industry best practices - meat institute

Industry Best Practices

E. Coli O157 Surveillance and Prevention BriefingArlington VA, January 23, 2008

Industry Best PracticesIndustry Best Practices

E. ColiE. Coli O157 Surveillance and Prevention O157 Surveillance and Prevention BriefingBriefingArlington VA, January 23, 2008Arlington VA, January 23, 2008

Beef Best Practice OverviewBeef Best Practice Overview

Coordinated through Beef Industry Food Coordinated through Beef Industry Food Safety Council (BIFSCO)Safety Council (BIFSCO)Best Practices for:Best Practices for:

Beef SlaughterBeef SlaughterVacuumVacuum--packed Subpacked Sub--primalsprimalsRaw Ground Beef ProductsRaw Ground Beef ProductsNonNon--Intact Tenderized Products Intact Tenderized Products NonNon--Intact Enhanced ProductsIntact Enhanced ProductsSampling and TestingSampling and TestingHolding Tested ProductHolding Tested Product

www.bifsco.org/bestpractice.aspxwww.bifsco.org/bestpractice.aspx

Slaughter Best PracticeSlaughter Best PracticeFundamental requirementsFundamental requirements

Facility designFacility designEnvironmental Environmental -- Air & WaterAir & WaterHide Removal & Dressing Hygiene Hide Removal & Dressing Hygiene Interventions Interventions –– Multiple HurdlesMultiple Hurdles00--Tolerance & Process ControlTolerance & Process ControlHead / Cheek Meat & Head / Cheek Meat & OffalsOffals for Ground Beeffor Ground BeefFinal Carcass Thermal Treatment [or equivalent]Final Carcass Thermal Treatment [or equivalent]Chilling & Cold Chain ManagementChilling & Cold Chain ManagementVerification Testing Verification Testing –– N60+N60+

Hide Removal & Dressing Hygiene

Employee Training

Hygienic sanitary hide removal & evisceration

Equipment sanitation and personal hygienic practices

Sterilizer dips for utensils between each carcass, e.g. dual-knife system

Process Control Monitoring

Hide Removal & Dressing Hygiene

Employee Training

Hygienic sanitary hide removal & evisceration

Equipment sanitation and personal hygienic practices

Sterilizer dips for utensils between each carcass, e.g. dual-knife system

Process Control Monitoring

Slaughter Best PracticeSlaughter Best Practice

Slaughter Best PracticeSlaughter Best PracticeFinal Carcass Thermal PasteurizationFinal Carcass Thermal Pasteurization

Multiple Hurdle Intervention‘Firewalls for Microbial Control’

ANTIMICROBIAL RINSE

LIVE ANIMAL STEAM TREATMENT

PRE-EVISCERATIONCARCASS SPRAY

STEAMVACUUMING

HIDEREMOVAL

THERMAL TREATMENT

N60+ Verification TestingN60+ Verification Testing

Cold chain Cold chain managementmanagementFacility designFacility designSanitationSanitationEmployee hygieneEmployee hygieneTreat with organic acidTreat with organic acidN60 verification testing N60 verification testing of trimof trim

Primal & SubPrimal & Sub--primal Best Practiceprimal Best Practice

High volume intact High volume intact subsub--primal sprayprimal sprayOrganic acid Organic acid applicationapplicationValidated reductionValidated reductionDesign to allow a Design to allow a drip time prior to drip time prior to bagging or final bagging or final packagingpackaging


Top side of Top side of product sprayedproduct sprayedBelt gets Belt gets incidental incidental sanitation and sanitation and carries over upon carries over upon rotationrotation


Low / high volume Low / high volume application by hand application by hand Applied to intact Applied to intact product prior to nonproduct prior to non--intact (slicing, cubing, intact (slicing, cubing, needling, tenderization, needling, tenderization, massaging, etc..)massaging, etc..)Sanitation carries over Sanitation carries over to equipment (needles, to equipment (needles, slicing blades, etcslicing blades, etc…….).)Use trained personnel Use trained personnel to confirm proper to confirm proper coveragecoverage


Used in reconditioning Used in reconditioning of productof productProcess is to trim, Process is to trim, wash, spray with wash, spray with organic acidorganic acidUse trained personnel Use trained personnel to confirm proper to confirm proper procedures are procedures are executed.executed.Validated reductionValidated reduction


BIFSCoBIFSCo Alerts!Alerts!

Two Alerts were sent to industry in 2007 Two Alerts were sent to industry in 2007 serving as reminders about best practices serving as reminders about best practices and offering further guidanceand offering further guidance

May, 2007:May, 2007: Critical Things to Do ListCritical Things to Do ListNovember, 2007:November, 2007: Handling of Products Handling of Products Destined for NonDestined for Non--intact Processing and intact Processing and Ground Beef ProductionGround Beef Production

Ground Beef Best PracticesGround Beef Best Practices

RAW MATERIALRAW MATERIALSupply Approval and OnSupply Approval and On--going going EvaluationEvaluationTest Methodology and Results Test Methodology and Results

DonDon’’t create a false sense of securityt create a false sense of securityA culture of test to findA culture of test to find

Lot Identity Match Test ResultLot Identity Match Test ResultThe lot is the tested lot and is considered The lot is the tested lot and is considered the same sourcethe same source

Ground Beef Best PracticesGround Beef Best PracticesFORMULATION FORMULATION CONTROLCONTROL

Lot control, external Lot control, external source, internal sourcesource, internal sourceRework control Rework control --carryover of product from carryover of product from day to dayday to dayProduct hold proceduresProduct hold procedures

clean up to clean up not clean up to clean up not the rule any morethe rule any more

Ground Beef Best PracticesGround Beef Best PracticesPROPOSED BEST PROPOSED BEST

PRACTICESPRACTICESProduct design:Product design:

Fresh, frozen, dimensions, Fresh, frozen, dimensions, surface modificationssurface modifications

Cook method and Cook method and consumer instructions consumer instructions Trim boxing by third partyTrim boxing by third party

Ponder for a Moment, PleasePonder for a Moment, Please

Tenderization vs. EnhancementTenderization vs. Enhancement

Top Sirloin

0

10

20

30

40

50

60

70

5 to 10 10 to 15 15 to 20 20 to 25 25 to 30 30 to 35 35 to 40 40 to 45

Slice shear force kg

Freq

uenc

y, %

31ºC; blade tenderized31ºC; not tenderized

Tender Not Tender

Why Blade Tenderize?

