Module 4 Ham & Cooked Pork

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.

For the purposes of category 2 and 3 ham, the primary hock (shank) is the muscle that surrounds the two bones below the knee. The secondary hock (shank) runs behind the knee and is therefore above and below the knee/patella joint. If the leg is cut across the knee/patella joint to remove the hock as a single bone-in joint the secondary hock is cut in half, lower half attached to the lower leg below the knee and the upper part attached to the rest of the leg joint above the knee. See diagrams below.

Most traditional butchers’ cuts are done in this way or the secondary hock is cut so that it is included in the upper leg joint going into hams. The joint can be cured as for other ham cuts and slow cooked to enable the whole muscle to be shredded.  This muscle, with its small sinews running through it has been included in whole leg ham joints historically, however needs a little extra cooking to enable the sinews to be broken down to be soft enough to eat, if used as a single muscle and sold as such (ham hock). 

The result shall only be described as ham hock and used as a shredded/pulled product and not as a formed sliced ham product.

View the hock guide here

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.

2.1.1 All pork raw material including rind and back fat to be used in the manufacture of BMPA Quality Assured Ham and Cooked Porkshall 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 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.

2.1.3 Ham and cooked pork feedstock brought in from a different site shall be sourced from a participant of the BMPA Quality Assured Ham and Cooked Pork module and the product shall be certified against that module, refer to charter rules.

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. 

Where the site is only slicing and packing ham or cooked pork and the pre-requisites of the site being BRC GFS certified (minimum Grade B), compliant with BMPA Quality Pork Charter Rules, and that the products being packed are certified against module 4, and traceable to an approved participating site, then only the clauses contained within BMPA Quality Assured Ham and Cooked Pork module appropriate to the process being undertaken shall apply.

Evidence

Copies of suppliers’ certificates of conformity against the BMPA pork module and/or the Ham and Cooked Pork Module shall be held by the site and these shall be valid for the period under review. The certificate 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.

2.2.1 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 met for all raw pork and cooked ham/pork deliveries to the site. 

2.2.2 When placed in the transport vehicles, raw pork 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. 

2.2.3 Raw pork material and cooked ham/pork feedstock supplied to the site shall be transported on clean, well-maintained temperature-controlled vehicles that pose no risk of product contamination. Where it is relevant, the vehicle shall be temperature controlled.

2.2.4 Each consignment of raw pork material and cooked ham/pork feedstock shall be examined on arrival to ensure that it is compliant with specification, free from contamination and indications of spoilage. The BQAP assured status and traceability back to BMPA approved source shall be maintained.

Guidance

If incoming raw pork material or cooked ham/pork feedstock 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. Cooked feedstock should be in fully sealed packaging/casings and not come into contact with raw pork material.

Evidence

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

2.3.1 During transportation and on arrival at the receiving site the temperature of chilled raw pork or cooked ham/pork feedstock shallnot fall outside of the range of -2°C to +5°C. 

2.3.2 The target temperature of frozen raw pork material or cooked ham/pork feedstock 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.

It is normal practise that for cooked feedstock the “between product temperature” is checked at intake as the internal probing of product would compromise food safety.

Evidence

Examples of intake records since the last audit.

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.

2.5.1 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 raw pork and cooked ham/pork feedstock.

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

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

2.5.4 The microbiological condition of incoming cooked ham/pork feedstock shall meet the microbiological standards set out in clause 11 of this module.

2.5.5 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 (including those transferred between sites of the same company) and the volume of material and the range of cuts being processed. 

Evidence

Review the following:

• 2.5.1 Testing schedule. 
• 2.5.2 Copy of risk assessment. 
• 2.5.3 Examples of microbiological reports since the last audit.
• 2.5.4 Check micro standards for compliance with clause 11
• 2.5.5 Trend analysis and where applicable root cause and corrective action reports. 

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

3.1.2 The temperature of the chilled raw pork material and cooked ham/pork feedstock during storage shall be between -2°C to +5°C. 

3.1.3 The temperature of frozen raw pork material or cooked ham/pork during storage shall be -18°C or colder.

3.1.4 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.

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.

Shelf life challenges at -8°C are recommended

Evidence

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

3.2.1 Pork raw material shall be processed within kill+4 days, however if the raw material is held in chill rooms which are not disturbed, and the pork raw material is not intended to be used in a meat preparation, 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 may be permitted

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 2.5.3.

