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Keeping Listeria at Bay:
The battle that ready-to-eat processors
can’t afford to lose
Host: Bill Kinross, Publisher, Meatingplace
Moderator: Lisa Keefe, Editor, Meatinglace
Presenter
Harshavardhan
Thippareddi,
Associate Professor
of Food Science,
Department of
Food Science and
Technology,
University of
Nebraska, Lincoln
Listeria Control:
Old Problem, New Solutions
Harshavardhan Thippareddi, Ph. D.
www.meatingplace.com
Sept 9, 2009
Prepared by: Martin Wiedmann, Ph. D., Cornell University, Ithaca, NY
Well Known “Facts”
• Human listeriosis can occur as an epidemic
or as sporadic cases
• L. monocytogenes common in certain/many
environments
• L. monocytogenes grows at refrigeration
temperatures
• Infectious dose is high
– Growth in foods is usually needed to reach
levels likely to cause human disease
Martin Wiedman, Cornell Univers
Well Known “Facts”
• Human exposure is common
• Majority (ca. 99%) of human listeriosis
cases are foodborne
• Potentially long incubation period (7-60
days)
• Human listeriosis affects predominantly
elderly and immunocompromised people,
pregnant women and newborns
Martin Wiedman, Cornell Univers
The FDA-CSFAN, USDA-FSIS, & CDC
Risk Assessment – Highlights
• Most human listeriosis cases in US appear to
be caused be contaminated deli meats
–
–
–
–
–
–
–
RTE deli meats – 1,598 cases
Pasteurized milk – 90 cases
High fat and other dairy products – 56 cases
Not-reheated frankfurters – 31 cases
Cooked ready-to-eat crustaceans – 2.8 cases
Smoked seafoods 1.3 cases
Fruits and vegetables – 1.1 cases
Percent Positives
Prevalence Of Listeria Monocytogenes
On RTE Meat And Poultry Products*
*FSIS results of ready-to-eat products analyzed for Listeria monocytogenes
Human Listeriosis - Trends
http://www.cdc.gov/FoodNet/factsandfigures/trends.html
Listeria Monocytogenes Prevalence(%)
On RTE Meat And Poultry, 2008
http://www.fsis.usda.gov/Science/Table22_Micro_Testing_RTE_2008/index.asp
Challenges Towards Continuous
Reduction Of Human Listeriosis
• LM is common throughout the food chain
• A single magic bullet will not work
• Focusing on one product (RTE deli meats) at
one point (processing) does not seem to work
USDA-FSIS Final Rule –
RTE Processing Establishments
Establishments producing post-lethality
exposed RTE product must comply with
requirements included in one of the following
alternatives (§430.4)
Alternative 1: Use post-lethality treatment AND
an antimicrobial agent or process
Alternative 2: Use post-lethality treatment OR
an antimicrobial agent or process
Alternative 3: Use sanitation measures ONLY
Physical Post-lethality Treatments
• Heating
– Steam
– Submersion in hot water
– Radiant oven heating
• High Pressure Processing
Thermal (Surface) Pasteurization
Systems for RTE Meat Products
• Meat product type and composition
– Whole muscle vs. restructured product - product
surface characteristics
– Thermal properties
• Product packaging
– Packaged vs. non-packaged
– Film thickness and material
• Product orientation & package design
– Single vs. double layer – hot dogs
– Sliced product – deli type products
Product Orientation Effects
.75”
Single-Layer
Franks
Single-Layer
Separated Franks
1.5”
Double-Layer
Franks
Courtesy: Alkar
Product Orientation Effects
Turkey breast
Roast beef
Ham
Courtesy: Alkar
Thermal (Surface) Pasteurization
Systems for RTE Meat Products
• Hot water-based systems
• Steam-based systems
– Non-condensing steam
– Condensing saturated steam
– Flash steam system
Destruction Of L. Monocytogenes
Using Hot Water System
Muriana et al., 2002
