OK Firm Recalls Nearly 1 Million Pounds of Breaded Chicken for Metal Complaints - Linked to Conveyor

A OK establishment is recalling close to one million pounds of breaded chicken products for the potential of metal contamination.  According to the notice: "The problem was discovered on March 21, 2017 after OK Foods Inc. received five consumer complaints stating that metal objects were found in the ready-to-eat chicken products and by FSIS inspection personnel during verification activities. After an internal investigation, the firm identified the affected product and determined that the objects in all the complaints came from metal conveyor belting." 

It would be interesting to know if the firm had a metal detector in place.  With a breaded chicken product, one would expect to see one.

USDA Recall Notice
https://www.fsis.usda.gov/wps/portal/fsis/topics/recalls-and-public-health-alerts/recall-case-archive/archive/2017/recall-030-2017-release
OK Food Inc. Recalls Breaded Chicken Products Due To Possible Foreign Matter Contamination
Class I Recall 030-2017
Health Risk: High 

Mar 23, 2017

Texas Firm Recalls Ground Meat Due to Complaint of Metal in Product

A Texas firm is recalling 60, 350 lbs of ground meat after a complaint was made from someone who found a piece of metal.  Unfortunately, the FSIS news release does not say what conditions, in addition to one complaint, were present to necessitate such a huge recall.  Were there more complaints logged in the companies consumer complain file, was there a non-conformance on metal detectors checks or grinder plate checks, or was there a noticeable metal issue in the facility?

Good reminder to have proper checks in place for metal.


FSIS Recall Notice
http://www.fsis.usda.gov/wps/portal/fsis/topics/recalls-and-public-health-alerts/recall-case-archive/archive/2016/recall-071-2016-release
Sam Kane Beef Processors, LLC Recalls Ground Beef Products Due To Possible Foreign Material Contamination
Class II Recall 071-2016
Health Risk: Low Aug 10, 2016

Supermarket Chain Recalls Bakery Items Due to Sugar Contaminated with Metal Pieces

Weiss Markets, a PA based store chain, has recalled bakery products due to the potential for metal fragments that came in with the sugar.  This recall is similar to the ConAgra recall for frozen entrees in that it is the same sugar supplier issue.

Entrée Products Recalled Due to Meat Contaminated Ingredient

ConAgra is recalling Chang's entrée products including Mongolian Beef and Spice Chicken for potential metal contamination due to a supplier issue.  According to the USDA posted recall notice:

"The problem was initially discovered on July 1, 2016, when an establishment employee observed metal fragments while dispensing sugar from a supplier for sauce formulation during processing. The resulting sauce is a component in the frozen entrée products. On July 14, 2016, ConAgra Foods was notified by the supplier of an FDA recall involving multiple production lots of sugar due to potential metal contamination. The recall action involved additional lots of sugar potentially used in FSIS regulated products at ConAgra Foods, and resulted in this expansion of the initial recall action."

 

There is no indication of whether there was an in-line metal detector or other control mechanisms for the entrée production or by the supplier for sugar production.

  

USDA News Release

http://www.fsis.usda.gov/wps/portal/fsis/topics/recalls-and-public-health-alerts/recall-case-archive/archive/2016/recall-056-2016-release-expansion

ConAgra Foods Recalls Frozen Chicken and Beef Products Due to Possible Foreign Matter Contamination

Class I Recall 056-2016 EXP

Health Risk: High Jul 15, 2016

 En Español

  

Peanut Butter Recalled Due to Potential Metal Pieces

Hormel is recalling 153 cases of 16.3 oz jars of Skippy Peanut Butter due to a potential for metal.  Metal pieces were found on an in-line magnet, which probably raised concern that some could have made its way to the jars. 

The interesting thing to note is that product was already shipped given that sufficient metal was found to raise concern.  Also 153 cases, about 3 pallets of product, would probably represent less than an hour of production.  These types of issues can arise for a number of reasons...just in time shipping where product is being shipped as it is made.   Another reason can be inadvertent shipping of product placed on hold because of fact there was an equipment malfunction where that product was placed 'on hold' because the malfunction resulted in metal pieces being generated as indicated by the in-line magnet. An indicator that this may have been the case is the production code / Best if Used By date...if this product had just been made, the code would probably be further out than next December.


