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Salmonella Control:Tighter Regs – New Realities
HOST Bill KinrossGroup Publisher,
Meatingplace
MODERATOR Ann Bagel StorckManaging Editor,
Meatingplace
Regulatory DiscussionElizabeth KrushinskieDVM, PhDDirector of QA and Food SafetyMountaire Farms, Inc.
Overview
• Setting the Stage• Current Features• Coming Attractions• Foreign Dramas
Poll Question
Are you aware of the Healthy People 2010 initiative and could you explain it to someone else? Yes No
Setting the Stage
• In 2000, HHS set objectives related to foodborne illness reduction in their Healthy People 2010 document– Salmonellosis infections were projected to be
reduced from 13.7 in 1997 to 6.8/100,000 by 2010• Preliminary FoodNet data for 2009 reported a
Salmonella infection rate of 15.19/100,000, well above the 2010 goal
Setting the Stage
• USDA’s Response– FSIS contributes to meeting this objective
by regulating the Salmonella burden of meat, poultry, and egg products through the Pathogen Reduction/Hazard Analysis Critical Control Point (PR/HACCP) System implemented in 1996
Setting the Stage
• In 1996, the Agency established a Performance Standard for the incidence of Salmonella on broiler carcasses post-chill (per 9 CFR 381.94)
• In 2006, FSIS classified establishments according to their performance relative to the Performance Standard (Category I, II, or III)
Current Features
• Salmonella Performance Standard - Broilers (9 CFR 381.94)
Class of Product Performance Std
No of Samples Tested
Max No of Positives
Broilers – Category II
20.0% 51 12
Broilers – Category I
10.0% 51 6
Setting the Stage
• 4th Quarter CY2009 results of FSIS testing have shown that only 3.5% of samples from large plants were positive, 18.4% of small, and 25.0% of very small with an overall average of 8.6%
Setting the Stage
• In addition, 82% of establishments were considered to be in Category I (achieving consistent process control) in Q4FY2009– FSIS’ goal is 90% by October 1, 2010– Only 2% were in Category III (failing to meet the
performance standard)
Current Features
• At this time, pathogen control in processing is governed by five key regulations :– On-line Reprocessing (OLR)
• 9 CFR 381.3(b)
– Off-line Reconditioning for Contamination• 9 CFR 381.91
– Zero Tolerance for Fecal Contamination• 9 CFR 381.65(e)
Current Features
• Chiller Chlorination and Water Reuse– FSIS Notice 45-03 Use of Chlorine to Treat Poultry
Chiller Water• Salmonella Performance Standard post-chill
Coming Attractions
• Salmonella Initiative Program (SIP) • Revised post-chill Performance Standard• Revised Salmonella criteria for Stuffed, Raw,
Not-Ready-To-Eat (NRTE) that appear to be Ready-To-Eat (RTE)
• Control of S. Enteriditis in broilers• Raw Chicken Parts Baseline
Coming Attractions
• Salmonella Initiative Program (SIP) – Announced in a January 2008 Federal Register
Notice– Described as a “voluntary” incentive-based
program for meat and poultry establishments that is intended to yield “significant data on attribution of human illness to FSIS-regulated products”
Coming Attractions• Salmonella Initiative Program (SIP)
– The Agency developed the SIP to “offer waivers to existing regulations (ie for increased line speed, changes to chilling of carcasses, etc) in return for increased process control efforts for Salmonella and Campylobacter”
– Industry is concerned that changes to current waivers would require participation in SIP
– Also concerned about having the micro data collected used against us
Coming Attractions
• Revised Post-Chill Salmonella Performance Standard– FSIS initiated a new young chicken baseline in June
2007– We are still waiting for the results to be published– Anticipate the Performance Standard to be
significantly reduced from the current 20%– Will add a new PS for Campylobacter
Coming Attractions
• Possibly revised Salmonella Performance Standard - Broilers (9 CFR 381.94)
Class of Product Performance Std
No of Samples Tested
Max No of Positives
Broilers – Category II
8.0% 51 4
Broilers – Category I
4.0% 51 2
