 During transportation and on arrival at the receiving site the temperature of the chilled pork or bacon raw material shall not fall outside of the range of -2°C to +5°C.

2.4.2 Unless bacon is received in a tempered form ready for slicing (typically -8°C), the target temperature of frozen pork raw material shall be -18°C or less during transport and it shall not exceed -12°C at intake.

Guidance

Verification is invariably undertaken whilst the product is on the delivery vehicle and at different points within the storage unit of the transporter.

Further verification may be sought by checking the temperature recording instrument of the vehicle.

Evidence

Examples of intake records since the last audit.

2.5 Labelling for pork & bacon received

Each batch of pork raw material and bacon shall be marked or labelled with the following as a minimum requirement on intake:

  • Site identification code (health mark)
  • Product description – e.g. rindless bellies
  • Weight – The number of units may also be indicated
  • Traceability batch code – In most cases the traceability batch code is the kill date however, where a production date is used, the information shall be able to trace the product backwards to a kill date. Slaughter code may be in ‘Julian’ calendar format or the actual kill date may be shown
  • Confirmation of assured status – The lettering BQAP may be used to confirm the products’ assured status to relate to the product within the container/box. Non-eligible material shall not be packed within the same dolav, container or box
  • Country of birth, rearing and slaughter or statement of pigs’ origin – Where pigs are born, reared and slaughtered in one country, a single statement of origin is sufficient for the traceability declaration
  • Date of freezing on all frozen raw material
  • Process-by date or (best before on frozen material) – Use by date is optional
  • Kill date (where applicable)

Guidance

Whether the material is being transported in dolav, rigid container or as boxed, the labelling information shall remain attached to the unit.

Evidence

Verification of labelling or markings.

2.6 Microbiological sampling and testing

2.6.1 The site shall have a standard operating procedure and testing schedule that details the frequency, scope and action limits for the microbiological testing of all incoming pork, bacon and/or gammon raw material.

2.6.2 The Charter participant shall have undertaken a risk assessment to justify the frequency of microbiological sampling.

2.6.3 The microbiological condition of the incoming raw pork material shall meet the following standard:

TargetUpper Limit
Aerobic colony count (ACC)<1 x 104 cfu/g1 x 106 cfu/g

2.6.4 The microbiological condition of incoming bacon and gammon shall meet the microbiological standards set out in clause 11.7 of this module.

2.6.5 Where microbiological results above these targets are found, there shall be evidence that these are subject to trend analysis and that where ongoing issues are highlighted that root cause has been established and corrective action has taken place.

Guidance

The testing schedule shall relate to the number of suppliers and the volume of material and the range of cuts being processed. 

Incoming material as internal transfer from co-located sites is exempt from incoming microbiological testing but must be tested as finished product. The exemption does not apply to intra-company transfer between different sites.

Evidence

Review:

  • 2.6.1  Testing schedule. 
  • 2.6.2  Copy of risk assessment. 
  • 2.6.3  Examples of microbiological reports since the last audit.
  • 2.6.4  Check micro standards for compliance with clause 11.7
  • 2.6.5  Trend analysis and where applicable root cause and corrective action reports. 

3.1 Temperature during storage

3.1.1 The storage area shall under maximum load maintain product temperatures within specification 

3.1.2 The temperature of chilled pork raw material and bacon during storage shall be between -2°C to +5°C. The temperature of chilled meat preparations such as sausage or meat-based stuffing’s during storage shall be between -2°C to +4°C. 

3.1.3 Where deep chilled storage is used there shall be a standard operating procedure that details control of deep chilling under normal operational conditions, but which considers emergency procedures that shall be followed if breakdown occurs. Validation of shelf life within the deep chill shall consider worst case scenarios.

3.1.4 It is permissible to crust-freeze/temper bacon feed stock at sub-zero temperatures prior to slicing.

3.1.5 The temperature of frozen pork raw material and bacon during storage shall be -18°C or colder.

Guidance

The storage area may be equipped with auto door closure, air or strip curtains to minimise ingress of warm air during stock transfers.

Dependent on the process e.g. cold storage or tempering the refrigeration temperature may be set to a target temperature to allow for temperature fluctuations caused by defrost cycles, doors opening during stock transfer etc. 

It may be acceptable for the air temperatures to be exceeded for short periods during defrost cycles/stock transfer etc. providing the product temperature remains within specification.

Evidence

Examples of temperature control records since the last audit. Validation records for deep chilling and Integrity of the packaging.

3.2 Length of storage and shelf life (chilled)

3.2.1 Pork raw material shall be processed within kill+4 days, however if the raw material is held in chill rooms that can maintain a constant temperature, the storage period may be extended by up to 3 days. Where pork raw material is vacuum packed, gas flushed or deep chilled and subject to the requirements of Clause 3.2.3 additional storage life beyond these limits can be used.

3.2.2 Any extension of shelf life greater than kill+4 days, shall be subject to satisfactory documented shelf life verification (sensory and microbiological evaluation) that shows that the extension of life does not, under worst case conditions, adversely affect product safety or quality. The microbiological limits shall not exceed the levels in clause 2.6.3

3.2.3 Chill temperature, traceability and shelf life records shall be maintained.

Guidance

For a co-located site where the pork has been slaughtered, cut and processed on the same site, extension of life beyond kill+4 days can be verified through the review of chill temperature monitoring records, without the requirement to package or deep chill the raw material. 

Consideration should also be given to the FSA guidance on the control of Clostridium Botulinum for products that exceed 10 days life.

Evidence

Examples of temperature monitoring records since the last audit. Review kill dates aligned to storage period, including verification of sensory and microbiological to ensure shelf life extensions. In relation to vacuum packed, gas flushed or deep chilled raw material, additional supporting evidence e.g. shelf life records

3.3 Length of storage and shelf life (Frozen)

3.3.1 Pork raw material shall be labelled with a date of kill and it shall not exceed kill+4 days at the point of freezing, unless the requirements of 4.2(c) have been met.

