food safety (microbiology, sanitation and haccp)

Food Safety (Microbiology, Sanitation and HACCP)

Frank T. JonesExtension Poultry Specialist

Cooperative Extension ServiceUniversity of Arkansas

Fayetteville, AR

Presentation Outline

• Sanitation Definitions

• Microorganisms – Overview

• Public Health Background

• Sanitation on Farm

• Sanitation in Plants

• HACCP Overview

What is Sanitation?• World Health Organization (WHO) – “All

precautions and measures which are necessary in production, processing, storage and distribution, in order to assure an unobjectionable, sound and palatable product which is suited for human consumption.”

• Sanitation from Greek Sanitas – Health• N. G. Marriott – “The creation and

maintenance of hygenic and healthful conditions.”

KillOrganisms

ExcludeContamination

PreventMultiplication

Sanitation Basics

Microorganisms

Bacteria Viruses

Fungi

Molds Yeasts

Beneficial Microorganisms

• Fermentation– Cheese, Beer, Wine, Bread, Yogurt

• Enzymes

• Aids to Human Metabolism

• Decay– Waste treatment, composting, decomposition

“The Enemies”

• Pathogens – Food Safety– Illness, Disease and Death

• Spoilage – Food Quality– Poor Quality, Short Shelf Life, Off Flavors,

Customer Dissatisfaction

Bacteria

• Microscopic single cells• Lots of moisture required• Cause most food illness• Three basic shapes

– Rod– Cocci (spheres)– Spiral

• Some spore formers• Grow, grow, grow

– Binary Fission

Bacterial Reproduction

– Binary Fission

Generation Cell Numbers

1 100

2 200

3 400

4 800

5 1,600

6 3,200

7 6,400

8 12,800

9 25,600

10 51,200

11 102,400

12 204,800

13 409,600

14 819,200

15 1,638,400

Generation Time

Generation Time (Min)

10 30 60 90

Hours from 100 to 1 Million

2.4 7.1 14.2 21.3

What Bacteria Need for Growth?

•F ood

•A cid (pH)

•T ime

•T emperature

•O xygen

•M oisture

FAT TOM

The Spore Cycle

• Spores VERY resistant• Two species form spores

– Bacillus– Clostridium

• Difficult to destroy – reduce strategy

• Problem in cooked foods

Fungi (Molds and Yeasts)

• Require less moisture• Can grow in acid pH• Very adaptable• Grow slower than

bacteria• Molds – multicellular• Form spores that are

less resistant than bacterial spores

• Yeasts bud

Basic Virus Structure

Genetic Material (DNA or RNA)Protein Coat

Tail Fibers

Hollow Protein Tail

Virus Life Cycle

Viruses

• Tiny• Simple

structure• Must grow in

cells• In foods –

fecal contam.• Personal

sanitation to prevent

• Living?

Our Losses…

• Every year (based on CDC data):

• Over 250 billion meals are prepared

• An estimated 76 million foodborne illnesses occur

• >5,000 foodborne associated deaths

• Costs = $7.7 to 23 billion

(Centers for Disease Control and Prevention, 2003)

Foodborne Illness

“... when a person becomes ill after ingesting a contaminated food...”

Foodborne illness can be caused by:• Biological hazards (bacteria, viruses, fungi)• Chemical hazards (cleaning agents, toxins)• Physical hazards (bone, glass, metal)

Foodborne Hazards

Hazard Est. Cases DeathsNorwalk virus 23,000,000 naCampylobacter 2,453,926 0.1%Salmonella 1,412,498 0.8%C. perfringens 248,520 .05%S. aureus 185,060 .02%E. coli O157:H7 73,480 .83%L. monocytogenes 2,518 20%C. botulinum 58 8.6%

(Centers for Disease Control and Prevention, 2001)

FOOD BORNE PATHOGENS:

• USDA – FSIS “Target Pathogens”

• Four major pathogens of food bone illness– Salmonella– E. coli 0157:H7– Campylobacter– Listeria monocyctogens

SALMONELLA

• Most frequently reported

• Introduced anywhere within the food chain

• Grown on any food under the right conditions: Moisture and Temperature

• Ideal growth temperature 40-140 ° F

• Cook temperature essential to kill-160 º F

• Safe handling of food by consumer essential

E COLI 0157:H7 & Campylobacter

• Natural inhabitant of the GI tract of all animals

• Sanitary practices throughout the Farm to Table essential for control

• Consumer education of safe handling practices for food, raw and cooked, essential for control

LISTERIA MONOCYTOGENS

• Commonly found in GI tract of all animals• Can survive for long periods in SOIL,

SEWAGE, DUST, VEGATATION AND WATER

• Resistant to cool temp - Cold storage• Can form biofilms on surfaces to resist

cleaning and sanitizing• Biggest threat:Pregnant women-

miscarriages and birth defects

Sanitation in Live Production

• Will never be sterile but don’t give up!• 7 Basic Steps in Live Production Sanitation

