“Assurance of The Safety of Meat Products” · “Assurance of The Safety of Meat Products ......

“Assurance of The Safety of Meat Products”

Prof. Dr. Suwimon Keeratipibul

Department of Food Technology

Faculty of Science

Chulalongkorn University

Bangkok, Thailand.

Suwimon.K@chula.ac.th

Tel: 668-1-333-1794

Fax: 662-254-4314

1

Global food safety challenges

2

From Dr. Leon Gorris

Risk of Product Contamination

• Biological

• Chemical and

• Physical Hazards

When we produce food we have risk.

3

4

Nature of Food Hazards

• Food hazards include

– Biological hazard

– Chemical hazard

– Physical hazard

• They cannot be seen

• They distribute in

food products unevenly.

INSPECTION METHODS

Traditional Food Safety Program focus on

5

6

To produce safe food:

Food Testing??

How many samples to be taken to

ensure safety of food??

3 73% 94% 97% 99%

10 35% 82% 90% 95%

60 <0.5% 30% 55% 74%

120 <0.5% 8.5% 30% 55%

180 <0.5% 2.6% 16% 41%

240 <0.5% 0.8% 9% 30%

Number of Samples Tested

% Contamination in Lot

10% 2% 1% 0.5%

Finished product testing has significant limitations

Probability of Missing Contamination

7 Paul A., Hall Kraft Foods N.A.

To manage the risk of

product contamination

Implement comprehensive food safety system

8

9

Manage the risk from farm to table wisely

Feed Farm SlaughterHouse

Consuming

Consumers

Processing Plant

Raw Material

Raw Material Producers

Distribution

DistributersFood ProducersFarmers

Introduction

10

(Retailers) (Processors/

Manufacturers)

(Farmers/

Growers)

(Collectors/

Brokers)

• GAP

• Eurepgap

• SQF1000CM

• AgroControl

• Own QA

Scheme

• Food hygiene

• GMP

• HACCP

• SQF2000CM

•Contract agreement

• Food hygiene

• GMP

• HACCP

• SQF2000CM

• BRC

• ISO 9001

• Food hygiene

• Vendor Assessment.

• Supplier evaluation

• Product monitoring

• Product recall.

Agri/food Supply Chain

(pressure) (pressure) (pressure)

To control food hazards

11

Where in the food chain can

food hazards best be

controlled?

12

For Chemical Hazards GAP(Good Agricultural Practice) or GFP (Good Farming Practice)

13

13

We need to know

• Pathogens of concern (pathogen & food

combination)

• Condition of growth/survival

• Resistant microorganisms (transient/resident pathogens)

14

15

To identify the pathogen of concern

Knowledge

Experience

Information

Examples of targeting foods

Salmonella

Low moisture foods

L. monocytogenes

RTE foods in which growth can occur E. sakazakii

Powdered infant formula

E. coli O157:H7

Ground beef, leafy greens, sprouts

Clostridium botulinum

Low acid foods in hermetically sealed containers

16

Control of Pathogens

• Control at farm e.g. Salmonella

or • Control at food processing plant e.g. Listeria

spp. , E.coli

17

18

Five Salmonella spp. that need to be controlled (EU Market)

Salmonella Enterititdis

Salmonella Typhimurium

Salmonella Virchow

Salmonella Infantis

Salmonella Hadar

19

Control of Salmonella is to implement Good Farming Practice&Compartmentalisation

BIOSECURITY

Bacteria

Nearby Flocks

Rodents

Personnel Feed

Viruses

Water

Equipment

Control of Pathogens

• Control at farm e.g. Salmonella, Vibrio cholerae

or • Control at food processing plant e.g. Listeria

spp. , E.coli, Salmonella

20

Listeria: more than L. monocytogenes

• The genus Listeria includes:

– Human and animal pathogens: L. monocytogenes and L. ivanovii

– Non-pathogenic species: L. innocua, L. seeligeri, L. welshimeri, and the divergent L. grayi

– 11 new non-pathogenic species described since 2010 (L. marthii, L. rocourtiae, L. weihenstephanensis, L. fleischmannii, L. floridensis, L. aquatica, L. cornellensis, L. riparia, L. grandensis, L. booriae, L. newyorkensis

• Many of these new non-pathogenic species have been isolated from produce related sources

