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USDA hopes to speed up poultry production lines

Tue., Dec. 18, 2012

Inspector Hamilton Cook inspects chickens at the White Oak Pastures processing plant in Bluffton, Ga., in July.
Inspector Hamilton Cook inspects chickens at the White Oak Pastures processing plant in Bluffton, Ga., in July.

But inspectors worry they will overlook tainted birds

WASHINGTON – The U.S. Department of Agriculture is poised to finalize major changes to the poultry slaughter-inspection process that critics warn could threaten food safety and harm workers.

The proposed rule would allow companies to speed up production lines from 35 birds per minute per inspector to 175 per minute, a fivefold increase. It also would cut hundreds of federal inspector jobs and turn over much of the responsibility for spotting defective or diseased birds to plant employees.

The agency says that the proposal, which has been in the works for more than a decade, reduces the risk of food-borne illness by relying on scientific testing to screen carcasses, rather than the naked eye.

Under the rule, one inspector would be stationed at the end of every production line to eyeball chicken carcasses as they whiz by on hooks. Plant employees, rather than federal inspectors, would cull defective birds farther up the line. USDA officials say that frees up the agency’s remaining workforce to perform more important tasks elsewhere in plants, such as random testing for pathogens and monitoring of sanitation.

Inspectors shouldn’t be doing quality-control tasks that have little to do with protecting public health, said Elisabeth Hagen, the undersecretary for food safety at the USDA.

“There’s a role for visual inspection, but in this day and age it can’t be the only way that we define inspection for food safety,” Hagen said. “We’re not doing the right thing by the consumer if we do that.”

The USDA estimates that the changes will save taxpayers $90 million over three years and $256 million in production costs annually. Industry proponents say the new rule will modernize the poultry inspection system, which hasn’t been updated much since the 1950s.

“Look at the data. This is not something that USDA cooked up overnight,” said Tom Super, a spokesman for the National Chicken Council. “This has been in a pilot program for 13 years.”

Twenty broiler-chicken plants have volunteered as “trial plants” to test the proposal since 1999. The food-safety and worker-safety records in the plants are on par or better than those plants participating in traditional inspection, Super said.

“Chicken companies and their employees on this line have every incentive to not let a product with a quality defect into the marketplace,” he said.

Super points out that plants in other countries already run much faster. In Germany and Belgium, for example, line speeds typically reach 225 birds per minute, Super said. In Canada, the maximum speed is 250, he said.

Federal poultry inspectors protest that they can’t see bruises, blisters, tumors, pus, broken bones and other signs of tainted birds when carcasses fly by them at a rate of a third of a second. They can’t look inside the birds for bile, partially digested feed or fecal matter, or examine entrails for diseases such as avian leukosis – contaminants that inspectors say can be disgusting at best and dangerous at worst.

“The rule continuously talks about how much money per pound the plants are going to save by going into this process,” said Stan Painter, the chairman of the National Joint Council of Food Inspection Locals, a union that represents about 6,500 federal inspectors. “Why the hell is an agency concerned about the money that the plant’s going to save? I realize that’s a stakeholder, but our focus should be food safety.”


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