SOUND OFF! THREE INDUSTRIES' SUCCESS STORIES FOR ENVIRONMENTAL MONITORING, FOOD SAFETY VALIDATION AND SANITATION

Transcription

1 SOUND OFF! THREE INDUSTRIES' SUCCESS STORIES FOR ENVIRONMENTAL MONITORING, FOOD SAFETY VALIDATION AND SANITATION We ve all seen media coverage of recent food pathogen disasters making it increasingly critical for the food industry to adequately monitor, verify and validate preventive controls. Creating and maintaining an effective environmental monitoring program (EMP) can serve as an early warning system to fend off potential contamination. Dr. Sanjay Gummalla, Brian Dunning, and Scott Goltry present the complexities, challenges, and takeaway strategies to help the food industry identify, react, and reduce the risk for foodborne illness. Ana Paula Craig and Robert Garrison organized and moderated the session on behalf of IFT s Quality Assurance and Refrigerated and Frozen Foods divisions. INSTITUTE OF FOOD TECHNOLOGISTS ALL RIGHTS RESERVED

2 THE THREAT: Listeria monocytogenes (Lm) This pathogenic bacterium is ubiquitous and readily grows in food processing facilities which can affect food ingredients and finished foods. In many cases, contamination can be avoided when the right measures are put into place. At-risk populations, including pregnant women, newborns, the elderly and those who are immunocompromised (such as those with HIV or cancer) are particularly vulnerable for developing listeriosis. 10 Every year 1,600 people get listeriosis in the US. RESULTING IN: Major outbreaks 27 % Industry is committed to: Many factors have led to a reduction in incidence of foodborne illness for listeria (between ). One successful example is the industry s SEEK AND DESTROY APPROACH to target listeria in food facilities. WHAT ELSE IS BEING DONE TO REDUCE THESE RISKS? Identifying risks and applying best manufacturing practices Modernizing facilities and training personnel Investing in novel processes and testing technologies 147 Cases since Let s look at how this has been done in the dry, meat, and frozen food sectors...

3 FROZEN FOOD INDUSTRY The American Frozen Food Institute's (AFFI) Food Safety Working Group, comprised of AFFI member companies, is mitigating the risk of Lm in the frozen food industry through the creation of frozen food specific food safety protocols for: Sanitation controls Sanitary design of equipment and facilities Process validation Environmental monitoring AFFI s Lm goals are ambitious and comprehensive: 1. Develop the most effective food safety practices for frozen foods based on science. 2. Develop consumer and customer education on proper handling and cooking of frozen foods for optimal food safety and quality. Lm may be a hazard throughout the supply chain. Ingredients & Suppliers Fresh produce Raw ingredients Farmers Distributors Identifying risk at all points of contact. Processes & Processors Washing Blanching Blending Freezing Manufacturers Products & Consumers Frozen produce as ingredients or retail Consumers Food Service HOW ARE YOU REDUCING THE RISK OF LM?

4 DRY FOOD ZONED SAMPLING LOCATIONS FACILITY Verification tools, like an aggressive Pathogen Environmental Monitoring Program (PEM), can determine the effectiveness of a facility s pathogen controls. PEMs can target Lm or larger threats, like Salmonella in dry food facilities. Implementing zones of control can help manage PEM program data. A facility is divided into four zones based on level of risk. REMBEMBER: Maintaining accurate records is crucial Positive results must trigger documentation, follow-up, and Corrective Actions Prioritize sampling in areas of higher risk Get the extent of the contamination prior to beginning sanitation activities A change in conditions (construction, rains, drain back-ups) should trigger elevated testing All facilities have risks- new and old ZONE 4 locker rooms cafeteria halls warehouse loading dock ZONE 3 phones hand trucks forklifts walls floors and drains ZONE 2 Non-product contact surfaces in close proximity to product exterior of equipment chill units framework equipment housing ZONE 1 Product contact surfaces slicers conveyors peelers strip tables utensils racks work tables employee hands dicers pumps ZONE 2-4 TESTING GOAL: Test environment to find pathogens that can migrate and cause problems. Store testing supplies correctly Identify, label, and record samples Wear sterilized gloves to swab, repackage, and send to Micro Lab for analysis Analysis lab then completes a PCR Analysis: RESULTS/CONFIRMATION: - + Swabs can be cleared Confirmation is required Initiate Vector Swabbing and Corrective Action Cleaning Request to Sanitation Hold Vector swabs pending confirmation results ZONE 1 TESTING GOAL: Verify sanitation Find the total Enterobacteriaceae (TEB) count: ACTION LIMITS: <10 Target <100 Acceptable

5 MEAT PRODUCTS Facilities should be designed with sanitation in mind. During remodels or new construction, consider the following: Provide zones of control Separate Raw and RTE areas Keep the environment cold and control moisture Be proactive with prevention programs like Seek and Destroy 10 PRINCIPLES OF SANITARY DESIGN A PREVENTATIVE "SEEK AND DESTROY" PROGRAM CAN REDUCE CONTAMINATION 1. Cleanable to a microbiological level 2. Made of compatible materials 3. Accessible for inspection, maintenance, cleaning and sanitation 4. No product or liquid collection 5. Hollow areas should be hermetically sealed Disassemble Observe Clean & Sanitize 6. No niches To catch all possible growth niches. Is the degree of disassembly acceptable? Normal cleaning and sanitation operations. Are all parts and components being adequately sanitized by heat or chemically? Are cleaning methods acceptable and are there any suspect areas that need to be inspected and swabbed? 7. Sanitary operational performance 8. Hygienic design of maintenance enclosures 9. Hygienic compatibility with other plan systems 10. Validated cleaning and sanitizing protocols This information has been modified with permission from its presenters from a session originally presented at IFT 17. For additional resources and information, visit the American Frozen Food Institute, Almond Board of California, North American Meat Institute, and the FDA s websites.

6 Inspiring Innovation to Feed the Future and Beyond IFTNEXT, an Institute of Food Technologists initiative, is a heightened, purpose-driven commitment to bringing provocative ideas and discoveries together to inspire thoughtful, important conversations that challenge conventional approaches with the goal of informing global issues related to the science of food. IFTNEXT is made possible through the generous support of Ingredion Incorporated, IFT s Platinum Innovation Sponsor. Learn more at ift.org/iftnext INSTITUTE OF FOOD TECHNOLOGISTS ALL RIGHTS RESERVED