– Obtain Clean Stock– Proper Bird Care– Vermin Control– Moisture Control– Feed Storage– Biosecurity– Water Sanitation

Obtaining Clean Stock

• Know the seller

• Don’t look for bargains

• Isolate birds for 2 wks

• Monitor birds daily and separate sick ones

Proper Birds Care

• Healthy birds are more resistant

• Pay attention to bird behavior

• Collect dead at least daily

• Provide ventilation

Vermin

• Damage facilities

• Eat feed

• Contaminate facilities

• Entry for other pests

• May kill animals

Moisture is often THETHE SINGLESINGLE Most Important Factor in Determining Microbial Growth

Moisture Control

• Litter moisture related to pathogens

• Moisture control related to:– Addressing obvious sources– Ventilation– Control of Drinkers

Feed Storage

• Protection from Rodents & Wild Birds

• Protection from Moisture

• Protection from Heat and Sunlight– Moisture Migration– UV Destruction

• Feed Freshness

Moisture Migration in Food

12%

12% 12%

12% 12%

12%

12%

12%

12%

16%

16% 13%

16% 13%

13%

10%

10%

10%

20%

20% 12%

20% 12%

12%

8%

8%

8%

Moisture Migration in Feeds

02468

1012141618

Moi

stu

re (

%)

50 70 90

Temperature (F)

Effect of Temperature on Feed Moisture

SwineCattlePig

From Headley 1969

From Headley, 1969

0

5

10

15

20

25

30F

eed

Moi

stu

re (

%)

25 40 58 75 82 93

Relative Humidity (%)

Effect of Relative Humidity on Feed Moisture

Pig Starter

Cattle Ration

0

5

10

15

20

25

30

Afl

ato

x

(pp

b)

1 to 5 6 to 10 11 to 15 16 to 20

Age in Days

Effect of Feed Age on Aflatoxin Concentration.

From Jones et al.1982

How Feeds Age on Farm

Birds preferto eat pelletsrather than fines

Concentration of Fines

Feed older thanaverage and highin fines

Biosecurity

• Procedures that work for bird pathogens also keep out human pathogens

• Basic Steps– No Visitor Policy – Have Farm Clothes– Protect Personnel – Clean Vehicles– Clean Equipment – No Contact Other Birds– Proper Dead Disposal – No Borrowed Equip– No Visits to Problems – No Wild Game– Locks & Security– Avoid Mixing Animal Species

Footbaths – The Good, The Bad and The Ugly

• Can be effective BUT

• MUST pay attention

• Use correct disinfectant

• Contaminated baths spread disease and pathogens

Basics Steps in Sanitizer Use• Avoid mixing sanitizers PARTICULARLY

Chlorine @ pH<4 = Chlorine Gas• In general, clean, scrub, rinse THEN sanitize• Store sanitizers away from feed and birds• Protect sanitizers from heat and light• Avoid long storage times• Use for Approved Purposes

– General Sanitation– Food Contact Surfaces

Disinfectant Types and QualitiesType Activity Organic

Mattter Effect

Cost Human Toxicity

Comments

Alcohols Wide no spores

Reduces effects

Exp Low Non Corrosive, Fire Hazard, conc 70-95%,

Hypochlorite Wide no spores

Kills effects

Low Low Can be corrosive

Iodophors Wide no spores

Reduces effects

Mod Low May stain clothing, porous surfaces

QAC (Quaternary

Ammonia Compounds)

Limited no

spores

Reduces effects

Low Low Soaps, detergents and hard water limit

effectiveness

Phenolic Wide no spores

Little to none

Mod Low Good residual activity

Aldehyde Wide Limits effects

Mod Mod Gets everything, but can be highly toxic

Oxidizer Mod. No spores

Kills effects

Mod Low Limited residual,

Mod corrosive

A Broad Look at DisinfectantsType Examples Uses

Alcohols Rubbing Alcohol, Isopropyl, Ethanol

Small objects, hands

Hypochlorite Chlorox, Chloramine-T, Halazone

Water, Clean surfaces

Iodophors Betadine, Iofec, Isodyne, Tamed Iodine, Weladol

Water, Hands, Equipment, Walls

QAC (Quaternary Ammonia

Compounds)

Roccal, Germex, Hi-Lethol, San-O-Fec, Warden, Zephiran

Hatcheries, with some soaps

Phenolic Lysol, Pine-Sol, Cresi-400, Environ, Tek-Trol

Hatcheries, Equipment, Footbaths

Aldehyde Formaldehyde, Glutaraldehyde

Fumigation, clean surfaces

Oxidizer Hydrogen Peroxide, Peracetic Acid

Clean surfaces

Water Sanitation

• Water – A GREAT organism transmitter

• Consider closed line systems – Nipples or cups

• Clean open waterers often, but don’t dump water in the litter

• Proper height adjustment

Bacterial Counts from Poultry Water Systems

2700

26600203000

2340000

600

282000

0

4775000

0500000

10000001500000

20000002500000

300000035000004000000

45000005000000

Bac

teri

al C

ou

nts

Farm A Farm B Farm C Farm D

Source

Line End

From: Watkins. 2003

Used with permission from: The Center for Biofilm Engineering at Montana State University – Bozeman

http://www.erc.montana.edu/CBEssentials-SW/bf-basics-99/bbasics-01.htm

Used with permission from: The Center for Biofilm Engineering at Montana State University – Bozemanhttp://www.erc.montana.edu/CBEssentials-SW/bf-basics-99/bbasics-01.htm