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.

3.3.1 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. 

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

Guidance

FSA guidance on Use By/Best Before coding + guidance on date coding associated with C Bot control.

Evidence

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

4.1.1 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 cooked ham or pork product type being manufactured. Relevant staff shall be trained against these.

4.1.2 The in-house ‘mini specification’ shall be developed in line with the QAS specified in clause 9.2 and provide through the use of words, measurements and/or photographs, specific quality attributes that clearly define acceptable and unacceptable key attributes for each finished product approved by the BMPA Quality Assured Ham and Cooked Pork module. 

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

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

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

Guidance

A range of methods may be used including injection, (cured or uncured) dry-curing, injection curing followed by immersion, injection curing followed by bag-maturing, massaging, tumbling etc. However, certain process methods may only relate to specific types of cooked ham/pork and these distinctions shall be observed.

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

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 specification displayed corresponds to the product going down the packing line at the time of the audit.

Butchery and trimming of raw pork cuts and primals shall be performed with minimum damage to the lean and fatty tissues.

Specifications shall be held that cover the butchery standards required for all raw pork materials intended to be used for BMPA Quality Assured Cooked Ham/Pork, as follows:

• Pork legs shall be separated from the side at a point not exceeding 150 mm from the anterior edge of the head of the femur
• The fore-end shall e 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.
• The back and belly shall be separated by a cut parallel to the dorsal edge of the middle, the location of the cut dependent on the width of the back required.

Evidence

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

4.3.1 The charter participant shall have standard operating procedures, work instructions, and records in place to ensure the effective thawing of frozen raw pork material before curing or injection. This shall include the monitoring of product temperature during the thawing process.

4.3.2 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

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

Evidence

Visual examination of product.

5.1.1 The composition of curing brines and non-injection solutions shall comply with standard operating procedures, specifications and brine/injection solution make-up recipes supported by chemical analysis and batch processing records. 

5.1.2 All curing brines and non-cure solutions, whether intended for injection or cover, shall be positive released for use based on the salt content (as documented within the process specification, and temperature (Injection curing brines shall not exceed 7°C and non-cure solutions/cover brines shall not exceed 5°C). 

5.1.3 Where non-conformance occurs, 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 ham and cooked pork. 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/non-cure solutions and where applicable corrective action reports since the last audit. 

Only certain ingredients shall be used in the production of BMPA Quality Assured Ham and Cooked Pork, as given below.

5.2.1 For BMPA Quality Assured Ham the permitted ingredients are:

• Salts: Sea salt and/or vacuum salt shall be used in the form of sodium chloride (NaCl), and/or sodium chloride substitutes such as potassium chloride (KCl) and magnesium chloride (MgCl₂) which may be used at up to 50% of the NaCl content subject to shelf life validation.
• Preservatives: Nitrates and nitrites shall be used in the form of sodium nitrate (NaNO₃) E251, potassium nitrate (KNO₃) E252, sodium nitrite (NaNO₂) E250 and potassium nitrite (KNO₂) E249 to cure products
• Lactates: Sodium/potassium lactate
• Nitrite replacements can used: 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.

5.2.2 For BMPA Quality Assured Ham the use of the following ingredients shall only be used in the specific product categories: Ham with no added water, ham with added water and dry cured ham.

• Antioxidants: L-ascorbic acid E300), sodium-L-ascorbate (E301), D-ascorbic acid (erythorbic acid) (E315), sodium-D-ascorbate (sodium erythorbate) (E316) may be used.
• Phosphates: sodium and potassium phosphates and polyphosphates (E450, E451, E452) may be used. The added phosphate content of the cooked product shall not exceed 0.3% (expressed as P₂ 0₅).

5.2.3 For BMPA Quality Assured Cooked Pork the permitted ingredients are:

• Antioxidants: L-ascorbic acid E300), sodium-L-ascorbate (E301), D-ascorbic acid (erythorbic acid) (E315), sodium-D-ascorbate (sodium erythorbate) (E316) may be used.
• Phosphates: sodium and potassium phosphates and polyphosphates (E450, E451, E452) may be used at a quantity that doesnot exceed 0.3% of the cooked product.
• Lactates: sodium / potassium lactate

Guidance

Usage 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 are specified on a product by product basis and takes into account product type and process)

Specifications shall be available. This shall be supported by appropriate in-house mini-specifications. Reference may be made to the corresponding regulations.

