Inspectors found mold, mildew and insects at the Boar’s Head plant at the center of a multi-state listeria outbreak.
Reports from the USDA’s Food Safety and Inspection Service showed the $1 billion company was warned of 69 violations at the Jarratt, Virginia, plant last year.
Concerns arose before Boar’s Head sausages triggered the largest listeria outbreak in the US in more than a decade, with dozens of its products contaminated.
In a report, inspectors said they saw flies entering and exiting a pickle tank, while a trail of ants was observed crawling up nearby walls.
Inspectors also detailed how mould and mildew had built up on surfaces and that in some areas of the factory there was a “musty odour” and “abundant blood” covering sections of the floor.
Pictured above is the Jarratt, Virginia, plant at the center of the Listeria outbreak.
This is the exterior of the plant, which Boar’s Head says is now closed for cleaning.
A total of nine people are reported to have died after consuming Boar’s Head meats, while 57 have been hospitalized in 18 states, including New York, Florida and New Jersey.
It is the largest foodborne illness outbreak to hit the United States since the cantaloupe outbreak in 2011, when a melon contaminated with listeria sickened 147 people and caused 33 deaths.
Among those who died was Gunter Morgenstein, a father of three and Holocaust survivor who regularly ate the company’s liver pate because it reminded him of his native Germany.
Boar’s Head has recalled about 7.2 million pounds of deli meats due to the outbreak.
It also closed the Jarratt plant for deep cleaning and sent all staff back for retraining.
The records, revealed under a Freedom of Information request by CBS NewsBoar’s Head was warned about problems at the plant from August last year until July 27, two days after its first recall was announced.
The map above shows the states where illnesses related to the listeria outbreak in deli meat have been reported.
Images of the mold and insects in the building have yet to be released.
Boar’s Head said in a statement: ‘We deeply regret the impact this recall has had on the families affected.
“There are no words that can fully express our condolences and the sincere and deep sorrow we feel for those who have suffered loss or suffered illness.”
In July of this year alone, the month in which the company ordered the first recall, they were warned of more than 15 safety violations.
This included mold growing around the sink where employees washed their hands before handling meat, black mold on the outside of four steel tubs, and at least 10 dead and live insects found in a produce storage area.
This month, inspectors also found condensation dripping from a ceiling with a dark brown or tan tint onto products, including Beechwood hams.
A clear liquid was also observed dripping from the ceiling in one area, and a fan was blowing the liquid onto uncovered hams in the hallway.
Other violations included a warning in January that there was a black, mold-like substance on the walls of the room near the smokehouse, and a warning in February of “copious amounts of blood” on the factory floor.
CDC urges people to check inspection labels before consuming any Boar’s Heada products, as some have expiration dates as late as October 2024.
Gunter ‘Garshon’ Morgenstein, a father of three from Newport, Virginia, is pictured above with his wife Peggy (left). He died after suffering a listeria infection from eating Boar’s Head cold cuts. Sue Fleming, also 88, of Missouri, has also filed a lawsuit over her listeria infection.
She had eaten Boar’s Head liver pate the day before she became ill. This meat is now included in the recall of products contaminated with listeria in several states.
The recalled products have codes EST.12612 or P-12612 inside the USDA mark of inspection on the product labels.
Those who purchased the products are advised to discard them and return them to stores for a full refund.
Customers are also urged to clean their refrigerators, containers and surfaces that may have come into contact with the cut meats.
Keeping meats cold does not eliminate listeria.
Bacteria can persist on surfaces for weeks, reaching cutting tools and countertops that are not thoroughly cleaned regularly.
Listeria, which kills about one in five people it infects, is particularly dangerous for the elderly, pregnant women and those with underlying health problems.
These people have weaker immune systems, which means they may be less able to fight off an infection.
Symptoms may begin a few days or 10 weeks after infection, and initially start as fever, chills, stomach cramps, and diarrhea.
But as the infection progresses, patients may also experience seizures, loss of balance and confusion.
Infections can be treated with antibiotics, which are given intravenously and can kill bacteria.