Coming Attractions
• Revised Salmonella criteria for Stuffed, Raw, Not-Ready-To-Eat (NRTE) that appear to be Ready-To-Eat (RTE)– FSIS has been informally discussing new policies to
address Salmonella in retail, non-RTE, frozen stuffed poultry products
• In effect, FSIS would like to declare Salmonella to be an adulterant in these products
Coming Attractions
• Control of S. Enteriditis (SE) in broilers– 2009 FoodNet results showed that SE infections
were the most common of the Salmonella serotypes identified
• It also showed that there was a 32% increase in SE compared to 1996-1998
– FSIS data has also shown an increase in the proportion of SE recovered from post-chill regulatory samples
Coming Attractions• Raw Chicken Parts Baseline
– In January 2010, FSIS published FSIS Notice 08-10 announcing the implementation of a nationwide raw chicken parts microbiological baseline data collection program for one year
– This will include all cut-up chicken parts: skin on, skinless, bone in, and boneless plus giblets
– May result in a Performance Standard at point of packaging
Foreign Dramas• Russian ban on the use of chlorine in
processing– The Russian Parliament banned the sale of raw
chicken products that have been treated with chlorine effective January 1, 2010
– Since that time, USDA and the U.S.A. Poultry & Egg Export Council (USAPEEC) have been in continuing negotiation with Russia trying to get a finalized trade agreement
Mike MullenCorporate Account ManagerFor more information contact:melissa.meinke@ecolab.com www.ecolab.com or 800-392-3392
Pre-Harvest Salmonella Interventions: Value and Methods
B.M. HargisDVM, PhDProfessor and DirectorUniversity of Arkansas Poultry Health LaboratoryTyson Endowed Chair for Sustainable Poultry Health
Purpose of Presentation• To demonstrate that the source of Salmonella
contamination of poultry carcasses is from pre-slaughter infections of poultry
• To provide evidence that ante-mortem interventions can markedly reduce post-mortem contamination
• To compare available ante-mortem intervention strategies with regard to efficacy
No “Silver Bullet” for Salmonella• Salmonella is Amazingly Frustrating• Many Strains (serotypes) – vaccination difficult• Differ in Ability to Cause Disease• Transmitted Vertically and Horizontally• Many Sources of Infection – many carriers – most
broilers are infected from the breeder flocks through the hatchery
• Maintaining Zero Infections is Expensive• Difficult to Maintain Free Status
Salmonella – Live Production Source
• Food Borne Pathogens Do Not Originate from Spontaneous Generation!
• Poultry from Salmonella-free farms arrive at processing - free of Salmonella
• Poultry that enter the processing plant free of Salmonella, exit the processing plant without contamination in facilities not contaminated by previously infected flocks
Evidence for Live Production Source
• Scheduling of infected flocks for the end of the shift has greatly reduced post-chill contamination
• Flocks that are not infected, when processed as the first flock of the day, are Salmonella free
• Effective live production interventions have resulted in marked reductions in contaminated carcasses in numerous published studies
Hargis, B. M., D. J. Caldwell, and J. A. Byrd. 2001. Microbial pathogens of poultry: Live bird considerations. Pages 121–136 in
Poultry Meat Processing. • Non-infected flocks are processed as
Salmonella negative• Carcass contamination increases markedly
after crop removal – crop is the primary source
• Once a plant is contaminated, negative flocks may be contaminated during processing
First 2 flocks of a Processing DaySalmonella positive/Total samples
Pre-Chill
Pre-Chill
Pre-Chill
Post-Chill
Flock Swab Skin C.R. C.R. 1 0/45 0/45 0/45 0/45 2 0/30 0/30 0/30 0/30
When flocks identified as Salmonella negative entered a processing plant as the firstFlocks of a shift – no Salmonella was detected at pre- or post-chill
EXPERIMENT 2Flock 1 - Low Level Detection Antemortem
0
5
10
15
20
25
30
Sampling Points
% S
alm
on
ella
Po
siti
ve
Post-Pick
Post-Evis.
