tyson foods - how are we applying what we've learned
TRANSCRIPT
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Tyson Foods
How Are We Applying What We’ve Learned?
Scott Stillwell
Vice President
Food Safety and Quality Assurance
Arkansas Association for Food Protection
September 14, 2011
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Jim LochnerChief Operations Officer
Hal CarperGVP R&D, Technical Services
SVP Science & Regulatory Affairs
EnvironmentalCompliance –
Health & Safety
Dir. of Food Safety & Regulatory Compliance
Dr. Kellye PfalzgrafSr. Dir. Animal Welfare
Dr. Neal AppleVP Lab & Research
Services
Dr. Dean DanilsonVP Food Safety & Q.A.
Fresh Meats
Scott StillwellVP Food Safety & Q.A.
Poultry & Prepared Foods
Dr. Dan ZelenkaSr. Dir. Statistical Process
Design
Research and Development
InformationServices
Logistics and Supply Chain
Donnie SmithPresident & CEO
DistributionAviation
Consumer Relations Manager
Dir. International FSQASr. Dir. Animal Welfare
VP Lab & Research Services
VP Food Safety & Q.A. Fresh Meats
VP Food Safety & Q.A. Poultry & Prepared Foods
Sr. Dir. Statistical Process Design
Tyson’s Food Safety Organization
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Food Safety Scope
Food Safety & Quality Assurance Manual Table of Contents
Detailed within the Tyson Foods’ FSQA Policies and Procedures
Involves a Step-Wise Approach:1) Policy / Program Development;2) Training;3) Monitoring – Process Control;4) Auditing; and5) Verification.
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Food Safety Philosophy
• Assure production of safe, high quality products in large volumes at competitive prices;
• Collaborate with academic institutions on applied research -- Conduct applied research;
• Work closely with regulators and customers to develop meaningful and reliable standards;
• Develop technologies to reduce risk;• Validate efficacy of technology;• Training and education of team members; and• System implementation and verification (audit oversight).
“Quality is expected, Food Safety is required…”
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Food Safety Scope
Involves a Step-Wise Approach:1) Policy / Program Development;2) Training;3) Monitoring – Process Control;4) Auditing; and5) Verification.
That’s all great and good, but if we’re not doing the right thing – it
won’t matter that we do it well!
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Policy and Program Development
"We want to do those things that will truly impact public health and prevent
foodborne illnesses… we have to work smarter, more efficiently with our
resources.”
~ Elizabeth Hagen, MD USDA Undersecretary for Food Safety
American Farm Bureau Annual Meeting January 2011
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Policy and Program Development
“Evolution is the law of policies: Darwin said it, Socrates endorsed it, Cuvier
proved it and established it for all time in his paper on The Survival of the Fittest.
These are illustrious names, this is a mighty doctrine: nothing can ever remove
it from its firm base, nothing dissolve it, but evolution.”
~ Mark TwainWhen in Doubt, Tell the Truth
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Policy and Program Development
So – How do we make sure our policies and programs are founded on a solid base and modified as necessary in response to evolutionary pressure?
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Applied Research Services and Research and Development
• Diversified Team Organizing and Directing Applied Research in Food Safety and New Technologies
• Coordinating Research on Microbiological Intervention Strategies
• Validation of Intervention Technologies• Designing and Conducting Field and Laboratory Testing
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Collaboration with Academic Researchers
Through Industry Trade Associations• American Meat Institute Foundation
– Monday September 12: Salmonella spp. Research Proposals– Tuesday September 13: Listeria monocytogenes Research
Proposals– Wednesday September 13: E. coli O157:H7 and other STEC
Research Proposals
• Other Trades: NCC, USPEA, NTF, etc.
Through Direct Collaboration• University of Arkansas• Iowa State University• USDA, ARS, MARC
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Collaboration with Other Researchers
Research Labs and Corporations• The National Food Lab
– Research Project # RES SERV-000004, “In-plant Thermal Process Validation Study Using a Non-Pathogenic Surrogate Microorganism to Determine Cross-Contamination Potential for Poultry Products with an Internal Temperature below 160F”, October 22-26, 2001.
• Deibel Labs– James N Bacus, Ph.D. Technical Ingredient Solutions, LLC
“Evaluation of a Commercial Starter Culture as a Potential Surrogate for Enteric Pathogens in Fermented Sausage Validation Studies”, June 2011
• Individual Corporate Interests– Project #: RES SERV-61 “Evaluation of Efficacy of Megan™
Vac 1 Vaccine in Broiler Chickens”, February – May, 1999.
