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Food Safety (Microbiology, Sanitation and HACCP)
Frank T. JonesExtension Poultry Specialist
Cooperative Extension ServiceUniversity of Arkansas
Fayetteville, AR
Presentation Outline
• Sanitation Definitions
• Microorganisms – Overview
• Public Health Background
• Sanitation on Farm
• Sanitation in Plants
• HACCP Overview
What is Sanitation?• World Health Organization (WHO) – “All
precautions and measures which are necessary in production, processing, storage and distribution, in order to assure an unobjectionable, sound and palatable product which is suited for human consumption.”
• Sanitation from Greek Sanitas – Health• N. G. Marriott – “The creation and
maintenance of hygenic and healthful conditions.”
KillOrganisms
ExcludeContamination
PreventMultiplication
Sanitation Basics
Microorganisms
Bacteria Viruses
Fungi
Molds Yeasts
Beneficial Microorganisms
• Fermentation– Cheese, Beer, Wine, Bread, Yogurt
• Enzymes
• Aids to Human Metabolism
• Decay– Waste treatment, composting, decomposition
“The Enemies”
• Pathogens – Food Safety– Illness, Disease and Death
• Spoilage – Food Quality– Poor Quality, Short Shelf Life, Off Flavors,
Customer Dissatisfaction
Bacteria
• Microscopic single cells• Lots of moisture required• Cause most food illness• Three basic shapes
– Rod– Cocci (spheres)– Spiral
• Some spore formers• Grow, grow, grow
– Binary Fission
Bacterial Reproduction
– Binary Fission
Generation Cell Numbers
1 100
2 200
3 400
4 800
5 1,600
6 3,200
7 6,400
8 12,800
9 25,600
10 51,200
11 102,400
12 204,800
13 409,600
14 819,200
15 1,638,400
Generation Time
Generation Time (Min)
10 30 60 90
Hours from 100 to 1 Million
2.4 7.1 14.2 21.3
What Bacteria Need for Growth?
•F ood
•A cid (pH)
•T ime
•T emperature
•O xygen
•M oisture
FAT TOM
The Spore Cycle
• Spores VERY resistant• Two species form spores
– Bacillus– Clostridium
• Difficult to destroy – reduce strategy
• Problem in cooked foods
Fungi (Molds and Yeasts)
• Require less moisture• Can grow in acid pH• Very adaptable• Grow slower than
bacteria• Molds – multicellular• Form spores that are
less resistant than bacterial spores
• Yeasts bud
Basic Virus Structure
Genetic Material (DNA or RNA)Protein Coat
Tail Fibers
Hollow Protein Tail
Virus Life Cycle
Viruses
• Tiny• Simple
structure• Must grow in
cells• In foods –
fecal contam.• Personal
sanitation to prevent
• Living?
Our Losses…
• Every year (based on CDC data):
• Over 250 billion meals are prepared
• An estimated 76 million foodborne illnesses occur
• >5,000 foodborne associated deaths
• Costs = $7.7 to 23 billion
(Centers for Disease Control and Prevention, 2003)
Foodborne Illness
“... when a person becomes ill after ingesting a contaminated food...”
Foodborne illness can be caused by:• Biological hazards (bacteria, viruses, fungi)• Chemical hazards (cleaning agents, toxins)• Physical hazards (bone, glass, metal)
Foodborne Hazards
Hazard Est. Cases DeathsNorwalk virus 23,000,000 naCampylobacter 2,453,926 0.1%Salmonella 1,412,498 0.8%C. perfringens 248,520 .05%S. aureus 185,060 .02%E. coli O157:H7 73,480 .83%L. monocytogenes 2,518 20%C. botulinum 58 8.6%
(Centers for Disease Control and Prevention, 2001)
FOOD BORNE PATHOGENS:
• USDA – FSIS “Target Pathogens”
• Four major pathogens of food bone illness– Salmonella– E. coli 0157:H7– Campylobacter– Listeria monocyctogens
SALMONELLA
• Most frequently reported
• Introduced anywhere within the food chain
• Grown on any food under the right conditions: Moisture and Temperature
• Ideal growth temperature 40-140 ° F
• Cook temperature essential to kill-160 º F
• Safe handling of food by consumer essential
E COLI 0157:H7 & Campylobacter
• Natural inhabitant of the GI tract of all animals
• Sanitary practices throughout the Farm to Table essential for control
• Consumer education of safe handling practices for food, raw and cooked, essential for control
LISTERIA MONOCYTOGENS
• Commonly found in GI tract of all animals• Can survive for long periods in SOIL,
SEWAGE, DUST, VEGATATION AND WATER
• Resistant to cool temp - Cold storage• Can form biofilms on surfaces to resist
cleaning and sanitizing• Biggest threat:Pregnant women-
miscarriages and birth defects
Sanitation in Live Production
• Will never be sterile but don’t give up!• 7 Basic Steps in Live Production Sanitation