High Hydrostatic Pressure Systems
• Non-thermal intervention technology
• Minimal quality changes
• Can be combined with other treatments such as
heat
• Pressures in the range of 250 MPa (36,260 PSI)
to 600 MPa (87,023 PSI)
100 MPa=14,504 PSI
High Pressure Processing Systems
High Hydrostatic Pressure Treatment
– Factors Controlling Application
• Product type and composition
• Processing time and temperature
• Types of microorganisms to be inactivated
High Hydrostatic Pressure Systems
High Hydrostatic Pressure Systems
Post-process Lethality Treatments –
Chemical Interventions
Antimicrobial Agents – Lethality
Treatments
•
•
•
•
•
Acidic calcium sulfate
Acidified sodium chlorite
Peracetic acid
Lauric arginate
ε- polylysine
Antimicrobial Agents – Lethality
Treatments
•
•
•
•
Liquid smoke fractions
Listeria phages
Octanoic acid
Ozone (ozonated water)
Acidic Calcium Sulfate
Nunez et al., 2004
Acidic Calcium Sulfate
Nunez et al., 2004
Acidified Sodium Chlorite
9.0
L/D/ASC (H)
L/D (H)
0
7
Cont (H)
L/D/ASC
L/D
Cont
8.0
Log CFU/cm2
7.0
6.0
5.0
4.0
3.0
2.0
14
21
28
Days of Storage
Luchansky et al. 2006
Model System – Ε- Polylysine
Geornaras et al., 2005
Smoke Derivatives –
L. Monocytogenes Control
Gedela et al. 2007
Antimicrobial Agents – Control
Lm Growth
Organic Acids Salts
• Approved for meat product use
– Sodium or Potassium salts of lactic acid
– Sodium acetate or diacetate
– Sodium citrate buffered with citric acid to
pH 5.6
• Live bacteria – Canbiocin
• Levulinate (not commercialized yet)
Synergism – Lactate and Diacetate
5.0
Log CFU/g
4.0
2.5 SL
3.0
0.1 SDA
0.2 SDA
2.0
2.5 SL + 0.1 SDA
2.5 SL + 0.2 SDA
1.0
0.0
Antimicrobial
Control Of Listeria Monocytogenes
In Taco Meat (Aerobic)
Log CFU/g
7.0
C
6.0
I1
I 1.3
5.0
I 2.5
4.0
IP 1
3.0
IP 2.5
IP 1.3
Opti 2.5
2.0
0
3
Days at 10 C
7
Acknowledgments
This Project was funded through a grant from the
National Integrated Food Safety Initiative (Special
emphasis grant No. 2005-51110-03278) of the
Cooperative State Research, Education and
Extension Service, U. S. Dept. of Agriculture
Presenter
John N. Butts,
Vice President of
Research,
Land O’ Frost
Data Analysis, Investigation and
Corrective Action
“Follow the data trail to the source but
always be alert and aware to the organism’s
ubiquitous presence and pervasive nature.”
John Butts
Land O’ Frost
Meatingplace Webinar
Sept 2009
Commitment Model
•
•
•
•
•
Resistant – don’t believe it has value
Accepting – why not
“Buy-in” – we will do it
Engagement – involved in solution
Commitment – hold self and others
accountable for achieving results
FSIS Regulatory Testing for Lm in RTE Products by
Calendar Year 1990-2007
(All Years All Projects)
5.0%
Percent Positive
4.5%
4.0%
3.5%
3.0%
2.5%
2.0%
1.5%
4.61%
4.03%
3.61%
3.44%
2.90%
3.02% 2.91%
2.54%
2.25%
1.91%
1.45%
1.32%
1.03%
1.0%
0.76%
0.5%
0.55% 0.64% 0.61%
0.43%
0.0%
1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007
Calendar Year
Incidence of Foodborne
Illness 1996-2007: Listeria*
0.6
Incidence per 100,000 Population
0.5
0.4
National
Health
Objective: .25
0.3
0.2
0.1
0
1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007
*Preliminary FoodNet Data on the Incidence of Infection with Pathogens Transmitted
Commonly Through Food --- 10 states, 2007
Sources of Ls in High-Risk RTE Area
•
Transferred from Zone 4 area outside of the
High-Risk RTE area
– Homeless, but looking for a harborage location
– Typically found with a transfer point monitoring
positive
•
Growth niches within High-Risk RTE area
1. This means they are established, and have found
a protective home in equipment or facility.