• Listeria spp. typically considered an “index” organisms that

reveal conditions where L. monocytogenes could reside

Control of Listeria monocytogenes

21 From: Prof.Dr.Martin Wiedmann , Cornell University

Factors affect growth of Listeria monocytogenes

aw %Salt Oxygen

Min Min Max Max Min Max Requirement

Facultative

Anaerobe

0.92 4.4 9.4 10 -0.4OC 45

OC (Grow either

with or without

oxygen)

pH Temperature

Doubling Time at 37OC ~ 45 min. Optimum Temperature=37๐C

Optimum pH= 7.0 22

Control of Pathogens including food

spoilage microorganisms requires:

1. Proper heat treatment (HACCP)

2. Proper equipment design and good

sanitation of production environment

(GMP/Pre-requisite program

especially cleaning and sanitizing

program, personal hygiene)

From: Dr. R. Bruce Tompkin 23

D - Value = time that reduces 90%bacteria (1 log) at the determined temp.

Z - Value = O F/ O C that reduces 1 log cycle thermal destruction curve

(D – Value reduces10 times)

24

Table 7 Summary of Some Findings on Thermal Destruction of L. monocytogenes

Heating Number of

Temp. D Value z Value

Cells/ml Heating Menstrum ( O C)

(sec.) ( O C)

Scott A, free suspension ~10 5 Sterile skim milk 71.7 1.7 6.5

~10 5 Sterile skim milk 71.7 2.0 6.5

~10 5 Sterile skim milk 71.7 0.9 6.3

Scott A, intracellular ~10 5 Whole raw milk 71.7 1.9 6.0

Scott A, free suspension ~10 5 Whole raw milk 71.7 1.6 6.1

F5069, intracellular ~10 6 Sterile whole milk 71.7 5.0 8.0

F5069, free suspension ~10 6 Sterile whole milk 71.7 3.1 7.3

Scott A, free suspension ~10 5 Ice cream mix 79.4 2.6 7.0

~10 8 pH 7.2 phos. buffer 70.0 9.0 -

~10 8 pH 5.9 meat slurry 70.0 13.8 -

~10 7 Liquid whole egg 72.0 36.0 7.1

Ten strains ~10 7 Irradiated ground meats 62.0 61.0 4.92

Chicken/meat isolate ~10 5 Beef 70.0 7.2

~10 5 Minced chicken 70.0 6.7

Strains Tested/State

ICMSF, Vol.5 25

26

Thickness

Initial Temperature

Overlaying

Heating Process: Steaming, Roasting, Frying

Heat distribution

Control of Pathogens including food

spoilage microorganisms requires:

1. Proper heat treatment (HACCP)

2. Proper equipment design and good

sanitation of production environment

(GMP/Pre-requisite program

especially cleaning and sanitizing

program, personal hygiene)

From: Dr. R. Bruce Tompkin 27

• The International

Commission on

Microbiological

Specifications for Foods

(ICMSF) has recognized

that even optimal HACCP and GHP programs…

International Commission on Microbiological Specifications for Foods. 2002. Chapter 11: Sampling to assess control of the environment. In ICMSF, Microorganisms in

Foods 7: Microbiological Testing in Food Safety Management. Kluwer Academic/Plenum, New York, NY.

Recontamination from the

environment

…are no

guarantee to

prevent post-

processing

environmental

contamination

28

GMP&HACCP lessons learned

• Foodborne disease outbreaks and finished product

contamination events linked to facilities with

GMP&HACCP plans

– Issues often with pre-requisite programs(GMP)

– Pre-requisite programs often were lacking proper

monitoring program, documentation, verification and

validation

• Need to focus on and strengthen “Sanitation

Programs” through effective environmental

monitoring program.

• Data Analysis &Manage the risk 29

•Separate low care and high care areas to prevent

cross contamination during operations.

low care high care

30

31 From: Prof.Dr.Martin Wiedmann , Cornell University

Industry User’s Sanitary

Design Perspective for RTE

Equipment

AMI Equipment Design Task Force

32

Rust,

peeling

paint

Niches,

thread

s

Stained

soft rubber

grips

Hard

plastic grips

Easy to

clean &

inspect

Smooth

finish

Prone to

damage

equipme

nt

Non-

corrosive

materials Fitted heads

for

equipment

longevity

Sanitary Design

Maintenance Tools

From This To This

Previous Design Sanitary Redesign

d:/santow/sanitation/halfmoon.ppt pg 15 5/10/02

33

34

Solid pulley Hollow pulley

From This To This

Previous Design Sanitary Redesign

From:AMI(American Meat Institute)