3.3.2 The pork material shall be in good condition at the time of freezing and shall be effectively packaged to prevent contamination and degradation of quality.

3.3.3 Frozen pork shall be labelled with the date of going into the freezer and a durability date that does not exceed 12 months.

3.3.4 Where frozen product is to be defrosted (tempered), the surface temperature shall not exceed +7C and it shall be carried out to a documented and validated procedure in line with the Charter participants processing specification

3.3.5 Stock control and defrost records shall be maintained.

Evidence

Review examples of stock control and defrost records since the last audit. Visual inspection of storage area to include product labelling and date coding. Review the documented procedure for the defrosting of frozen product process aligned to the Charter participants processing specification. Review of records to ensure the sensory and microbiological of extended shelf life products.

3.4 Durability dates

All pork raw material and bacon shall be used within its stated durability date.

Guidance

FSA guidance on Use By/Best Before coding.

Evidence

Examples of shelf life records and verification of maximum period of storage

4.1 Standard operating procedures

All standard operating procedures, work instructions, quality attribute specifications (QAS), in-house ‘mini specifications’ and finished product specifications shall be established and maintained for the bacon or gammon product type being manufactured. Relevant staff shall be trained against these.

4.1.1 The in-house ‘mini specification’ shall be developed in line with the QAS specified in clause 8.1  and provide through using words, measurements and/or photographs, specific quality attributes that clearly defines acceptable and unacceptable key attributes for each finished product approved by the BMPA Quality Assured Bacon (and Gammon) module. 

4.1.2 The ‘mini specification’ shall be prominently displayed at appropriate points of the production line to assist staff with quality monitoring and compliance.

4.1.3 A documented check shall be carried out on each production run to verify that the quality standards are being achieved.

4.1.4 Where there is evidence of attribute failure, the site shall investigate root cause and implement corrective action. 

Guidance

A range of curing methods may be used including dry-curing, injection curing followed by immersion, injection curing followed by bag-maturing, Wiltshire curing etc. However, certain curing methods relate only to specific types of bacon.

The ‘mini specification’ is a short version of specific key quality attributes from the QAS displayed on the manufacturing line.

Where there is evidence of attribute failure, the site may investigate the root cause, agree and implement corrective action to minimise/prevent the issue from re-occurring. Follow up checks may be undertaken. 

Evidence

Visual inspection of butchery and finished product standards at point of production. Review ‘mini specification’ and verification that the quality attributes are aligned to those detailed in the QAS and checking that the mini spec displayed corresponds to the product going down the packing line at the time of the audit.

4.2 General butchery standards

Butchery and trimming of sides, cuts and boneless pork shall be performed with minimum damage to the lean and fatty tissues.

Specifications shall be held that cover the butchery standards required for all pork raw materials intended to be used for BMPA Quality Assured Bacon and Gammon, as laid out in Clauses 4.3 and 4.4.

Evidence

Visual inspection of butchery standards. Copy of specification(s).

4.3 Butchery standards for whole sides, part sides and bone-in cuts

4.3.1 The neck shall be removed by a cut square to the dorsal edge of the side not more than 216mm forward of the posterior edge of the first rib.

4.3.2 Neck bones shall be removed cleanly.

4.3.3 The pocket hole shall be neat with minimal damage to the surrounding muscle.

4.3.4 The sternum (breast) bone shall be cleanly removed.

4.3.5 The loin (eye) muscle shall show minimal damage after removal of surface bones.

4.3.6 The fore-feet shall be removed through the upper of the two joints between the radius-ulna and carpus bones.

4.3.7 The hind feet shall be sawn off through the middle of the heel bone (between the tarsal bones and the fibular tarsal bones) to show the characteristic star pattern on the cut surface.

4.3.8 The aitch bone shall be carefully removed with minimal damage to the face of the gammon.

4.3.9 If required, the fore-end shall be separated from the side by a cut at right angles to the dorsal (loin) edge of the side and passing between the ventral ends of the third/fourth or fourth/fifth ribs.

4.3.10 If required, the gammon shall be separated from the side by a cut at right angles to the dorsal (loin) edge of the side. Its location may be varied but it shall fall between 20mm and 150mm forward of the anterior head of the femur.

Evidence

Visual inspection of butchery standards. Copy of specification(s).

4.4 Butchery standards for boneless fore-ends

4.4.1 Ribs and associated cartilage shall be removed cleanly.

4.4.2 The knuckle joint may be removed by a clean cut at the joint between the humerus and radius/ulna bones.

4.4.3 The blade-bone (scapula) shall be removed with minimal damage to the surrounding tissues and the humerus tunnel-boned.

4.4.4 Neck bones shall be removed cleanly.

4.4.5 Rind and surface fat shall be removed with minimal damage to underlying tissues.

4.4.6 The boneless fore shall be trimmed to remove loose tissue and surface glands.

4.4.7 Where still present, the neck shall be removed.

Evidence

Visual inspection of butchery standards. Copy of specification(s).

5.1 Thawing of frozen raw material

5.1.1 The Charter participant shall have standard operating procedures and records in place to ensure the effective thawing of frozen raw material before curing. This shall include the monitoring of product temperature during the thawing process.

5.1.2 The outer surface of the product shall not exceed +7°C during the defrosting period.

Evidence

Documented procedures for the thawing of frozen raw material. Examples of defrost temperatures records since the last audit.

5.2 Raw material cleanliness

All prepared pork raw materials for curing shall be clean, free of blood, bruising, bone splinters, dust and loose pieces of meat or glands.

Evidence

Visual examination of product.

5.3 Curing brines

5.3.1 The composition of curing brines shall comply with standard operating procedures, specifications and brine make-up recipes supported by chemical analysis and batch processing records.

5.3.2 Curing brines, whether intended for injection or cover, shall be positively released for use based on the salt content (as documented within the process specification) and temperature (Injection brines shall not exceed +7c and cover brines shall not exceed +5c). 

