Poultry and rabbit meat refrigeration, chilling, and freezing procedures

On this page

• 1.0 Introduction
• 2.0 Definitions (for chilling standards)
• 3.0 Chilling time and temperature standards
  • 3.1 Dressed poultry carcasses
  • 3.2 Giblets, carcass parts and salvaged portions
  • 3.3 Air chilling time standards
  • 3.4 Alternate chilling procedures
  • 3.5 Delayed evisceration time before chilling
  • 3.6 Corrective actions when there is failure of chilling standards
• 4.0 Chilling methods
• 5.0 Water chilling, water thawing and water rehydration
  • 5.1 Chilling in tanks
  • 5.2 Make-up water for water immersion chillers and combination chillers (using both water chilling and air chilling)
  • 5.3 Salt addition to water or ice
  • 5.4 Thawing poultry in water
  • 5.5 Water immersion of poultry carcasses and parts for rehydration
• 6.0 Air chilling
  • 6.1 Labeling and advertising claims standard for air chilling
• 7.0 Freezing
  • 7.1 Crust freezing "surface freezing"
  • 7.2 Liquid freezing
• 8.0 Refrigeration of rabbit meat products
• 9.0 Assisting CFIA with verification activities

1.0 Introduction

The licence holder's Preventive Control Plan (PCP) must include measures to demonstrate how their product meets the Safe Food for Canadians Regulations (SFCR) section 89(1)(a); is not misleading section 89(1)(b) and Canadian Standards of Identity, Volume 7 – Meat Products, Section 20.

Refrigeration allows removal of body heat from pre-chill carcass temperature (approximately 37°C - 39°C) to 4°C or less. The primary purpose of refrigeration is to preserve meat products by slowing down the chemical and enzymatic changes which occur in tissues after slaughter and by slowing down or stopping the multiplication of microorganisms which might give rise to spoilage or food safety concerns. As a general rule, refrigeration of carcasses and parts must begin promptly after the end of carcass dressing and product must be chilled as quickly as possible.

Freezing keeps food safe by slowing the movement of molecules, causing microbes to enter a dormant stage. Freezing preserves food for extended periods because it prevents the growth of microorganisms that cause both food spoilage and foodborne illness. Freezing inactivates microbes (bacteria, yeasts, and molds) present in food. Once thawed, however, these microbes can again become active, multiplying under the right conditions to levels that can lead to foodborne illness. Since they will then grow at about the same rate as microorganisms on fresh food, the licence holder must handle thawed poultry and rabbit meat as you would any perishable food.

2.0 Definitions (for chilling standards)

Refrigeration

Refrigeration means keeping the poultry carcass and parts at a temperature of 4°C (40°F) or less, without being frozen.

Chilling

Chilling means process of lowering the temperature (cooling) of poultry carcass and parts. Poultry establishments may use water, air, combination of water and air, ice, liquid etc. for chilling.

Freezing

Freezing means reducing the temperature of food below the freezing point so that most of the water contained in the food turns into ice. The freezing point depends upon the concentration of different solutes in the tissue fluids.

Freezing point for water is 0°C or below.

Freezing point of poultry is -2°C or below.

Frozen poultry is stored at - 18 °C (0 °F) or less.

Crust freezing "surface freezing"

The crust freezing "surface freezing" is temporary freezing of a thin outer layer of skin and muscle. The surface freezing may completely surround the bird but may not be deeper than 4 mm. Surface freezing must be easily broken with slight pressure.

Normally, surface freezing may occurs during holding and transportation. Crust freezing may be used by poultry establishments for holding poultry provided it does not compromise food safety and product meets all regulatory requirements at all times.

When the surface freezing is deeper than 4 mm and freezing cannot be easily broken with slight pressure the product must be considered to have been frozen and labelled accordingly.

Carcass parts

Refers to edible poultry parts from dressed carcasses, for example, trimmed breasts, breasts, drumsticks, thighs, legs, wings, wing drumettes, winglets, backs, stripped backs, necks (including detached necks), halves, front quarters, hindquarters, breast fillets etc.

Salvaged portions

Refers to edible poultry harvested as part of salvaging operations, for example wings, wing drumettes, breasts (with skin and/or skinless), breast fillets, legs, drumsticks, thighs, wings etc.