FDA Recall Notice
Recall: Firm Press Release
http://www.fda.gov/Safety/Recalls/ucm470175.htm
Hormel Foods Sales LLC Voluntarily Recalls a Limited Number of Jars of Skippy Reduced Fat Creamy Peanut Butter Spread Due to Possible Metal Pieces
For Immediate Release
October 29, 2015

Poultry Products Recalled Due to Metal Shavings Generated by Ice Machine

A Mississippi establishment is recalling approximately 550,000 lbs of poultry products after metal shavings were found by one of their customers.  The manufacturing established reported that a faulty ice machine was to blame.  The product being large cases and combos, so this indicates the product was packed on ice.

The ice machine....that neglected piece of equipment.  Whether packing product on ice, adding ice as an ingredient to facilitate cooling, or adding to our beverage, ice is just as much as part of the process as the other ingredients used.  Ice machines have often been cited for high microbiological counts when the machines are not cleaned.  Here, a malfunctioning machine had metal-on-metal contact, probably in the ice chopper/flaker that generated the metal shavings.

In these cases, ice machines are part of the process and need to identified as a source for microbiological, physical, and probably even chemical hazards.  Good preventive maintenance and periodic quality checks should be included with regard to controlling metal as a physical hazard,

USDA Recall Notice
http://www.fsis.usda.gov/wps/wcm/connect/FSIS-Content/internet/main/topics/recalls-and-public-health-alerts/recall-case-archive/archive/2015/recall-124-2015-release
Sanderson Farms Recalls Poultry Products Due To Possible Foreign Matter Contamination
Class I Recall 124-2015
Health Risk: High Sep 24, 2015
En Español

Congressional and Public Affairs  Katherine Scheidt   (202) 720-9113

WASHINGTON, Sept. 24, 2015 – Sanderson Farms, a Hazlehurst, Miss. establishment, is recalling approximately 551,090 pounds of poultry products that may be contaminated with extraneous metal materials the U.S. Department of Agriculture’s Food Safety and Inspection Service (FSIS) announced today.

Kraft Recalls Mac&Cheese Due to Complaints about Metal Pieces

Kraft Foods is recalling Mac and Cheese product after receiving 8 complaints about metal. Approximately 242,000 cases (approx. 6.5 million boxes) are being recalled.

From the report, the product was produced on one manufacturing line over the period of approximately one month.  One would expect that the company would have a metal detector in place at the end of the line / after filling and sealing of the box.

It is good that the consumer complaint system was able to identify this, but the bad thing is that it was not caught through the preventive maintenance or quality program.


The News Gazette
 http://www.news-gazette.com/news/local/2015-03-18/updated-recalled-mac-cheese-was-made-champaign-plant.html
Updated: Recalled mac & cheese was made at Champaign plant

Wed, 03/18/2015 - 5:05pm | Don Dodson

CHAMPAIGN — Kraft Foods is trying to determine how small pieces of metal got into some boxes of original-flavor Kraft Macaroni & Cheese at the Champaign plant where it's made.

"We believe a piece of stainless steel got wedged in a metal piece of equipment, which may have generated friction that resulted in small pieces of metal potentially falling into the product," Kraft spokeswoman Joyce Hodel said.

On Tuesday, Kraft voluntarily recalled about 6.5 million boxes of the product after receiving eight reports of consumers finding metal in the boxes. No injuries were reported.

Two recalls the result of metal fragment contamination

There were two recalls announced today that were both related to metal fragment contamination. One recall was packaged bagels and it was discovered due to the presence of metal fragments found in two different packages. The other was frozen pizza product. Here, small metal fragments were found in the flour. It was an ingredient issue in that the flour used to make the product had been contaminated – the third party flour mill had a faulty metal mesh screen. The fragments were reported to be too small to be detected by conventional metal detectors that were being used.

For many products, metal control is important. Too often, poorly operating metal detectors are all that stand in line for protection. Unfortunately companies may not be willing to allocate sufficient resources to buy well-built detectors or to provide proper maintenance including yearly equipment-supplier calibration. It is important that metal detectors must are properly spec’d for the type of product and process. Another important part of metal control is preventive maintenance, with a regular inspection and scheduled replacement of parts subject to operational fatigue. The cost of these recalls goes a long way against the cost of properly operating equipment.


