MicroMessenger. Newsletter. 3M Microbiology Food Safety Products and Services. In this issue. News from 3M Microbiology

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1 M Microbiology Food Safety Products and Services Published by M Microbiology April, 2008 MicroMessenger Newsletter In this issue News from M Microbiology...1 Gold n Plump Poultry Improves Quality and Efficiency Fun Facts...2 Tech Talk...4 Where to Test in a Plant for ATP...5 International Focus: Are you getting true value for your money from your ATP system?...6 News from M Microbiology We are pleased to introduce the brand new portfolio of products available from M Microbiology! Following the acquisition of Biotrace International PLC in November 2006, M Microbiology is able to provide you with an extended range of high quality products to help you ensure the safety and quality of your production processes. The new product range includes the widely used M Petrifilm Plates, ATP and Protein based rapid hygiene monitoring systems, rapid pathogen, toxin and allergen kits, ATP-based end-product screening systems; sample collection, dilution and enrichment products. We have a new look that you will notice in the coming months as explained below: Brand New Names Great Quality Products! We have grouped our products into four families and adjusted individual product names to reflect this new architecture. The quality and reliability you have come to expect remain the same. M Clean-Trace Products (formerly Biotrace ): Effective hygiene monitoring solutions for verifying cleanliness with either ATP or protein indicators. Examples: M Clean-Trace Surface ATP (formerly Clean-Trace ), M Clean-Trace Water ATP (formerly Aqua-Trace ), M Clean-Trace NG Luminometer (formerly Uni-Lite NG), M Clean-Trace Protein Plus (formerly Pro-tect ) M MLS Products (formerly Cogent ): End product screening systems for UHT dairy products. Example: M Microbial Luminescence System (MLS) (formerly Cogent MLS) M Tecra Products (formerly TECRA ): Rapid test kits for some of the major causes of foodborne illness: pathogens such as Salmonella, Listeria and Staphylococcus aureus, toxins and allergens. Examples: M Tecra Listeria Visual Immunoassay (formerly TECRA Listeria VIA), M Tecra Peanut Visual Immunoassay (formerly TECRA Peanut Allergen VIA) M Sampling Handling Products and Specialty Media (formerly International BioProducts and TECRA ): Sampling devices such as swabs and sponges, ready to use dilution products and dehydrated and prepared enrichment solutions. Examples: M Hydra-Sponge (formerly HydraSponge ), M Flip-Top Dilution Bottle (formerly Flip Top ), M Swab-Sampler (formerly RediSwab ). The M Petrifilm Plate products names remain the same. l

2 Quality and Efficiency Improved Using the Powerful M Clean-Trace Hygiene Monitoring System Did you know? Fun Facts In 2006, M spent $1.5 billion on research and development and filed 570 patents. M was ranked seventh on Business Week s World s 50 Most Innovative Companies list. Business Week, May 4, M was ranked number three on Wall Street Journal s 2006 list of Best Corporate Reputations. Gold n Plump Poultry is the largest, fully integrated producer of chicken products in the upper Midwest region of the United States. With distribution to grocery stores, deli s and restaurants as well as international exports, maintaining high quality standards is essential to protecting their reputation and remaining successful in a competitive global marketplace. Routine sanitation verification using an ATP testing system has been a key component in Gold n Plump s quality assurance program over the last six years. Sanitation is a key part of our total system. It affects product shelf life and performance, says Renju Simon, Quality Services Manager at the Gold n Plump Poultry facility in Cold Spring, MN. Approximately 500 pieces of manufacturing equipment are utilized in our three plants. It is critical for us to have real-time data about equipment cleanliness before we begin daily manufacturing. Previously, when we sampled for microorganisms, we had to wait 24 to 48 hours for test results. We need responses in real time so we switched to surface ATP testing to obtain immediate feedback. Despite the satisfaction that Gold n Plump had with ATP as a method for sanitation verification, there were some drawbacks to the ATP testing system they were using. The first ATP luminometer we used required manual calibration. We wanted a more convenient instrument that could perform a self-check and quickly be ready for use, said Simon. Our original ATP system also categorized results as pass, caution or fail. We needed numerical values for surface cleanliness to improve our sanitation effectiveness. Continued on Page The average consumer uses 17 M products in some shape or form every day. 2

