> Cargill Meat Solutions

CMC Updated E coli O157:H7 policy: Training Seminar

Cargill

CMC Updated E. coli O157:H7 policy: Training Seminar

Dr. Angie Siemens

June 11, 2008

> Cargill Meat Solutions: our scope

> $15B Revenues

> 35 000 Employees

> Sales/Distribution 40 countries

> 7 Business Units> 35,000 Employees

> Operations in 4 Countries

> 7 Business Units

CargillCargill Meat Solutions

> Cargill Meat Solutions: our ranking

> Second largest fed beef processor in North America

F h l k d i N h A i> Fourth largest pork producer in North America

> Largest processor of fresh whole turkeys

> Leading supplier of case ready products

> Largest supplier of ground beef in North Americaa gest supplie of g ou d beef i o t e ica

CargillCargill Meat Solutions

> Cargill Meat Solutions: our precious resources

> Feed 725,000 head of cattle annually

> Process 7 4 million cattle per year> Process 7.4 million cattle per year

> Process 9.1 million hogs per year

> Process 45.3 million turkeys per year

> Ship over 1.5 billion pounds of ground beef per year

CargillCargill Meat Solutions

> Cargill Meat Solutions: Our products & brands

Cargill Meat Solutions produces more than 5,000 products and markets under several brands including:

Cargill

AgendaAgenda

Beef SlaughterBeef Slaughter• What are we fighting?

H fi h i i ?• How are we fighting it?• How are we measuring it?• Verify, Verify, Verify

Cargill

AgendaAgenda

Beef SlaughterBeef Slaughter

• What are we fighting?• How are we fighting it?• How are we measuring it?g• Verify, Verify, Verify

Cargill

Escherichia coli O157:H7

a k a = E coli O157:H7

Cargill

a.k.a = E. coli O157:H7

Prevalence of E coli O157:H7Prevalence of E. coli O157:H7

• Summer – 3 162 cattle 29 pensSummer 3,162 cattle, 29 pens--23% of cattle infected

(1 80% of cattle in a feedyard pen)(1-80% of cattle in a feedyard pen)--100% of pens

• Winter 1 848 cattle 20 pens• Winter – 1,848 cattle, 20 pens --8.5% of cattle infected

(0 56% f ttl i f d d )(0-56% of cattle in a feedyard pen)--12/20 pens

Moxley 2001/2002—

Cargill

yUniversity of Nebraska

Results: Location of E. coli O157:H7

DorsumFlank

Results: Location of E. coli O157:H7(Percent positive by site in 139 cattle in 4 feedlot pens)

Mouth74.8%

74.1%54.0%Feces60.4%

Neck62.6%HockHock

41.7%Ventrum51 1%

Cargill

51.1%51.1% Keen and Elder, 2002

E. coli Attachment to the Carcass

• Use their hair like “fingers” to attach

• Attach to fat more easily than lean b f hbecause of rough surface

Cargill

AgendaAgenda

Beef SlaughterBeef Slaughter• What are we fighting?

• How are we fighting it?• How are we measuring it?g• Verify, Verify, Verify

Cargill

How are we fighting it?How are we fighting it?

• Interventions• Operational• Operational

Excellence

Cargill

What is an Intervention?What is an Intervention?

• Process, practice, or chemical applied

• To the meat or processing environmentp g

• In order to reduce levels of foodborne pathogensof foodborne pathogens– slow/stop/remove

Cargill

Multiple Hurdle ConceptMultiple Hurdle Concept

• Combination of 2 to 5 interventions– Hide on carcass wash– Pre-evisceration rinse/spray – Steam vacuum– Hock or tail steam vacuums or washes– Carcass wash– Steam or hot water pasteurization – Final acid rinse/spray

Cargill

HOCW

Vacuum

Cattle Sl h

Dehiding

VacuumSlaughter Schematic

Pre-evisceration Spray

Steam Vacuum

Hock or Tail Wash

Schematic

EviscerationList of process steps is

Splitting

Steam Vacuumnot all inclusive—only major steps are listed.

