Hormel Foods Corporation is a multinational manufacturer and marketer of consumer-branded meat and food products. Hormel commands a tremendous amount of respect and its products are highly regarded for quality, taste, and nutrition by consumers, grocers, foodservice and industrial customers alike. To this end, it is extremely important for Hormel to ensure their customers always receive a superior and safe product.
The retort (cook) process at Hormel is the most important process in their business of food manufacturing. If the cook process is completed correctly, all bacteria can be killed. However, if any detail is overlooked or incorrect, the product may have to either be re-cooked or destroyed, which is extremely costly. It is extremely important to maintain accurate workplace records and to take corrective action immediately in response to out-of-specification results or non-compliance. Any corrective action required needs to be reported and/or recorded. In rare circumstances when mistakes are made, a process needs to be in place whereby mistakes are caught within moments of being made. In order to alleviate as many mistakes as possible and ensure food safety, some equipment must be monitored at all times to confirm operating condition and status as well as monitoring control points to confirm performance is maintained within specifications. A very important aspect of record maintenance is the backup system. After maintaining accurate records, these records need to be backed up in such a way that they are easily accessible for a period of time acceptable to the USDA.
To meet USDA guidelines for record keeping, there must be two records. The operator writes one record and the other record is a chart of temperature and pressure for each retort. If either record is incomplete or in error, the cook is invalid. Potential problems with the written record are numerous. The operator is cooking for fourteen retorts and has to fill out twenty-two separate boxes of information for each retort.