5.3.3 Where non-conformance occurs, the site shall investigate root cause and implement corrective action.

Guidance

The type of brine and cure shall be subject to the scope of the site’s processes and requirements of customer specification. 

Evidence

Documented production procedures, specifications, brine make-up recipes, chemical analysis and batch processing records. Examples of positive release records (salt & temperature) for curing brines and where applicable corrective action reports since the last audit. 

5.4 Curing procedures: Injection cured bacon

5.4.1 There shall be standard operating procedures, recipes and work instructions in place for the operation and management of the injection process.

5.4.2 The product temperature during the injection process shall be 0°C to +5°C.

5.4.3 Injection gains shall be monitored, recorded and checked against specified ‘pick-up’ targets for each batch of pork being processed by weight checks measured pre and post-injection on a specified number of products. 

5.4.4 Checks shall be carried out on the injection needles before injection commences to verify that needles are intact and there is no blockage of the needles that could result in ‘mis-cure’. 

5.4.5 Where non-conformance occurs, the site shall investigate root cause and implement corrective action

Guidance

‘Pick up’ is the amount of cure retained by the pork during curing. Recipes and work instructions shall detail the required criteria for the range of products produced on site. It is acknowledged that customers own brand label products may determine the recipe formulation.

Whilst the legal maximum temperature limit for meat in process is <8°C EHO`s tend to give some flexibility which maybe reflected by the approach taken by the auditor i.e. if temperatures of >8°C are seen but there is clear evidence that product temperatures are returning to <8°C within 4hours of final packing then it would be appropriate to raise this as an observation, however if the product was still at >4°C 4hours after final packing then this shall be viewed as a minor non-conformance.

Irrespective of the recipe formulation, in-process checks shall be undertaken to monitor the product temperature up to the point of filling. Records of temperatures shall be held.

Evidence

Documented procedures, recipes and work instructions for the operation and management of the injection process. Examples of product temperature records, injection gains and checks on needle integrity and evidence of records where corrective action was undertaken. 

5.5 Curing procedures: Dry cured bacon

5.5.1 There shall be standard operating procedures and work instructions in place for the operation and management of the dry curing process.

5.5.2 Curing shall, by definition, be carried out using only dry ingredients – the use of brines or other wet ingredients is not permitted.

5.5.3 Curing gains shall be monitored, recorded and checked against specified “pick-up” targets for each batch of pork being processed by weight checks measured pre and post cure on a specified number of products.

5.5.4 Where bacon is also air dried, there shall be evidence of net weight loss in compliance to specified tolerances.

Evidence

Documented procedure, work instructions, recipes, specifications and process records for the operation and management of the dry curing process. 

Review curing gain records and ‘pick up’ target records.

Where bacon has been air dried review records of net weight loss aligned to specified tolerances.

Visual inspection of product to verify adherence to specification.

5.6 Curing procedures: Traditionally cured Wiltshire bacon

5.6.1 Pork raw material intended for Wiltshire curing shall be either cured on the side, as primal cut, or as individually butchered muscles. The use of ham hock incorporating primary and/or secondary hock muscle) may be used.

5.6.2 The injection and cover brine shall only contain salt, (NaCI) sodium or potassium nitrite and/or sodium or potassium nitrate. 

5.6.3 Injection may be carried out manually or by multi-needle injection.

5.6.4 It is a characteristic feature of Wiltshire curing that the live cover brine shall be re-used continually. Therefore, standard operating procedures work instructions, and records shall be in place that state the compositional targets and tolerances (salt, nitrate, nitrite, pH and temperature), and the actions to be taken when these fall outside of stated limits, so that the condition of the live cover brine can be maintained and where necessary corrected. All actions and brine amendments shall be recorded.

5.6.5 Due to yield loss, the quantity of live cover brine will deplete over time. Therefore, a standard operating procedure shall be in place for the process to “top-up” an existing live cover brine or, in extreme circumstances, the creation of a new batch of live cover brine.Where a “top-up” brine is used this shall not exceed 25% of the mother batch of live cover brine.

5.6.6 use of a starter culture in the production of Wiltshire bacon shall be restricted to the creation of a fresh batch of cover brine after the original has been lost or has soured.

5.6.7 In order for the live cover brine to mature and stabilise the fresh batch shall be used to cure products for at least two months before it can be used to manufacture product that can be certified as BMPA Quality Assured Bacon and Gammon (Wiltshire).

5.6.8 Live cover brines not in regular use shall be regularly aerated and monitored (d) to maintain their condition

5.6.9 Records shall be maintained for live cover brine composition. A recorded log of cover brine history, adjustment and “top-up” shall be maintained to demonstrate composition and provenance.

5.6.10 Pork shall be fully immersed in the live cover brine for a minimum period of 3 days (72hours).

5.6.11 After immersion, and prior to further processing, the cured sides/pork cuts shall be allowed to drain and then matured in air at +2°C to +5°C for a minimum of 4 days and to a clearly specified maximum time that shall be validated using shelf life and food safety analysis.

Guidance

In a Wiltshire-curing system, the objective is to maintain the live cover brine in a stable condition with a predictable and controlled rate of conversion of nitrate to nitrite. 

Brines used in different plants vary in their behaviour due to differences in their micro flora and this behaviour should be recognised. Because of their singular nature, a unique characteristic is that the live brine is continually re-used. The practice of freshly and routinely preparing the live cover brine by the addition of a starter culture is a modern short cut intended to circumvent the traditional time aged process and is not compliant with the requirements of clause 5.6 that is specific to the traditional process. To be certified by the Charter such products, for the purpose of labelling and differentiation from authentic and traditionally Cured Wiltshire Bacon, should be clearly described as “Wiltshire-Style” (or similar) within the legal name of the product.