Evidence

Specifications shall be available, and these shall be relevant to the category of product being produced. These may be supported by appropriate in-house specifications/recipes. Copies of current specifications/recipes.

Ingredients that shall not be permitted in any product category of BMPA Quality Assured Ham or Cooked Pork:

• Meat proteins, in any form, other than those naturally present in the raw pork material used to prepare the product. This includes such materials as meat bouillon*, dried meat, rind*, pork gelatine*, blood, blood derivatives and connective tissue in any form
• Mechanically separated meat (MSM)
• Starches and other polysaccharides. These ingredients may only be used for decorative/garnish purposes
• Non-meat proteins, hydrolysed vegetable proteins and yeast extracts
• Monosodium glutamate (MSG) and other flavour enhancers such as sodium inosinate and sodium guanylate
• Smoked flavours, flavourings and extract
• Colourings. These ingredients may only be used for decorative/garnish purposes

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

6.1.2 The product temperature during preparation process may be 0°C to +5°C. If this is exceeded it shall not exceed +8°C and shall return to <5°C within 4 hours.

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

6.1.4 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. 

6.1.5 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’. 

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

Guidance

Appropriate recipes and work instructions shall be in place and 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 temperature was still at higher than 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 record keeping where corrective action was undertaken. 

6.2.1 The raw pork material being cured shall be in the form of either whole bone-in legs, legs which have been partly or completely boned, or individual leg muscles which are subsequently reassembled before cooking.

6.2.2 Curing shall be carried out by using dry ingredients. Permitted additives (caramelised syrups, honey, purees and sauces) may be added after the dry cure application. 

6.2.3 The pork muscles, if cured individually or in groups, shall be restricted to the following major muscles- topside, silverside, thick flank, chump or muscles from the oyster region (but excluding the primary hock) of the leg. Single or mixtures of all five muscle types may be used to form the ham. 

6.2.4 The curing mixture shall be applied dry to all accessible surfaces of the meat.

6.2.5 Dry-cured ham may be cured in a variety of ways but only using only those ingredients listed in clause 5.2.1 and 5.2.2.

6.2.6 Whole boneless legs or individual muscles may be massaged or tumbled during the curing process, but this shall not cause significant breakdown of the pork.

Evidence

Documented procedures, work instructions, recipes and in- house specifications for the operation and management of the process. Examples of production records since the last audit Visual inspection of product to verify adherence to specification.

6.3.1 Pork Legs intended for Wiltshire curing shall be either cured on the side, part-side, or as individually butchered legs or associated muscles. 

6.3.2 Ham Hock (comprising of primary and/or secondary shank as defined within Appendix 1) shall be slow cooked to breakdown the gristles and sinews associated with these cuts. 

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

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

6.3.5 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 & temperature), and 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.

6.3.6 A starter culture shall only be used in the conception of the fresh immature live cover brine. At conception, the brine shall be regularly aerated and checked to ensure that the starter culture is active and that the condition of the brine is developing. To facilitate development the immature live cover brine 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 Ham and Cooked Pork. 

6.3.7 Over time the volume of live cover brine will deplete so occasional “top-up” using a freshly prepared brine incorporating a starter culture may occur. The mother brine to which the “top-up” brine has been added can continue to be used on the condition that the “top up” brine shall not exceed 25% of the mother batch of live cover brine. 

6.3.8 Live cover brines not in regular use shall be regularly aerated and condition monitored to maintain its condition. 

6.3.9 A recorded log of cover brine history, top-ups, and adjustment shall be maintained to demonstrate composition and provenance.

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

6.3.11 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 96 hours (4days) and to a clearly specified maximum time that shall be validated using shelf life and food safety.

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 must 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 6.3 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 Ham and Ham Hock, should be clearly described as “Wiltshire-Style” (or similar) within the legal name of the product. Such products, depending on the final water content of the finished product would either fall with the definition of a Category 3: Ham with No Added Water (see Clause 6.4) or Category 4: Ham with Added Water (see Clause 6.5).

The function of the starter culture is to ensure that the right microbiological flora is present in order 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 of a count greater than 10⁶ and 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, except for occasional top-up as explained below. 

