MCGILL FOOD SAFETY AND QUALITY PROGRAM FORUM FEBRUARY 21, 2014 DR SYLVAIN FOURNAISE V.M., M.SC. VICE-PRESIDENT, FOOD SAFETY AND TECHNICAL SERVICES

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1 How do we use technology to address concerns/issues around Food Safety MCGILL FOOD SAFETY AND QUALITY PROGRAM FORUM FEBRUARY 21, 2014 DR SYLVAIN FOURNAISE V.M., M.SC. VICE-PRESIDENT, FOOD SAFETY AND TECHNICAL SERVICES

2 Presentation Introduction Process validations (cooking and chilling) Effectiveness validation of programs and process (Bioluminescence, MAP, Leakers) Listeria control program (ozone, steam) Food safety hazards (MIC, Challenge study, shelflife) 2

3 OUR MISSION A leader in the agrifood industry, and proud of its Quebec roots, the superior quality of its products and its 10,000 employees, Olymel has a single motivation and mission: TOGETHER, WE FEED THE WORLD

4 OUR VALUES Integrity Respect Trust

5 OLYMEL ANNUAL SALES 2.5 BILLION EMPLOYEES 10,000 (including Big Sky) PLANTS 17 DISTRIBUTION CENTERS 5 SALES OFFICES 6 A COMPLEX OF HOG PRODUCTION Facilities are located in Saskatchewan and Manitoba

6 OLYMEL Success based on integrated expertise: production, slaughtering, processing, distribution, machining and transport OlySky: 42,000 sows/1 million pigs Annual supply from its partners: 8.3 million pigs 83 million chickens 5.2 million turkeys

7 EARNING THE TRUST OF CONSUMERS OLYMEL OWNS RETAIL TRADEMARKS TRUSTED ACROSS CANADA pork and poultry products sold across Canada pork products sold across Quebec chicken and turkey products sold across Canada

8 FOOD SAFETY AND TECHNICAL SERVICES

9 Our Role : To Ensure the safety of foods manufactured. compliance to CFIA FSEP/HACCP program and all programs and related procedures. compliance with the requirements of the countries where we export to. compliance with the specifications and requirements from our clients....compliance of operations performed by co-packers. compliance of products manufactured and delivered by our suppliers as well as the compliance of their establishments. 9

10 Quality Programs Animal Welfare Good Manufacturing Practice FSEP/HACCP HIP MPIP Biosecurity / C-TPAT Traceability / Product Recall Procedure Management system complaint Third party audit through the national audit program in collaboration with Silliker GFSI/SQF 10

11 Cooking validation 1. Identify the coldest point in the smokehouse. 2. Position of the probes in the smokehouse. The probes must be positioned so that the top, middle and bottom of a rack are measured and the bottom, center and a point near the entrance in the chamber are also measured. 3. Repeat the test for at least 3 cookings to validate the results. 11

12 Probes 12

13 Cooking Graph 13

14 Chilling Curves Sonde 21 haut Sonde 6 milieu Sonde 27 bas

15 Bioluminescence 15

16 Bioluminescence 16

17 Bioluminescence 17

18 Bioluminescence 18

19 Bioluminescence 19

20 Luminometer Stand PC Software 20 20

21 AccuPoint Sampling Method 21

22 Screen 22

23 DATAS Manager 23

24 Packaging controls Seal integrity from MAP and vacuum packages is a CCP. Frequency of monitoring: each product code at start-up, each time a new product is introduced, and once/hour when introducing a new film lot # until end of shift. MAP also requires residual O 2 measurement. 24

25 Residual O 2 measurement 25

26 Leak Detector 26

27 Leak Detector 27

28 Leak Detector 28

29 Leak Detector 29

30 OZONE for a sanitized air and as a sanitizer 30

31 Steam sanitation during process 31

32 Mobile steam equipment 32

33 Ozone in water 33

34 Pathogen modelling program Software predicting the growth or survival of microorganisms has been developed (e.g. Pathogen Modelling Program, United States Department of Agriculture, and ComBase, Institute of Food Research, Norwich, UK). These predictive models can typically be used for screening the microbial hurdles of a product or process to support decisions. Predictive models are tools to assist in the design of products or processes, addressed at the early stages of the development. However, the accuracy of predictions must be validated through tests under conditions as close as possible to those of the final product. 34