No product or liquid collection

No product or liquid collection

or

35

Self Draining

No product or liquid collection

Not Good Good

36

No Niches

37

=NO

38 From: Prof. Bon Kimura, Tokyo University of Marine Science and Technology, Japan

Cleaning

• Removal of soil

Disinfection/Sanitising

• Destruction or removal of microorganisms

Aim: to reduce to an acceptable level -

little or no risk

Cleaning & Sanitising

39

**Cleaning Procedure should be validated**

“Aggregation of microorganisms and their associated

extracellular polymeric substances (EPS), actively attached to,

growing and multiplying on a surface either an inert or living

surface”

“Complex consortium of microorganisms enmeshed within an

extracellular matrix”

What is a Biofilm?

40

41 From: Prof. Bon Kimura, Tokyo University of Marine Science and Technology, Japan

If possible!

From: Prof.Dr.Martin Wiedmann , Cornell University 42

How do we develop a validated SSOP

(Cleaning &Sanitizing) for a piece of equipment

• Perform regular standardized cleaning and sanitation

• Assemble equipment and do normal start-up

• Stop before product is put onto equipment

• Disassemble to normal daily level and test with ATP, total plate

count (TPC)/aerobic plate count (APC) and pathogen test

• Disassemble to the extent possible and test with ATP, total plate

count (TPC)/aerobic plate count (APC) and pathogen test

• If all samples are negative/below threshold that indicates that

SSOP assures effective cleaning and sanitation.

From: Prof.Dr.Martin Wiedmann , Cornell University 43

44

Be careful when use “High Pressure”

Air Dry/Store Properly

45

Environmental Swabs

• Design swab plan, methods to be used, frequency

46

Goals of a microbial environmental testing program

• Verify food safety and quality procedures, such as

– Hygenic zoning

– Cleaning

– Sanitation

– Sanitary equipment design

• Identify problem are as harboring pathogen sources (“niches”)

and locate contamination sources

• Characterize transmission pathways

• Confirm effectiveness of problem-solving procedures

• Validate food safety and quality procedures (for example

SSOPs for a specific piece of equipment)

47 From: Prof.Dr.Martin Wiedmann , Cornell University

Growth niches

Locations harboring the organism after the routine sanitation process for that area has been completed.

Examples – Hollow roller on conveyor

transporting food product • Hollow rollers not disassembled

cleaned and sanitized or heat treated in a manner to eliminate any contaminating organisms can become growth niches.

48 From: Prof.Dr.Martin Wiedmann , Cornell University

L. monocytogenes persisted in rubber floor

mats despite sanitation

Listeria can be protected from sanitizer in “micro-cracks”,

but can be squeezed out by pressure if people stand on

mats From: Prof.Dr.Martin Wiedmann , Cornell University 49

50 From: Prof.Dr.Martin Wiedmann , Cornell University

Which Methods to Be Used:

• A number of methodologies are available:

– Swabs – gauze, sponge or stick

– Rinse samples (from enclosed systems)

Protein check swabs

ATP

Indicator/Index microorganisms/Total

Bacteria/Pathogens

Molecular testing for pathogens

“What do you want to know??” 51

How to collect samples

• Sterile sampling techniques (sponges with gloves or handles)

• Typically use sponge for pathogen sampling

52

53

54

Sanitary Zones

Zone 4 e.g., Locker rooms, cafeteria, hallways

Zone 3 Non-food contact:

e.g., Table legs, forklifts; walls; drains

Zone 2 Non-food contact:

e.g., Equipment framework; chill units; floor

Food Contact:

e.g., Conveyors, chutes, tables, utensils

Zone 1

From Dr. R.Bruce Tompkin 54

Plant ID Prevalence

(from routine)

Prevalence

(from

validation)

A 5.1% (34/664) 1.3% (2/150)

E 11% (88/795) 10% (6/60)

F <0.3% (0/334) 6.0% (3/50)

G 9.1% (19/209) 2.4% (2/85)

H 23% (24/106) 4% (2/50)

I 0.4% (1/222) <2.0% (0/50)

J 0.9% (1/106) 14% (7/50)

“Validation” results

55 From: Prof.Dr.Martin Wiedmann , Cornell University

2

RESULTS

56

RESULTS

57

RESULTS

4. P

5. P

58

How can we track back

when the contamination occurred?