There will be occasions when existing cover brines will need to be replenished by the addition of a top-up cover brine normally created by using a starter culture – this should be an occasional practice rather than routine.

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 take 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. 

Temperature-control plays a vital part in the production of cured pork. In most of the curing systems used commercially the operations are performed at +2°C to +5°C.

Wiltshire-cured legs are frequently stored in an unprotected form. Excess surface brine drains off (the use of hooks, racks, or slatted trays/dolavs are acceptable if free drainage can be demonstrated) and the lean and fat become firmer in texture and noticeably drier. These changes are concerned with 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

6.4.1 Curing may be carried out on either whole bone-in or boneless leg, or on selected leg cuts/muscles (see clause 6.4.2.

6.4.2 The pork cuts/muscles if cured individually or in selected groups shall i be obtained from the major leg muscles; topside, silverside, thick flank and/or secondary hock. 

6.4.3 Individual cuts/muscles may be separated for subsequent reassembling. 

6.4.4 Ham with no added water may be cured in a variety of ways but is restricted to only using those ingredients listed in clause 5.2.1 and 5.2.2.

6.4.5 Whole legs or their associated cuts/muscles may be massaged or tumbled during the curing process, but this process shall not cause significant breakdown of individual muscles.

6.4.6 The ham may be dressed with added sheets of rind and/or back fat. and be cooked in tight netting, casings or presses to ensure adequate adhesion. 

Evidence

Documented procedures, work instructions, recipes and in- house specifications for the operation and management of the process.Examples of production records since the last audit Visual inspection of the process.

6.5.1 Curing may be carried out on either whole bone-in or boneless legs, or on selected leg cuts/muscles (see clause 6.4.2.

6.5.2 The pork cuts/muscles if cured individually or in selected groups shall be obtained from the major leg muscles; topside, silverside, thick flank and/or secondary hock. 

6.5.3 Individual cuts/muscles may be separated for subsequent reassembling.

6.5.4 Whole legs or their associated cuts/muscles may be massaged or tumbled during the curing process, but this process shall not cause significant breakdown of individual muscles.

6.5.5 Ham with no added water may be cured in a variety of ways but restricted to only using those ingredients listed in clause 5.2.1 and 5.2.2.

6.5.6 The ham may be dressed with added sheets of rind and/or back fat. and be cooked in tight netting, casings or presses to ensure adequate adhesion. 

Evidence

Documented procedures, work instructions, recipes and in-house specifications for the operation and management of the process. Examples of production records since the last audit Visual inspection of the process. Verification by analysis is covered under clause 9.2.

6.6.1 Any pork cuts may be used.

6.6.2 Individual muscles may be separated before processing for subsequent reassembly. 

6.6.3 Cooked pork may be processed in a variety of ways but shall only use those ingredients listed in clause 6.1.4.

6.6.4 Individual muscles may be massaged or tumbled but this shall not cause significant breakdown of individual muscles.

6.6.5 The pork may be dressed with added sheets of rind and/or back fat. and be cooked in tight netting, casings or presses to ensure adequate adhesion. 

6.6.6 Injection solutions may be used but the cooking process shall be sufficient to ensure that no added water remains in the finished product.

Evidence

Documented procedures, work instructions, recipes and in- house specifications for the operation and management of the process.Examples of production records since the last audit Visual inspection of the process. Verification by quality assessment is covered under clause 9.2.1.

6.7.1 All requirements as stated in Category 5 shall be met (see clause 6.6).

6.7.2 In addition, injection solutions may be used but cooking yields shall ensure that the maximum added water retained in the finished product does not exceed 20%.

Evidence

Documented procedures, work instructions, recipes and in- house specifications for the operation and management of the process.Examples of production records & yields. Visual inspection of the process. Verification by analysis is covered under clause 10.

7.1.1 There shall be standard operating procedures, work instructions and process records in place for the handling of product prior to cooking.

7.1.2 Product not cooked immediately shall be held in chilled storage at -2°C to +2 °C or deep chilled. 

7.1.3 Where precooked storage is carried out, the process shall be subjected to shelf-life verification under worst case conditions that includes sensory evaluation and microbiological quality of the finished product.

7.1.4 Product to be deep chilled shall be suitably packaged, date marked, and carry sufficient information to allow traceability. 