35 Chilling validation C. perfringens Predictor from Combase is a user friendly tool developed to enable accurate prediction, through simulation, of the response of C. perfringens during the cooling process, for cooked meats. In the web site the user has to fulfill the blank space with the ph of the meat, concentration of salt and with the time/temperature data. 35

36 ComBase 36

37 Challenge study / shelf life validation As shelf life study and challenge tests are often very time-consuming, careful planning is necessary and must be done as early as possible in the development process. The product and the potential microbial hazards must be described in as much detail as possible. Typically this is done during the hazards analysis in the HACCP development. 37

38 When to do a shelf Life study? Storage tests should be carried out: during the development of new products/processes as a part of the development steps. at first production, at first commercial production, and after onetwo months of production to confirm that the shelf life of the products is consistent. Shelf life at 4 C + 0 C + sometime we challenge. Day 0, 50% of expected shelf life and every 7 days. Micro + organoleptic evaluations. 38

39 Challenge study Challenge study is now necessary to validate a process, the effectiveness of a growth inhibitor, etc. When designing the challenge test, the objective/s must be clear and the acceptable or unacceptable results defined. 39

40 Get prepared Typically one of the following questions are addressed: the limit of microbial growth/no growth the lag phase and growth rate of the target organism the time at which a toxin is detectable in the product criteria to obtain a required reduction the time needed to detect a certain non-desired quality criterion (e.g. acid taste or liquid separation) 40

41 When not to do a challenge study A microbiological challenge test must not be carried out: if the product is preserved under conditions beyond the possible growth of the inoculated microorganism (e.g. growth of Listeria monocytogenes in a product acidified to ph 4.0). if it is evident that the inoculated microorganism will grow in the product (e.g. growth of Salmonella in a neutral, high moisture, ambient stable product). if it is evident that a heat process is not sufficient to inactivate the organism of concern. 41

42 Important considerations When microorganisms are in extreme environments, all relevant chemical and physical parameters (e.g. packaging atmosphere, ph and a W ) must be measured before and after inoculation and at the end of the test. Measurements of parameters like modified atmosphere packaging atmosphere and ph during the entire storage often provide valuable supplementary information on microbial growth. It is recommended to analyse a minimum three replicates per sampling point. Thus, for every sampling point and treatment during the challenge test, three individual samples should be available. 42

43 Selection of strains In the selection of organisms for challenge tests, care should be taken to ensure that strains are appropriate to the type of food being evaluated and for the purpose of the study. To cover strain variability it is useful to inoculate with a mixture (cocktail) of strains of the species selected for the test. The cocktail consists of minimum 5 strains of one species of different origin. Ideally strains for the test are isolated from similar products, ingredients or process environments to the one to be tested. For traceability and to be able to compare results between studies, it is advisable to include a strain from an official culture collection. Unless for a specific purpose different pathogens must not be studied in the same challenge test. Important to define the inoculation level. 43

44 Interpretation of data Combining the quantitative enumeration results for each time point with those for the background microflora and the relevant chemical and physical parameters gives a powerful and broad representation of the microbiological safety and stability of the product under evaluation. 44

45 Growth patterns Growth (log) A B C D F Week 45

46 References Listeria monocytogenes Challenge Testing of Refrigerated Ready-to-Eat Foods International Commission on Microbiological Specifications for Foods (ICMSF) Microbiological Challenge Testing. In: Microorganisms in Foods 5. Characteristics of Microbial Pathogens. Blakie Academic & Professional, London, UK. 46

47 How do we do MIC (Minimum inhibitory concentrations) MICs are defined as the lowest concentration of an antimicrobial that will inhibit the visible growth of a microorganism after incubation, and minimum bactericidal concentrations (MBCs) as the lowest concentration of antimicrobial that will prevent the growth of an organism Definition : J. Antimicrob. Chemother. (2001) 48 (suppl 1): doi: /jac/48.suppl_1.5 47

48 MIC The main objectives of the MIC is to: Assess the bactericidal or bacteriostatic capacity of potentially effective compounds. Have data on the bactericidal / bacteriostatic ability of these agents in optimal condition Guide future product formulations Assess the impact on costs 48

49 MIC plate 49

50 Conclusion I made a very quick overview. Science and technologies are available to help. May need help and support. Do not hesitate to contact a counterpart. Universities may help. McGill Food Safety team should be considered. 50

51 Never forget that Food Safety is a non competitive issue. THANK YOU 51