Sp gSteam Pasteurization System Steam Vacuumor

“Hot box”

Organic Acid WashHot Water Wash

Hide on Carcass WashHide on Carcass Wash

Includes high pressure washer, battery of cleaning and sanitizing g gagents, and water removal process.

Eliminate bacterial contamination; focused ;on pattern area

CargillKEYS: WATER TEMP/PRESSURE AND pH LEVEL

Before and AfterBefore and After

Cargill

Effectiveness of Commercial Hide Wash

A bi Pl t E li O157 H7Aerobic Plate Count, log cfu

E. coli O157:H7Percent Positive

Hide On 10.2 5015,849,000,000 31%-81%

Post Wash 7.9 16

15,849,000,000 31% 81%

0% 38%

Pre-Evisceration 5.8 30%-8%631 000

0%-38%

Cargill

0% 8%631,000

Koohmarie, 2003

Pre-EviscerationPre Evisceration Acid Rinse

di l f•Immediately after hide removal

I l d W t•Includes a Water Rinse followed by an Organic Acid Spray

•Potential Acids Used

LacticLacticAcetic

Cargill

Citric

KEYS: CONC/WATER TEMP/PRESSURE

SteamSteam Vacuum

P i i l i t l• Principle is to apply steam to carcass surface -Heat Shock

• Pull vacuum on carcass surface to remove bacteria plus any foreign y gmaterial present

• Used on locations prone to contaminationto contamination

• May be used at various points in the dressing process

Cargill

process

KEYS: TEMP OF STEAM/VACUUM

Carcass WashCarcass Wash

• Application of warm• Application of warm water (~ 140°F to 160°F) at carcass surface

• Original intervention• Standard Equipment forStandard Equipment for

many years• Still important for

removal of bothremoval of both physical and microbial contaminants

CargillKEYS: WATER TEMP/PRESSURE/VOLUME

Thermal interventionsThermal interventions

H t W t W h li ti f h t tHot Water Washes - application of hot water (~ 180°F) at carcass surfaceSteam Pasteurization System - chamber with application of steam under pressure to entire carcass surfacePrinciple of both interventions is to raise pcarcass surface temperature to > 180°F for ~ 10 seconds

Cargill

Steam PasteurizationCh b ith li ti• Chamber with application of steam under pressure to entire carcass surface

• Raise carcass surface t t ttemperature to

> 180°F for minimum 66 sec.

• Originally developed and patented by Excel, Corp.

Cargill

& Kansas State University

KEYS: TIME/STEAM TEMP/CHILL TEMP

Final A id RiAcid Rinse

•Removes contaminationRemoves contamination after evisceration

•Same principle as Pre-p pevisceration Rinse

•Many times a different acid will be used here than on other parts of the process to provide anotherprocess to provide another shock to bacteria

CargillKEYS: CONC/CHEMICAL/TEMP/ PRESSURE

VerifEYE - EmergeVerifEYE Emerge

• Machine filters everything that’s not• Machine filters everything that s not chlorophyll

All f d i d t t d• All feed is detected• Detects anything that isn’t meat, fat,

blood or connective tissueblood, or connective tissue• Must be plant derived

Cargill

Cargill

Chilling and Carcass SpacingChilling and Carcass Spacing

• Impacts both spoilage and pathogens• Impacts both spoilage and pathogens• Surface conditions are “critical”

Air temperature– Air temperature– Air flow– Relative humidity (%)y ( )

• Amount of water vapor in the air• Compared to the amount the air could hold if it was totally

saturatedsaturated.

• Carcass spacing– Heat migration to the surface and it’s removal from

Cargill

Heat migration to the surface and it s removal from the carcass are essential

Correct Carcass Spacing

Cargill

Log Mean of APC Counts for Each SamplingLog Mean of APC Counts for Each Sampling Site by Plant (N= 144 each plant)

Sampling Site Log avg.

Log Reduction

Plant 1- Mid-West Plant 2- Great PlainsLog ReductionLog avg.