2. They may exist in a transient home such as
rework pans, trash containers or other difficult to
clean mobile container / environment.
Transfer Points vs Niches
Many positive sites found during monitoring
are not growth niches. They are transfer
points (i.e., a product handler’s gloved
hands, floor sample in high traffic pathway).
Transfer points are not growth niches
because the organism is eliminated
during the cleaning and sanitizing
process.
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.
Growth Niches
Hollow roller with solid stainless steel
shaft in center (almost press fit).
When center shaft removed organic
matter is evident.
Growth Niches
Must either be designed out of the system or
managed as a part of the process.
• Design Examples
– Equipment is redesigned to eliminate or seal hollow
areas
•
Hollow areas of equipment (e.g., frames, rollers) must be
eliminated where possible or permanently sealed (caulking
not acceptable). Bolts, studs, mounting plates, brackets,
junction boxes, name plates, end caps, sleeves and other
such items must be continuously welded to the surface of
the equipment and not attached via drilled and tapped holes.
AMI Equipment Design Task Force
Growth Niches
Minimize with process control techniques
• The potential to support growth still exists
within the machine, part or area
» Whenever this becomes the chosen path remember
to implement methods that will hold the gains with
turnover in both hourly and management ranks.
Growth Niches
• Examples of how to minimize with process
control techniques
– Disassemble clean and sanitize
– Heat sanitize
• Cook in oven or smokehouse
• Cover with tarp and inject steam
• Place in COP tank
Sanitation Process Control Steps Necessary for
Effective Control of Complex Equipment
Equipment at End
of Production
Routine
/ Daily
D
To isas
a g se
rea mb
ter le
lev
el
Predefined
Interval based
on need
e
bl
ot
sp
m
d
ol
se
lc
as
is
nt
ro
co
D
To
Pasteurize
Normal level
a
mb
le
Clean &
Sanitize
Predefined
Interval based
on need
Hand Clean &
Sanitize. Parts to COP
Intensive level
Cooking level
Clean &
Sanitize
Dis
e
ss
Clean &
Sanitize
Hand Clean & Sanitize,
Small Parts to COP and
Large Parts to Smokehouse
Sanitation Process Control Steps Necessary for
Effective Control of Complex Equipment
Equipment at End
of Production
Critical
Factor
Routine
/ Daily
Normal Level
Degree of
Disassembly
Clean &
Sanitize
Predefined
Interval based
on need
Predefined
Interval based
on need
Critical
Factor
Intensive Level
Degree of
Disassembly
Clean &
Sanitize
Critical
Factor
Cooking Level
Degree of
Disassembly
Critical
Factor
Hand Clean & Sanitize,
Small Parts to COP and
Large Parts to Smokehouse
Critical
Factor
Clean &
Sanitize
Pasteurize
Hand Clean &
Sanitize. Parts to COP
Critical
Factor
Seek and Destroy Process
Normal cleaning and
sanitatio
n
Observe flood
sanitization
Observe assembly
Observe Post assembly sanitizer
application
Observe normal setup and
start up activities
Are all parts and
components being
adequately
sanitized (chemical
or heat)?
Are GMP's
followed?
Stop operation before product
is placed on the line
Disassemble to normal daily
sanitation level
Disassemble any remaining
machine components
Inspect and swab
any suspect areas
Clean and flood or heat sanitize all
disassembled line components
Is degree of
disassembly
acceptable?
Are cleaning
methods
acceptable?
If area is Ls positive then it
is a growth niche
Evidence of
unacceptable
organic
buildup?
If APC growth is supported then
the suspect area is a potential
growth niche
Time Study
Product transport
Operator tools
Line workers
Locating a
Transfer
Vector
Sample everything coming to line
Materials
Maintenance
Process 1
A Time Study consists
of sampling the line
components and
every thing that
comes to the line over
a period of time
Process 2
Process 3
Process 4
~
The Time Study
typically starts during
setup and assembly .