Giblets

Refers to edible poultry livers, hearts and gizzards prepared as per Dressing procedures and preparation of edible parts.

3.0 Chilling time and temperature standards

The rate of temperature decline will depend upon factors such as size of the bird, chilling method, amount of insulating fat, refrigeration facility, time of contact with chilling agent and amount of poultry product moving through the chilling system.

3.1 Dressed poultry carcasses

Immediately following evisceration and washing, all dressed poultry carcasses (other an air chilled) must be continuously chilled according to the following table:

Note:

• As continuous chilling process has several steps, the license holder must ensure that chilling method does not contribute to increase in temperature limits allowed for each weight category in the water-chill standards table.
• The water chilling process may be momentarily interrupted provided:
  • the interruption of chilling for each step must not result in temperature increase of the carcasses (temperature may plateau)
  • must not lead to any food safety hazards

3.2 Giblets, carcass parts and salvaged portions

Immediately following evisceration and washing, all giblets, dressed poultry parts and salvaged portions (other than air chilled) must be continuously chilled according to the following table:

3.3 Air chilling time standards

Unlike water chilling, there are no time requirements to meet the internal temperature of 4°C or lower as long as the chilling process is continuous and air chill room temperature is maintained at 4°C or lower. This is because the pathogens would be confined to surface and due to absence of water; the pathogens are not expected to permeate into the meat.

The time to air chill for carcasses, giblets, carcass parts and salvaged portions should be parts of the licence holder's PCP, must be validated for each poultry product and must not lead to any food safety hazards.

The air chilling process may be momentarily interrupted provided:

• the product must have reached 10°C or less
• the interruption of chilling for each step must not result in temperature increase of the carcasses (temperature may plateau)
• the chilling protocol be validated and must not lead to any food safety hazards

3.4 Alternate chilling procedures

An alternate procedure may be implemented provided the chilling process is validated according to licence holder's PCP which has been examined by the veterinary inspector.

Following are alternate chilling procedures which have been previously validated by the licence holders:

1. Alternative times for chilling poultry carcasses, giblets, carcass parts, and salvage portions thereof to 4°C or lower.
2. Packaging of poultry carcasses, giblets, carcass parts, and salvage portions before an internal temperature of 4°C is reached.
3. Shipping of carcasses before reaching 4°C. Licence holder may ship poultry, prior to being chilled to an internal temperature of 4°C to another establishment provided that:
   • both sending and receiving establishment operate under a PCP which includes the chilling of poultry product and does not lead to any food safety hazards
   • the chilling process is continuous (including during transport) and achieves a deep muscle internal temperature of 4°C within chilling standards table
   • product is not shipped prior to achieving a surface temperature of 7°C or lower
   • the chilling process results in chilled product which complies with the Poultry Pathogen Reduction Program requirements

3.5 Delayed evisceration time before chilling

When there is stoppage of evisceration (for example due to breakdown of evisceration line), the maximum time allowed for delayed evisceration will be 30 minutes.

If the delayed time is greater than 30 minutes, the licence holder will need to validate the food safety and suitability of the product.

Note:

• The licence holder can validate alternate delayed evisceration time (other than 30 minutes).
• The delayed evisceration time must be incorporated into total chilling time for the affected product.
• The delayed evisceration should not lead to food safety hazard.

3.6 Corrective actions when there is failure of chilling standards

When there is failure of chilling standards, the licence holder must notify local CFIA. The licence holder must assess both chilling process for failure and affected product for food safety.

1. Chilling Process:

   When there is deviation of the chilling standards, the licence holder must immediately implement corrective action(s) to bring process under control.

2. Chilled Product:

   The affected product not meeting licence holder's chilling standard as written in the PCP will be handled as below:

   • the product must continue the chilling process and may be cooked or kept fresh
   • if product will be kept fresh, the shelf life/best before date must be re-evaluated and labelled accordingly
   • if the violation results in spoilage of the product then licence holder must dispose spoiled product of as inedible product and must notify local CFIA

4.0 Chilling methods

The poultry establishments may use single or multiple methods to chill poultry products.