The function of the starter culture is to ensure that the right microbiological flora is present for the live brine to mature to a point where it can be self-maintaining with occasional additions of salt, nitrite and nitrate to maintain its condition. Typical levels of microflora are a count greater than 10and are predominantly made up of large concentrations of micrococci and lactobacilli. Once the mature live cover brine has been created the brine can then be re-used without further addition of the starter culture

There will be occasions when existing cover brines will need to be replenished by the addition of a top-up cover brine – this should be an occasional practice rather than routine. weekly. It is expected that the manufacturer should know the quantity (in litres) of live cover brine they have on stock, so it should be a simple calculation to work out the 25%. Details of the opening stock, closing stock, and top up additions would need to be documented. “this should be an occasional practice rather than routine e.g. weekly, not daily.” 

Immersion forms an essential part of the Wiltshire process. In Wiltshire curing, the relative concentrations of the injection and live cover brines result in a net withdrawal of water from the pork during curing because the concentration of salt in the injection brine is considerably less than that of the live cover brine.

The pH of a live cover brine is usually stable and typically falls within a range of 5.0 to 6.9. The pH value may be checked whenever brine is being re-strengthened and live cover brine with pH outside this range may be used if the Charter participant can demonstrate that the brine remains stable (different starter cultures can create different pH levels). Occasional peaks outside of the set limits would not be an issue if the Charter participant is monitoring the pH trends and takes corrective action when non-typical pH profiles emerge. A gradual and persistent rise in the pH value indicates that the brine is becoming unstable, and a critical situation will arise if this goes above 6.9, when off-odours will develop.

The rise in pH is usually accompanied by an increase in the nitrite level, as a more rapid reduction of nitrate occurs.

Wiltshire-cured sides and cuts are frequently stored in an unprotected form Excess surface brine drains off (the use of hooks, racks, or slatted tray are acceptable as long as free drainage can be demonstrated) and the lean and fat become firmer in texture and noticeably drier. These changes are due to the gelling of the water/salt/protein complex formed within the meat during curing and a gradual hardening of the fat as the crystallizing process continues after slaughter.

Evidence

Examples of records to be reviewed since the last audit shall comprise:

  • Live cover brine composition
  • Log of cover brine history, adjustments and “top-up” to demonstrate provenance.
  • Temperature monitoring
  • Shelf life and food safety analysis
  • Appropriate work instructions

5.7 Post cure processing of bacon

5.7.1 Post cure boning, cutting, slicing and similar operations shall be carried out with minimal damage to soft tissues.

5.7.2 During further processing, the temperature of the bacon shall not exceed +7°C (except for smoked and further heat-treated product) and shall subsequently be reduced to +5°C or lower.

Guidance

Any potential increase in the product temperature shall be minimised by controlling the volume of product being processed which shall be aligned to pre-production plans. 

Evidence

  • Visual inspection of butchery standards.
  • Examples of temperature monitoring records since the last audit.

5.8 Smoking

5.8.1 There shall be standard operating procedures, work instructions and records in place for the bacon smoking process that details the operation of the smoking chamber and the time, temperature, and wood types specific to each product specification. 

5.8.2 For smoked bacon, only natural wood smoke shall be used in the smoking process. Synthetic smoke mixtures and extracts of wood smoke shall not be used.

5.8.3 Care shall be taken to ensure that the bacon is uniformly smoked in compliance to the process specification (time and temperature of smoking) and quality attribute specification (colour and taste) and it is not contaminated with tar in the smoke chamber

Guidance

Traditionally, smoke is produced from hard woods, normally beech, oak, applewood – scented or resinous woods like conifers are not used due to excess tarring or flavour migration.

Product may be hung on racks or hooks but shall not touch walls or other product that may impede the circulation of smoke around the chamber. Any covering used e.g. bags, netting etc. shall be suitable for intended use. The smoke chamber and racks shall be kept clean.

Evidence

Review standard operating procedures. 

Copy of current wood specifications and review examples of completed processing records since the last audit. 

Visual inspection of smoke chamber. Review process specification, QAS and examples of quality control records since the last audit

5.9 Handling of cured product prior to heating or cooking

5.9.1 There shall be standard operating procedures, work instructions and process records in place for the handling of bacon/gammon prior to heating/cooking.

5.9.2 Bacon/gammon shall be held in chill storage at −4°C to +5°C for up to 7 days unless it has been massaged or tumbled, in which case it shall be cooked within 24 hours. 

5.9.3 The period of storage prior to cooking can exceed 7 days if bacon/gammon is either deep chilled to a validated process or if it frozen and held at -12°C or below. The site shall undertake shelf-life verification under worst case conditions that includes sensory evaluation and microbiological quality of the finished product. 

Evidence

Examples of temperature monitoring records where deep chilled cured or frozen bacon has been stored for longer than 7 days shelf life data for the product shall be available. Validation data for the deep chill or freezing facility.

6.1 Heating for heat set bacon/gammon

6.1.1 Standard operating procedures, work instructions and process records shall be documented and maintained for the heating process.

6.1.2 The cabinet operating temperature, heating time and core temperature shall be clearly specified, and recorded checks documented for each batch of product processed.

6.1.3 Where the intention is to heat set the bacon/gammon the maximum core temperature necessary to achieve the desired product appearance/texture shall be clearly specified and monitored.

Guidance

Heating profiles shall take into account the potential temperature ranges within the heating cabinet (hot and cold spots) and the design/capability of the equipment. It is advisable when heating batches, to select product from within a narrow a weight band as is practically possible. Cabinets invariably have continuous recording of the heating programme appropriate to the product being heat set.

Evidence

Review procedures, work instructions and examples off heating process records since the last audit. 

6.2 Cooking of bacon/gammon

6.2.1 Standard operating procedures, work instructions and process records shall be documented and maintained for the cooking process.

6.2.2 The cooking process shall be such that the time/temperature achieved at the core is equivalent to a minimum of 2 minutes at +70°C.

6.2.3 Where static cooking chambers are used, the core and chamber temperature of the product shall be measured and recorded throughout the cooking period.

6.2.4 Where other forms of cooking equipment are used (travelling ovens), the validation of the process shall be based on specified time/temperature requirements.