Post-Crop
Pre-Chill
Post-Chill
EXPERIMENT 2Flock 2 - High Level Detection Antemortem
0
10
20
30
40
50
60
70
80
Sampling Points
% S
alm
on
ella
Po
siti
ve
Post-Pick
Post-Evis.
Post-Crop
Post-Trim
Pre-Chill
Post-Chill
EXPERIMENT 2Flock 3 - Low Level Detection Antemortem
0
10
20
30
40
50
60
70
80
Sampling Points
% S
alm
on
ell
a Po
sit
ive
Post-Pick
Post-Evis.
Post-Crop
Post-Trim
Pre-Chill
Post-Chill
Hargis, B. M., D. J. Caldwell, R. L. Brewer, D. E. Corrier, and J. R. DeLoach. Evaluation of the chicken crop as a source of
Salmonella contamination from broiler carcasses. Poult. Sci 74:1548–1552.1995.
• The crop was found to be several times more frequently contaminated with Salmonella than the ceca
• The crop ruptured during processing 80x more frequently than the ceca
Ramirez, G. A., L. L. Sarlin, D. J. Caldwell, C. R. Yezak, M. E. Hume, D. E. Corrier, J. R. DeLoach, and B. M. Hargis. Effect of feed withdrawal on the incidence of
Salmonella in the crops and ceca of market age broiler chickens. Poult. Sci 76:654–656.1997.
• The incidence of crop contamination pre-slaughter was greatly increased by pre-slaughter feed withdrawal
• The longer the feed withdrawal period, the greater the incidence of crop Salmonella recovery
• Several subsequent papers also confirmed this and linked to increased processing plant contamination
Poult Sci. 2002 Jan;81(1):70-4.Fluorescent marker for the detection of crop and upper gastrointestinal leakage in
poultry processing plants.Byrd JA, Hargis BM, Corrier DE, Brewer RL, Caldwell DJ, Bailey RH, McReynolds JL,
Herron KL, Stanker LH.
Thoracic Cavity With Visible Contamination -Lights Off - with Black Light
• Note: zero tolerance for visible ingesta caused a common response of extended pre-slaughter feed withdrawal – resulting in greater Salmonella (and Campylobater contamination of crops pre-slaughter
Poult Sci. 2001 Mar;80(3):278-83.Effect of lactic acid administration in the drinking water during preslaughter feed
withdrawal on Salmonella and Campylobacter contamination of broilers.Byrd JA, Hargis BM, Caldwell DJ, Bailey RH, Herron KL, McReynolds JL, Brewer RL,
Anderson RC, Bischoff KM, Callaway TR, Kubena LF.
• Treatment of chicks with high levels of certain organic acids during the feed withdrawal reduced carcass contamination post-chill by more than 50%
• Issue of reduced water consumption, carcass shrinkage, and cost of organic acid treatment
• A commercial product, developed at the University of Arkansas, uses a blend of acids and flavoring agents overcomes water refusal issue
Hargis, B. M., D. J. Caldwell, and J. A. Byrd. 2010. Microbial pathogens of poultry: Live bird considerations, C. Owens, Ed.
• Vaccination generally only has modest effects on intestinal colonization
• Vaccination is complicated by the more than 30 serovars of Salmonella that commonly infect poultry – relatively serotype specific
• While injected killed vaccines often protect against disease, only live vaccines have the potential to reduce enteric infection through development of mucosal immunity
Current USDA-sponsored Research Project at the UA - PHL
• We have developed a methodology for incorporating Salmonella and Campylobacter antigens (epitopes) into a non-pathogenic Bacillus vector
• This vector co-presents selected highly conserved antigens with an immunostimulatory molecule – oral application is possible
• Early research indicates that Campylobacter constructs are nearly 100% effective for eliminating infection in broiler chickens
• Current Salmonella constructs elicit moderate protection, research is ongoing
Bacillus-vectored Vaccine AgainstCampylobacter
Bacillus-vectored Vaccine
• Cell surface expression of epitopes and immunostimulatory molecules.