Voluntary Regional Recall Of Thomas', Sara Lee, Publix, And Weight Watchers Bagels
http://www.fda.gov/Safety/Recalls/ucm336565.htm?source=govdelivery

FOR IMMEDIATE RELEASE - January 16, 2013 - BBU, Inc., the parent of the Bimbo Bakeries companies, has initiated a voluntary recall due to possible presence of fragments of metal caused by a faulty manufacturing part. Recalled products are the following fresh bagels with "Best Buy" dates (month and day) "JAN 18" to and including "JAN 27"found on the lock tab bag closures in the following states:

Thomas' Everything Bagels 1 lb 4 oz AL, FL, GA, TN
Thomas' Blueberry Bagels 1 lb 4 oz AL, FL, GA, TN
Thomas' Onion Bagels 1 lb 4 oz AL, FL, GA, TN
Thomas' Plain Bagels 1 lb 4 oz AL, FL, GA, TN
Thomas' Cinnamon Raisin Bagels 1 lb 4 oz AL, FL, GA, TN
Thomas' Hearty Grains 100% Whole Wheat Bagels 1 lb 4 oz AL, FL, GA, TN
Thomas' Cinnamon Swirl Bagels 1 lb 4 oz AL, FL, GA, TN
Thomas' Honey Wheat Bagels 1 lb 4 oz AL, FL, GA, TN
Sara Lee Deluxe Bagels Honey Wheat 20 oz AL, FL, GA, LA, MS, NC, SC, TN
Sara Lee Deluxe Bagels Plain 20 oz AL, FL, GA, LA, MS, NC, SC, TN
Sara Lee Deluxe Bagels Blueberry 20 oz AL, FL, GA, LA, MS, NC, SC, TN
Sara Lee Deluxe Bagels Cinnamon Raisin 20 oz AL, FL, GA, LA, MS, NC, SC, TN
Publix Premium Original Bagels 20 oz AL, FL, GA., SC, TN
Publix Premium Multi-Grain Bagels 20 oz AL, FL, GA., SC, TN
Publix Premium Cinnamon Raisin Swirl Bagels 20 oz AL, FL, GA., SC, TN
Weight Watchers 6 Original Bagels 15 oz AL, FL, GA, NC, SC, TN 

The company announced the recall after discovering metal fragments in two packages. No consumer reports have been received. There are no reports of injury.
All recalled products are being removed from store shelves. No other THOMAS', SARA LEE, PUBLIX or WEIGHT WATCHERS products are affected.

 Consumers who have purchased the product can return the product to its place of purchase for a full refund. Consumers with questions may contact the company at 1-800-984-0989 at any time 24 hours a day.



California Firm Recalls Frozen Pizzas Due To Possible Foreign Matter Contamination
http://www.fsis.usda.gov/News_&_Events/Recall_006_2013_Release/index.asp


CLASS II RECALL
HEALTH RISK: LOW

FSIS-RC-006-2013
January 23, 2013

Congressional and Public Affairs
(202) 720-9113
Richard J. McIntire

WASHINGTON, Jan. 23, 2013 – - Annie's Homegrown Inc., a Berkeley, Calif. establishment, is recalling an undetermined amount of frozen pizzas that may be contaminated with extraneous materials and are the subject of a Food and Drug Administration (FDA) recall, the U.S. Department of Agriculture's Food Safety and Inspection Service (FSIS) announced today.

All varieties of "Annie's Homegrown RISING CRUST FROZEN PIZZA" with a "Best By" date including and between "09Jan13" and "14Sep13" are affected.

