Food safety considerations for food innovation & reformulation Foods for health & wellness seminar

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1 Food safety considerations for food innovation & reformulation Foods for health & wellness seminar Sandra Olivier Food Research Microbiologist 4 th June 2018 CSIRO AGRICULTURE & FOOD Overview Drivers of innovation & reformulation Healthy or safe? Finding the balance Food preservation toolkit How to innovate & reformulate safely - The hurdle approach to food preservation - The Food Safety Objective (FSO) - Predictive modelling - Validation: challenge & shelf-life testing 2 Food safety considerations for food innovation & reformulation Sandra Olivier 1

2 Staying on trend in 2018! Environmentally friendly N a t u r a l FRESH! Image source: Natural Marketing Institute 3 Food safety considerations for food innovation & reformulation Sandra Olivier Staying on trend in 2018! Consumers are demanding miracle foods that are totally natural, have zero calories, zero fats and cholesterol, delicious taste, total nutrition, low price, environmentally friendly production, green packaging.and that guarantee perfect bodies, romance and immortality Carol Brookins, Global Food and Agriculture Summit, Food safety considerations for food innovation & reformulation Sandra Olivier 2

3 Healthy or safe? finding the balance Can we meet these demands and still have safe & stable foods? Need to control /eliminate microbes C o n v e n t i o n a l Tastes great & is healthy Safety / stability assured I n n o v a t i v e Cook it to death Tastes bad add more salt/sugar Still unstable add preservatives 5 Food safety considerations for food innovation & reformulation Sandra Olivier Innovation in food is multi-disciplinary Food nutrition Microbial risk assessment Microbial physiology Sensory sciences Innovation in food Risk management Food chemistry & structure Process engineering Hazard/ microbial detection 6 Food safety considerations for food innovation & reformulation Sandra Olivier 3

4 Food preservation toolkit: the options Inhibiting/delaying growth of microorganisms Reduce temperature: freezing, chilling Reduce available water (water activity): drying, curing (salting), conserving (sugar) Reduce ph: acidifying, fermenting Preservatives: antimicrobial compounds, organic/inorganic acids, smoke Removal/Replacement of oxygen (vacuum/modified atmosphere packaging) Inactivating microorganisms Physical processing: heat (pasteurisation/canning), pressure (HPP) Chemical sanitisers: chlorine & other chemicals to surface inactivate microorganisms Some formulations: e.g. mayonnaise (acid, salt, ph, water activity) Intrinsic: in the food Extrinsic: outside the food Processing: applied to the food 7 Food safety considerations for food innovation & reformulation Sandra Olivier The hurdle concept a holistic approach HEAT Inherent in the food Food system Process/Intrinsic/Extrinsic HURDLES still viable in the food Figure adapted from Leistner & Gould, Food safety considerations for food innovation & reformulation Sandra Olivier 4

5 The hurdle concept a holistic approach Food safety & stability is dependant on the interplay between processing, intrinsic & extrinsic factors as well as the microbes in there to start HEAT ph a w CHILL Food system Inherent in the food Process/Intrinsic/Extrinsic HURDLES still viable in the food Each combination of hurdles defines the microbiological safety & stability of a food Figure adapted from Leistner & Gould, Food safety considerations for food innovation & reformulation Sandra Olivier The hurdle concept a holistic approach Making a change to any of these hurdles can destabilise the system! UNSAFE! HEAT ph a w CHILL Food system Inherent in the food Process/Intrinsic/Extrinsic HURDLES still viable in the food salt = water ac vity (a w ) a w can be a critical preservative factor Figure adapted from Leistner & Gould, Food safety considerations for food innovation & reformulation Sandra Olivier 5

6 The hurdle concept a holistic approach With innovative processing & novel/natural preservatives there is a real opportunity to for exciting NPD for healthier foods SAFE! HEAT ph a w CHILL INNOVATE Food system Inherent in the food Process/Intrinsic/Extrinsic HURDLES still viable in the food Figure adapted from Leistner & Gould, Food safety considerations for food innovation & reformulation Sandra Olivier Smarter food safety OLD prescriptive, inflexible Traditional food safety based on adherence to prescriptive approaches to achieve compliance - Inflexible - prescribe approach for achieving the goal - Difficulties arise for validating novel technologies constrains innovation NEW smarter, more flexible innova on (ICMSF, 1998) proposed new scheme for management of microbial hazards in foods - The Food Safety Objective (FSO) approach defines the goal - Flexible - does not prescribe approach for achieving the goal - Permits demonstration of equivalence of control measures supports innovation 12 Food safety considerations for food innovation & reformulation Sandra Olivier 6