Guidance

The storage facilities shall be capable of maintaining the temperature within specification. Monitoring of temperatures shall be undertaken and details recorded.

The packaging shall be appropriate for its intended purpose.

Evidence

Examples of temperature monitoring records. Validation of shelf-life data where product is stored precooked or deep chill.

Visual inspection to verify the integrity of the packaging, date coding and traceability information on the product.

7.2.1 Detailed standard operating procedures, work instructions and process records shall be maintained and documented for the cooking process. 

7.2.2 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. 

7.2.3 Different types of cooking systems may be used, but these shall comply with the process validation and verification requirements specified within the site’s HACCP plan.

Guidance

It is recognised that there shall be a range of different types of cooking systems e.g. traditional cooking chamber, travelling ovens or cooking by micro wave. 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 shall influence the rate at which micro-organisms are killed during the cooking and how many survive this process including the time/temperature relationship, the concentration of salt and of curing salts where relevant) in the product and the initial microbial load on the product when cooked.

Cooking profiles shall be in place to demonstrate the controls necessary for product safety. The initial microbial load on the uncooked product 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 product was determined and shall be available for evaluation. 

Evidence

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

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

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

Guidance

During the development of the cooking profiles and the capabilities of the cooker being used, the profiles developed shall have considered the potential temperature ranges within the cooker (hot and cold spots). 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.

Evidence

Review cooking profiles and examples of cooking records since the last audit.

7.4.1 Where product is 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 procedures and work instruction and cross-reference to the sites HACCP plan.

7.4.2 Cooked product shall be stored at between -2°C and +5°C.

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

Guidance

Records of core temperature measurements taken as part of clause 7.4.1 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).

The traceability of the cooking process and each batch of cooked product shall be supported by accurate record keeping including traceability of product.

Evidence

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

Cooking and temperature control records covering the period since the last audit.

7.5.1 Detailed standard operating procedures, work instructions and process records shall be maintained.

7.5.2 Where cooking is followed by a period of roasting, the roasting phase shall be carried out before the surface temperature of the product falls below +60°C. Failing this, the product shall be cooled to less than +5°C prior to the roasting operation taking place. 

7.5.3 Where product is smoked, garnished, glazed or crumbed, this shall be carried out in a way that does not compromise the safety of the product. 

Guidance

The process shall ensure that food safety and/or quality is not compromised. The storage facilities shall be capable of cooling the product within specification. Appropriate record keeping shall be maintained. See FSA guidance on the definition of roasting.

Evidence

Production and temperature control records. Visual inspection of process and align to requirements laid down in procedures and workinstructions. Examples of processing records since the last audit.

7.6.1 Detailed standard operating procedures, work instructions and process records shall be maintained and documented for the cooling process. The procedures shall detail the time/temperature requirements and cross reference to the sites HACCP plan.

7.6.2 Cooked product shall be cooled rapidly after cooking to ensure that the safety of the product is not compromised. 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.

7.6.3 Product which has been cooked without cover shall be cooled in chilled air.

7.6.4 Product cooked in sealed containers/ casings/ bags may be cooled in chilled air or by a combination of cold water spraying followed by chilled air or brine and may be held in these containers until required for further processing or packing.

Guidance

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

Evidence

Review procedures, work instructions and cooling process records.

7.7.1 For smoked ham and cooked pork, only natural wood smoke shall be used in the smoking process. Synthetic smoke mixtures and extracts of wood smoke shall not be used.

7.7.2 Care shall be taken to ensure that the product is uniformly smoked in compliance to the process specification (time and temperature of smoking) and quality attribute specification (colour and taste) and free from tar contamination.

Guidance

A variety of wood types can be used (oak, beech, Applewood etc) – scented/resinous woods are to be avoided due to their tendency to tar. 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

Copy of current wood specifications and review examples of completed processing records. Visual inspection of smoke chamber. Review process specification, QAS and examples of quality control records.

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

7.8.2 Product shall be chilled between 0°C to +5°C and stored at this temperature.

7.8.3 Subsequent processing operations shall be performed with no detriment to the product

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

7.8.5 All finished chilled product shall be held at a temperature no higher than +5°C, before despatch.

Guidance

To avoid any potential rise in the product temperature during handling, the volume of product being processed at any one time shall be closely aligned to the number of production staff and production plans. The temperature of the environment and product shall be monitored throughout the process. 