Hide

Pre- Evis

8.4

3.8-4.6

7.3

3.2-4.1

Pre Evis

Hot Scale

Hot Box

3.8

3.7

1.2

-0.1

-2.5

3.2

3.8

1.3

+0.6

-2.5

Post Chilled 1.20.0

1.30.0

Cargill

Total Log Reduction - 7.2 Logs Total Log Reduction - 6.0 Logs

What Makes Interventions Work?What Makes Interventions Work?

P lPeopleWater PressureTTemperatureType of chemical and concentrationTime of exposureMethod of applicationEquipment designLocation of application

Cargill

Verification, Verification, Verification

AgendaAgenda

Beef Slaughterg• What are we fighting?• How are we fighting it?How are we fighting it?

• How are we measuring it?

Cargill

• Verify, Verify, Verify

OPEX ProgramOPEX Program

• Kill floor sectioned into “Areas”• Full time monitor for floorFull time monitor for floor.• All data input to a Palm Pilot.

P l i f \ d b• Palm interfaces w\ database.• Analyze data to monitor interventions &

research any high micro trends.

Cargill

Slaughter OPEX ComponentsSlaughter OPEX Components

• Slaughter zone checks• Mechanical intervention systems• Final carcass audit• Microbiological verification• Carcass spacing• Spinal cord and SRM removalp

Cargill

Slaughter Zone ChecksSlaughter Zone Checks

1. Qualified/trained employees

2. Personnel sanitation practices/dressing

dprocedures 3. Cleanliness of the

carcasses

Cargill

Trained EmployeesTrained Employees

180 F180 F

Cargill

EE Sanitation PracticesEE Sanitation Practices

Cargill

EE Sanitation PracticesEE Sanitation Practices

Cargill

Zone Checker AuditZone Checker Audit

Cargill

Zone Checker using PalmZone Checker using Palm

Cargill

M h i l I t ti A ditMechanical Intervention Audit

Cargill

Mechanical Intervention AuditMechanical Intervention Audit

HIDE-ON CARCASS WASH 1. Wash (NaOH) Requirements:a) Cattle must be double shackledb) Pressure: 600-900 psigc) Temperature: 130-140o Fd) Volume: 400 gpme) 12.3 to 12.7 pH at return to the mixing tank

2. Rinse (Chlorine) Requirements2. Rinse (Chlorine) Requirementsa) Cattle are double shackledb) Rinse: 750-900 psigc) Temperature: 40-110o Fd) Volume: 300-400 gpme) Chlorine: Minimum1-ppm detected as free residual

chlorine measured at the mixing tank

3. Water Removal Requirementsa) Squeegee or vacuum pattern

Cargill

) q g p

Final Carcass Audit (11 head check)

Cargill

Hot Box SpacingHot Box Spacing

CARCASS SPACING1. One rail will be randomly selected

once per production period. 2. Each hot box will be randomly y

audited.a) Carcasses should be turned in order

to create best airflow (cross shanked).b) No double sides per dog.3. Carcass spacing calculation:

A – (B+C) X 100

Where:A = Total sidesB = # of doublesC = # non-crossed shanks

Cargill

C = # non-crossed shanks

Microbiological & Other Verification ActivitiesMicrobiological & Other Verification Activities

• . Carcass generic E. gcoli are used to verify the system.

Cargill

AgendaAgenda

Beef SlaughterBeef Slaughter• What are we fighting?

H fi h i i ?• How are we fighting it?• How are we measuring it?

• Verify, Verify, Verify

Cargill

Remember

• Interventions and programs can be installed with the best intentionsinstalled with the best intentions.

• Dials are made for changing settings.• Verify, Verify, Verify

Cargill

SummarySummary

1 People are the best most effecti e Inter ention1. People are the best, most effective Intervention 2. Multiple Hurdle Approach 3. Thermal Interventions are critical 4 Process capability must be measured4. Process capability must be measured 5. Process capability must match worst case

scenarios of incoming microbial loads forscenarios of incoming microbial loads for hazard “not likely to occur”.

Cargill6. Verify, Verify, Verify

Cargill