The most common methods used in poultry establishments are:

• water chilling (with or without ice)
• air chilling
• combo chilling (combination of water and air)

Water Retention – When water (including ice) is used for chilling and comes in contact with carcasses, carcass parts and giblets during chilling process, the water retention must be assessed. In such case the water retention standards will apply as written in "Retained Water Control Programs" and published as Canadian Standards of Identity, Volume 7 – Meat Products, Section 20.

5.0 Water chilling, water thawing and water rehydration

5.1 Chilling in tanks

Where conventional tank chilling is used, care must be taken to ensure that:

• sufficient overflow of water is provided to ensure the removal of extraneous matter prior to final icing
• poultry products are not kept in the chilling water for more than 24 hours (if kept in tanks for more than 24 hours, continuous drainage is required)

5.2 Make-up water for water immersion chillers and combination chillers (using both water chilling and air chilling)

Continuous water chilling systems are to be provided with a flow-meter, to measure total water used.

Water used in the inside/outside carcass washer may be credited as part of the preceding water volumes provided that a flow-meter, to measure total, and a pressure gauge, is installed on the inside/outside carcass washer.

Note: licensed holder will follow manufacturer recommendations to determine make-up water and use clean water for chilling.

In absence of manufacturers recommendations, following parameters have been historically acceptable for replacement water for water immersion and combination chillers.

• Water immersion chillers

  The volume of the initial potable water and ice in the chilling system, plus subsequent amounts added, may equate to not less than:

  • 2L per carcass weighing up to 2.5 kg
  • 2.75L per carcass weighing > 2.5 kg - 6.5 kg
  • 3.5L per carcass weighing > 6.5 kg
• Combo chillers using water chilling and air chilling

  The volume of the initial potable water and ice in the chilling system, plus subsequent amounts added, may equate to not less than:

  • 0.5 L per carcass

5.3 Salt addition to water or ice

The licence holder may add common salt to the ice or chill water, provided this is declared on the label of the finished product.

The immediate container or package for carcasses, parts or portions so chilled must bear the statement: "Turkeys (chicken, etc.) chilled in ice with salt added" or words of similar meaning.

5.4 Thawing poultry in water

The thawing procedures must

• prevent the product from becoming adulterated by the absorption of water
• prevent net gain in weight over the frozen weight, when poultry products are thawed for repackaging

When ready-to-cook poultry may be thawed in water by one of the following methods:

• using continuous running tap water of sufficient volume and for such limited time as is necessary for thawing. The thawing medium must not exceed a temperature of 21°C
• in re-circulated water, maintained at a temperature not in excess of 10°C, for such limited time as is necessary for thawing
• by placing frozen ready-to-cook poultry into cooking kettles, without prior thawing. This will be permitted when a representative sample of the entire lot has been thawed and found to be sound and unadulterated

Thawed poultry may be held in tanks of crushed ice with continuous drainage, pending further processing or packaging.

5.5 Water immersion of poultry carcasses and parts for rehydration

Licence holder's chilling system may be used for immersing previously chilled poultry carcasses, for example, to rehydrate or restore bloom or to "soften-up" ice packed carcasses prior to cut-up, provided that:

• the water temperature does not exceed 4°C
• the average water retention up does not exceed 2% and this is confirmed by tests conducted by plant personnel for each lot
• the tank is drained and cleaned prior to use for re-hydration
• carcasses are not immersed with or after current production
• the immersion process does not lead to food safety hazards

The above standards will also apply when tanks or vats containing non-agitated water are used for water immersion.

6.0 Air chilling

"Air Chilled" is commonly used to describe carcasses, giblets, carcass parts and salvaged portions which have been chilled predominantly with cold air.

Water sprays or misting devices may be used during air chilling processes to prevent skin dehydration.

The carcasses may be air chilled in chillers/coolers, by hanging carcasses on racks in coolers etc.

The giblets, carcass parts and salvaged portions may be air chilled using similar methods as used for carcasses. These can be individually chilled or chilled together in a group such as in lugs, totes etc.

Note: when water, air with water sprayers etc. is used for chilling the carcasses and parts, the poultry will be subject to "Poultry Retained Water Control Program" and water retention standards as listed in Canadian Standards of Identity, Volume 7 – Meat Products, Section 20.

