A Case Study by the Food Industry Center; University Of

Westland/Hallmark: 2008 Beef Recall A Case Study by The Food Industry Center January 2010 A Humane Society video, made secretly at the Westland/Hallmark plant in late 2007 and released in early 2008, led to the recall of 143 million pounds of beef. This case study illustrates the complexity of the food industry and the food recall process.1 Although ultimately, the incident had more to do with animal welfare than food safety — no sicknesses were tied to the recalled beef, it resulted in changes to the nation’s food safety procedures. The 2008 Westland/Hallmark beef recall, the largest beef recall in U.S. history, is a stepping-off point to examine the beef supply chain generally and the ground beef supply chain specifically. USDA This case was prepared by Jon Seltzer, marketing instructor at the University of St. Thomas and consultant to The Food Industry Center, Jeff Rush, research assistant, and Jean Kinsey, Director of The Food Industry Center. This case was developed under a grant from the National Center for Food Protection and Defense, a Department of Homeland Security Center of Excellence funded by U.S. Department of Homeland Security Science and Technology Assistance Agreement No. 2007-ST-064-000003. It has not been formally reviewed by the Department of Homeland Security. The views and conclusions contained in this document are those of the authors and should not be interpreted as representing the official policies, either expressed or implied, of the Department of Homeland Security. The Department of Homeland Security does not endorse any products or commercial services mentioned in this publication. Cases are developed as the basis for class discussion. Cases are not intended to serve as endorsements, sources of primary data, or illustrations of effective or ineffective management. No part of this publication may be reproduced, stored in a retrieval system, used in a spreadsheet, or transmitted in any form or by any means — electronic, mechanical, photocopying, recording, or otherwise — without the permission of The Food Industry Center at the University of Minnesota. © 2010 Regents of the University of Minnesota. All rights reserved. The University of Minnesota is an equal opportunity educator and employer. 1 This case is the third in a series of three food recall cases. Castleberry’s 2007 botulism recall was the subject of the first, and the 2006 E. coli recall of fresh spinach the subject of the second. Thank you to Donald W. Schaffner, Extension Specialist in Food Science and Professor at Rutgers, and Timothy L. Sellnow, Professor of Communication at the University of Kentucky, for their contributions to the cases. Schafner and Sellnow are subject matter experts for the National Center for Food Protection and Defense. Table of Contents The Largest Beef Recall in U.S. History Page 4 Felony-Abuse Convictions Page 6 Insiders’ View of the Recall Page 6 History of Westland/Hallmark Page 7 New Owners Page 7 New Practices Page 8 National Policy Changes Page 8 A Closer Look at the Meat Industry Page 9 Beef Cattle Production Page 10 Dairy Cattle Production Page 11 Packing Plants Page 12 Case-Ready Meats Page 12 The Retail Meat Case Page 13 In-Store Meat Cutting Page 14 Ground Beef Page 16 Ground Beef Patties Page 16 When the System Fails Page 20 Ground Beef Safety Measures Page 21 Is Irradiation an Answer? Page 24 What is a Recall? Page 27 HACCP Page 29 What if Contamination Were Intentional? Page 30 Conclusions and Questions Page 31 Glossary Page 34 Appendix I: 2008 Beef Recall Timeline Page 35 Appendix II: Distributors Affected by the Recall Page 37 Appendix III: Deaths and Illnesses Caused by Food Contamination Page 37 Appendix IV: History of Beef Page 39 Appendix V: Stages in Beef Production Page 43 Appendix VI: A Closer Look at Ground Beef Page 45 Appendix VII: A Closer Look at the USDA and the FSIS Page 48 Appendix VIII: Selected Readings on the Beef Recall and Ground Beef Safety Page 51 TABLES Table 1: Sales Distribution by Grocery Category Page 13 Table 2: Pounds of Product in an Animal Page 15 FIGURES Figure 1: Top Six Meat Recalls in U.S. History Page 3 Figure 2: U.S. Meat Production by Percentage in 2007 Page 10 Figure 3: U.S. Per Capita Meat Consumption in 2007 Page 10 Figure 4: U.S. Monthly Commercial Slaughter Cattle Page 11 Figure 5: Cuts of Beef Page 13 Figure 6: USDA “Gold Standard” Log Example Page 15 Figure 7: 100% Ground Beef Fresh Flow Chart Page 18 Figure 8: Ground Beef Lotting Page 19 Figure 9: The Decision Diamond Page 33 2 FIGURE 1: Top Six Meat Recalls in U.S. History 1. Westland/Hallmark Meat Co. 2. Thorn App le Valley Inc. (Michigan), 1999 (California), 2008 The recall: 35 million pounds of fr ozen, re ady-to-eat The recall: 143 million pounds of beef meat products The problem: Plant employees allowed “downer” The problem: Potential contamination with Listeria cattle to be slaughtered. bacteria of meat at a processing plant in Arkansas. No illnesses reported. 