Inspection report reveals history of sanitation issues at Boar’s Head plant linked to deadly Listeria outbreak

Over a year of repeated sanitation failures — totaling 69 violations — at Boar’s Head’s Virginia plant, appears to have fueled the ongoing Listeria outbreak that has sickened 57 people across 18 states and claimed nine lives.

A U.S. Department of Agriculture inspection report detailing significant sanitation failures at a Boar’s Head meat processing facility in Jarratt, VA, has revealed significant sanitation issues. This revelation comes as the Centers for Disease Control and Prevention continues to monitor the Listeria outbreak linked to the company’s deli meats. The inspection report, obtained by CBS News through a Freedom of Information Act (FOIA) request, documents 69 instances of noncompliance observed by USDA Food Safety and Inspection Service (FSIS) inspectors between Aug. 1, 2023, and Aug. 2, 2024.

Ongoing Listeria outbreak
The CDC this week reported 14 additional illnesses and five more deaths related to the Listeria outbreak since its previous update on Aug. 8. All 57 confirmed patients have required hospitalization, and public health officials warn that the actual number of cases could be higher, as many individuals may recover without seeking medical care or being tested for Listeria.

The outbreak has been traced to deli meats, particularly those sliced at deli counters, with Boar’s Head liverwurst being a significant contributor. Epidemiologic and laboratory data have identified Listeria in Boar’s Head deli meats sampled from retail stores in Maryland and New York, with whole genome sequencing confirming that the bacteria strain found in these products matches the one causing the outbreak.

Sanitation failures at Boar’s Head facility
The FSIS inspection report highlights a troubling series of sanitation violations at the Jarratt plant, raising concerns about the facility’s ability to prevent contamination. The violations documented in the report include the presence of mold and mildew on surfaces that employees use to wash their hands, on the outside of steel vats and in holding coolers between smokehouses. These conditions are particularly concerning given the ability of Listeria monocytogenes to thrive in cold, moist environments.

In a statement to CBS News, Boar’s Head spokesperson Elizabeth Ward expressed the company’s regret over the impact of the recall and emphasized that food safety is their “absolute priority.” Ward also attempted to lay blame on the government, “As a USDA-inspected food producer, the agency has inspectors in our Jarratt, VA, plant every day, and if at any time inspectors identify something that needs to be addressed, our team does so immediately, as was the case with each and every issue raised by USDA in this report.”

Some of the key findings from the inspection report
Below is a list of some of the violations found at the Boar’s Head Jarratt plant:

• Aug. 3, 2023: Inspectors found heavy discolored meat buildup on a hydraulic pump and meat particles in injection needles. The area emitted a strong odor, and inspectors observed meat, wood pieces, and plastic debris on the floor.
• Aug. 25, 2023: Beaded condensation was found along the doorframe of a cooler in the Ready-to-Eat (RTE) Packaging Department. This could lead to contamination of products stored in the cooler.
• Sept. 22, 2023: Inspectors found meat residue on food contact surfaces within the Stitch Pump department, including in tank hoppers and on injector needles. A drain in a saddle tank was also clogged with meat, creating an unsanitary condition.
• Nov. 7, 2023: An inspection revealed that five HACCP (Hazard Analysis Critical Control Point) documents had discrepancies in thermometer calibration, posing a risk to food safety.
• Jan. 9, 2024: A black mold-like substance was found throughout the holding cooler between the smokehouses and stitch pump. The affected areas ranged in size from small spots to several feet in diameter.
• Feb. 21, 2024: Multiple combos in the Raw Receiving cooler were found saturated with blood and heavily soiled, with a rancid odor permeating the area.
• March 13, 2024: Inspectors observed significant buildup of meat protein and trash in the Inedible Room #2, along with improperly handled inedible products, including whole pork muscles left inside stainless-steel vats.
• March 20, 2024: A product tree of Boar’s Head Brand Bologna in the RTE department’s Equalization Cooler #2 was missing proper ID tags or labeling, leading to concerns about product traceability.
• May 20, 2024: The Frank Stuffing Department was found with white meat residue covering multiple areas of the floor, a backed-up drain causing overflow, and pieces of meat embedded in production lines.
• June 7, 2024: Three metal product tree racks in the New Gourmet staging area were found with meat residue from prior production on their food contact surfaces.

The full inspection report can be found here.

Impact of sanitation failures on Listeria contamination
The inspection report’s findings are especially alarming given Listeria’s ability to survive and even thrive in cold, moist environments like those found in food processing facilities. The repeated failures to adequately clean and maintain equipment and surfaces within the Jarratt plant create conditions ripe for Listeria contamination. The ongoing outbreak, which has already led to severe illness and death, underscores the public health risks associated with these sanitation lapses.

The FSIS report notes that many of the observed noncompliances were addressed by recleaning and sanitizing the affected areas. However, the recurrence of these issues suggests systemic problems within the facility’s sanitation practices. The presence of mold, mildew, and meat residue in critical areas of the plant highlights the challenges the facility faces in maintaining a safe processing environment.

Public Health concerns
The USDA and FSIS have been actively involved in addressing the Listeria outbreak, working alongside the CDC and state health departments to trace the source of the contamination and oversee product recalls. Boar’s Head has already recalled more than 7 million pounds of deli meats because of the outbreak. However, the inspection report raises questions about the effectiveness of the company’s corrective actions and its ability to prevent future contamination.

Public health officials continue to emphasize the importance of strict adherence to sanitation protocols in meat processing facilities. The findings from the Jarratt plant inspection serve as a stark reminder of the critical role that sanitation plays in ensuring food safety. The conditions observed at the plant not only violate regulatory standards but also pose a direct threat to public health.

About Listeria infections
Food contaminated with Listeria monocytogenes may not look or smell spoiled but can still cause serious and sometimes life-threatening infections. Anyone who has eaten recalled products and developed symptoms of Listeria infection should seek medical treatment and tell their doctors about possible Listeria exposure.

Also, anyone who has eaten any of the recalled products should monitor themselves for symptoms during the coming weeks because symptoms of listeriosis can develop up to 70 days after exposure to Listeria. 

Symptoms of Listeria infection can include vomiting, nausea, persistent fever, muscle aches, severe headache, and neck stiffness. Specific laboratory tests are required to diagnose Listeria infections, which can mimic other illnesses. 

Pregnant women, the elderly, young children, and people such as cancer patients who have weakened immune systems are particularly at risk of serious illnesses, life-threatening infections, other complications, and death. Although infected pregnant women may experience only mild, flu-like symptoms, their infections can lead to premature delivery, infection of the newborn, or even stillbirth. 

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Source: https://www.foodsafetynews.com/2024/08/inspection-report-reveals-history-of-sanitation-issues-at-boars-head-plant-linked-to-deadly-listeria-outbreak/