Food Safety Microbiology, Sanitation and HACCP

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Food Safety (Microbiology, Sanitation and HACCP)

• Frank T. Jones
• Extension Poultry Specialist
• Cooperative Extension Service
• University of Arkansas
• Fayetteville, AR

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Presentation Outline

• Sanitation Definitions
• Microorganisms Overview
• Public Health Background
• Sanitation on Farm
• Sanitation in Plants
• HACCP Overview

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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.

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Sanitation Basics
Exclude Contamination
Kill Organisms
Prevent Multiplication
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Fungi
Molds
Yeasts
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Beneficial Microorganisms

• Fermentation
• Cheese, Beer, Wine, Bread, Yogurt
• Enzymes
• Aids to Human Metabolism
• Decay
• Waste treatment, composting, decomposition

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The Enemies

• Pathogens Food Safety
• Illness, Disease and Death
• Spoilage Food Quality
• Poor Quality, Short Shelf Life, Off Flavors,
  Customer Dissatisfaction

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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

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Bacterial Reproduction Binary Fission
Generation Time
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What Bacteria Need for Growth?
FAT TOM

• F ood
• A cid (pH)
• T ime
• T emperature
• O xygen
• M oisture

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The Spore Cycle

• Spores VERY resistant
• Two species form spores
• Bacillus
• Clostridium
• Difficult to destroy reduce strategy
• Problem in cooked foods

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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

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Basic Virus Structure
Genetic Material (DNA or RNA)
Protein Coat
Tail Fibers
Hollow Protein Tail
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Viruses

• Tiny
• Simple structure
• Must grow in cells
• In foods fecal contam.
• Personal sanitation to prevent
• Living?

Virus Life Cycle
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Our Losses

• Every year (based on CDC data)
• Over 250 billion meals are prepared
• An estimated 76 million foodborne illnesses occur
• gt5,000 foodborne associated deaths
• Costs 7.7 to 23 billion

(Centers for Disease Control and Prevention, 2003)
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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)

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Foodborne Hazards
Hazard Est. Cases Deaths Norwalk
virus 23,000,000 na Campylobacter
2,453,926 0.1 Salmonella 1,412,498
0.8 C. perfringens 248,520 .05 S.
aureus 185,060 .02 E. coli O157H7
73,480 .83 L. monocytogenes
2,518 20 C. botulinum
58 8.6
(Centers for Disease Control and Prevention, 2001)
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FOOD BORNE PATHOGENS

• USDA FSIS Target Pathogens
• Four major pathogens of food bone illness
• Salmonella
• E. coli 0157H7
• Campylobacter
• Listeria monocyctogens

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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

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E COLI 0157H7 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

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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 threatPregnant women-miscarriages and
  birth defects

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Sanitation in Live Production

• Will never be sterile but dont give up!
• 7 Basic Steps in Live Production Sanitation
• Obtain Clean Stock
• Proper Bird Care
• Vermin Control
• Moisture Control
• Feed Storage
• Biosecurity
• Water Sanitation

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Obtaining Clean Stock

• Know the seller
• Dont look for bargains
• Isolate birds for 2 wks
• Monitor birds daily and separate sick ones

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Proper Birds Care

• Healthy birds are more resistant
• Pay attention to bird behavior
• Collect dead at least daily
• Provide ventilation

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Vermin

• Damage facilities
• Eat feed

• Contaminate facilities
• Entry for other pests
• May kill animals

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Moisture is often THE SINGLE Most Important
Factor in Determining Microbial Growth
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Moisture Control

• Litter moisture related to pathogens
• Moisture control related to
• Addressing obvious sources
• Ventilation
• Control of Drinkers

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Feed Storage

• Protection from Rodents Wild Birds
• Protection from Moisture
• Protection from Heat and Sunlight
• Moisture Migration
• UV Destruction
• Feed Freshness

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Moisture Migration in Food
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Moisture Migration in Feeds
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From Headley 1969
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From Headley, 1969
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From Jones et al.1982
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How Feeds Age on Farm
Birds prefer to eat pellets rather than fines
Concentration of Fines
Feed older than average and high in fines
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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

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Footbaths The Good, The Bad and The Ugly

• Can be effective BUT
• MUST pay attention
• Use correct disinfectant
• Contaminated baths spread disease and pathogens

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Basics Steps in Sanitizer Use

• Avoid mixing sanitizers PARTICULARLY Chlorine _at_
  pHlt4 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

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Disinfectant Types and Qualities
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A Broad Look at Disinfectants
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Water Sanitation

• Water A GREAT organism transmitter
• Consider closed line systems Nipples or cups
• Clean open waterers often, but dont dump water
  in the litter
• Proper height adjustment

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Bacterial Counts from Poultry Water Systems
From Watkins. 2003
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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
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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
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Biofilm in a Municipal Water Line
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Water Line Cleaners for Use Once a Week When
Birds are Present
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Cleaning Closed Watering Systems with Birds in
the House
Prepare a stock solution
Meter stock solution at 1 oz / 128 oz (gal) water
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Basic Steps in Poultry Processing
Pre-slaughter
Kill Line
Immobilize
Feather Removal
Separation Wall
Air Flow
Evisceration
Evisceration Line
Chilling
Further Processing or Packaging
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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)
• Dont spare the water
• Cool processed carcasses quickly and keep them
  cool
• Clean and sanitize equipment before storage

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Wood Should be Avoided in Processing Areas
Loblolly Pine
Birch
100µ
Staphylococcus - 1.0µ Clostridium - 0.4 x 3µ
Treponema 0.2x 11µ
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Sanitizers for Food Contact Surfaces
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Natural Disinfecting Agents

• Sunlight (Ultraviolet rays)
• Heat (gt85F)
• Cold (Freezing or below)
• Drying (Aided by wind, light and heat)
• EFFECTIVE, But are they reliable?

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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.

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HACCP - What is it?

• HACCP involves only food safety issues.
• Out of control unsafe food produced.
• Plans unique for each unit and product.

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HACCP What is it?
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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

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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

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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

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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.