The Importance of Microbiological Testing in Food Safety Management Marcel Zwietering Jeanne-Marie Membré Anett Winkler
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1 The Importance of Microbiological Testing in Food Safety Management Marcel Zwietering Jeanne-Marie Membré Anett Winkler ILSI Europe: Lilou van Lieshout
2 EXPERT GROUP: History-Based Performance of the HACCP Control Systems to Verify the Effectiveness of Food Safety Management Marcel Zwietering, Liesbeth Jacxsens, Jeanne-Marie Membré, Maarten Nauta, Mats Peterz ILSI: Alessandro Chiodini
3 Relevance of microbial testing for verification in the production of Anett Winkler chocolate 3
4 Agenda General Considerations Chocolate production A Microbiologist View Verification (and Controls) Summary 4
5 General Considerations Examples of Salmonella outbreaks related to chocolate (products): 1970/71 Sweden cocoa powder? 1982 Italy chocolate low number 1985/86 Canada chocolate cfu/g 2001 USA (raw) almonds cfu/g 2001 Germany chocolate cfu/g 2002 Australia Tahini? 2006 UK chocolate 0.03 cfu/g 2009 USA pistachios? Data refer to a very low amount of microorganisms that could cause illness!! 5
6 General Considerations Since the Beginning of the 1970ies statistical considerations have been made towards the risk to accept a contaminated material applied sampling plans Foster Plan (1971) 6
7 General Considerations Foster Plan (1971)!! Official recognition/acceptance that it is impossible to be 100% certain that salmonellae are absent Recommendation of sampling plans: designed to assure that the Salmonella contamination level would be below an arbitrarily defined figure and aimed towards balancing safety against practicability 7
8 General Considerations Although Salmonella doesn t grow in dry (low water activity) products, it will survive for long time periods. Examples of prolonged detection at ambient storage: S. Typhimurium, S. Enteritidis: months S. Typhi & S. Paratyphi B: 4-8 months S. Anatum: initial inoculum 50cfu/100g after 15 months storage 14cfu/100g 8
9 General Considerations Heat resistance of Salmonella also depends on water activity / moisture and composition (e.g. fat, sugar) of the materials to be heat-treated. Examples: Salmonella Senftenberg in raw milk Salmonella Senftenberg in chocolate D-value at 67.5 C: 0.046min D-value at 70 C: min. 440 min 9
10 General Considerations Chocolate Products caused illness / outbreaks where very low amount of cells was found in products (left overs) Salmonella survives for a long time in chocolate Heat resistance of Salmonella depends on food matrix (increased in high fat, high sugar / salt, low water activity matrixes) Adequate Process Controls are required! BUT: Originally, processes had been designed for product quality, not safety! 10
11 Chocolate production A Microbiologist View 11
12 Other Ingredients (sugar, dairy) Cocoa products (liquor, butter, powder) Crumb Making Mixing / Refining Extrusion Other Ingredients (cocoa butter, flavors) Conching Other Ingredients (inclusions, fillings) Moulding Storage / Distribution Packing Cooling 12
13 13
14 Cocoa processing - A Microbiologist View Raw Cocoa Beans Debacterization (Steam) Drying Pre-cleaning Bean Dry Roasting Breaking / Winnowing Pre-heating Cocoa butter Grinding Cocoa liquor Pressing Nib Roasting / alcalization Cocoa powder 14
15 Nut processing - A Microbiologist View Pre-cleaning Harvest (Raw Nuts) Storage De-Shelling Storage Cleaning & Sorting Storage Roasting / Pasteurization Packing Sorting 15
16 Verification (and Controls) 16
17 Microbiological analyses in Food Processing Microbiological Testing Low number of sample compared to batch Indicate control at the sampling interval After the fact find out too late Process Controls (HACCP) Control is applied to all the product not limited to sample Continuous validated operational controls Timely response to out of control process Product quality/food safety is manufactured, not tested. 17
18 Process Controls - Validation Role of microbiological analyses in Food Processing Validation of microbiological critical control points: target organism(s) behavior of target organism(s) in products / processes method(s) of detection & enumeration required level of reduction / change available indicator organisms? Verification activities once the CCP is validated 18
19 Role of Verification Testing Finished Product testing is a verification of process controls. Note: Adequate lot management is important, and the frequency of verification should be based on best knowledge of the process. 19
20 Supplier Selection & Management Proactive means of identifying and controlling microbiological and other food safety risks at supplier level: Supplier Control programs based on risk ranking of materials Adequate Food Safety management in place Validation of Critical Control Points Zoning (adequate separation between raw and RTE) / Pathogen Environmental Monitoring Environmental Monitoring (non-pathogen) 20
21 Role of Verification Testing Raw Materials (Ingredient) testing is a verification of supplier s process controls. Note: Testing ingredients without a robust supplier quality program does not ensure safety / quality of ingredients. 21
22 Environmental Controls Zone: An area or a region distinguished from adjacent parts by a distinctive feature or characteristic. 22
23 Environmental Controls Prolonged survival in processing environment Salmonella Agona Salmonella Agona 23
24 Environmental Controls Use of appropriate hygiene indicators Enterobacteriaceae Coliforms Salmonella STEC E. coli Listeria monocytogenes Listeria spp. 24
25 Role of Verification Testing Environmental monitoring is a verification of segregation (Hygienic Zoning) and GMPs 25
26 Chocolate Confectionery production other ingredients Raw Cocoa Beans Raw Nuts Supply of Sensitive Ingredients CCP monitoring (verification) Biological control step Biological control step Incoming Control (verification) Measures Hygienic Zoning (Verification by Environmental Monitoring) FP Testing (verification) Chocolate Production Hygiene monitoring (Cleaning Verification) Finished Product 26
27 Thank you for your attention. For more information please visit the ILSI Europe booth #23
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