The following products are subject to USDA recall: [View Label]

23.6-oz. Organic Pepperoni Pizza, UPC code 0 13562 20000 9

25.4-oz. Organic Supreme Pizza, UPC code 0 13562 20002 3

22.6-oz. Pepperoni Pizza, UPC code 0 13562 20006 1

23.1-oz. BBQ Recipe Chicken Pizza, UPC code 0 13562 20009 2

Each product package above has an establishment number of "EST. 5699", "EST. 15815B", "P-5699" or "P-15815B" ink jetted on the upper flap of carton's side panel.
In addition, the following products are subject to FDA recall: 
23.5-oz. Organic Four Cheese Pizza, UPC code 0 13562 20001 6 
22.5-oz. Four Cheese Pizza, UPC code 0 13562 20007 8 
25-oz. Organic Spinach and Mushroom Pizza, UPC code 0 13562 20005 4

The products were manufactured at two facilities from May 9, 2012 to Jan. 17, 2013, and shipped to retail establishments across the United States.

The problem was discovered when metal fragments were visually detected in the flour and pizza dough at a third-party crust production facility. The problem was traced back to a defective metal mesh screen at a third party flour mill. Some wire fragments are too small to be detected by standard industry metal detectors, so it may be possible for fragments to become lodged in a finished pizza. FSIS, FDA and the company have received no reports of injury associated with consumption of these products.

FSIS routinely conducts recall effectiveness checks to verify that recalling firms notify their customers of the recall and that steps are taken to make certain that the product is no longer available to consumers.

Consumers with questions about the recall should contact the Annie's Homegrown Pizza hotline at (888) 825-6720. Media with questions about the recall should contact Donald C. Cutler, of Kekst & Company acting on behalf of Annie's, at (415) 852-3903.

Consumers with food safety questions can "Ask Karen," the FSIS virtual representative available 24 hours a day at AskKaren.gov or via smartphone at m.askkaren.gov. “Ask Karen” live chat services are available Monday through Friday from 10 a.m. to 4 p.m. ET. The toll-free USDA Meat and Poultry Hotline 1-888-MPHotline (1-888-674-6854) is available in English and Spanish and can be reached from l0 a.m. to 4 p.m. (Eastern Time) Monday through Friday. Recorded food safety messages are available 24 hours a day. The online Electronic Consumer Complaint Monitoring System can be accessed 24 hours a day at: www.fsis.usda.gov

A metal bristle from a grill brush, an example of a metal hazard

As reported by CBS News New York, a man swallowed a metal bristle and caused a severe laceration of his intestine. The bristle, off the grill cleaning brush, had become embedded in the steak and was unknowingly swallowed as the man ate his steak. As it moved through the intestine, it pierced the intestine, leading to a life threatening infection.

When evaluating hazards in food, there is a tendency to minimize the seriousness of metal hazards. This is a great example of how a piece of metal can be missed during chewing as well the type of damage it can cause.

New Jersey Man Recovering After Eating Metallic Bristle From Grill Brushhttp://newyork.cbslocal.com/2012/05/21/new-jersey-man-recovering-after-eating-metallic-bristle-from-grill-brush/#.T7qpLEQFU1c.mailto

RIVER EDGE, N.J. (CBSNewYork) – Think twice before you put the metal to the barbeque this grilling season.

A New Jersey man’s brush with death last week was apparently due to a grilling tool.

Michael DeStafan went to Hackensack University Medical Center thinking he had appendicitis after experiencing excruciating pain in his stomach.

Doctors conducted tests and found a 1 ½-inch-long metallic object had pierced the 54-year-old’s large intestine.  Doctors thought he had swallowed a nail, fish hook or paper.

DeStafan’s wife figured out one of the metal bristles on his grill brush broke off, got stuck to the grill grate and embedded itself in the shell steak her husband had cooked and eaten days before visiting the hospital.
Doctors performed emergency surgery to remove the wire and repair the hole that it made in DeStefan’s large intestine.

“”There was an infection, they just didn’t know how big the infection was, or how much of a hole it had torn inside my intestines, and they didn’t know that until they went in,” DeStafan said. “When I went under he told me I have to do this immediately, because we don’t know what we’re going to find, and there’s a chance that you might not make it.”

DeStafan is hoping his brush with death serves as a warning to others.

“I hope no one will have to go through that,” DeStafan said. “I want people to be aware of the fact that something as simple and innocent as going outside and grilling steaks and hamburgers for your family and friends could potentially be life-threatening.”

The Record reports half a dozen similar cases have been documented in Rhode Island.

DeStafan has since ditched the brush and instead uses a stone to clean the grill.