6.2.5 Where bacon/gammon joints are being cooked, then prior to release from the cooking chamber, the core temperature of the product shall be measured and recorded either by cooker probe and/or manually at the top, middle and bottom of each rack. All product temperature readings shall be equal to or greater than the minimum core temperature specified within the standard operating procedure and work instruction shall cross-reference to the sites HACCP plan.

6.2.6 Where the bacon is comprised of individual slices and cooked using microwave or other forms of in-line cooking e.g. grilling, the site shall have validated the cooking process to a documented protocol which shall be detailed within the sites HACCP plan.

6.2.7 Where infra-red monitoring equipment is used to verify the cooked temperature of the product, the frequency of recording shall be aligned to the documented protocol detailed within the sites HACCP plan.

Guidance

Refer to corresponding subclauses above

6.2.2 Cooking profiles shall be in place to demonstrate the controls necessary for product safety. It is recognised that there are a range of different types of cooking systems e.g. traditional cooking chamber, travelling ovens or cooking by microwave. Whichever system is used, the equipment shall have been validated to a documented protocol. It is expected that protocol shall have been verified at the time of the BRC audit.

Various factors influence the rate at which micro-organisms are killed during the cooking and how many survive this process:

  • the time/temperature relationship
  • the concentration of salt and of curing salts in the product
  • the initial microbial load on the bacon when cooked.

The initial microbial load on the uncooked bacon shall also fall within the limits set out when determining the shelf life of the final product. These requirements shall have been fully laid out when the durability of the cooked cured pork is determined and shall be available for evaluation.

Regular monitoring of finished product standards shall be in place. 

6.2.4 Heating/cooking profiles shall take into account the potential temperature ranges within the cooker (hot and cold spots) and the design/capability of the cooking equipment. It is advisable when cooking batches, to select product from within a narrow a weight band as is practically possible. Accurate records of cooking shall be held. Cookers invariably have continuous recording of the cooking programme appropriate to the product being cooked.

6.2.7 This shall form part of the cooking profiles and routine monitoring of the cooking programme. This shall be supported by in-situ temperature monitoring probes (where applicable). 

Evidence

Refer to corresponding subclauses above

6.2.2 Review procedures, work instructions and examples off cooking process records since the last audit.

6.2.4 Review cooking profiles and examples of cooking records. 

6.2.7 Review cooking profiles and examples of cooking records. (Note: verification of the temperature monitoring equipment shall be covered at the time of the BRC GFS audit and HACCP shall be reviewed).

6.3 Cooling of smoked, heat set or cooked product

6.3.1 Standard operating procedures, work instructions and process records shall be documented and maintained for the cooling process.

6.3.2 Product shall be cooled rapidly after completing the specified heating/cooking process to ensure that the safety and quality of the product is not compromised. 

6.3.3 All product shall cool to <5°C before further processing

6.3.4 Bacon/gammon heat set/cooked in sealed containers/casings/bags may be cooled in chilled air or by a combination of cold water showering followed by chilled air or brine to <5°C and may be held in these containers until required for further processing or packing. 

6.3.5 To allow traceability of the heating/cooking process each batch of heat set/cooked product shall be clearly identified with date and time of heating/cooking and details of cooker and product temperature achieved.

Guidance

Documented procedures shall be in place to ensure product safety/product quality is not compromised. This shall be supported by evidence of temperature monitoring and recording.

If the product is more than 5kg, it shall achieve a core temperature of +5°C or lower in accordance with Campden BRI Guidelines (Review 8) on ‘Identification and Prevention of Hazards associated with Slow Cooling of Hams and Other Large Cooked Meats and Meat Products’. If the product is less than 5kg, 4 hours shall be the maximum time permitted to reach less than +5°C.

This shall be supported by accurate record keeping including traceability of product.

Evidence

Review documented procedures, work instructions and examples of cooling process records since the last audit.

Cooking records since the last audit.

6.4 Post-cook handling of heat set/cooked bacon/gammon

6.4.1 The site shall have standard operating procedures, work instructions and process records in place to ensure product safety and quality is not compromised during post heat/cook handling.

6.4.2 Subsequent processing operations shall be performed with no detriment to the product safety/quality. 

6.4.3 Product containing exposed bone shall be adequately protected to ensure pack integrity.

6.4.4 Finished chilled product shall be held at a temperature no higher than +5°C, before despatch.

6.4.5 Where finished product is to be frozen prior to despatch it shall be stored at -18°C or less.

Evidence

Review procedures, work instructions and cooling process records

Visual inspection of finished product.

Examples of temperature control records (air and product) since the last audit.

7.1 Labelling for traceability & mass balance

All pork raw material shall be identified as BMPA Quality Assured Pork or “BQAP” by labelling of the rack, chandelier or other transport medium.

Each batch of pork raw material to be used for the manufacture of any BMPA Quality Pork Charter products shall be marked or labelled with the following information as a minimum:

  • Site identification code (health mark)
  • Product description
  • Weight
  • Traceability batch code 
  • Confirmation of assured status
  • Country of birth, rearing and slaughter or statement of pigs’ origin
  • Date of freezing (if frozen)
  • Durability / process-by date
  • Date of kill

Evidence

Visual inspection of labelling of the transport medium, outer case and/or retail pack.

7.2 Traceability and mass balance audits

7.2.1 The Charter participant shall carry out 4 mass balance and 8 traceability audits during the certification year. The schedule mayconsider the mass balance requirements specified within BRC GFS.

7.2.2 All Charter participants shall ensure that they have a documented system and schedule for challenging traceability and mass balance of all assured pork raw material, work in progress material (WIP), rework and finished products and that these are clearly identified with assured status at each stage of the process from intake through to dispatch. The system shall facilitate both forward and backwards traceability and mass balance of both assured and non-eligible pork raw material by the conclusion of the Charter audit and that mass balance shall include any wastage and processing yield losses to account for the full batch to be completed within an accuracy of not less than 95% and not greater than 100% accountability. It shall include all forms of assured pork material used in the product i.e. rind, added back fat etc. 