3 The Gold n Plump Poultry team began searching for a new surface ATP testing system by establishing the following selection criteria: Software with open architecture that allows customization and add-on features Ruggedness User-friendliness of the unit and swabs Quantifiable results Sensitivity Repeatability of results Self-calibration Multiple security features Affordability Cost per test equivalent or less than traditional swabs The Gold n Plump Poultry team conducted background research on three systems and viewed presentations and demonstrations by each manufacturer. We focused on features that went beyond numerical results, said Simon. After narrowing our search to one system, we tested it in our facilities. We evaluated the system for repeatability of measurements as well as software compatibility with other Gold n Plump Poultry systems. Ultimately, we chose the M Clean-Trace Surface ATP System because it met the greatest number of our requirements and preferences. The driving factor in our decision to choose the Clean-Trace System was the M Clean-Trace Data Trending Software, explained Simon. Our quality engineer found it was easy to use and offered the most flexibility. He liked the open architecture that enabled us to generate statistically sound sampling plans, randomly generate testing sites and add extra sites on a daily basis that are not on the random schedule. It gave us the advantage of collecting fewer samples while maintaining acceptable confidence in our sanitation process. This flexibility is also compatible with our Six Sigma program. The software in the other ATP systems we considered was more limited. In comparative laboratory studies with other ATP surface testing systems, the Clean-Trace ATP System demonstrated superior repeatability and high sensitivity of results. 1,2 The repeatability of the Clean-Trace ATP System was particularly important to Gold n Plump. We need accurate, repeatable results from a surface ATP testing system to make good decisions about proceeding to manufacturing line or taking the time to re-clean equipment. If the results we obtain are unreliable, we could give false information to departments, telling them to make unneeded changes in sanitizers, chemicals or labor. We The repeatability of the Clean-Trace ATP System was particularly important to Gold n Plump. could also lose valuable time and spend additional money doing unnecessary re-cleaning or fail to clean equipment properly based upon a false result, which could affect product quality. explained Simon. Within Gold n Plump Poultry, the results from the Clean-Trace ATP testing system are used for more than just immediate clean vs. not clean decisions. The report generated from the M Data Trending Software is sent nightly to Kaiser Sanitation, the contract cleaning company used by Gold n Plump. Kaiser managers meet with their personnel to analyze any failures and make adjustments to the cleaning process, such as re-cleaning certain areas or adding more cleaning solution, etc. The Clean-Trace ATP system also allows Gold n Plump to emphasize the importance of quality in their operations. Over time, the results of the testing are compiled and used as part of a bonus structure in what Gold n Plump calls their Gold n Reward Bonus Program. Within this program, employees are awarded bonuses for their part in maintaining the quality and safety standards that Gold n Plump has put in place. It s another reason that having an ATP testing system which provides accurate and repeatableresults is very important, said Simon. Our employees are relying on the data we provide and other measurements to make sure they receive bonuses. Continued on Page 4

4 M MicroMessenger April, 2008 FAQ Tech Talk Tech Topic: M Clean-Trace Hygiene Monitoring Tests Q Do RLU results from ATP testing equate to numbers of microbial cells present or a Total Viable Count reported in CFU? A No, ATP (Adenosine Tri-Phosphate) hygiene testing, such as the M TM Clean-Trace TM Surface ATP tests, measures all biological contamination. The RLU (Relative Light Unit) results represents ATP measured from all sources of ATP whether living or not i.e. food residue, microbial cells and other biological contamination. ATP tests are designed to determine clean vs. dirty and not to measure numbers of viable bacteria. Linking incentives to measurable results is a clear, unmistakable message from management about the importance of sanitation and the participation of employees and contractors in the cleaning and testing program. The results of the Clean-Trace ATP system are critical to maintaining the high standards of safety and product quality at Gold n Plump. Gold n Plump also uses the data to identify equipment that is becoming difficult to clean. If a piece of Gold n Plump Poultry equipment fails five times, it is tagged for investigation to determine why the equipment is not able to be cleaned effectively. We compare swabbing results from multiple days and weeks with our process limits, explained Simon. If we see data approaching upper control limits, we will investigate the situation, do additional surface ATP testing or take other preventive or corrective actions. These activities correlate with our Six Sigma initiatives. In addition, maintaining records helps us comply with HACCP requirements. Simon and his team also use the trended data from the Clean-Trace ATP System to track long-term equipment performance and provide information for purchasing new equipment. We have identified the material, such as plastic or stainless steel, in every piece of equipment in our three facilities. When we consistently see failures in ATP results, we use that data to convince our managers not to purchase a particular material Gold n Plump Poultry is a shining example of ATP testing done right. They have utilized both the reliability of the Clean-Trace ATP testing results as well as the power of the M Clean-Trace Data Trending software to impact both immediate and long-term decision making. With these prerequisites, Gold n Plump Poultry has extracted great value out of their ATP testing dollars. l References 1. Simpson, WJ, Archibald, JL, Giles, C.J. Protocol for assessing the sensitivity of hygiene test systems for live microorganisms and food residue. Cara Technology Limited, Report , October Simpson, WJ, Files CJ, Flockhart, HA. Repeatability of hygiene test systems in measurement of low levels of ATP, Cara Technology Limited, Report 0606, July 27,

