New federal regulations focus control at the processing plant level. This project examines the microbial reductions and costs associated with the use of a HACCP system in large pork slaughter and processing plants. Based on survey and test results from large plants and data gathered from manufacturer sources, costs of individual technologies to reduce microbial contamination range from $0.03 to $0.20 per carcass for hogs; on-going HACCP-related costs were an additional $0.14 per carcass, and in total 1–2% of processing costs. The cost effectiveness of specific food safety controls will depend on product control throughout the production process.