Evidence

Product temperature records that cover the period since the last audit. Visual inspection of product to verify butchery operations. Visual inspection of finished product containing exposed bone. Examples of temperature control records (air and product) since the last audit. 

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 outer case and/or retail pack

8.2.1 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.

8.2.2 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. 

8.2.3 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. 

8.2.4 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’.

8.2.5 Documentary evidence containing a summary of each traceability and mass balance exercise shall be maintained to demonstrate that the requirements of the pork charter are being met.

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

8.2.7 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:

Month	Scope	Basis
April	BRC 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)
May	BMPA backward trace to raw material intake	On BMPA quality assured product
June	BMPA forward trace from raw material intake to finished product	*On non-eligible product
July	BMPA forward mass balance from raw material intake to finished product	On BMPA quality assured product (incorporating a forward trace from raw material intake to finished product)
August	BMPA backward trace to raw material intake	On BMPA quality assured product
September	BMPA forward trace from raw material intake to finished product	*On non-eligible product
October	BRC 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)
November	BMPA backwards trace to raw material intake	On BMPA quality assured product
December	BMPA forward trace from raw material intake to finished product	*On non-eligible product
January	BMPA forward mass balance from raw material intake to finished product	On BMPA quality assured product (incorporating a forward trace from raw material intake to finished product)
February	BMPA backward trace to raw material intake	On BMPA quality assured product
March	BMPA forward trace from raw material intake to finished product	*On non-eligible product

Evidence

• Clauses 8.2.1, 8.2.2 and 8.2.5 Review traceability and mass balance reports since the last audit. 
• Clause 8.2.3 review sampling plan. 
• Clause 8.2.4 verify independency and competency of the auditor undertaking the traceability and mass balance checks.
• Clause 8.2.6 Where non-conformance has been raised by the independent auditor review evidence of root cause analysis, corrective action and monitoring.
• Clause 8.2.7 Copy of risk assessment.

9.1.1 The following general standards shall apply to all BMPA Quality Assured Ham and Cooked Pork products:

• The surface of the product shall be clean and free from extraneous matter including tar.
• Rind, if present shall be free hair, stubble and bruising.
• The fat shall be firm and white and no evidence of bruising, separation, softness, or discolouration.
• The lean shall be free of bruising and bone fragments with minimal blood spots. 
• The flavour of the product shall be free from off flavours.
• The texture of the product shall be firm but not tough and not give any evidence of excessive moisture in the tissues. 
• The product shall be free as reasonably possible of gristle and tough connective tissue.
• For bone-in product, all bone shall be splinter free. 
• All garnishes and glazes including added strips of fat and rind shall adhere to the surface of the product.
• The amount of internal fat shall be specified within the QAS and not exceed 20mm in diameter.
• Holes are usually a natural part of the process however, tolerances for these cavities shall be documented in relevant process documentation.

9.1.2 Permitted subcutaneous fat levels (with or without rind) for BMPA Quality Assured Ham are:

Category 4 ham may contain visible fat particles but not exceeding 5mm in diameter. The analytical fat content shall not exceed 7.5%.

9.1.3 Permitted subcutaneous fat levels (with or without rind) for BMPA Quality Assured Pork are:

Evidence

Visual inspection of product and align to QAS. Examples of analysis reports since the last audit.

9.2.1 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 Quality Assured Ham and Cooked Pork module.

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

Guidance

Where unnecessary cuts have occurred, there is the potential that after cooking and subsequent slicing the structure of the cooked product may disintegrate. 

Evidence

Reviewexamples offormally agreed QAS and that these are aligned to the approved products listed on the certificate of conformity. Review the ‘mini specification’ and verify that the quality attributes are aligned to those detailed in the BMPA Quality Assured Ham and Cooked Pork module. Visual inspection of finished product standards. Review examples of records of QAS verification checks since the last audit. 

9.3.1 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.

9.3.2 An organoleptic sampling schedule shall be established for finished product certified by the BMPA Quality Assured Pork module at an appropriate frequency and as a minimum once per week to demonstrate compliance against the documented QAS. The product assessment shall include tenderness, succulence, flavour and visual appearance.

9.3.3 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.