Biofilm in a Municipal Water Line

Water Line Cleaners for Use Once a Week When Birds are Present

Clear Household Ammonia

Household Bleach

White Household

Vinegar

Iodine (18.05%)

½ teaspoon per gallon of water

½ teaspoon per gallon of water

1 oz per gallon of water

¼ teaspoon per gallon of water

Cleaning Closed Watering Systems with Birds in the House

Clear Household Ammonia

Household Bleach

Clear Vinegar

Iodine (18.05%)

6 oz per gallon

6 oz per gallon

128 oz per gallon

2 oz per gallon

Meter stock solution at 1 oz / 128 oz (gal) water

Prepare a stock solution

Basic Steps in Poultry Processing

Pre-slaughter

Immobilize

Feather Removal

Evisceration

Chilling

Further Processing orPackaging

Kill Line

Evisceratio

n Line Separation Wall

Air

Flo

w

Sanitation in Small Processing

• Work indoors if possible• Avoid the use of wood surfaces• Use sanitizers labeled for Food Contact

Surfaces• Clean and sanitize equipment before use• Separate slaughter and picking from

evisceration and cut up -- Job Specialize• Avoid long delays• Keep things as clean as possible (insects)• Don’t spare the water• Cool processed carcasses quickly and keep

them cool• Clean and sanitize equipment before storage

Loblolly Pine Birch100μ

Staphylococcus - 1.0μ Clostridium - 0.4 x 3μ Treponema 0.2x 11μ

Wood Should be Avoided in Processing Areas

Sanitizers for Food Contact SurfacesCategory Advantages Disadvantages

Chlorine, Dioxides

Broad Act., Not temp. sensitive, Cheap, No Foam

Cl gas, Corrosive, Organic material, Degrades, THM’s, pH range

Iodophores Broad Act., Low Tox., Stable, Color, Good Residual

Stains, Hard water, Temps (High & Low), Odor, Cl cheaper

QAC Stable, Innocuous, Some Residual

Low temps, Hard water, Little effect on gram negative bacteria

Acid-Anionic Stable, W/ Organic Matter, Non Corrosive, Odorless

Cost, pH

Carboxylic Acid

Broad Act., Stable, W/ Organic Matter, High Temp

Low Temp., Corrosive

Peroxy Acid Broad Act., Degrade, Non Corrosive, Temp. Tolerant

Co, Cu, Ti, Mishandling Danger, Concentrate Odor

Natural Disinfecting Agents

• Sunlight (Ultraviolet rays)

• Heat (>85°F)

• Cold (Freezing or below)

• Drying (Aided by wind, light and heat)

• EFFECTIVE, But are they reliable?

HACCP -What is it?• HACCP -(HAS-SIP)• H azard• A nalysis and• C ritical• C ontrol• P oints• HACCP often misused term.• A systematic method of documenting

that food safety hazards have been addressed.

HACCP - What is it?

• HACCP involves only food safety issues.

• Out of control = unsafe food produced.

• Plans unique for each unit and product.

HACCP – What is it?Step Meaning

1. Hazard Analysis What are the controllable food safety hazards?

2. Establish Critical Control Points

Where do things go wrong and how can we reliably control it?

3. Establish Critical Limits What value indicates the process is in control?

4. Establish Monitoring Procedures

Who, what, when , where and how will CCP’s be monitored?

5. Establish Corrective Actions

What happens if we exceed a Critical limit?

6. Establish a Record Keeping System

If you don’t write it down it doesn’t exit.

7. Establish Verification Procedures

How do you know the system works?

HOW DOES HACCP WORK?

• Processors must take the following steps:– assemble a HACCP team to design their plan – describe the product and its method of

production, distribution and intended consumer.

– Develop and verify process flow diagrams

How does HACCP Work?

• Identify at each step of the production flow chart any hazard to food safety as to:– Chemical – Physical– Bacterial

• Support the hazard with a decision making document and scientific data

How does HACCP Work?

• If a CCP deviation is found the following must take place:– Identify the cause of deviation– Describe how the critical limit was

restored– Describe how the deviation can be

prevented from happening again– Describe how the adulterated product was

reconditioned or what happened to the product

FARM TO TABLE FSIS GOALS

• FSIS has made a commitment to expanding into the pre harvest areas of the food chain, working in a non regulatory capacity, to promote food safety.

• Commitment to utilize the knowledge, skills and abilities of FSIS veterinary medical expertise to contribute to the goal of food safety.