7.2.3 When completing traceability back to farm, 3 slap marks from 3 separate producers from the same kill date shall be checked against the pig producer’s animal movement licence. Verification of the slap mark or ear tag shall include the assured status of the farm, livestock vehicles and where applicable, assured collection centres using the relevant assurance checker. 

7.2.4 The Charter participant shall have a sampling plan for the traceability and mass balance audits that include all the products approved by each module of the BMPA Quality Pork Charter and a minimum one product per month shall be challenged. 

7.2.5 Traceability and mass balance audits shall be carried out by a competent, trained individual who is independent of the manufacturing operation. For further guidance, refer to the BMPA Quality Pork Charter rules appendix 3 ‘Competency and independence of internal/external auditors undertaking traceability and mass balance audits’ and appendix 4 ‘Traceability and mass balance guidance’.

7.2.6 Documentary evidence containing a summary of each traceability and mass balance exercise shall be maintained to demonstrate that the requirements of the Quality Pork Charter are being met.

7.2.7 Where a non-conformance is raised for traceability and mass balance exercises, records shall detail evidence of root cause analysis and corrective action. 

7.2.8 Charter participants shall carry out a risk assessment at least once during each certification year to verify that the traceability systems and procedures are robust and effective for the identification and traceability of all pork materials.

Guidance

Traceability checks are carried out to verify the assured supply chain and mass balance checks may be carried out on part of the process and may include non-eligible products. Product identification shall facilitate both backwards and forwards traceability i.e. from which batch did it originate and within which batch(s) was it used.

See below an example of a suggested schedule. The mass balance and traceability exercises carried out during a BRC GFS and BMPA Quality Pork Charter surveillance audit may count towards this requirement.

MonthScopeBasis
AprilBRC annual mass balance On BMPA quality assured product (incorporating a backward trace to farm and a forward trace from raw material intake to finished product)
MayBMPA backward trace to raw material intakeOn BMPA quality assured product
JuneBMPA forward trace from raw material intake to finished product*On non-eligible product 
JulyBMPA forward mass balance from raw material intake to finished productOn BMPA quality assured product (incorporating a forward trace from raw material intake to finished product)
AugustBMPA backward trace to raw material intakeOn BMPA quality assured product
SeptemberBMPA forward trace from raw material intake to finished product*On non-eligible product
OctoberBRC provenance mass balance On BMPA quality assured product (incorporating a backward trace to farm and a forward trace from raw material intake to finished product)
NovemberBMPA backwards trace to raw material intakeOn BMPA quality assured product
DecemberBMPA forward trace from raw material intake to finished product*On non-eligible product
JanuaryBMPA forward mass balance from raw material intake to finished productOn BMPA quality assured product (incorporating a forward trace from raw material intake to finished product)
FebruaryBMPA backward trace to raw material intakeOn BMPA quality assured product
MarchBMPA forward trace from raw material intake to finished product*On non-eligible product
*Note – sites that do not handle non-eligible material shall carry out the required mass balance and traceability exercises on BMPA quality assured products).

Evidence

In seeking compliance, objective evidence shall be aligned to the following sub clauses:

  • Clauses 7.2.1, 7.2.2, 7.2.3, 7.2.6 Review traceability and mass balance reports since the last audit. 
  • Clause 7.2.4 review sampling plan. 
  • Clause 7.2.5 verify independency and competency of the auditor undertaking the traceability and mass balance checks. 
  • Clause 7.2.7 Where non-conformance has been raised by the independent auditor review evidence of root cause analysis, corrective action and monitoring. 
  • Clause 7.2.8 Copy of risk assessment.

8.1 Quality Attribute Specification (QAS) monitoring

8.1.1 The Charter participant shall monitor the quality attributes of each product type certified by this BMPA module against a documented quality attribute specification (QAS) that has been formally agreed by the Charter participant and their customer. All products shall achieve the standards set by the BMPA BQAP module.

8.1.2 Where there is evidence of repeat attribute failure, the site shall investigate the root cause and implement corrective action to minimise/prevent the issue from re-occurring.

Evidence

Reviewexamples of formally agreed QAS and that these are aligned to the approved products listed on the certificate of conformity.Review records of QAS verification checks since the last audit. 

8.2 Organoleptic testing

8.2.1 A standard operating procedure for organoleptic testing shall be in place and be conducted by a member of staff who is trained against the procedure.

8.2.2 An organoleptic sampling schedule shall be established for all categories of bacon/gammon and composite packs like “Pigs-in-Blankets” for finished products certified by the BMPA Quality Assured Pork Module.

8.2.3 Records of assessment shall be retained. Where there is evidence of attribute failure, the site shall investigate root cause and implement corrective action. 

Evidence

Review of organoleptic testing procedure, sampling schedule, assessment and training records.

9.1 Sampling & testing plan for analytical standards

9.1.1 The site shall have a sampling plan and testing regime in place for the routine monitoring of the analytical compliance of all finished products listed on the sites BMPA Quality Assured Bacon and Gammon certificate of conformity. and assessed against the requirements of this module and the product specification agreed with the customer. 

9.1.2 Bacon/gammon products shall be assessed against the analytical standards detailed below in Clauses 9.2 to 9.5.

9.1.3 Analytical testing frequency: The analytical testing of the meat, added water, salt, nitrite and nitrate content of the bacon/gammon shall be carried out at least once per month.

9.1.4 Where out of specification results occur, there shall be evidence that this is subject to investigation, trend analysis or other specific corrective actions.

Guidance

Occasional out of specification analytical results is not uncommon and is not, in isolation, a non-conformance. 

Non-conformance would occur where product is repeatedly reported as out of specification or where the average of results within a stipulated period fall outside of the specification. 