Can conventional method be used to

track actually where they come from ?? *No!*

ATCGTAC

ATCGTAC

ATCGTCC

ATCGTGC

Although this microorganism look alike, they have different DNA fingerprint

ATCGTAC

59

60

• The major source of contamination (58.6%) was the exhaust pipe of the in-feed liquid N2 chiller where the product was fed into the chiller.

Table 5. Prevalence of L. innocua strains on the environmental surfaces in the three zones of the processing line.

Zone Swab surfaces

L. innocua strains / substrains

LI

1.1

LI

1.2

LI

1.5

LI

1.6

LI

2.1

LI

2.2

LI

3

1

Out-feed conveyor belt of cooker - - - 0.6 - - -

In-feed conveyor belt of liq. N2 chiller 2.3 - - - - 0.6 -

In-feed conveyor belt of chiller 0.6 - - - - 0.6 -

Out-feed conveyor belt of chiller 0.6 0.6 - - - - -

Conveyor belt of dicer 1.7 - - - - - -

Gloves of QC worker after dicing 1.1 - - - - - -

In-feed conveyor belt of freezer 0.6 - - - - - -

Out-feed conveyor belt of freezer 1.1 0.6 - - - - -

Gloves of worker at freezer 1.1 - - - - - -

Gloves of packing worker 0.6 0.6 - - - - -

2

Frame of the exit of cooker 0.6 - - - - - -

Tray supporter under conveyor belt of

the cooker 0.6 - - - - -

Exhaust pipe of liquid N2 chiller 58.6 0.6 - 2.9 2.3 9.2 -

Tray supporter under conveyor belt of

liquid N2 chiller 4.0 - - - - - -

Monitor of dicer controller 0.6 - - - - - -

External area of the dicer 0.6 - - - - - 1.1

Controller box of dicer 1.1 - - - - 0.6 -

Packing table 1.1 - - - - - -

Conveyor belt of metal detector and

heat sealer 7.5 - - 1.7 - - 0.6

Belt for transferring equipment 0.6 - - - - - -

3

Gloves of worker carrying used

equipment 0.6 - - - - -

Floor of dicing room 9.8 1.1 - 1.1 - 2.3 0.6

Wall of freezer - - - - - 0.6

Draining pipe of freezer 22.4 - 0.6 - - - 0.6

Floor at packing area 14.4 0.6 - - 0.6 0.6 -

Random Amplification of Polymorphic DNA (RAPD)

Controlled

Traffic

Patterns

GMP’s Clean Dry

Uncracked

Floors

Sanitary

Design

Equip &

Building

Effective

Sanitation

Procedures

Listeria Control (Environmental pathogen and spoilage control)

=

+ + + +

Listeria Equation (Environmental pathogen and spoilage equation)

61

From: Prof.Dr.Martin Wiedmann , Cornell University

APC GRAPH CORN 2008

0

50000

100000

150000

200000

250000

300000

350000

1

25

49

73

97

121

145

169

193

217

241

265

289

313

337

361

385

409

433

457

481

505

529

553

577

601

625

649

673

697

721

745

769

793

817

841

865

889

SAMPLE NUMBER

CFU/G

19/0121/04

Introduction of ATP testing

2009 corn season APC results

0

50000

100000

150000

200000

250000

300000

350000

1

19

37

55

73

91

10

9

12

7

14

5

16

3

18

1

19

9

21

7

23

5

25

3

27

1

28

9

30

7

32

5

34

3

36

1

37

9

39

7

41

5

43

3

45

1

46

9

48

7

50

5

52

3

54

1

55

9

57

7

59

5

61

3

63

1

64

9

66

7

68

5

sample number

AP

C

spec limit

28010902/02/09

18/04

Significant

improvement in

finished product quality

almost immediately

Provided by 3M Food Safety

Food manufacturer case study

62

• Food processing environment is an important source of

pathogens and spoilage organisms (such as L.

monocytogenes and Lactic acid bacteria)

– Pathogens and spoilage that persist in processing

environment have been linked to costly recalls and outbreaks

• Environmental Monitoring Programs are a critical

component of food safety and quality

– Range of tests can provide valuable data

– Results need to be used for immediate corrective actions

as well as long term improvements (equipment design

etc.)

Summary

Steaming equipment 63

-Change master sanitation schedule and cleaning and

sanitation procedures

Scheduled disassembly and

cleaning required

Looks clean from this perspective But….

64 From: Prof.Dr.Martin Wiedmann , Cornell University

Summary(Cont.)