quality assurance in low moisture foods. control of the
TRANSCRIPT
Quality Assurance in low moisture foods. Control of the Enterobacteriaceae family and Salmonella spp Jean-Louis Cordier
Quality Assurance for RUTF & RUSF – Supplier Meeting
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ICMSF Founding Members Dr. F.S. Thatcher, Canada
Dr. C. Cominazzini, Italy
Dr. M. Ingrams, UK
Dr. R. Paul Elliott, USA
Dr. C. E. Dolman, Canada
Dr. K. Lewis, USA
Dr. G.G. Slocum, USA
Dr. H.E. Goresline, U.S.A./Austria
Prof. D.A.A. Mossel, Netherlands
Mrs. Mildred Galton, USA
Dr. Leon Buchbinder, USA
Dr. Holger Lundbeck, Sweden
Dr. Betty C. Hobbs
United Kingdom/India
Dr. R. Buttiaux, France
Founded in 1962 through International Union of Microbiological Societies (IUMS)
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ICMSF
Subcommissions
Latin America
China / NE Asia
SE Asia
SADC (S. Africa)
India
IUMS ICSU
Audiences:
•Intergovernmental agencies (WHO,
FAO, Codex, EC, …)
•National governments
•Industry (Processors, food service and
retail, from farm to fork)
•Academics
•Trade, professional and consumer
organizations (ILSI, IAFP, IFT, ICD …)
•Industry technology and service
providers
•Private standard-setting bodies (ISO,
CIES-GFSI, AOAC, Global GAPs)
ICMSF and its Food Safety World audiences
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ICMSF membership currently consists of 18 food microbiologists from 13 countries.
Members' professional experience includes research, process development, public health, agriculture, food technology, quality control, and education.
We also seek assistance from an extensive network of consultants considered to be experts in various areas of food microbiology.
Members, as well as consultants, are selected based on their technical expertise, not as national delegates.
All work is voluntary and without honoraria. Partners, ILSI, ICD, FAO, WHO, IUFoST
About ICMSF
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Revised principles for the establishment and application of microbiological criteria for foods (1995)
The control of L. monocytogenes in foods (1995)
Establishment of sampling plans for microbiological safety criteria for foods in international trade (1996)
Recommendations for the management of microbiolo-gical hazards for foods in international trade (1996)
The role of Food Safety Objectives in the management of the microbiological safety of food according to Codex documents (2001)
Use of Epidemiologic Data to Measure the Impact of Food Safety Control Programs (2005)
Microbiological criteria for powdered infant formula (2005)
Discussion documents for Codex Alimentarius
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1978/’88
1982/’86
1980 1988
1996 2002
1998/2005
“Microorganisms in Foods” Series
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“Microorganisms in Foods” Series
www.icmsf.org
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The recommendations of ICMSF have no official status, the official promulgation of such recommendations being nationally the province of governments and internationally the province of the United Nations and its agencies such as WHO and FAO.
Internationally advise of ICMSF has been passed to organisations such as WHO, FAO.
ICMSF - Recommendations
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Quality Assurance in low moisture foods. Control of the Enterobacteriaceae family and Salmonella spp
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Salmonella – Outbreaks and Recalls
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Salmonella – Outbreaks and Recalls
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Salmonella – Outbreaks and Recalls
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Salmonella – Outbreaks and Recalls
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Salmonella – Outbreaks and Recalls
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Salmonella – Outbreaks and Recalls
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Salmonella – Outbreaks and Recalls
Almonds
Peanuts
Pistacchio
Sesame
Hazelnuts
Pecan nuts
Walnuts
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Salmonella – Outbreaks and Recalls
Numerous Products Containing
Peanut Butter
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Salmonella – Outbreaks and Recalls
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Salmonella – Characteristics in low moisture foods
Low levels of contamination
Chocolate Eastbourne 2.5 CFU/g Napoli 2 CFU/g Nima 0.04 – 0.24 CFU/g Typhimurium 1 CFU/g Oranienburg 1.1 – 2.8 CFU/g
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Dry Dairy Products Several serotypes several months Pasta Infantis, Typhimurium one year Chocolate Eastbourne several months Peanut Butter Several serotypes several weeks Paprika Several serotypes several months
Salmonella – Characteristics in low moisture foods
Prolonged survival in products
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Salmonella – Characteristics in low moisture foods
Prolonged survival in processing environment
Salmonella agona Salmonella agona
1998 2008
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Salmonella – Control Measures and Management
Is testing a solution to avoid presence
of Salmonella?
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0.1%
20 %
~1% probability of detection
n = 10
~35% probability of acceptance
Salmonella – Limitations of products testing
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TODAY
Salmonella – Limitations of product testing
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YESTERDAY
Salmonella – Limitations of product testing
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TOMORROW
Salmonella – Limitations of product testing
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Salmonella – Characteristics in low moisture foods
Numerous difficult matrices
Presence of inhibitory substances
Need for modified enrichment procedures for several of them
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Salmonella – Outbreaks and Recalls
What are the Root Causes for the presence of Salmonella
in low moisture products?