7 The Food Safety Objective H o - ΣR + ΣI H o = initial level of the hazard ΣR = hazard reduction (inactivation or removal) ΣI = hazard increase (growth or recontamination) Which bugs/how many? How do we kill them? All expressed in log 10 units How do stop them? FSO FOOD SAFETY OBJECTIVE The maximum frequency &/or concentration of a [microbiological] hazard in a food at the time of consumption A through chain approach Food safety considerations for food innovation & reformulation Sandra Olivier 13 The FSO in practice RTE, short shelf-life, chilled meal Hazard - Listeria monocytogenes FSO To achieve a level of <1 cfu/25g at the point of consumption Performance Criteria 6-log 10 reduction Process Criteria Heat 2 70 o C High pressure processing Smelt, Food safety considerations for food innovation & reformulation Sandra Olivier 7

8 Predictive modelling Using mathematical models to describe & predict the behaviour of microorganisms in food Can assist in product development by assessing the impact of process deviation &/or product reformulation on safety & stability They can: Quantify the effect of preservation factor combinations Identify growth boundaries Optimise existing processes or suggest alternatives Enable equivalence determination They can t: Replace challenge studies: validation of key points still required Replace HACCP, GHP, GMP or other process controls Manage risk 15 Food safety considerations for food innovation & reformulation Sandra Olivier Predictive modelling in practice Listeria monocytogenes: Replacement of salt with a combination of lactic and acetic acid ph = 6.5 a w = 0.98 (3.5% NaCl) Lactic Acid = 0% Acetic Acid = 0% = 0.42 ph = 6.5 a w = (~0% NaCl) Lactic Acid = 2.5% Acetic Acid = 0.1% = 0.41 Pujol et al., Food safety considerations for food innovation & reformulation Sandra Olivier 8

9 Predictive modelling resources Pre-existing databases exist for a large proportion of foodborne pathogens Combase ComBase is the world s largest, freely-accessible database of quantified microbial responses in diverse food environments USDA Pathogen Modelling Program (PMP) 17 Food safety considerations for food innovation & reformulation Sandra Olivier Why challenge testing? Building a predictive model GOLD STANDARD! Product development Validation Why? Formulation changes Proof for regulators / retailers Response to safety / spoilage event New ingredient / source Process / storage changes Food safety considerations for food innovation & reformulation Sandra Olivier 18 9

10 How to validate a process A challenge! Challenge test How your product will perform if faced with a worst case microbe scenario CHALLENGED Shelf-life study How your product will perform given the microbes in it at the time of production NOT CHALLENGED Deliberately inoculate with a specific microorganism at a known concentration Includes both pathogenic (safety) & spoilage (stability) microorganisms Challenging performance related to Formulation hurdles (ph, a w, salt): Inactivation / Inhibition Process efficacy (thermal, HPP, chemical sanitisation): Inactivation Shelf-life conditions (atmosphere, packaging, temperature, time): Inhibition 19 Food safety considerations for food innovation & reformulation Sandra Olivier How to validate a process Shelf-life testing Shelf-life study How long will my product remain microbiologically (and chemically) stable? TIME TO SPOILAGE Process product according to conditions that would apply in a commercial setting & monitor both pathogenic (safety) & spoilage (stability) microorganisms Assessing shelf-life duration related to Process conditions (e.g. thermal processing, HPP, HPT) Formulation hurdles (e.g. ph, a w, salt) Shelf-life conditions (e.g. atmosphere, packaging, temperature [abuse], time) 20 Food safety considerations for food innovation & reformulation Sandra Olivier 10

11 Summary Consumer demands & a focus on healthier foods are driving reformulation & innovation in the food industry NPD must be approached with food safety being front & centre; changes to the food system can have serious consequences on safety & stability Safe innovation & reformulation incorporates an understanding of the hurdle concept, food safety objectives & novel approaches for assessing safety Challenge testing plays a critical role in assessing the safety & stability of foods 21 Food safety considerations for food innovation & reformulation Sandra Olivier Thank you Sandra Olivier Research Microbiologist and Team Leader Applied Food Microbiology t e sandra.olivier@csiro.au w AGRICULTURE AND FOOD 11