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Proprietary ResearchListeria monocytogenes
• Sentinel Site Program® (v12)– Environmental Monitoring– Search and Destroy
• Sanitation Standard Operating Procedures– Master Sanitation Schedule and Equipment Design
Reviews• Existing Equipment Evaluations• New Equipment Design task Force
• Validated Process Interventions or Product Formulations
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Proprietary ResearchListeria monocytogenes
• High Pressure Pasteurization
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Proprietary ResearchListeria monocytogenes
• Formulation / Intervention ChemicalsRTE Validation: Roasted Chicken
0
1
2
3
4
5
6
0 5 10 15 20 25 30 35 40
Days
Treated - Ional LC3 + Turbinado - UU
Treated - Ional LC3 + Splenda - VV
Treated - Mionix + Wild Flavor - WW
Treated - Mionix + Firmenich Flavor - XX
Control - YY
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Proprietary ResearchListeria monocytogenes
• Inherent Product CharacteristicsRTE VALIDATIO N: PEPPERO NI
Complete
0.00
0.20
0.40
0.60
0.80
1.00
1.20
1.40
1.60
0 20 40 60 80 100 120
Days
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Proprietary ResearchListeria monocytogenes
FSIS Average = 0.89%
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Proprietary ResearchEscherichia coli O157:H7 (and Other STECs)
• Pre-Slaughter Application of O157 Phage• Pre-Harvest Interventions [probiotic, vaccine, phage,
feedlot management practices] • SPS Steam Pasteurization [post final rail]• Hot Water Carcass Wash• PECS [Pre-evisceration carcass spray w/ lactic/acetic
acid or180F hot water]• Hide Washing / Treatments• Slaughter Process Control and Verification
– Carcass PREP™: Dressing and Hygiene• Organic Acids; Halogens; Steam Pasteurization
– Tyson Total-N60™: Sampling Plan Design and Statistics [Prerequisite Program]• Statistical Validation
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Proprietary ResearchEscherichia coli O157:H7 (and Other STECs)
5.0
2.7
0.4
5.0
2.7
0.5
0
1
2
3
4
5
Log10 cfu/ml
S. typhimurium E. coli (O157:H7)
Pre-Treatment Post-Water Wash Post-Treatment 1200 ppm ASC
Residual Populations of Salmonella typhimurium and Escherichia coli (O157:H7) on Inoculated Carcass
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Proprietary Research
http://www.fsis.usda.gov/Science/Ecoli_O157_Summary_Tables/index.asp#2006
Table 6. Calendar Year 2009 through 2010
CY 2009 CY 2010*
Source Analyzed Positive Analyzed Positive
Federal Plants 12,065 36 11,616 29
Verification 11,573 35 11,291 26
Follow-up 492 1 325 3
Retail Stores 631 2 905 0
Verification 619 2 905 0
Follow-up 12 0 0 0
State Plants 0 0 0 0
Imports 101 3 29 1
Totals 12,797 41 12,550 30
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Proprietary ResearchSalmonella spp. in Broilers
• Efficacy of Attenuated Broiler-Breeder Vaccine• Effects of Water Treatments on Colonization of
Broilers with Salmonella spp.• Efficacy of Hot Water Dip vs Spray for Reduction of
Salmonella and Campylobacter spp.• Efficacy of Bio-Mapping for Evaluation of Multi-Hurdle
Interventions for Reduction of the SalmonellaeSummary by Quarter MPN:
Months Salmonella % Positive
Average cfu per 400ml WBCR
Average log10 per 400ml WBCR
Jan - March 2007 15/18 = 83% + AVG = 36,131 AVG LOG = 3.28April - June 2007 23/24 = 96% + AVG = 48,881 AVG LOG = 3.70
July - September 2007 12/14 = 86% + AVG = 73,703 AVG LOG = 4.0
October - November 2007
11/16 = 69% + AVG = 24,523 AVG LOG = 2.84
February - March 2008 19/25 = 76% + AVG = 11,217 AVG LOG = 2.92
Apr-08 1/3 = 33% + AVG = 67 AVG LOG = 1.4
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Proprietary Research
1/1/
2004
4/1/
2004
7/1/
2004
10/1
/200
4
1/1/
2005
4/1/
2005
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/200
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1/1/
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/200
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1/1/
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/200
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/200
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/200
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2010
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/201
0
0.00%
2.00%
4.00%
6.00%
8.00%
10.00%
12.00%
14.00%
16.00%
18.00%
20.00%
Prevalence of Salmonella spp. Positive in Broiler WBCRs
C-8 Data Linear (C-8 Data) FSIS Data
Linear (FSIS Data) Tyson Data Linear (Tyson Data)
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How Are We Doing?
http://www.cdc.gov/foodborneburden/PDFs/FACTSHEET_B_TRENDS.PDF
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How Are We Doing?
http://www.cdc.gov/foodborneburden/PDFs/FACTSHEET_B_TRENDS.PDF
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“…in this place it takes all the running you can do, to keep in the same place.“ ~ Red Queen to Alice in Through the Looking Glass
The Red Queen Principle - Leigh van Valen (evolutionary biologist, 1973)
Tyson’s FSQA Principle
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Tyson’s Commitment
Ensuring Safe, Quality Food from Farm to
Fork
Questions?