• Similar to expression system previously evaluated in Salmonella.
Campylobacter jejuniEnumeration by qPCR
0
1
2
3
4
5
6
7
Day 24 Day 36
log
CF
U/g
m Ilia
l C
on
ten
t
Saline
BSBB
BS/Campy IEII 10 6̂
BS/Campy IEII 10 8̂
Campylobacter jejuni-specificIgG Antibody Levels
0
0.1
0.2
0.3
0.4
0.5
0.6
Day 21 Day 36
S/P
Ra
tio
Saline
BSBB
BS/C IEII 10^6
BS/C IEII 10^8
Campylobacter jejuni-specificIgA Antibody Levels
0
0.1
0.2
0.3
0.4
0.5
Day 21 Day 36
S/P
Ra
tio
Saline
BSBBBS/C IEII 10 6̂
BS/C IEII 10 8̂
A Probiotic/DFM Developed at the University of Arkansas
• This lactic acid-based culture, laboratory designation “B11”, has been evaluated in more than 26 refereed papers during the last 7 years and reduces Salmonella in both laboratory and field studies
• Application in field trials has resulted in more than 80% reductions in Salmonella entering processing plants
• Commercial product (FloraMax® )is limited by drinking water administration
• Current field trials with in-feed application of a new Spore-based culture are promising
Limitations of Lactic Acid Bacterial-Based Probiotics
• Shelf life
• Heat stability
• Application
In Vitro Antimicrobial Screening
• In Vitro Antimicrobial Activity (Overlay)– Salmonella – Clostridium – Campylobacter
Hard Agar Nutrient Media
Soft Agar Overlay w/ Pathogen
Bacillus Colony
Overlay: Salmonella ssp.
Spore Yield
• High Concentration of Spores–1011-1012 spores/g of fermentate–Highly heat resistant –survive pelleting–GRAS – safe isolates
In vivo Screening
P-value < 0.05
Body Weight Gain: Chick In vivo Trial
100
110
120
130
140
150
160
170
180
190
200
Candidate Isolates
BW
G (
g)
DE
DE
DE
E
CD
DE
In vivo Screening
*Denotes significant Difference from ControlP-value < 0.05
0
10
20
30
40
50
60
70
80
90
100
Candidate Candidates
Perc
en
t R
eco
very
Crop
Ceca
* *
*
*
*
**
Recovery of S. typhimurium: Chick In vivo Trial
FIELD TRIAL
Field Trial
650
660
670
680
690
700
710
720
730
740
750
Control Histostat Sporulin B1 MM65
Body Weight Gain Langham Field TrialDay 23 of Experiment
a
B
b
b
BW
G (
g)
P-value < 0.05
a
b
Field Trial
Salmonella CFU from Langham Field Trial Day 23 of Experiment
00.20.40.60.8
11.21.41.61.8
22.22.4
Control Histostat Sporulin B1 MM65
cfu
/g (
log
10)
a
ab
b
ab
P-value < 0.05
Necrotic Enteritis Model - Broilers
250
270
290
310
330
350
370
Control BMD Sporulin Bacillus Group 2
Body Weight Gain and Mortality 22-29 Days
BW
G (
g)
8.5%16%
0% 0%b
b
aa
Summary• Live birds are the source of processing plant
contamination – infections are mostly from parent flocks
• The crop is the major site of infection/contamination leading to carcass contamination
• Extended feed withdrawal increases the contamination problem
• Antemortem disinfection of the crop will reduce processing plant contamination
Summary- Continued• Reducing infections in live birds reduces carcass
contamination• Current vaccines can reduce vertical transmission but
only modestly affect intestinal carriage and plant contamination – new vaccine technology holds promise
• Water-based probiotics (Lactic Acid Bacteria) are commercially available with demonstratable efficacy – though not all work
• Some available probiotic products also improve production efficiency
Summary- Continued• New specially-developed spore-based DFM for
feed treatment hold tremendous promise – large scale field trials are ongoing
• A multipronged approach is likely the most cost-effective way for reducing Salmonella contamination of carcasses to acceptable risk levels
Jeb Supplejs@carometec.com www.carometec.com(563) 582-4230
Post-Harvest InterventionsElizabeth KrushinskieDVM, PhDDirector of QA and Food SafetyMountaire Farms, Inc.