5 Where Are You Conducting Your ATP Testing? Ken Davenport, Ph.D. Hygiene Monitoring is an important part of a company s overall safety and quality program in the food and beverage industry. As we all know, equipment isn t safe if it isn t clean. Tools such as M Clean-Trace Surface ATP tests are used frequently to monitor how well manufacturing equipment has been cleaned prior to beginning food manufacturing. One frequently asked question regarding an ATP monitoring program is where should I do my testing? Unfortunately there is not a one-size-fits-all answer to this question. However there are some universal guidelines that can help identify where to start in the design of a thorough testing program. The first step is to understand your process, equipment, and product in order to identify which locations are most critical to test. This is the basics of a HACCP (Hazard Analysis and Critical Control Point) approach to safety and quality. The idea is to focus time and effort on points that are most critical to the safety and quality of the finished product. The processing area has historically been broken down into a series of zones based on the proximity to the food ZONE 1: Direct Contact ZONE 2: Indirect Contact ZONE : Close Proximity ZONE 4: General Area Zone divisions of your processing area can help you asses the level of risk and identify where to start your testing program. Most Risk Less Risk product. Food Contact Surfaces Zone 1: (Meat cutting blades, sausage grinders, milk transfer lines, filler heads, etc.) represent the most serious risk to the product if they are not cleaned appropriately. These critical surfaces should be tested every time the production line is run. Indirect contact surfaces Zone 2: (conveyor belts, housing around filler heads, lid handling equipment, etc.) are less critical and should be tested frequently (weekly). Surfaces near the manufacturing lines Zone : (control panels, door knobs, HVAC systems) and Distant surfaces Zone 4: (sinks, drains, wheels on carts, etc.) are less critical and can be monitored less frequently. The second step is to turn a critical eye to the design of the equipment itself to determine where cleaning is likely to be difficult or likely to be overlooked. Nooks and crannies, areas where CIP systems may have difficulty reaching, and gaskets/ seams/connectors are all potential test points. The third step is to identify those points that are cleaned with poor repeatability by analyzing the test results of the equipment that has been tested over a period of a week or two. This can be done with the M Clean-Trace Data Trending Software. Analyzing the results of a large number of tests when ATP testing protocols are initially developed, as well as in annual or quarterly reviews of the existing protocol can help to identify problematic areas that need to be tested with higher frequency and also areas that can be tested less frequently. For example, areas that are problematic and critical (zone 1) should be tested daily, while areas that are zone 4 and easily cleaned could be tested quarterly. Knowing where to test, how often to test and analyzing your ATP test results over time using the M Clean-Trace Data Trending Software will not only help ensure that your quality program is working but will also optimize the dollars being spent on chemicals and labor by putting those resources to work where they are needed the most. l 5

6 International Focus: Are you getting true value for your money from your current ATP system? Colin Hunt, Global Market Development Manager (ATP) M Microbiology Commenting on the findings Colin Hunt, Global Market Development Manager (ATP) M Microbiology, said: We are delighted that our dedicated focus on ensuring very high technical performance from the Clean-Trace products have been recognised by these studies. These results provide strong evidence that not all ATP hygiene tests are the same. Our customers across the world rely on the Clean-Trace system as a central part of their hygiene programs. These studies show they can have every confidence they have made the right decision. A healthy, competitive market offers the customer a selection of products to choose from, and as with most, the ATP based hygiene monitoring market is no different. There are a number of systems available around the world, offering various features and benefi ts to the customer, such as a hand-held luminometer and sophisticated data trending software. Again, in line with many markets, price is often a key factor in the decision making process. However, where ATP hygiene monitoring is concerned, is the lowest price necessarily the best factor for making a decision? A number of recent independent studies have found that not all ATP-based systems provide the same performance. This raises the question of whether you are getting true value for money from your ATP system. In two independent studies carried out by Cara Technology Limited, Clean-Trace Rapid Surface Hygiene test from M proved to be the most repeatable and to have superior performance in detecting microbes. Repeatability, the measure of how well a test provides the same result under the same circumstances is a vital aspect of any test s performance. It broadly indicates the level of reliability a test can provide. The Clean-Trace products allow food and beverage manufacturers When placed against three competing products in the study the Clean-Trace system was shown to be the most repeatable. to objectively assess the cleanliness of a surface in seconds to allow positive release of production facilities. When placed against three competing products in the study the Clean-Trace system was shown to be the most repeatable. The ability to reliably detect microbes as well as food residues is a vital aspect of hygiene testing. Ultimately microbial cross contamination due to ineffective cleaning is the key risk that hygiene programs are established to avoid. Microbial cross contamination can lead to product spoilage or reduced shelf-life. In the case of pathogenic organisms the consequences could be more severe. In the second study from Cara Technology Limited, which looked at the detection of a range of microbes and food residues over various dilutions, the Clean-Trace system detected contamination in more than twice as many samples as the competing product. In a study comparing the Clean-Trace system (referred to in this study as the Biotrace system) and the Hygiena system, James Brewster of Brewing Quality Innovations in the UK concluded that The Hygiena system detected a significantly lower number of Fail and Caution results than the Biotrace [M] system. The Hygiena system also gave a significant number of results indicating very low levels of ATP. The differences observed in terms of the quantity of Pass results from the Hygiena system compared with the Biotrace system gave cause for concern, and would strongly suggest that not all ATP systems provide the accuracy and reliability the user should expect: Hygiena tests failed to detect contamination in 0.6% of samples where Biotrace showed Fail or Caution results. Biotrace tests detected contamination in all samples where the Hygiena result indicated a Fail or Caution result. l Microbiology M, Petrifilm, Clean-Trace, Tecra, and Biotrace are trademarks of M or Biotrace Int l Plc, a M company, and are used under license in Canada. Gold n Plump is a trademark of Gold n Plump Poultry.