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Poultry and rabbit meat refrigeration, chilling, and freezing procedures

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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:

Table 1: Water-chill standards for dressed poultry carcasses
Weight of Dressed Poultry Carcasses Initial Time (hours) to Reach
≤ 14°C Table Note 1
Additional Time (hours) to Reach
≤ 6°C Table Note 1
Additional Time (hours) to Reach
≤ 4°C Table Note 1
Under 1.8 kg 2 2 4
1.8 kg to 3.6 kg 2 4 4
3.6 kg to 5 kg 2 6 4
5 kg to 7 kg 2 8 4
7 kg to 12 kg 2 10 4
Over 12 kg 2 Table Note 2 10 6

Table Notes

Table note 1

internal temperature.

Return to table note 1  referrer

Table Note 2

in this weight category, the temperature to reach within the first 2 hours is ≤ 16°C

Return to table note 2  referrer

Note:

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:

Table 2: Water-chill standards for giblets, carcass parts and salvaged portions
Name Time to Reach (hours) ≤ 4°C Table Note 3
Giblets (heart, liver and gizzard) 2 Table Note 4
Carcass parts (all birds except turkey) 2
Carcass parts (turkey) 4
Salvaged portions (all birds except turkey) 2
Salvaged portions (turkey) 4
Edible feet 4

Table Notes

Table Note 3

Internal temperature

Return to table note 3  referrer

Table Note 4

The foie gras liver may be chilled to 4°C in longer than 2 hours' time provided the licence holder validates the chilling process and resulting product for food safety and suitability.

Return to table note 4  referrer

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:

Table 3: Air chill standards for carcasses, giblets, carcass parts and salvaged portions
Name Time to Reach (hours) ≤ 4°C Table Note 5
Carcasses (all) Continuous chilling Table Note 6
Giblets (all) Continuous chilling Table Note 6
Carcass parts (all) Continuous chilling Table Note 6
Salvaged portions (all) Continuous chilling Table Note 6

Table Notes

Table Note 5

Internal temperature

Return to table note 5  referrer

Table note 6

No time requirement as long as chilling is continuous

Return to table note 6  referrer

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:

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 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:

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.

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

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

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 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:

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

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:

7.2.1 Procedure for monitoring liquid freezing

When developing the monitoring procedure following must be followed:

Table for sample, sizes and acceptance/rejection levels for poultry carcasses packaged in plastic bags and crust frozen by immersion within liquid refrigerant
ISO/2859-1 Single Sampling Plans
Inspection Type Line Speed (Carcasses/hour) Code Letter Sample Size Acceptance Quality Limits Accepted Acceptance Quality Limits Rejected
Normal Inspection 0-3,200 E 13 0 1
Normal Inspection 3,201-10,000 F 20 0 1
Retest Inspection 0-3,200 G 32 1 2
Retest Inspection 3,201-10,000 H 50 1 2
Reduced Inspection 0-3,200 E 5 0 1
Reduced Inspection 3,201-10,000 F 8 0 1
Tightened Inspection 0-3,200 F 20 0 1
Tightened Inspection 3,201-10,000 G 32 0 1
Flowchart - decision tree. Description follows.
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.

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:

Additional Guidance:

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