Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda

Canadian Recalls Mitchells Gourmet Foods, Saskatoon: Wieners JM Schneider, Kitchener, Ont. sliced luncheon meats Golden Valley Farms, Arthur, Ont.: Fletchers smoked chicken and smoked turkey breast Maple Leaf Foods, Ont. Deli meats, sausage, Canada wide recall

Listeria monocytogenes Named for Joseph Lister Non-spore forming, Gram-positive rod Grows aerobically and anaerobically Grows between -0.4 and 50 C Grows at pH 4.4 to 9.6 Grows at 10% NaCl Studies suggest up to 10% of human gastrointestinal tracts may be colonized

Lm is unique Grows (slowly) at refrigeration temperatures Difficult to inactivate RTE contaminated post processing Can survive vacuum packaging Is ubiquitous

Lm Policy - Canada ( 1) RTE foods linked to listeriosis0/50g (2) RTE foods, support growth, 0/25g SL>10 days (3) RTE foods, SL<10days or RTE<100/g foods not supporting growth

CDC Estimated Food-Related Deaths*: 5 Pathogens = 90% of Total *Approximately 5,000/year 100/week

What are we dealing with? Listeria is the clean plant organism To manage Listeria requires change, not only in actions but to our thought process This includes, Sanitation Management Training SSOPS HACCAP

Conduct a Listeria Audit Data driven management decisions Objective risk assessment Identify areas for improvement Assess equipment & personnel Vehicle for training Demonstrate compliance

Purpose of a Listeria Audit Evaluate the effectiveness of the environmental sanitation program Assist in implementing the QA/QC program – –QA - Are we doing the right things? – –QC - Are we doing things right? Confirm the areas compliance with procedures Identify opportunities for improvement

Stages in a Listeria Audit

Environmental: Floors Drains Walls (cracks) Ceilings, overheads Cat walks Condensation (bio-aerosols) Wet insulation Standing water Equipment moving from raw to finished Sources of Product Contamination

Equipment: Trolleys, forklifts Cleaning tools Maintenance tools Pallets

Sources of Product from raw materials Raw Materials Ingredients: Meats Spices Water Beef Sweeteners Pork Concentrates Poultry Turkey 1) Keep ingredients, raw materials, and products as cool as possible; (below 7 C) during processing, storage, and distribution.

Sources of Product Contamination Packaging Materials: Cartons Cans Films Combos Tape Plastic coverings

Sources of Product Contamination Engineering Design – –Dead Ends – –Cross Connections – –Improper Welds – –Difficult to Clean Areas – –Exposed Insulation – –Sandwiched Materials - Niches

Sources of Product Contamination Processing Equipment – –Smokehouses – –Cookers – –Coolers – –Freezers (Spiral -Blast) – –Refrigeration Units – –Air handling Units – –Seals & Gaskets – –Flexible Hosing – –Air Baggers

Sources of Product Contamination Employees – –Orientation – –Operators – –Mechanics – –Employee traffic patterns

Sources of Product Contamination Employees - GMPS – –Bathroom practices – –Washing & sanitizing hands – –Footwear

Identify Growth Areas Limit Microbes Food/Water Store trash properly Drains should be properly cleaned and sanitized

Identify Growth Areas Find the organisms growth niches Worn Gaskets Unsealed Equipment Areas

Identify Growth Areas Maintain Air Handling Systems

Identify Growth Areas Beware of Temporary Repairs!!

The Problem with High Pressure - Aerosols Aerosols Low pressure High pressure

Effects of Water Pressure - Aerosols Air sampling Counts of micro-organisms in filter on a vacuum system A high pressure system still leaves more airborne contamination after 45 mins than low pressure after 15 mins

Conclusion High Pressure Not Recommended Where Listeria is an Issue

Sanitary Design of Processing Equipment

Transmission of Microbes Brushes should be properly stored By Brushes/Hoses/Tools:

Transmission of Microbes By People: > walking > moving carts > using tools Moving from a raw to finished area without handwashing, cleaning equipment, etc.

Transmission of Microbes By Vehicles: Could this Hi-Lo move microbes around? What is happening here?

Transmission of Microbes Condensation is a real threat! Condensation Exposed product

Outside Factors Black Mold entering from leak in column All cracks/gaps should be sealed Not just open doors, but any openings that facilitate insect or rodent and ultimately microbial movement.

Bulls Eye Approach to Control Direct Product Contact Filling or packaging equipment Conveyors Chilling solutions Slicers, dicers, shredders, blenders (after heating, before packaging) Collators Racks Hand tools apparel Spiral/blast freezers Bins, tubs, or baskets

Secondary Level of Concern, Indirect Product Contamination Equipment framework and other equipment in the area Floors Drains Walls and ceilings, especially if cracked Overhead structures, catwalks Condensate Insulation in walls or around pipes Walkways Cleaning tools Maintenance tools

Tertiary Level; Recontamination of Processing Area Traffic in the processing and packaging areas people equipment such as trolleys and forklifts Unscheduled equipment maintenance

Niches, the Dark Holes of Lm Control Hollow conveyor rollers Slicers, dicers On/off switches Rubber seals around doors Damp insulation Fibrous or porous conveyor belts Conveyor scrapers, especially if in poor condition Open bearings in equipment

More Niches Hollow implements, including box cutters Trash cans and other ancillary items Standing water in production areas Cleaning tools, including mops and sponges In-line air filters for compressed air Wet, rusting or hollow framework Motor housings Walls/crevices of spiral freezers; Ice makers

Lm Control in Niches Good control involves identifying the source or niche of the Listeria contamination and eliminating it.

Some Conditions That Have Caused Problems Moving or significantly modifying a packaging line Installing used equipment brought from storage or another plant Equipment breakdown

More Red Flag Situations Construction or major modifications in an RTE area. A new employee, unfamiliar with the operation and L. monocytogenes controls in the RTE product area.

Keep in Mind…………. Initially most equipment is of a sanitary design; however, over time it has been welded, repaired, re-positioned to the extent that the sanitary design has now been lost...

LISTERIA Environmental survey reported at the AMI List. workshop Drains & Trenches355 samples % Floors269 samples79 +29% Condensate265 samples % Walls & Ceilings114 samples % Exhaust Hoods 23 samples % Brine system 24 samples % Cleaning Aids 86 samples % Wash Areas 17 samples 4 +24% Potable water 25 samples % Compressed air 25 samples % Product contact surfaces740 samples % Others333 samples % TOTALS *21% * *60% monocytogenes 40% Other Listeria(All areas Post Processing)

Top Ten Drains, Floors Cleaning equipment Exhaust hoods Condensation Wash areas.

Top Ten Unsanitary welds and niches Tools Staff, operators, maintenance Gaskets Aerosols, high pressure cleaning.