– Obtain Clean Stock– Proper Bird Care– Vermin Control– Moisture Control– Feed Storage– Biosecurity– Water Sanitation
Obtaining Clean Stock
• Know the seller
• Don’t look for bargains
• Isolate birds for 2 wks
• Monitor birds daily and separate sick ones
Proper Birds Care
• Healthy birds are more resistant
• Pay attention to bird behavior
• Collect dead at least daily
• Provide ventilation
Vermin
• Damage facilities
• Eat feed
• Contaminate facilities
• Entry for other pests
• May kill animals
Moisture is often THETHE SINGLESINGLE Most Important Factor in Determining Microbial Growth
Moisture Control
• Litter moisture related to pathogens
• Moisture control related to:– Addressing obvious sources– Ventilation– Control of Drinkers
Feed Storage
• Protection from Rodents & Wild Birds
• Protection from Moisture
• Protection from Heat and Sunlight– Moisture Migration– UV Destruction
• Feed Freshness
Moisture Migration in Food
12%
12% 12%
12% 12%
12%
12%
12%
12%
16%
16% 13%
16% 13%
13%
10%
10%
10%
20%
20% 12%
20% 12%
12%
8%
8%
8%
Moisture Migration in Feeds
02468
1012141618
Moi
stu
re (
%)
50 70 90
Temperature (F)
Effect of Temperature on Feed Moisture
SwineCattlePig
From Headley 1969
From Headley, 1969
0
5
10
15
20
25
30F
eed
Moi
stu
re (
%)
25 40 58 75 82 93
Relative Humidity (%)
Effect of Relative Humidity on Feed Moisture
Pig Starter
Cattle Ration
0
5
10
15
20
25
30
Afl
ato
x
(pp
b)
1 to 5 6 to 10 11 to 15 16 to 20
Age in Days
Effect of Feed Age on Aflatoxin Concentration.
From Jones et al.1982
How Feeds Age on Farm
Birds preferto eat pelletsrather than fines
Concentration of Fines
Feed older thanaverage and highin fines
Biosecurity
• Procedures that work for bird pathogens also keep out human pathogens
• Basic Steps– No Visitor Policy – Have Farm Clothes– Protect Personnel – Clean Vehicles– Clean Equipment – No Contact Other Birds– Proper Dead Disposal – No Borrowed Equip– No Visits to Problems – No Wild Game– Locks & Security– Avoid Mixing Animal Species
Footbaths – The Good, The Bad and The Ugly
• Can be effective BUT
• MUST pay attention
• Use correct disinfectant
• Contaminated baths spread disease and pathogens
Basics Steps in Sanitizer Use• Avoid mixing sanitizers PARTICULARLY
Chlorine @ pH<4 = Chlorine Gas• In general, clean, scrub, rinse THEN sanitize• Store sanitizers away from feed and birds• Protect sanitizers from heat and light• Avoid long storage times• Use for Approved Purposes
– General Sanitation– Food Contact Surfaces
Disinfectant Types and QualitiesType Activity Organic
Mattter Effect
Cost Human Toxicity
Comments
Alcohols Wide no spores
Reduces effects
Exp Low Non Corrosive, Fire Hazard, conc 70-95%,
Hypochlorite Wide no spores
Kills effects
Low Low Can be corrosive
Iodophors Wide no spores
Reduces effects
Mod Low May stain clothing, porous surfaces
QAC (Quaternary
Ammonia Compounds)
Limited no
spores
Reduces effects
Low Low Soaps, detergents and hard water limit
effectiveness
Phenolic Wide no spores
Little to none
Mod Low Good residual activity
Aldehyde Wide Limits effects
Mod Mod Gets everything, but can be highly toxic
Oxidizer Mod. No spores
Kills effects
Mod Low Limited residual,
Mod corrosive
A Broad Look at DisinfectantsType Examples Uses
Alcohols Rubbing Alcohol, Isopropyl, Ethanol
Small objects, hands
Hypochlorite Chlorox, Chloramine-T, Halazone
Water, Clean surfaces
Iodophors Betadine, Iofec, Isodyne, Tamed Iodine, Weladol
Water, Hands, Equipment, Walls
QAC (Quaternary Ammonia
Compounds)
Roccal, Germex, Hi-Lethol, San-O-Fec, Warden, Zephiran
Hatcheries, with some soaps
Phenolic Lysol, Pine-Sol, Cresi-400, Environ, Tek-Trol
Hatcheries, Equipment, Footbaths
Aldehyde Formaldehyde, Glutaraldehyde
Fumigation, clean surfaces
Oxidizer Hydrogen Peroxide, Peracetic Acid
Clean surfaces
Water Sanitation
• Water – A GREAT organism transmitter
• Consider closed line systems – Nipples or cups
• Clean open waterers often, but don’t dump water in the litter
• Proper height adjustment
Bacterial Counts from Poultry Water Systems
2700
26600203000
2340000
600
282000
0
4775000
0500000
10000001500000
20000002500000
300000035000004000000
45000005000000
Bac
teri
al C
ou
nts
Farm A Farm B Farm C Farm D
Source
Line End
From: Watkins. 2003
Used with permission from: The Center for Biofilm Engineering at Montana State University – Bozeman
http://www.erc.montana.edu/CBEssentials-SW/bf-basics-99/bbasics-01.htm
