Keeping Listeria at Bay: The battle that ready-to-eat processors can

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Keeping Listeria at BayThe battle that
ready-to-eat processors cant afford to lose

• Host Bill Kinross, Publisher, Meatingplace
• Moderator Lisa Keefe, Editor, Meatinglace

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Presenter

• Harshavardhan Thippareddi,
• Associate Professor of Food Science, Department
  of Food Science and Technology, University of
  Nebraska, Lincoln

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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
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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 University
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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 University
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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

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Prevalence Of Listeria Monocytogenes On RTE Meat
And Poultry Products
Percent Positives
FSIS results of ready-to-eat products analyzed
for Listeria monocytogenes
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Human Listeriosis - Trends
http//www.cdc.gov/FoodNet/factsandfigures/trends.
html
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Listeria Monocytogenes Prevalence() On RTE Meat
And Poultry, 2008
http//www.fsis.usda.gov/Science/Table22_Micro_Tes
ting_RTE_2008/index.asp
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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

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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

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Physical Post-lethality Treatments

• Heating
• Steam
• Submersion in hot water
• Radiant oven heating
• High Pressure Processing

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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

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Product Orientation Effects
.75
Single-Layer Separated Franks
Single-Layer Franks
1.5
Double-Layer Franks
Courtesy Alkar
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Product Orientation Effects
Courtesy Alkar
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Thermal (Surface) Pasteurization Systems for RTE
Meat Products

• Hot water-based systems
• Steam-based systems
• Non-condensing steam
• Condensing saturated steam
• Flash steam system

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Destruction Of L. Monocytogenes Using Hot Water
System
Muriana et al., 2002
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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 MPa14,504 PSI
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High Pressure Processing Systems
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High Hydrostatic Pressure Treatment Factors
Controlling Application

• Product type and composition
• Processing time and temperature
• Types of microorganisms to be inactivated

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High Hydrostatic Pressure Systems
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High Hydrostatic Pressure Systems
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Post-process Lethality Treatments Chemical
Interventions
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Antimicrobial Agents Lethality Treatments

• Acidic calcium sulfate
• Acidified sodium chlorite
• Peracetic acid
• Lauric arginate
• e- polylysine

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Antimicrobial Agents Lethality Treatments

• Liquid smoke fractions
• Listeria phages
• Octanoic acid
• Ozone (ozonated water)

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Acidic Calcium Sulfate
Nunez et al., 2004
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Acidic Calcium Sulfate
Nunez et al., 2004
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Acidified Sodium Chlorite
Luchansky et al. 2006
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Model System ?- Polylysine
Geornaras et al., 2005
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Smoke Derivatives L. Monocytogenes Control
Gedela et al. 2007
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Antimicrobial Agents Control Lm Growth
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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)

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Synergism Lactate and Diacetate
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Antimicrobial agents in formulation
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Control Of Listeria Monocytogenes In Taco Meat
(Aerobic)
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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

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Presenter

• John N. Butts,
• Vice President of Research,
• Land O Frost

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Data Analysis, Investigation and Corrective
Action

• Follow the data trail to the source but always
  be alert and aware to the organisms ubiquitous
  presence and pervasive nature.

John Butts Land O Frost Meatingplace
Webinar Sept 2009
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Commitment Model

• Resistant dont 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

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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
• This means they are established, and have found a
  protective home in equipment or facility.
• They may exist in a transient home such as rework
  pans, trash containers or other difficult to
  clean mobile container / environment.

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Transfer Points vs Niches

• Many positive sites found during monitoring are
  not growth niches. They are transfer points
  (i.e., a product handlers 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.
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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.

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Growth Niches
Hollow roller with solid stainless steel shaft in
center (almost press fit). When center shaft
removed organic matter is evident.
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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
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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.

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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

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Seek and Destroy Process
Normal cleaning and
sanitation
Observe flood
sanitization
Are all parts and
components being
Observe assembly
adequately
sanitized (chemical
or heat)?
Observe Post assembly sanitizer
application
Observe normal setup and
Are GMP's
start up activities
followed?
Stop operation before product
is placed on the line
Disassemble to normal daily
sanitation level
Disassemble any remaining
Inspect and swab
machine components
any suspect areas
Clean and flood or heat sanitize all
disassembled line components
Evidence of
unacceptable
organic
Are cleaning
Is degree of
buildup?
methods
disassembly
acceptable?
acceptable?
If APC growth is supported then
If area is Ls positive then it
the suspect area is a potential
is a growth niche
growth niche
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Time Study
Locating a Transfer Vector
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
A Time Study consists of sampling the line
components and every thing that comes to the line
over a period of time
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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

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Presenter

• Mike DeSmet,
• Vice President of Food Safety,
• West Liberty Foods

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Listeria DefenseA Multi-Hurdle Approach
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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.

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Multiple Hurdle Approach

• Building Design/Physical Barriers
• Chemical Interventions
• Preventive Programs
• Product Design/Handling
• Training
• Verification Activities

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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.

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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
  lt38F.
• Design eliminates cardboard and wood from
  entering exposed product areas.

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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.

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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 PMs
• Maintenance Tool Cleaning

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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.
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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.
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Product Design/Handling

• Proper Cooking
• Antimicrobial Ingredients
• Modified Atmosphere Packaging
• Freezing
• Shelf Life Determination
• Temperature Control (cold chain management)

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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

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Verification Activities

• Strong Listeria program
• gt3500 Listeria species swabs per month company
  wide
• Zone 1 (conveyors, slicers, product beds)
• Zone 2 indirect contact (on off buttons,
  framework, etc.)

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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

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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.

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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.

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Questions Answers
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For More Information

• Harshavardhan Thippareddi hthippareddi2_at_unlnotes.
  unl.edu
• John N. Butts John.Butts_at_landofrost.com
• Mike DeSmet Mike.DeSmet_at_wlfoods.com
• Bill Kinross bkinross_at_meatingplace.com
• Lisa M. Keefe lkeefe_at_meatingplace.com
• Download special supplement
• www.meatingplace.com