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

10.1.2 Added water, meat, salt and for cured products – nitrite content shall be tested analytically at least once per month against the following meat/added water limits and the salt/nitrite limits specified by product type in section 10.1 of this module:

10.1.3 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 results occur, 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.

Salt content (sodium chloride) shall be limited to the following levels:

10.2.1 For BMPA Quality Assured Ham the salt content shall average no greater than 1.63%. Traditional hams in categories 1 and 2 are exempt from the FSA salt targets.

10.2.2 For BMPA Quality Assured Cooked Pork the salt content shall average 0.68 % in line with the FSA guidelines

10.2.3 Where the product is produced and labelled as reduced salt or lower salt or contains added ingredients mustard, honey, syrups, glazes, sauces and purees, the salt level may fall below the above targets provided there is satisfactory validation to support shelf-life and food safety.

For BMPA Quality Assured Cooked Hams 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.

Added phosphates/polyphosphates shall be limited to the following levels:

10.4.1 For BMPA Quality Assured Ham, categories 1, 3 & 4 shall be limited to 0.3% max. For category 2, none is permitted.

10.4.2 For BMPA Quality Assured Cooked Pork, categories 5 &6 shall be limited to 0.3% max.

11.1.1 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 Ham and Cooked Pork certificate of conformity. 

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

Guidance

It is important that the sampling plan covers the scope of approved products listed on the Certificate of Conformity.

ACC counts in excess of 1 x 10⁴ cfu/g may result in further investigation for example, Listeria monocytogenes.

Enterobacteriaceae counts in excess of 10² may result in further Investigation for e.g. Salmonella spp/E.coli.

Evidence

Records shall cover the period since the last audit. Although the accreditation element shall have been covered under the core requirement, the site shall retain a copy of the laboratory’s accreditation and the scope of the tests of the certification. Sampling schedules 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.

Product shall be tested weekly to demonstrate compliance with the following start of life microbiological targets:

Product shall be tested weekly to demonstrate compliance with the following start of life microbiological targets:

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

12.1.2 During transport, pork raw material, ham and cooked pork shall be covered in clean, intact containers, cartons or trays that pose no risk of contamination to the contents. 

12.1.3 Pork raw material, ham and cooked pork shall be transported on clean, well-maintained temperature-controlled vehicles that pose no risk of product contamination. 

12.1.4 Each consignment of pork raw material and ham and cooked pork 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 clause 12.1.1. 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. 

12.2.1 The doors of the delivery vehicle shall remain closed to the point when the product temperature is being checked.

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

12.2.3 The target temperature of frozen pork raw material shall be -18°C or less during transport and shall not exceed -12°C at intake. 

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.

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

12.3.2 The temperature of chilled pork raw material, ham and cooked pork during storage shall be -2°C to +5°C. 

12.3.3 The temperature of frozen pork raw material, ham and cooked pork during storage shall be -18°C or colder. 

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

12.3.5 All pork raw material 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 12.3.1 and 12.3.2 records of temperature monitoring system at maximum load
• Clause 12.3.3 and 12.3.5 examples of temperature control records since the last audit
• Clause 12.3.4 review documented protocol aligned tor the tempering process

12.4.1 Pork raw material shall not exceed kill+4 days at point of freezing. 

12.4.2 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. 

12.4.3 Pork raw material to be frozen shall be placed into a freezer immediately following receipt.

12.4.4 Frozen pork raw material shall be labelled with a date of kill (where applicable); freezing durability date and it shall not be stored for longer than 12 months.

12.4.5 Where frozen pork raw material is to be defrosted (tempered), this shall be in line with the charter participant’s specification. The tempering process shall be to a documented and validated protocol.

12.4.6 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.

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.

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. 

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

12.7.1 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.

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

12.7.3 Traceability and mass balance audits of the raw material back to intake shall be undertaken in alternate months to check that the materials in the cold store comply with the requirements of the pork charter. 

12.7.4 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 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.

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

• Site identification code (health mark)
• Product description – e.g. rindless bellies
• Weight – The number of units may also be indicated
• Traceability batch code – In the majority of 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 – use by is optional
• Kill date (where applicable)

Guidance

The labelling requirement covers pork raw material, ham and cooked pork for further processing. Whether the material is being transported in dolav, rigid container or as boxed, the labelling information shallremain attached to the unit.

Evidence

Verification of labelling or markings.