6.1 Labeling and advertising claims standard for air chilling

Licence holders of slaughtering and processing establishments wishing to label poultry products with the term "air chilled" or "no water added" must have a written PCP procedure which has been examined by the veterinarian with supervisory authority.

The PCP procedure must assure that only eligible product is labelled with the claim "air chilled" or similar phrases.

Use of the term "air chilled" or similar phrases must be restricted to carcasses or portions when:

• chilled predominantly by means of cold air with/without water sprays or mists which apply the minimum water necessary so as to prevent excessive dehydration of the skin
• individually frozen or crust frozen by means of nitrogen or carbon dioxide gas
• licence holder can demonstrate through a written PCP program and validation data that there is no net increase in the weight of the carcasses as a result of post evisceration washing, chilling and drainage as per "Poultry Retained Water Control Program"

When using combo chilling for chilling, the poultry product may be labelled as air chilling provided

• majority of the chilling is conducted cold air with/without water sprays or mists
• the final product does not lead to water retention
• the poultry product is subjected to "Poultry Retained Water Control Program"

7.0 Freezing

7.1 Crust freezing "surface freezing"

Rapid chilling methods, for poultry carcasses or parts, which temporarily freeze a thin outer layer of skin and muscle, must be performed under the following conditions:

1. The licence holder must submit to the veterinary inspector a written protocol for each all poultry products which will be crust frozen outlining:
   • the type and temperature of the chilling procedure/refrigerant
   • the duration of exposure to sub-freezing temperatures
   • the time period and location for the equilibrium of internal and external product temperatures such that an internal temperature is between 4°C and -2°C
   • the duration of crust freezing i.e. how long will the product be kept crust frozen
   • how the process must be monitored by designated plant employee for surface freezing and internal product temperature
   • how product will be identified and segregated into lots
   • the packaging
2. When crust frozen product is thawed, the following parameters must be used to assess thawing and appropriate labelling:
   • the surface crusting (freezing) must disappear within 2.5 hours (150 minutes);
   • the process must be monitored, by a designated plant employee, a minimum of every 2 hours for crust disappearance and internal product temperature;
   • the product must be labelled as either "previously frozen" or "frozen" whenever crust disappearance takes more than 150 minutes
3. The poultry product will be considered "frozen" and labelled accordingly when:
   • freezing becomes more extensive i.e. deeper than 4mm
   • significant portion of the poultry product have been frozen i.e. greater than 50%

7.2 Liquid freezing

Where liquid immersion or spray freezing is employed for poultry carcasses:

• the licence holder must have a written PCP procedure which has been examined by the veterinarian with supervisory authority
• the liquid freezing must be monitored to ensure liquid freezing is conducted as per procedure
• the poultry carcasses
  • must be packaged to prevent contact with the refrigerant
  • may be packaged in either clear or opaque bags for immersion in liquid refrigerant freezers
• an accepted coloring agent must be used in immersion refrigerants to make for easier detection of leakers
• the carcasses or portions contaminated with refrigerant are considered adulterated and must be condemned, except when the contamination with refrigerant is slight and limited to the surface areas. In such cases, the protective bag or wrap must be immediately removed and the carcass or portions must be decontaminated.

7.2.1 Procedure for monitoring liquid freezing

When developing the monitoring procedure following must be followed:

• Define the unit for examination:

  A unit refers to a bagged poultry carcass.

• Select time for examination:

  Before the start of each shift, licence holder must randomly select hourly subgroup test times for each production hour and record these times before product reaches the sampling location.

• Determine the sample location:

  Samples must be randomly selected at the exit (chute) of the immersion freezer.

• Monitoring Plan:

  The licence holder will use the following table depending upon inspection type based upon the line speed to determine sample size

• Examination procedure:
  • Each sample must be visually and manually examined. The visual verification will verify the bag integrity, and for opaque bags, a mandatory palpation must be made to detect soft spots indicative of the presence of coolant liquid.
  • All packaged carcasses must be verified by a designated licence holder employee after the shrink tunnel and before the immersion freezer for bag and clip integrity.
• Decision Tree for inspection levels for bagged poultry carcasses crust frozen by immersion in liquid refrigerant:

Description for Decision Tree for inspection levels for bagged poultry carcasses crust frozen by immersion in liquid refrigerant

The Decision Tree for Bagged Poultry Carcasses Crust Frozen by Immersion in Liquid Refrigerant starts with Box # 1 Normal Inspection Level.