Blade Tenderization Best PracticesBlade Tenderization Best Practices

Cold Chain ManagementCold Chain ManagementAgingAgingRaw Material AuditRaw Material AuditDeDe--BagBagIntervention ?Intervention ?Blade TenderizationBlade TenderizationTraceability ProgramTraceability ProgramIntegrated Lethality (Food Service Cook)Integrated Lethality (Food Service Cook)

AgingAging

2929--323200FF1414--26 Days26 DaysPotential Competition from Lactic Acid Potential Competition from Lactic Acid Bacteria ? Bacteria ?

Smith et al., J. Food Protection, 2005.Smith et al., J. Food Protection, 2005.Kostrzynska, M and A. Bachand, Can J. Kostrzynska, M and A. Bachand, Can J. Microbiol., 2006.Microbiol., 2006.Food Safety Net Services, Final Report, 2006.Food Safety Net Services, Final Report, 2006.

Blade TenderizationBlade Tenderization

Inside / OutInside / OutBlade SanitationBlade SanitationSingle PassSingle PassPenetration StudiesPenetration Studies

DeDe--BagBag

0

10000

20000

30000

40000

50000

60000

70000

80000

0 5sec 10sec 15sec

In The BagUnbagged

Picture of BladePicture of Blade

1 x 3 mm

Penetration of surface Penetration of surface microorganismsmicroorganisms

1

10

100

1000

1 2 3 4 5 6

Top Surface Bottom Surface

Middle

Each Section represents 1cm

Integrated LethalityIntegrated LethalityDetermine lethality of common degrees of Determine lethality of common degrees of doneness (rare, medium, etc) for blade doneness (rare, medium, etc) for blade tenderized steaks.tenderized steaks.I.L. is not the timeI.L. is not the time--temperature requirements temperature requirements listed in Appendix A or the Food Code.listed in Appendix A or the Food Code.I.L. takes into consideration comeI.L. takes into consideration come--up timeup time--temperature as well as cooltemperature as well as cool--down.down.Initial tests show 2Initial tests show 2--6 log lethality in coolest spot.6 log lethality in coolest spot.

Not Reasonably Likely to OccurNot Reasonably Likely to Occur

Vendor Vendor InterventionsInterventionsLow Incidence and Low Incidence and Level (<0.09%)Level (<0.09%)ColdCold--Chain Chain Management (no Management (no growth, 46growth, 46--50F 50F mimimummimimum))Aging (competition)Aging (competition)Raw Material AuditRaw Material Audit

DeDe--bag (reduction in bag (reduction in population)population)Blade inside/out Blade inside/out (reduce possibility)(reduce possibility)Blade shape and Blade shape and function (cuts not function (cuts not presses)presses)Blade SanitationBlade SanitationIntegrated LethalityIntegrated Lethality

NonNon--Intact Intact PrimalsPrimalsEnhancedEnhanced

In addition to the items mentioned for In addition to the items mentioned for tenderizationtenderizationPlant needs a raw material receiving Plant needs a raw material receiving program (Supplier Preprogram (Supplier Pre--ReqReq))

Lays out minimum supplier expectationsLays out minimum supplier expectationsHACCP, SRM, ReHACCP, SRM, Re--assessments, 3assessments, 3rdrd party audits, party audits, etc..etc..

Part of your HACCP program!!Part of your HACCP program!!


Maintain water / solution temp at 40F or less


Injection needle integrity checks


Validated CIP needle sanitation


Use chilled water to prepare solutionUse chilled water to prepare solutionLimit age of solution Limit age of solution

Microbial validationMicrobial validationLimit time sanitize after each break in Limit time sanitize after each break in solution cyclesolution cycle


Use antimicrobial intervention in re-circulating systems


Security – of the solution room and storage tanks


Supplier requirements for ingredient Supplier requirements for ingredient supplierssuppliersLot number tracking for ingredients Lot number tracking for ingredients usedusedVerification of CIP and Sanitizing Verification of CIP and Sanitizing steps of the injectors and the tankssteps of the injectors and the tanks

Hold and Test Best PracticeHold and Test Best Practice

Key PointsKey Points

Hold product before sample is taken.Must know which raw materials and/or finished product(s) are impacted.Assume every sample is positive, until you receive a negative test result.

Hold product before sample is taken.Must know which raw materials and/or finished product(s) are impacted.Assume every sample is positive, until you receive a negative test result.

Raw Material SourceRaw Material Source

Considerations:Fresh vs FrozenBoxes vs Combo

Received on multiple days“Test” lot vs “Production” lot

Considerations:Fresh vs FrozenBoxes vs Combo

Received on multiple days“Test” lot vs “Production” lot

CommunicationCommunication

Talk to the inspection personnel now, not later.Ensure that all employees understand the hold and test policy.Know what the laboratory is doing.

Talk to the inspection personnel now, not later.Ensure that all employees understand the hold and test policy.Know what the laboratory is doing.

Best Practices SummaryBest Practices Summarywww.bifsco.org/bestpractice.aspxwww.bifsco.org/bestpractice.aspx

industry best practices - meat institute

Documents