controlling salmonella and listeria in low moisture food manufacturing facilities frederick cook dfa...
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Controlling Salmonella and Listeria inLow Moisture Food Manufacturing Facilities
Frederick CookDFA Annual Conference
April 3, 2013
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Contamination of Low Moisture Foods
Pathogen Contamination Examples
Raw Grains Spices Seeds Tree Nuts Ground Nuts
Wheat flour Pepper Sesame Almonds PeanutsCookie dough Paprika Sunflower Pistachios Peanut butterCake batter ice cream Oregano Celery Hazelnuts Peanut paste
Pumpkin PecansWalnuts
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Low Moisture Foods
Lower moisture can eliminate the ability of pathogenic bacteria to multiply
Not a “Potentially Hazardous Food” (Aw >0.85 and pH >4.6) requiring time/temperature control to prevent growth for safety
But in dry conditions:• Bacteria have increased heat resistance• Bacteria may survive for very long periods of time• Bacteria can transfer and contaminate the product stream
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Finished Product Testing for Pathogens
5% of Samples Contaminated 1% of Samples ContaminatedProbability of Probability of Probability of Probability of
nLot Acceptance Lot Rejection Lot Acceptance Lot Rejection
1 0.95 0.05 0.99 0.01 5 0.77 0.23 0.95 0.05 15 0.46 0.54 0.86 0.14 30 0.21 0.79 0.74 0.26 60 0.05 0.95 0.55 0.45300 <0.01 >0.99 0.05 0.95
Source: International Commission on Microbiological Specifications for Food
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General Controls for Food Safety in Facilities - Preventive
Food Safety Plan – HACCP based – including validated CCPsPrerequisite Programs
• Raw material control• Pest control• Allergen control• Glass/physical hazard control• Sanitation SOPs• Water control• Personal Hygiene• Environmental contamination control
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General Controls for Food Safety in Facilities
Conditions that Allow Multiplication of Pathogenic Bacteria• Food• Acidity• Temperature• Time• Oxygen• Moisture
Exclusion of Moisture will prevent multiplication of pathogens in the food facility and reduce risk of their spread
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Water Control
WAR ON WATERTime
Microbial Growth
Food WaterMinimize presence of water by eliminating , reducing
and controlling it wherever possible
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Water Control
WAR ON WATER1. Determine areas where water is exposed in the facility2. Map the Facility for Presence of Water / Dry Areas3. Understand why water is used4. Determine strategies for eliminating/reducing/controlling
Necessary Water StrategyProcessing Reduce/controlWet cleaning/sanitizing Eliminate/reduce
Unnecessary Water StrategyCondensation Fix root causeLeaks
Ingress Fix root causeInternal Fix root cause
DrainsBackup Fix root causeLeaks Fix root cause
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Water Control
WAR ON WATERMinimize water usage where possibleReduce frequency of cleaning/sanitizing if appropriateEnhance sanitary design (reduce wet time)
Accessible - Cleanable – Sanitizable – Dryable – Inspectable
Substitute dry cleaning/dry sanitizing methods for wet methods and validate them (scrape, brush, vacuum, wipe, alcohol-quat)Visibly clean – ATP standard criteria – Allergen test negatives – APC standard criteria
Enhance water controlPipe directly to drainsEstablish dedicated wash roomsFix leaks / backups
Track water use and water exposure events
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Environmental Pathogen Control Program
Prevent transfer of potentially contaminated materials associated with risk to food product safety
• Conduct hazard analysis• Determine boundaries for control• Hygienic Zones different from Product Zones • Establish physical controls• Establish procedural controls
HYGIENIC ZONING
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Hazard Analysis – Identify Risks
• Location• Line, process step• Potential contamination type• Origin of potential contamination• Possible Transfer method(s)• Areas that may be affected• Product stream affected• Risk score
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Hazard Analysis - Score Risks
• Severity of contamination type• Likelihood of presence• Detectability of presence• Likelihood that product will be contaminated• Detectability of product contamination
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Barriers to Sources of Contamination
Barriers to outside sources• Pest control• Security• Physical barrier to water• Physical barrier to air• Physical barrier to other materials
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Barriers to Sources of Contamination
Barriers to potentially contaminated materials brought in• Pallets: wooden, plastic• New manufacturing equipment: hygienic condition• Other equipment: hygienic condition• Construction materials: contain• People: captive footwear, uniforms, visitor smocks & shoe cover• Ingredients: sourcing
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Employee Entrance
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Employee Entrance
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Employee Entrance
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Hygienic Zones Within the Plant
Barriers to contamination by materials, people, and equipment• GMP Support Zones: employee welfare areas, offices,
maintenance shop, inner docks• GMP Zones
- High Sensitivity GMP Zone: exposed to high sensitivity materials
- General GMP Zone
- High Hygiene GMP Zone: protect post kill product
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Hygienic Zone Map of Plant
General GMP Zone
High Sensitivity Zone
High Hygiene Zone
GMP Support
ZoneGMP
Support Zone
Non GMP Zone
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Physical & Procedural Barriers Between Hygienic Zones