3. Pilgrim's Pride 4. Hud son Foods Corp./ Wampler Foods 5. Topps Meats Co. Co. (Nebraska), 1997 (Pennsylvania), 6. ConAgra Foods (New Jersey), 2007 2002 (Colorado), 2002 The recall: 25 million The recall: 21.7 pounds of ground beef The recall: 27.4 million pounds of The recall: 18.6 The problem: E. coli million pounds of frozen hamburger million pounds of beef contamination. Fewer cooked turkey and patties The problem: E. coli than 20 illnesses chicken sandwich The problem: E. coli contamination. Thirty- reported. Beef meat contamination. More four illnesses reported supplied to quick The problem: Listeria than 30 illnesses in 10 states. service retailers. contamination. Fifty- reported in eight two illnesses and states. seven deaths reported in the Northeast in association with the bacterial outbreak. Sources: U.S. News and World Report, February 2 0, 2008, usda.gov, cnn.com, Associated Press 3 The Largest Beef Recall in U.S. History On February 17, 2008, the U.S. Department of Agriculture (USDA) issued a recall release stunning in its scope, the largest beef recall in U.S. history. The release began: “Hallmark/Westland Meat Packing Co., a Chino, Calif., establishment, is voluntarily recalling approximately 143,383,823 pounds of raw and frozen beef products (mostly from aging dairy cows2) that FSIS (the Food Safety and Inspection Service, part of the USDA) has determined to be unfit for human food because the cattle did not receive complete and proper inspection.” The recalled products had been sent to wholesale distributors across the nation. Some were purchased for CBS News federal food and nutrition programs, including the National School Lunch Program.3 In most cases, ground beef was delivered to companies that processed it into other items.4 More than 10,000 establishments received the recalled meat, according to USDA Undersecretary for Food Safety Richard Raymond.5 In California alone, more than 5,000 supermarkets, restaurants, retailers and school districts received meat recalled by Westland/Hallmark.6 It was not just size — two years of product from the plant — that made the recall unusual. The recall was designated as Class 2 “due to the remote probability that the beef being recalled would cause adverse health effects if consumed,”7 rather than a more dangerous Class 1. Ultimately, no sicknesses were tied to the recalled beef. Perhaps most significantly, the incident resulted in changes to the nation’s food safety procedures. Finally, Westland/Hallmark went out of business, and two employees were convicted of criminal behavior. All of this came as the result of video footage shot by an undercover investigator for the Humane Society who worked at the Westland/Hallmark plant. He secretly filmed abuse between October 7, 2007, and November 20, 2007.8 On January 30, 2008, after showing footage to USDA officials and U.S. Agriculture Secretary Ed Schafer, the Humane Society released a video of two Westland/Hallmark workers abusing “downer” cattle — those too sick or injured to stand for slaughter. The video, posted on YouTube, showed employees kicking, beating, jabbing and dragging the cattle, spraying them in the face with high- pressure hoses and shoving them with heavy machinery, apparently in attempts to move them to 2 Michael Jacobson, executive director of Center for Science in the Public Interest, Nutrition Action Health Letter, “Playing dinner table roulette,” May 2008 3 USDA, “California firm recalls beef products derived from non-ambulatory cattle without the benefit of proper inspection,” February 17, 2008 4 USDA, “Questions and answers Hallmark/Westland Meat Packing Co.,” updated March 6, 2008 5 Mary Waters, Frozen Food Age, “Hallmark/Westland recall: Where’s the beef?” March 2008 6 Julie Schmit, USA Today, “California lists where recalled beef was shipped,” March 5, 2008 7 USDA, “California firm recalls beef products derived from non-ambulatory cattle without the benefit of proper inspection,” February 17, 2008 8 A sample of the video can be seen at www.youtube.com/watch?v=CrxvxewC-gA, but be warned that some viewers will find the footage disturbing. 4 slaughter. The video provided evidence that downer cattle – animals that couldn’t walk – were illegally slaughtered for food, a federal violation that spurred the recall.9 Federal regulations mandate that cattle must be able to stand and pass inspection to be fit for the food supply, and if an animal fell after inspection, a veterinarian had to reexamine it and approve it for slaughter. The law was intended to prevent problems such as E. coli O157:H7, Salmonella and mad cow disease from entering the food supply.

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