Overview
• Current Strategies• Russia
Current Strategies
• FSIS Directive 7120.1 Safe and Suitable Ingredients Used in the Production of Meat, Poultry, and Egg Products– Lists all of the currently approved acidifiers and
antimicrobials for use in poultry processing– Also specifies which products they can be used on
and the locations they can be used at
Antimicrobials
• Chlorine and chlorine-based products are the most commonly used antimicrobials– Applicable to all processing locations– Very effective– Inexpensive
Antimicrobials• Other products available include:
– Peroxyacetic acids– Bromine– Cetylpyridinium chloride– Trisodium phosphate
• These typically have restrictions on the product type and location where they can be used
• Expensive
Poll Question
Do you include your pathogen interventions in your HACCP plan or are they part of a pre-requisite program? HACCP Plan Pre-Requisite Program
Current Strategies
• Most companies use more than one intervention strategy in a “multiple hurdle” approach– These interventions can be packaged together in a
pre-requisite program (ie Pathogen Management Program) that support the HACCP plan or can be included directly in the HACCP plan
Poll Question
Do you use a post-chill antimicrobial intervention?
Yes – If so, what kind? No
Current Strategies
• The most common processing steps where antimicrobial interventions can be included:– Pre-scald brush cabinets– Scalders– Picking rails– Post-picking rinse cabinets (New York washers)
Current Strategies
• The most common processing steps where antimicrobial interventions can be included:– Equipment rinses– On-line Reprocessing (OLR) brush and wash
cabinets– Off-line reprocessing and salvage (required to use
chlorine per 9 CFR 381.91)
Current Strategies
• The most common processing steps where antimicrobial interventions can be included:– Chillers– Post-chill rinse cabinets– Belts or conveyors in second processing
Current Strategies
• The results of these efforts, as measured by the FSIS post-chill Salmonella testing, show that the large establishments reduced their post-chill positive rate to 3.5% (4QFY09)– This is a significant improvement from the 20%
positive rate reported from the baseline study in 1996
– Obviously, what we are doing is working
Poll Question
Are you affected by the Russian ban on the use of chlorine?
Yes No
Russia
• As of January 1, 2010, chlorine treated poultry products are prohibited in Russia– Largely a de facto non-scientific trade barrier– Has stopped export of U.S. leg quarters to Russia
for 4 months already• USDA and the USTR office are in negotiations
with the Russian Veterinary Service
Russia
• No clear guidance at this point on which antimicrobials will be approved or which locations they will be required for – chiller, eviseration equipment sprays, off-line
reprocessing, post-chill cabinets, etc
Russia
• At this point, the only non-chlorine chemical products that are legally approved for chiller application are:– Peroxyacetic acid blends– Bromine
• The industry is scrambling to investigate and adopt alternatives to chlorine in a vacuum of accurate information
QUESTIONS & ANSWERS
FOR MORE INFORMATION:
Beth Krushinskie: bkrushinskie@mountaire.comDr. Billy Hargis: bhargis@uark.edu
Bill Kinross: bkinross@meatingplace.comAnn Bagel Storck: astorck@meatingplace.com
Webinar recording and PowerPoint presentation available at:www.meatingplace.com/webinars
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