Where occasional out of specification occurs, there shall be no non-conformance if there is evidence that this has been alerted, investigated, and, where deemed necessary, action taken – it is possible for this to develop into non-conformance over time if it is apparent that the corrective action has failed.

Evidence

Sampling plans aligned to the scope of approved products. Examples of analytical result, trending, and out of specification investigations and action reports.

9.2 Salt content

Uncooked bacon/gammon, including that to be used for cooked product, shall fall within the range of 1.8 % – 3.8% of the product weight. 

Where Potassium Chloride (KCl) or Magnesium Chloride (MgCl2) is used as a partial replacement for common salt (NaCl) the combined weights of both salts shall fall within the above range. 

Where the bacon/gammon is produced and labelled as reduced salt or lower salt or contains added ingredients such as glaze or decorations, the salt level may fall below the above targets provided there is satisfactory validation to support shelf-life and food safety.

9.3 Nitrates and nitrites content & nitrite replacements

Nitrates and nitrites content shall be compliant with the requirements of The Miscellaneous Food Additive Regulations 1995 (NOTE: maximum amounts are stipulated as either “that added during manufacture” or the “residual amount in product” – the application of these requirements is specified on a product by product basis and takes into account product type and process) 

The standard allows the use of nitrite replacements, however this does not apply to the use in Wiltshire Cured products. You are required by legislation to ensure that the replacement that you choose to use performs in much the same way e.g. colour, taste/flavour, texture, and a level of food safety that you normally get when using nitrite. It is your responsibility to ensure that any food when placed on the market is safe.

9.4 Added water content

Added water content shall not exceed 10% of the uncooked weight of injection cured product.

9.5 Meat content

Meat content shall comply with that stated on the retail pack or within the product specification agreed with the customer.

10.1 Sampling & testing plan for microbiological standards

10.1.1 The site shall have a sampling plan and testing regime in place for the routine monitoring of the microbiological compliance of the finished products listed on the sites BMPA Quality Assured Bacon and Gammon certificate of conformity.

10.1.2 Where out of specification results occur, there shall be evidence that this is subject to investigation, trend analysis or other specific corrective actions.

Evidence

Sampling plans aligned to the scope of approved products and microbiological reports since the last audit. Evidence of corrective actions taken where non-conformance has been highlighted.

10.2 Uncooked bacon/gammon

Uncooked bacon/gammon shall be tested weekly to demonstrate compliance with the following microbiological targets:

TestTarget (cfu/g) Unacceptable (cfu/g)
Total Viable Count ACC @ 30°C, 48 hours <1 x 105>1 x 106
Coliforms or Enterobacteriaceae @ 37°C, 24 hours <10>1 x 103 
Staph aureus (coag. +ve)@ 37°C, 24 hours <20>5 x 102 
Lactobacilli @ 25°C, 24 hours (optional) <1 x 103>1 x 104
Yeasts, Moulds @ 25°C, 3 – 5 days (optional) <1 x 103>1 x 105 

10.3 Cooked bacon/gammon

Cooked bacon/gammon shall be tested weekly in accordance with a documented sampling schedule to demonstrate compliance with the following microbiological targets:

TestTargetUnacceptable
ACC<100cfu/g>1000cfu/g
SalmonellaAbsent in 25gPresent in 25g
*Listeria spp Absent in 25gPresent in 25g
Staph Aureus<20 cfu/g>100cfu/g
* Where a positive test for Listeria spp. is reported, a test for the presence and enumeration of Listeria Monocytogenes shall be undertaken to demonstrate that the count at end of life is <100cfu/g

11.1 Reception into external cold store

11.1.1 The cold store shall have standard operating procedures and inspection records for the reception, assessment, temperature monitoring and details of the action to be taken if requirements are not met for all pork deliveries. 

11.1.2 During transport, pork raw material, bacon and/or gammon shall be covered in clean, intact containers, cartons or trays that pose no risk of contamination to the contents. 

11.1.3 Pork raw material, bacon and/or gammon shall be transported on clean, well-maintained temperature-controlled vehicles that pose no risk of product contamination. 

11.1.4 Each consignment of pork raw material, bacon and/or gammon shall be examined on arrival to ensure that it is compliant with specification, free from contamination and indications of spoilage and that assured status and traceability back to source has been maintained.

Guidance

If product is not being received at the time of the audit, verification shall be sought by talking to key personnel to confirm the system for the transport of product. Verification of the cleanliness may be taken by examining the cleanliness of any deliveries in the intake chill or associated area. 

Packaging shall be appropriate to the product being delivered. E.g. naked product delivered in dolavs/shrouded (liners). Vacuum packed product in boxes or containers.

Evidence

Documented procedure aligned to 10.1.1 a). Visual inspection of interior of transport, condition of storage containers for product, integrity of packaging (where applicable). Examples of intake records since the last audit. 

11.2 Temperature during transport

11.2.1 The doors of the delivery vehicle shall remain closed to the point when the pork raw material, bacon and/or gammon temperature is being checked.

11.2.2 During transport and on arrival the temperature of chilled pork raw material and bacon shall not fall outside of the range of -2°C to +5°C. 

11.2.3 The target temperature of frozen pork raw material and bacon shall be -18°C or less during transport and shall not exceed -12°C at intake. Bacon may only exceed -12°C at intake when received in a tempered from ready for slicing (typically – 8°C). 

Guidance

Verification is normally undertaken whilst the product is on the delivery vehicle and at different points within the storage unit of the transporter.

Verification shall be sought by checking the temperature recording instrument of the vehicle.

Evidence

Verification of product temperature records during transport and at point of receipt since the last audit.

11.3 Temperature during storage

11.3.1 The storage area shall, under maximum load, maintain product temperatures within specification 

11.3.2 The temperature of chilled pork raw material, bacon and/or gammon during storage shall be -2°C to +5°C. 

11.3.3 The temperature of chilled meat preparations such as sausage or meat-based stuffing during storage shall be between -2°C to +4°C. 