• Box # 1: Normal Inspection Level has two outcomes:
  • If the sample is accepted, go to box # 2.
  • If sample is rejected go to box # 11.
• Box # 2: The sample unit is accepted. This has two outcomes:
  • If the sample is accepted and the number of accepted lots in the last 10 consecutive lots is equal to 10, go to box # 3.
  • If, the sample is accepted and the number of accepted lots in the last 10 consecutive lots is less than 10, go to box # 4.
• Box # 3: If last 10 consecutive lots are accepted, go to box # 5, which leads to switching sampling to Reduced Inspection Level .
• Box # 4: If last 10 consecutive accepted lots are less than 10, go to box # 1, which leads to continuing sampling at Normal Inspection level.
• Box # 5: The Reduced Inspection Level has 2 outcomes:
  • If sample is accepted, go to box # 6.
  • If sample is rejected, go to box # 7.
• Box # 6: The sample unit is accepted, go to box # 5 and stay in Reduced Inspection Level.
• Box # 7: The sample unit is rejected, advise CFIA and go to box # 8 for immediate retest.
• Box # 8: Immediate retest a sample unit, this has two outcomes:
  • If sample is accepted, go to box # 9.
  • If sample is rejected, go to box # 10.
• Box # 9: Sample accepted, go to box # 5 and continue sampling at Reduced Inspection Level.
• Box # 10: Sample rejected, advise CFIA, go to box # 15 and take Corrective Action plus switch to Tightened Inspection Level.
• Box # 11: The sample unit is rejected, advise CFIA and go to box # 12.
• Box # 12: Immediate retest a sample unit, this has two outcomes:
  • If sample is accepted, go to box # 13.
  • If sample is rejected, go to box # 14.
• Box # 13: The sample unit is accepted, go to box # 1, conduct sampling at Normal Inspection Level
• Box # 14: The sample unit is rejected, advise CFIA, go to box # 15 and take Corrective Action plus switch to Tightened Inspection Level.
• Box # 15: Take corrective action plus switch to Tightened Inspection Level. This has two outcomes:
  • If sample is accepted, go to box # 16.
  • If sample is rejected, go to box # 17.
• Box # 16: The sample unit is accepted, go to box # 1, conduct sampling at Normal Inspection Level
• Box # 17: The sample unit is rejected, advise CFIA, go to box # 15 and take Corrective Action plus switch to Tightened Inspection Level.

The Safe Food for Canadians Regulations has precedence over this decision tree.

• Corrective Action:

  When a deviation is noticed, the licence holder must

  • tag the affected unit
  • segregate all products back to the time of the last satisfactory test for the lot
  • re-examine each tagged carcass for evidence of adulteration and/or loss of package integrity,
  • release satisfactory packages
  • remove the refrigerant from affected units and repackage satisfactory carcasses
• Additional Comments:
  • When previous shift ends in no corrective action, the next shift continues at the same level as previous shift.
  • When previous shift ends in corrective action, the licence holder may elect to start at Normal Inspection level.

8.0 Refrigeration of rabbit meat products

Methods similar to those used for chilling and refrigeration for poultry carcasses may be used to chill rabbit carcasses in water, air or combination thereof.

As part of PCP, licence holder must have control measures in place to ensure that, at the time of packaging there is no increase of the hot weight of the carcass as a result of water chilling.

Rabbit carcasses may also be hung on racks or chilled in coolers.

9.0 Assisting CFIA with verification activities

Licence holder must assist CFIA inspection staff with the following inspection activities:

• verification of licence holder's implementation and ongoing application of chilling, freezing protocols and procedures (at least once per half shift)
• present associated records
• assist in conducting on-site observation of the designated licence holder employee (at least 1 test, at least once per day)

Additional Guidance:

1. Poultry water retention control program
2. Poultry Pathogen Reduction Program