Food Safety Microbiology Sanitation and HACCP Frank T

Food Safety (Microbiology, Sanitation and HACCP) Frank T. Jones Extension Poultry Specialist Cooperative Extension Service University 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. ”

Sanitation Basics Kill Organisms Exclude Contamination Prevent Multiplication

Microorganisms Fungi Bacteria Molds Yeasts Viruses

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 – Binary Fission

Bacterial Reproduction – Binary Fission Generation Time (Min) 10 30 Hours from 100 to 1 Million 2. 4 7. 1 14. 2 21. 3 60 90 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

What Bacteria Need for Growth? • F ood • A cid (p. H) • 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 p. H 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

Viruses Virus Life Cycle • 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 Norwalk virus Campylobacter Salmonella C. perfringens S. aureus E. coli O 157: H 7 L. monocytogenes C. botulinum Est. Cases 23, 000 2, 453, 926 1, 412, 498 248, 520 185, 060 73, 480 2, 518 58 (Centers for Disease Control and Prevention, 2001) Deaths na 0. 1% 0. 8%. 05%. 02%. 83% 20% 8. 6%

FOOD BORNE PATHOGENS: • USDA – FSIS “Target Pathogens” • Four major pathogens of food bone illness – Salmonella – E. coli 0157: H 7 – 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: H 7 & 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 womenmiscarriages 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 THE SINGLE 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

Moisture Migration in Feeds 12% 12% 12% 16% 13% 10% 20% 12% 8% 8% 8%

From Headley 1969

From Headley, 1969

From Jones et al. 1982

How Feeds Age on Farm Birds prefer to eat pellets rather than fines Co nc en tra tio no f. F in es Feed older than average and high in 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 @ p. H<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 Qualities Type Alcohols Activity Organic Cost Human Mattter Toxicity Effect Comments Wide no Reduces spores effects Exp Low Non Corrosive, Fire Hazard, conc 70 -95%, Wide no spores Low Can be corrosive Wide no Reduces spores effects Mod Low May stain clothing, porous surfaces Limited no spores Reduces effects 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 Gets everything, but can be highly toxic Oxidizer Mod. No spores Kills effects Mod Low Limited residual, Mod corrosive Hypochlorite Iodophors QAC (Quaternary Ammonia Compounds) Kills effects

A Broad Look at Disinfectants Type 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 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 (Quaternary Ammonia Compounds)

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 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

Biofilm in a Municipal Water Line

Water Line Cleaners for Use Once a Week When Birds are Present Clear Household White Household Bleach Household Ammonia Vinegar ½ teaspoon 1 oz per gallon of of water Iodine (18. 05%) ¼ teaspoon per gallon of water

Cleaning Closed Watering Systems with Birds in the House Prepare a stock solution Clear Household Bleach Ammonia 6 oz per gallon Clear Vinegar Iodine (18. 05%) 128 oz per gallon 2 oz per gallon Meter stock solution at 1 oz / 128 oz (gal) water

Basic Steps in Poultry Processing ll i K ne i L Pre-slaughter Immobilize Air Flow Feather Removal n io t a er Separation Wall Li ne Evisceration c E s vi Chilling Further Processing or Packaging

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

Wood Should be Avoided in Processing Areas Loblolly Pine Staphylococcus - 1. 0μ 100μ Birch Clostridium - 0. 4 x 3μ Treponema 0. 2 x 11μ

Sanitizers for Food Contact Surfaces Category Advantages Disadvantages Chlorine, Dioxides Broad Act. , Not temp. sensitive, Cheap, No Foam Cl gas, Corrosive, Organic material, Degrades, THM’s, p. H range Iodophores Broad Act. , Low Tox. , Stable, Stains, Hard water, Color, Good Residual 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, p. H Carboxylic Acid Peroxy Acid Broad Act. , Stable, W/ Organic Matter, High Temp Low Temp. , Corrosive 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 5. Establish Corrective Actions 6. Establish a Record Keeping System Who, what, when , where and how will CCP’s be monitored? 7. Establish Verification Procedures How do you know the system works? What happens if we exceed a Critical limit? If you don’t write it down it doesn’t exit.

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.