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, grow

Binary Fission

Bacterial Reproduction Binary Fission

Generation Time

Generation 1 2 3

Cell Numbers 100 200 400

4
5 6 7

800
1,600 3,200 6,400

8
9 10 Generation Time (Min) Hours from 100 to 1 Million 11

12,800
25,600 51,200 102,400

10 2.4

30

60

90

12
13 14 15

204,800
409,600 819,200 1,638,400

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

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

Virus Life Cycle

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 O157:H7 L. monocytogenes C. botulinum Est. Cases 23,000,000 2,453,926 1,412,498 248,520 185,060 73,480 2,518 58 Deaths na 0.1% 0.8% .05% .02% .83% 20% 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 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 womenmiscarriages and birth defects

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

Obtaining Clean Stock

Know the seller Dont 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% 12% 12% 12%

12% 12% 12%

16%

13%

10% 10%

16% 13%

16% 13% 10%

20%

12%

8% 8% 8%

20% 12% 20% 12%

Effect of Temperature on Feed Moisture 18 16 14 12 10 8 6 4 2 0 50

From Headley 1969

Swine Cattle Pig

Moisture (%)

70
Temperature (F)

90

Effect of Relative Humidity on Feed Moisture

Feed Moisture (%)

30 25 20 15 10 5 0 25

Pig Starter Cattle Ration

40

58

75

82

93

From Headley, 1969

Relative Humidity (%)

Effect of Feed Age on Aflatoxin Concentration. 30 25

Aflatox (ppb)

20 15 10 5 0
1 to 5
From Jones et al.1982

6 to 10

11 to 15

16 to 20

Age in Days

How Feeds Age on Farm

Birds prefer to eat pellets rather than fines

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 @ 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 Qualities

Type Activity Organic Cost Human Mattter Toxicity Effect
Wide no Reduces spores effects Wide no spores Kills effects Exp Low Mod Low Low Low Low Low

Comments

Alcohols Hypochlorite Iodophors QAC

(Quaternary Ammonia Compounds)

Non Corrosive, Fire Hazard, conc 70-95%, Can be corrosive May stain clothing, porous surfaces Soaps, detergents and hard water limit effectiveness Good residual activity Gets everything, but can be highly toxic Limited residual, Mod corrosive

Wide no Reduces spores effects Limited no spores Wide no spores Wide Mod. No spores Reduces effects Little to none Limits effects Kills effects

Phenolic Aldehyde Oxidizer

Mod Mod Mod

Low Mod Low

A Broad Look at Disinfectants

Type
Alcohols Hypochlorite Iodophors QAC
(Quaternary Ammonia Compounds)

Examples
Rubbing Alcohol, Isopropyl, Ethanol Chlorox, Chloramine-T, Halazone Betadine, Iofec, Isodyne, Tamed Iodine, Weladol Roccal, Germex, Hi-Lethol, San-O-Fec, Warden, Zephiran Lysol, Pine-Sol, Cresi-400, Environ, Tek-Trol Formaldehyde, Glutaraldehyde Hydrogen Peroxide, Peracetic Acid

Uses
Small objects, hands Water, Clean surfaces Water, Hands, Equipment, Walls Hatcheries, with some soaps Hatcheries, Equipment, Footbaths Fumigation, clean surfaces Clean surfaces

Phenolic

Aldehyde Oxidizer

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

Bacterial Counts from Poultry Water Systems

5000000 4775000 4500000 4000000 3500000 3000000 2500000 2340000 2000000 1500000 1000000 282000 26600 500000 203000 2700 600 0 0 Farm A Farm B Farm C Farm D
From: Watkins. 2003

Bacterial Counts

Source Line End

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 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
teaspoon teaspoon 1 oz per per gallon per gallon gallon of of water of water water

Iodine (18.05%)
teaspoon per gallon of water

Cleaning Closed Watering Systems with Birds in the House

Prepare a stock solution Clear Household Household Bleach Ammonia 6 oz per gallon 6 oz per gallon Clear Vinegar 128 oz per gallon Iodine (18.05%) 2 oz per gallon

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

Basic Steps in Poultry Processing

Pre-slaughter

Immobilize Feather Removal

Air Flow

Separation Wall Evisceration 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) Dont 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 - 1.0

100

Birch
Treponema 0.2x 11

Clostridium - 0.4 x 3

Sanitizers for Food Contact Surfaces

Category
Chlorine, Dioxides Iodophores QAC Acid-Anionic Carboxylic Acid Peroxy Acid

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

Disadvantages
Cl gas, Corrosive, Organic material, Degrades, THMs, pH range Stains, Hard water, Temps (High & Low), Odor, Cl cheaper Low temps, Hard water, Little effect on gram negative bacteria Cost, pH Low Temp., Corrosive

Broad Act., Low Tox., Stable, Color, Good Residual Stable, Innocuous, Some Residual Stable, W/ Organic Matter, Non Corrosive, Odorless Broad Act., Stable, W/ Organic Matter, High Temp Broad Act., Degrade, Non Corrosive, Temp. Tolerant

Co, Cu, Ti, Mishandling Danger, Concentrate Odor

Natural Disinfecting Agents

Sunlight (Ultraviolet rays) Heat (>85F) 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
1. Hazard Analysis 2. Establish Critical Control Points 3. Establish Critical Limits 4. Establish Monitoring Procedures 5. Establish Corrective Actions 6. Establish a Record Keeping System

Meaning
What are the controllable food safety hazards? Where do things go wrong and how can we reliably control it? What value indicates the process is in control? Who, what, when , where and how will CCPs be monitored? What happens if we exceed a Critical limit? If you dont write it down it doesnt exit. How do you know the system works?

7. Establish Verification Procedures

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.