Samples will be taken
as workers and
product come to the
line, repeated after
line is running then
every 2 hrs thereafter
Swat Team Sampling
• Sample during an idle period after sanitation,
before production i.e. Saturday when no
production is running
• Sample large areas using sponges or gauze.
• Sample areas not typically sampled during
routine sampling
– We found a transient growth niche using this method
– COP basket handle
Presenter
Mike DeSmet,
Vice President of
Food Safety,
West Liberty Foods
Listeria Defense:
A Multi-Hurdle Approach
Scope: It Takes More Than One
• There is no one magic bullet.
• There is no one department responsible.
• Attitude must start from the top one down.
• For every one dollar spent up front, multiple
dollars are saved later.
• No one is immune.
Multiple Hurdle Approach
•
•
•
•
•
•
Building Design/Physical Barriers
Chemical Interventions
Preventive Programs
Product Design/Handling
Training
Verification Activities
Building Design/Physical Barriers
• Each product slicing cell has separate positive
pressure, air handling system.
• HEPA air filtering systems keep with our clean
room focus.
• Separate slicing cells prevent cross
contamination.
• Encapsulated suits to prevent cross
contamination from employees.
Building Design/Physical Barriers
• Separate drain system in each slicing cell with
capability of back flooding each drain system.
• Ceilings, floors and walls are designed for easy
cleaning and sanitizing.
• Exposed product production areas are targeted to
<38°F.
• Design eliminates cardboard and wood from
entering exposed product areas.
Chemical Interventions
• Foamers/bootwashes
• Sanitizer challenge studies
• Rotating Sanitizers
• Equipment Fogging
• Choosing the correct cleaners and sanitizers for
your equipment, your environment and the
organism.
Preventive Programs
• Equipment audits/repair
• Deep cleaning programs (see next 2 slides for
examples)
• Use of indicator organisms to identify potential
niches
• GMP audits
• Maintenance PM’s
• Maintenance Tool Cleaning
Operator Side Spindle Cover
Assembled
Dissembled
cover
Cover
removed
When removed this cover exposed the spindle to allow for cleaning. This cover
is removed and cleaned with a Solvaxx solution once a week.
Flip Flop Electrical Cabinet
Operator side
Non-operator side
These cabinets are
opened up and
inspected weekly.
These areas can
be carefully
cleaned with a
Wypall lightly
saturated with
isopropyl alcohol
by a qualified
member of the
maintenance
department.
Product Design/Handling
•
•
•
•
•
•
Proper Cooking
Antimicrobial Ingredients
Modified Atmosphere Packaging
Freezing
Shelf Life Determination
Temperature Control (cold chain management)
Training
• Partnered with Iowa State
• Use of Visual Aids
• Food Safety Certification as a pre-hire concept
• GAP Training (Getting Acquainted Period)
successive classes throughout the first 90 days
• Annual Re-training
Verification Activities
• Strong Listeria program
• >3500 Listeria species swabs per month
company wide
• Zone 1 (conveyors, slicers, product beds)
• Zone 2 – indirect contact (on off buttons,
framework, etc.)
Verification Activities
• Zone 3 environmental (floors, ceilings walls)
• Zone 4 adjacent to RTE areas (employee welfare
areas, hallways, dry storage)
• Every line, every week
• Random product sampling
• Rapid detection methods
It Never Ends
• The listeria control system is a never ending
process.
• Constant changes due to continuous education,
extensive training and monitoring processes.
• Watching for new technology.
• Utilize Trade organizations as valuable resource
for latest topics and technical expertise.
• Utilize your chemical representatives and
equipment representatives.
Sharing Technology
• Growing concept that Food Safety is not
proprietary.
• When one company stumbles we are all affected
in the eyes of the consumer.
• WLF and IA State teamed up to sponsor a food
safety conference to share our training program
with everyone.
Questions & Answers
For More Information
Harshavardhan Thippareddi: [email protected]
John N. Butts: [email protected]
Mike DeSmet: [email protected]
Bill Kinross: [email protected]
Lisa M. Keefe: [email protected]
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