GMP Support Zone into General GMP Zone• Handwashing
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Physical & Procedural Barriers Between Hygienic Zones
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Physical & Procedural Barriers Between Hygienic Zones
GMP Support Zone into General GMP Zone• Handwashing• Footwear sanitation
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Physical & Procedural Barriers Between Hygienic Zones
Sanitizer Spray Unit for Footwear
23Source:
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Physical & Procedural Barriers Between Hygienic Zones
GMP Support Zone into General GMP Zone• Footwear sanitation• Handwashing• Hairnet/beardnet• Safety items: glasses, hearing protection• GMP policies for jewelry, no eating, etc• Illness restriction policy
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Physical & Procedural Barriers between Hygienic Zones
High Sensitivity Zones: Contain high sensitivity materials• Walls and doors• Limited access• Air balancing• Hygienic Entrance Area (HEA) – for people• Hygienic Transfer Area (HTA) – for materials and equipment
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Example of Hygienic Entrance Area Layout
Hand wash sink
Shoe Sanitize
MirrorBlue
Smocks
Brown Smocks
Supplies
V
TVac Brush Box
High Sensitivity GMP Hygienic Zone
General GMP Hygienic Zone
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HEA Procedure – Into High Sensitivity Zone
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HEA Procedure – Out of High Sensitivity Zone
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Physical & Procedural Barriers between Hygienic Zones
Vacuum Brush Box for Footwear
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Physical & Procedural Barriers between Hygienic Zones
Protect High Hygiene Zones to reduce contamination risk• Walls and doors• Limited access• Air balancing• Hygienic Entrance Area (HEA)• Hygienic Transfer Area (HTA)
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HEA Procedure – Into High Hygiene Zone
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Hygienic Transfer Area Procedure – into High Sensitivity Zone
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Hygienic Transfer Area Procedure – out of High Sensitivity Zone
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Hygienic Transition Zone (HTA)
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Hygienic Transfer Area Procedure – into High Hygiene Zone
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Acceptance of Hygienic Zoning Implementation
Safety #1 - committmentCommunicate risk mitigationMinimize costMinimize disruption of manufacturing operationsTraining
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Footwear Sanitation – Decontamination Efficacy
Objectives:1. Determine amounts of microbial reduction on footwear
soles using several decontamination treatments.
2. Determine amounts of microbial transfer to floors following various footwear decontamination treatments.
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Footwear Sanitation – Decontamination Efficacy
a cb
Pre-treatment boot swabPost-treatment boot swab
R
Slide courtesy Scott Burnett
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Footwear Sanitation – Decontamination Efficacy
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Reductions on Footwear Soles
5
4
3
2
1
0
0.59, C0.22, C
2.34, B
3.54, A
0.06, C
Aqueous QAC
Dry QAC IPA/QAC IPA/QAC & Dry QAC
No Treatment
Burnett, Egland, McKelvey and Cook, 2013. Food Protection Trends 33:74-81.
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IPA/QAC under wet floor conditions
41
6
5
4
3
2
1
0Site ‘b’
IPA QAC
Site ‘b’
None
Site ‘c’
IPA QAC
Site ‘c’
None
Sole
IPA QAC
Sole
None
Burnett, Egland, McKelvey and Cook, 2013. Food Protection Trends 33:74-81.
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Footwear Sanitation – Footwear Sanitation
Conclusions:- Aqueous QAC footbath achieved about 0.5 log reduction under conditions of the study.- Nonaqueous IPA-QAC spray achieved > 2.0 log reduction under conditions of the study.- Drawback of dry QAC outweighed the benefit.
Recommendations:- Consider the use of IPA-QAC spray instead of QAC footbath.
• Four times more effective under brief exposure conditions• Reduces water exposure in the facility
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Footwear Sanitation – Particulate Pickup and Cleanability
Objective:To classify and determine the ability of various footwear tread
patterns to pick up particulate materials.To evaluate the cleanability of soles having various tread patterns.
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Footwear Sanitation – Particulate Pick-up & Cleanability
Wheat berriesCorn gritsRice kernels
Dry and wet floor conditions
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Footwear Sanitatioin - Particulate Pick-up & Cleanability
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Footwear Sanitation – Particulate Pickup and Cleanability
Conclusions:- Footwear tread patterns can be classified for their ability to pick up particles.- Soles classified as "A" picked up wheat berries, corn grits and rice kernels much less
readily than those classified as "C".- The ability to pick up particles correlates directly with difficulty of particle removal by
brushing or use of a picking tool.- Footwear classified as "C" were much more difficult to clean than those classified as "A".
Recommendations:- Consider the use of “A” soles for enhanced footwear sanitation. This may have benefit for
reducing risks of transfer of potentially contaminated materials within plants, that could pose food safety risk.
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Summary
War on WaterHygienic Zoning
Footwear Sanitation
Fred Cook, Ph.D.
Microbiology Fellow
MOM Brands
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Thank You!