Major UK meat plant probed over 'contamination' after leaked factory images

19 March 2024 , 12:13

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An image from a leaked internal report at Kepak's site in Merthyr Tydfil

A meat processing plant supplying UK supermarket giants is not being cleaned properly, a source claimed, and is being probed over contamination.

Kepak, in Merthyr Tydfil, serves Aldi and Tesco among other chains, and a whistleblower claimed facilities are not being cleaned while staff face "impossible" demands. They shared pictures of meat left on surfaces at the Pengarnddu Industrial Estate plant's cutting, processing, and packing lines.

"After a night shift, a quality auditor does the inspection at 5am and is meant to show the hygiene team of around four to five people what needs to be cleaned," they told WalesOnline. "But the hygiene team don't clean up properly because they don't have time before production starts at 6am. There is only an hour for both the quality auditor to do the inspection and the hygiene team to clean up the issues raised in the inspection.

"To do a proper audit you have to spend a minimum of 10 minutes on a line and there are 18 lines. An hour to check 18 lines is impossible for one person. By the time the auditor does the inspection the hygiene team has gone home. They are never around when the audit finishes. Pictures are taken after every night shift clean-down but they are left like that because production needs to start."

A whistleblower claimed that the machinery has not been cleaned properly

Kepak, an Irish meat processor that owns Rustlers and Celtic Beef, employs more than 4,500 people, including around 1,000 at the Merthyr site. Its spokesman pointed out the business has the best possible rating from the British Retail Consortium (BRC), adding that "health and safety are key priorities and stringent hygiene policies are rooted firmly in our daily operations".

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The Welsh Retail Consortium told WalesOnline that retailers will "investigate [the whistleblower's] claims and take swift action where necessary". But the source at the plant said: "When there is an unannounced visit from clients all the lines are stopped and the factory is cleaned before they come on the factory floor. But they don't see the reality of a normal day. The findings of the audit are not cleaned. Meat is not being cleaned from the lines properly therefore it’s contaminating freshly-produced meat."

An investigation is now being undertaken

An internal pre-production hygiene report which found meat and fat "contaminants" had been left on various "dirty" pieces of equipment including conveyor belts, crusters, a drying tunnel, and knives, has been seen by WalesOnline. There were issues at 14 of the 43 spots inspected. The report says these areas were placed on hold, recleaned, and "the cleaning team were informed for review".

And the whistleblower said: "There is very poor management. Why insist on doing [the inspection and clean-up] in less than an hour?" A Kepak spokesman said: "Our food safety standards are independently verified, working closely with the Food Standards Agency who have a daily presence onsite. Meanwhile, USDA (United States Department of Agriculture) audits are conducted monthly and include rigorous pre-production hygiene assessments.

It is also alleged that staff face "impossible demands"

"We have the highest accreditation available through BRC, which recently awarded us an AA+ rating based on an unannounced four-day audit. We are also regularly audited by our customers. Through our robust processes we continue to maintain the very highest quality control procedures throughout the production and distribution process.”

The Mirror has contacted Kepak for comment. The trade association's head Sara Jones said: “Retailers take food safety extremely seriously and expect their suppliers to uphold the highest standards. They will investigate these claims and take swift action where necessary.”

Tesco reportedly says its processes ensure suppliers uphold food hygiene standards and it will investigate the allegations, including with a review of Kepak's cleaning procedures, while Aldi did not provide a statement beyond the response from the Welsh Retail Consortium. Both Tesco and Aldi have been contacted by The Mirror for comment.

Conor Gogarty