Used with permission from: The Center for Biofilm Engineering at Montana State University – Bozemanhttp://www.erc.montana.edu/CBEssentials-SW/bf-basics-99/bbasics-01.htm
Biofilm in a Municipal Water Line
Water Line Cleaners for Use Once a Week When Birds are Present
Clear Household Ammonia
Household Bleach
White Household
Vinegar
Iodine (18.05%)
½ teaspoon per gallon of water
½ teaspoon per gallon of water
1 oz per gallon of water
¼ teaspoon per gallon of water
Cleaning Closed Watering Systems with Birds in the House
Clear Household Ammonia
Household Bleach
Clear Vinegar
Iodine (18.05%)
6 oz per gallon
6 oz per gallon
128 oz per gallon
2 oz per gallon
Meter stock solution at 1 oz / 128 oz (gal) water
Prepare a stock solution
Basic Steps in Poultry Processing
Pre-slaughter
Immobilize
Feather Removal
Evisceration
Chilling
Further Processing orPackaging
Kill Line
Evisceratio
n Line Separation Wall
Air
Flo
w
Sanitation in Small Processing
• Work indoors if possible• Avoid the use of wood surfaces• Use sanitizers labeled for Food Contact
Surfaces• Clean and sanitize equipment before use• Separate slaughter and picking from
evisceration and cut up -- Job Specialize• Avoid long delays• Keep things as clean as possible (insects)• Don’t spare the water• Cool processed carcasses quickly and keep
them cool• Clean and sanitize equipment before storage
Loblolly Pine Birch100μ
Staphylococcus - 1.0μ Clostridium - 0.4 x 3μ Treponema 0.2x 11μ
Wood Should be Avoided in Processing Areas
Sanitizers for Food Contact SurfacesCategory Advantages Disadvantages
Chlorine, Dioxides
Broad Act., Not temp. sensitive, Cheap, No Foam
Cl gas, Corrosive, Organic material, Degrades, THM’s, pH range
Iodophores Broad Act., Low Tox., Stable, Color, Good Residual
Stains, Hard water, Temps (High & Low), Odor, Cl cheaper
QAC Stable, Innocuous, Some Residual
Low temps, Hard water, Little effect on gram negative bacteria
Acid-Anionic Stable, W/ Organic Matter, Non Corrosive, Odorless
Cost, pH
Carboxylic Acid
Broad Act., Stable, W/ Organic Matter, High Temp
Low Temp., Corrosive
Peroxy Acid Broad Act., Degrade, Non Corrosive, Temp. Tolerant
Co, Cu, Ti, Mishandling Danger, Concentrate Odor
Natural Disinfecting Agents
• Sunlight (Ultraviolet rays)
• Heat (>85°F)
• Cold (Freezing or below)
• Drying (Aided by wind, light and heat)
• EFFECTIVE, But are they reliable?
HACCP -What is it?• HACCP -(HAS-SIP)• H azard• A nalysis and• C ritical• C ontrol• P oints• HACCP often misused term.• A systematic method of documenting
that food safety hazards have been addressed.
HACCP - What is it?
• HACCP involves only food safety issues.
• Out of control = unsafe food produced.
• Plans unique for each unit and product.
HACCP – What is it?Step Meaning
1. Hazard Analysis What are the controllable food safety hazards?
2. Establish Critical Control Points
Where do things go wrong and how can we reliably control it?
3. Establish Critical Limits What value indicates the process is in control?
4. Establish Monitoring Procedures
Who, what, when , where and how will CCP’s be monitored?
5. Establish Corrective Actions
What happens if we exceed a Critical limit?
6. Establish a Record Keeping System
If you don’t write it down it doesn’t exit.
7. Establish Verification Procedures
How do you know the system works?
HOW DOES HACCP WORK?
• Processors must take the following steps:– assemble a HACCP team to design their plan – describe the product and its method of
production, distribution and intended consumer.
– Develop and verify process flow diagrams
How does HACCP Work?
• Identify at each step of the production flow chart any hazard to food safety as to:– Chemical – Physical– Bacterial
• Support the hazard with a decision making document and scientific data
How does HACCP Work?
• If a CCP deviation is found the following must take place:– Identify the cause of deviation– Describe how the critical limit was
restored– Describe how the deviation can be
prevented from happening again– Describe how the adulterated product was
reconditioned or what happened to the product
FARM TO TABLE FSIS GOALS
• FSIS has made a commitment to expanding into the pre harvest areas of the food chain, working in a non regulatory capacity, to promote food safety.
• Commitment to utilize the knowledge, skills and abilities of FSIS veterinary medical expertise to contribute to the goal of food safety.