The process starts with the arrival of the raw ingredients. Fresh and frozen meat are used to make the burgers. Some frozen meat is used because it keeps the ambient temperature of the meat low during processing and assists in the binding process. All products used in the food industry must be traceable to the original suppliers.

Every animal born after July 1996 must be given a passport. This has details of its birth, parentage, health and farms. This passport follows the animal from when it is sold to when the carcass arrives from the abattoir. When the containers of meat arrive they will include meat from several carcasses. Each container will have the name of the abattoir, a container number and the date.

This information is transferred onto a barcode so it can be tracked throughout the manufacturing process using a computer tracking system. The meat goes through a number of checks on arrival.

• meat must be from a current audited and approved supplier
• all vehicles must be sealed on delivery
• vehicles must be clean, without off-odours, fit for purpose and free from other materials
• fresh meat temperature: target <+4degrees C
• frozen meat temperature: target <minus 18 degrees C
• fresh meat less than 6 days from kill date
• packaging fully protects meat against possible contamination risks
• meat is bright red colour, no off odours, free of any slime or contamination
  
  If the meat passes all these checks the container is accepted and put into chilled storage. The temperature of the chilled and frozen storage is checked regularly.

• chiller storage operating between 0 and +5 degrees

• freezer temperature operating between minus 15 and minus 25 degrees

Blending and Grinding

The fresh and frozen meats are initially ground together. The batch is blended and checked to make sure the fat content meets the specification. If the batch is within 1% of the product specification, the computer allows it to move onto the next stage. If it is outside the parameters, the computer calculates the adjustments needed and these are made.

Computers areused to track the progress of each batch of meat stage by stage. The fat content is important as it affects the taste, texture and cooking properties. Too little fat may cause under-cooking problems and too much may result in shrinkage on cooking.

The batch goes onto further grinding. The bore size of the grinders is very small and this helps the patties stick together. There is also an elimination point here where any meat that will not go through the small bore and any pieces of bone are rejected.

CCP4: Defect eliminators

• defect eliminators fitted to all final grinding heads to remove bone and gristle fragments

A forming machine is used to shape 600 beef patties or 300 quarter pounders per minute. Experienced operators carry out a visual check on the shaped burgers and make any adjustments to the machinery if necessary.

Freezing

• in-line metal detectors fitted with automatic rejection systems at freezing tunnel exits
• detector sensivity set at 1.2mm ferrous, 1.5mm non-ferrous

CCP6: Product storage

• the product is kept at minus 18 degrees C

Inspection

Cleaning

CCP7: Factory hygiene

• daily strip down and clean of all manufacturing equipment
• foam detergent followed by sanitiser
• daily visual inspection
• microbiological swabbing

The fresh and frozen meats are ground together. The batch is blended and checked using computers, to make sure the fat content meets the specification.

A forming machine is used to shape 600 beef patties or 300 quarter pounders per minute. Forming is carried out under pressure in mould plates and this determines the patty shape, size and weight.

Experienced operators carry out visual checks on the shaped burgers and make any adjustments to the machinery if necessary.

Patties are checked at regular intervals by the quality assurance team for temperature and weight.

Samples of the patties are taken from the production line and cooked as they would be in food outlets. Regular patties should cook in 42 seconds (42-46 seconds is the tolerance) and quarter pounders in 120 seconds (118-124 seconds is the tolerance). Regular taste tests are carried out.

Where the burgers are cooked and sold to consumers, regular checks are carried out to ensure that they are prepared to the required standards, eg. cooked burgers must reach a minimum internal temperature of 70 degrees C.

• Does the food contain sensitive ingredients that may present microbiological hazards (egs. salmonella, staphylococcus aureus); chemical hazards ( egs. pesticide residues); or physical hazards (stones, glass, metal)?
• Is water, steam or ice used in formulating the food or in handling the food - if so, where does the water come from?

• What hazards will result if the food composition is not controlled?
• Does the food permit survival or multiplication of pathogens and/or toxin formation during processing?
• Are there similar products in the market place? What has been their safety record?

• Does the process include a controllable processing step that destroys pathogens (if so, which ones?)
• Will there be a possibility of recontamination between processing and packaging - which biological, chemical physical hazards are likely to occur?

• What is the normal microbial content of the food?
• Does the microbial population change during the normal time the food is stored prior to consumption?
• Does the subsequent change in microbial content alter the safety of the food?
• Do the answers to the above questions indicate a high likelihood of certain biological hazards?

• Does the layout separate raw materials from ready-to-eat food, if this is important to food safety?
• Can moving people and equipment be a significant source of contamination?

• Will the equipment provide the time-temperature control that is necessary for safe food?
• Is the equipment the right size for the volume of food that will be processed?
• Can the equipment be controlled so that the variation in performance will be within the tolerances required to produce a safe food?
• Is the equipment reliable or is it prone to frequent breakdowns?
• Is the equipment easily cleaned and sanitised?
• Is there a chance for product contamination with hazardous substances eg. glass?
• What product safety devices are used, egs. metal detectors, magnets, sifters, filters, thermometers, screens, bone removal devices, dud detectors?
• Is equipment wear and tear likely to cause a physical hazard (eg. metal) in the product?
• Are allergy precautions needed in using equipment for different products ( eg. nuts)

• Does the method of packaging affect the multiplication of microbial pathogens and or the formation of toxins?
• Is the package clearly labelled "Keep Refrigerated" if this is required for safety?
• Does the package include instructions for the safe handling and preparation of the food by the end user?
• Is the packaging resistant to damage?
• Are tamper evident packaging features used?
• Is each package and case legibly and accurately coded?
• Does each package contain the proper label?
• Are potential allergens included in the list of ingredients

• Does sanitation have an impact upon the safety of the food that is being processed?
• Can the facility and equipment be easily cleaned and sanitised to permit the safe handling of food?
• Is it possible to provide sanitary conditions consistently and adequately to assure safe foods?

• Can employee health and personal hygiene practices impact upon the safety of the food being processed?
• Do the employees understand the process and the factors they must control to assure the preparation of safe foods?

• What is the likelihood that the food will be improperly stored at the wrong temperature?
• Would an error in improper storage lead to unsafe food?

• Will the food be heated by consumers?
• Will there be leftovers?

• Is the food intended for the general public?
• Is the food intended for those who may be susceptible to illness (egs. infants, the elderly)