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“Assurance of The Safety of Meat Products”
Prof. Dr. Suwimon Keeratipibul
Department of Food Technology
Faculty of Science
Chulalongkorn University
Bangkok, Thailand.
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
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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
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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.)