11.3.4 The temperature of frozen pork raw material, bacon and/or gammon during storage shall be -18°C or colder, except where tempering in preparation for slicing and packing is taking place in which case a product temperature of -3°C to -8°C would be acceptable

11.3.5 Where deep chilled storage is carried out, the standard operating procedure shall clearly state the minimum and maximum storage/meat temperature, and the action to be taken if this cannot be maintained

11.3.6 All pork raw material (carcase or cuts) shall maintain identify, its assured status, kill date, and durability date throughout storage.

Guidance

The storage area may be equipped with auto door closure, air or strip curtains to minimise ingress of warm air during stock transfers.

Dependent on the process e.g. cold storage or tempering the refrigeration temperature may be set to a target temperature to allow for temperature fluctuations caused by defrost cycles, doors opening during stock transfer etc. 

Evidence

The following shall be verified:

  • Clause 10.2.1 a) records of temperature monitoring system at maximum load
  • Clause 10.2.1 b) and e) examples of temperature control records since the last audit
  • Clause 10.2.1 c) review validation procedure
  • Clause 10.2.1 d) review documented protocol aligned tor the tempering process

FSA guidance on Use By/Best Before codes

11.4 Freezing pork raw material

11.4.1 Pork raw material shall be labelled with a date of kill and it shall not exceed kill + 4 days at point of freezing.

11.4.2 The pork raw material and bacon shall be in good condition at the time of freezing and shall be effectively packaged to prevent contamination and degradation of quality. 

11.4.3 Pork raw material and bacon to be frozen shall be placed into a freezer immediately following receipt.

11.4.4 Frozen pork and bacon shall be labelled with the date of freezing and a durability date that does not exceed 12 months.

11.4.5 Where frozen product is to be defrosted (tempered), it shall be carried out to a documented and validated procedure in line with the Charter participant’s processing specification.

11.4.6 Stock control and defrost records shall be maintained.

Guidance

The integrity of the packaging shall be appropriate for the product. The site may have procedures in place for the control of stock and this shall be supported by stock control checks.

Evidence

Visual inspection of storage area to verify integrity of packaging. Verification of product labelling in storage. Review documented protocol for tempering process. Examples of stock control and temperature control records since the last audit.

11.5 Cold store operating procedures

The cold store shall have standard operating procedures in place for the control (quantity, durability and location) of stock. 

Evidence

Examples of stock control checks since the last audit. Verification of the process for the movement and stock control of product on site.

11.6 Cold store risk assessment

Charter participants shall carry out a risk assessment of the cold store to verify that the traceability systems and procedures are robust and effective for the identification, stock rotation, handling and traceability of all materials received by the cold store. 

Guidance

The labelling of pork material shall clearly indicate that the pork material is assured, and the product is traceable to point of intake at the cold store.

Evidence

Copy of risk assessment undertaken. Discussion with key site personnel to confirm the systems for the identification, traceability and segregation of assured and non-assured product.

Review sites documented procedures and their appropriateness. 

11.7 Cold store traceability system

Charter participants shall ensure that the cold store traceability system is independently monitored on a regular basis. The following points clarify the requirements:

11.7.1 These audits shall be undertaken by the Charter participant and may be an extension to the scope of the monthly traceability and mass balance checks undertaken at the participant’s site.

11.7.2 These audits shall be carried out by someone competent and independent of the cold store operation.

11.7.3 Traceability and mass balance audits of the pork material back to intake shall be undertaken in alternate months to check that the assured pork materials in the cold store comply with the requirements of the Quality Pork Charter.

11.7.4 Documentary evidence containing a summary of each traceability and mass balance check undertaken shall be made available to the service provider to demonstrate that the requirements of the Quality Pork Charter are being met.

Guidance

At the time of the announced surveillance audit, the service provider shall undertake a mass balance exercise and challenge simultaneously the robustness and effectiveness of the traceability systems and procedures at the cold store. The service provider shall record the details from a specific batch of assured material received from the cold store at the processing site, establish the size of the batch and systematically challenge the mass balance, verifying the ‘road map’ e.g. volumes despatched/received and destination.

Consideration shall be given to any remaining batches/volumes still held in stock at the cold store and whether the volumes reconcile with the original quantities despatched/received at the processing site. It is expected that the Charter participant shall have developed appropriate procedures to assist the independent auditor in undertaking the traceability exercise at the cold store. 

The verification of the traceability exercise shall include all the process steps at the cold store including associated delivery and despatch documentation. The procedure shall detail the administration that shall be used to carry out the traceability exercise and the documentation to be collated. The procedure shall detail the system for the management of non-conformances that may arise. 

Evidence

Copies of the traceability and mass balance exercises. Non-conformance reports to include root cause analysis, corrective action and monitoring.

11.8 Labelling for reception, storage & despatch

Each batch of pork to be used as a raw material for the manufacture of any BMPA Quality Assured Bacon and Gammon products shall be marked or labelled with the following as a minimum requirement on reception, storage and despatch:

  • Site identification code (health mark) – Charter participant’s site licence number
  • Product description – e.g. rindless bellies
  • Weight – The number of units may also be indicated
  • Traceability batch code – In most cases the traceability batch code is the kill date however, where a production date is used, the information shall be able to trace the product backwards to a kill date. Slaughter code may be in ‘Julian’ calendar format or the actual kill date may be shown.
  • Confirmation of assured status – The lettering BQAP may be used to confirm the products’ assured status to relate to the product within the container/box. Non-eligible material shall not be packed within the same dolav, container or box 
  • Country of birth, rearing and slaughter or statement of pigs’ origin – Where pigs are born, reared and slaughtered in one country, a single statement of origin is sufficient for the traceability declaration.
  • Date of freezing on all frozen raw material
  • Process-by or use by date – FSA guidance on Use By/Best Before codes

Guidance

The labelling requirement covers pork raw material and bacon. Whether the product is being transported in dolav, rigid container or as boxed, the labelling information shallremain attached to the unit.

Evidence

Verification of labelling or markings.