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Contaminated Ingredients
Salmonella – Outbreaks and Recalls
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Processing Environment/Lines
Salmonella – Outbreaks and Recalls
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HAZARD
FSO
Process Variability
Foodborne Illness
Cole, 2012
Managing the ‘Food Safety Cliff’
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GAPs/GMPs/GHPs
HACCP
FSO/PO
Microbiological Risk Analysis
Food Safety Control & Food Safety Management
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Industrial Food Safety Management
HACCP Study
Potential Hazard
Significant Hazard
Non-Significant Hazard
PRP CCP OPRP
PRP
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Industrial Food Safety Management
HACCP Study
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Can cause fatality A
Can lead to serious illness B
Can cause illness C
Can cause inconvenience D
Almost of no significance E
1 2 3 4 5
Unlikely Rare Could occur
Likely Frequent
Likelihood of occurrence
Seve
rity
of
health e
ffect
s
Significant hazards
controlled by OPRPs or HACCP/CCP
Non-significant hazards
controlled by PRPs or may
not need to be controlled
Industrial Food Safety Management
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Ho - Σ R + Σ IRC+G FSO / PO
Starting level
Reduction
Hazard level in the food chain
Increase RC: Recontamination G: Growth
Hazard level at moment of consumption
Industrial Food Safety Management
ICMSF Conceptual Formula
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Simplified scheme of a processing line
Ho - Σ R + Σ IRC+G
Industrial Food Safety Management
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Criteria along the food chain are interlinked
Finished Product
Raw Material
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Criteria along the food chain are interlinked
n=30, c=0, m=0 (in 25g)
n=30, c=0, m=0 (in 25g)
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Simplified scheme of a processing line
Ho - Σ R + Σ IRC+G
Industrial Food Safety Management
Shared Lines
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Simplified scheme of a processing line
Ho - Σ R + Σ IRC+G
Industrial Food Safety Management
Shared Lines
STRICTEST REQUIREMENTS NEED TO
BE APPLIED
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Milk powder Whey powder Soy proteins Sucrose Vitamins
High Risk Medium Risk Low Risk
Salmonella – Likelihood of Occurrence (Risk)
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Salmonella – Management by Supplier
0.1%
20 %
~1% probability of detection
n = 10
~35% probability of acceptance
Limitations of testing
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Assessment of control measures at the supplier
Salmonella – Management by Supplier
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Salmonella – Management by Supplier
Between Lot Variability
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Salmonella – Management by Supplier
Between Lot Variability
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HIGH CONFIDENCE SUPPLIER
LOW CONFIDENCE SUPPLIER
Salmonella – Management by Supplier
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Ho - Σ R + Σ IRC+G
Industrial Foods Safety Management
Simplified scheme of a processing line
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A solid tree – only with strong roots!
Hygiene Concept
Zoning
Equipment Design Air Handling Personnel
Routines
Other Details
Building Details
Cleaning Layout
Industrial Food Safety Management
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Basic Medium High Level of
Hygiene
Wet Controlled
Wet Dry
Cleaning
Systems
Ingress
Growth
Industrial Food Safety Management
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High Level of
Hygiene
Controlled
Wet Dry
Cleaning
Systems
Industrial Food Safety Management
Infant Formulae
Follow-up Formulae
Infant Cereals HealthCare
Salmonella
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Industrial Food Safety Management
Chocolate Breakfast Cereals
Medium Level of
Hygiene
Controlled
Wet Dry
Cleaning
Systems Salmonella
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Basic Medium High Level of Hygiene
Pre-requisite programs – their stringency
Control Measures
GHP/GMP HACCP
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High Hygiene
Medium Hygiene
Zoning includes appropriate
• Design of building(s),
•Design of air handling/flow,
• Flow of people and materials
Pre-requisite programs – their stringency
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Dust filter + F7-filter
Pre-requisite programs – their stringency
Control Measures
GHP/GMP HACCP
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WET CLEANING
DRY CLEANING
Salmonella management
Preventing the ingress and establishment of Salmonella
!
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WET CLEANING
DRY CLEANING
DRY CLEANING
No wet cleaning at all is key to control
Enterobacteriaceae
Salmonella management
Pre-requisite programs – their stringency
Control Measures
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Sampling of the processing environment
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The use of appropriate hygiene indicators
Enterobacteriaceae
Coliforms Salmonella
Cronob acter spp
E.coli STEC
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The use of appropriate hygiene indicators
Enterobacteriaceae ≠ Salmonella However it is
Rapid Quantitative Cheap Reactive Operational
Not a replacement of Salmonella
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The use of appropriate hygiene indicators
>1000 cfu/g = DANGER (Increased risk of presence of Salmonella)
100-1000 cfu/g = CAUTION (Poor hygiene level, improvements necessary)
<100 cfu/g = UNDER CONTROL (Acceptable values)
The levels will depend on the product category
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The use of appropriate hygiene indicators
0
500
1000
1500
2000
2500
30001
16
31
46
61
76
91
106
121
136
151
166
181
196
211
226
241
256
271
286
301
316
331
346
361
Days
Lev
els
of
En
tero
bact
eria
ceae
(cfu
/g)
H2O
H2O
H2O
H2O H2O
Salmonella
Cordier 2008 Ingress of Salmonella
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n = 30, c = 0, m = 0 (10g)
Non compliant
Impact of a microbiological criterion
10-2 to 10-3 cfu/g
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n = 30, c = 0, m = 0 (10g)
Non compliant
Impact of a microbiological criterion
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n = 30, c = 0, m = 0 (10g)
Non compliant
Impact of a microbiological criterion
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n = 30, c = 0, m = 0 (10g)
Non compliant
10-5 to 10-7 cfu/g
Impact of a microbiological criterion
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n = 30, c = 0, m = 0 (10g)
Non compliant
Impact of a microbiological criterion
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n = 10, c = 0, m = 0 (10g)
Impact of a microbiological criterion
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n = 5, c = 0, m = 0 (10g)
Impact of a microbiological criterion
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n = 1, c = 0, m = 0 (10g)
Impact of a microbiological criterion
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Some statistics ……
Sampling plan Salmonella
n = 60, c = 0, m = 0 (25g)
Geometric mean concentration (per g or mL) at 95% probability of rejection of a lot
s.d. 0.25 s.d. 0.50 s.d. 0.80 s.d. 1.20
1 cell in 590 g 1 cell in 910 g 1 cell in 2000 g 1 cell in 7400 g
ICMSF 2011