1. Producing Safe Beef Carcasses: Pre- And Post-Slaughter Strategies

4. Objective: Beef Carcasses that are Visually and Microbiologically Clean
Theories:
The Microbiological contamination that occurs during the slaughter process is limited to the outside surface of carcasses
Meat inside the carcass is naturally free of microorganisms
By decontaminating carcass surfaces during and after the slaughter process, we can greatly reduce the potential for contamination of ground beef and other processed beef products downstream 4

5. Objective: Beef Carcasses that are Visually and Microbiologically Clean
How to achieve the objective:
Prewash cattle to reduce contamination
Phage Treatment prior to slaughter
Eliminate gross contamination of the hide using high pressure wash
Apply Advanced technologies for hide removal
Utilize validated antimicrobial carcass spray treatments i.e. PAA; Sanova; Bromous Acid 5

6. Objective: Beef Carcasses that are Visually and Microbiologically Clean
Thermal Pasteurization with Steam or Hot Water.
Control environmental sources of contamination on the slaughter floor using Advanced Oxidation Technologies – This will address contamination carried on water droplets, particles and in the air.
Utilize Steam Vacuuming and Sanitary Knife Trimming to assure the removal of visible physical defects. 6

7. Objective: Beef Carcasses that are Visually and Microbiologically Clean
Post-Slaughter Control:
Assure that carcasses are properly spaced during chilling process.
Employ Advanced Oxidation Technology in Cooler – this will provide an additional reduction in microbiological contamination and prevent recontamination from environmental sources. 7

8. Objective: Beef Carcasses that are Visually and Microbiologically Clean
Carcass Pasteurization - A validated intervention employed after carcass chilling to address possible recontamination and outgrowth of microorganisms - This will provide a bridge from the slaughter operation to fabrication and further processing.
Carcass Irradiation is not currently an option.
Apply RTE principles in fabrication and further processing operations.
N-60 Testing provides useful verification that the process is working and is under control. 8

9. Theoretical System vs. Actual Implementation
It is much easier to lay out a theoretical system than it is to make it a reality.
Dan Schaefer, assistant vice president of R&D for Cargill Beef and Dean Danilson, vice president of food safety and quality assurance for Tyson Foods will explain what their companies have done to meet the objective of safe and clean beef carcasses. 9

11. Topics Existing Technology Emerging Technologies
Hide On Carcass Wash systems
Emerging Technologies
E. coli O157 Vaccine
Sodium Chlorate

12. Pre-Harvest Objective
To lower pathogen contamination on beef carcasses
Target this Not this

13. Hide On Carcass Wash High Pressure (>600 psi), Moderate Flow
Existing Technology
Hide On Carcass Wash
Caustic Wash
Chlorine Rinse
Water Removal
High Pressure (>600 psi), Moderate Flow
Three Stages
Treatment
E. coli O157 Prevalence (%)
Before HOCW
44%
88%
After HOCW
16%
_____
Carcasses before Pre-Evisceration Intervention 2%
17%
Bosilevac et al. (2005) J. Food Prot. V.68 N.2 pp

14. Salmonella spp. Prevalence Salmonella spp. Enumerable
Existing Technology
Hide On Carcass Wash
Water Wash
Chlorine Rinse
Low pressure, High Flow (231g/min)
Two stages
Treatment
E. coli O157 Prevalence (%)
E. coli O157 Enumerable
(% with >40 cfu)
Salmonella spp. Prevalence
(%)
Salmonella spp. Enumerable
Before
98%
35%
95%
40%
After
90%
13%
69% 7%
Arthur et al. (2007) J. Food Prot. V.70 N.5 pp

15. E. coli O157 Vaccine Bioniche Product
Emerging Technology
E. coli O157 Vaccine
Bioniche Product
Targets Type III secreted proteins that are involved in E. coli O157 attachment to mucosal epithelial cells
Builds herd immunity to Type III secreted proteins
Fully Licensed in Canada
Marketed as EconicheTM

16. Number of Fecal Cultures Positive
Emerging Technology
E. coli O157 Vaccine
Bioniche Product
Treatment
Number of Fecal Cultures Positive
for E. coli O157 (%)
Vaccinates (3 doses)
36/564 (6.4%)
Non-Vaccinates
43/564 (7.5%)
Peterson, et al (2007) J. Food Prot. V.70 N.11 pp
NOTE: Fecal samples were taken serially on Days 14, 28, 42, and 56 (harvest) post final dose vaccination. Vaccinates showed numerically lower prevalence on all sampling days except day 56, cattle harvest. The authors noted a significant weather event occurred just prior to Day 56 sampling.

17. E. coli O157 Vaccine Epitopix Product
Emerging Technology
E. coli O157 Vaccine
Epitopix Product
Targets Siderophore Receptors and Porins (SRPs)
SRPs are “highly conserved” outer cell membrane proteins that transport iron through the bacterial cell wall
Causes bacterial cell death due to inability to intake iron
Conditionally licensed in the United States

18. Vaccine Targets Siderophore Receptors and Porins (SRPs)
Emerging Technology
Vaccine Targets Siderophore Receptors and Porins (SRPs)
Epitopix, LLC

19. E. coli O157 Vaccine Emerging Technology
86% reduction in fecal prevalence of E. coli O157
98% reduction in fecal concentration of E. coli O157
Both comparisons associated with P ≤ 0.02
Thomson et al. Foodborne Path and Disease. 6(7):

20. Sodium Chlorate Mode of action
Emerging Technology
Sodium Chlorate
Mode of action
Under anaerobic conditions, Gram negative bacteria utilize a nitrate reductase enzyme to respire by converting
Nitrate (NO3) Nitrite (NO2)
The enzyme will also convert
Sodium Chlorate (NaClO3) Sodium Chlorite (NaClO2)
NaClO3 is inert to bacteria & organisms lacking nitrate reductase enzyme
To bacteria with the enzyme the resulting NaClO2 is Cytotoxic

21. Sodium Chlorate Intended Usage
Emerging Technology
Sodium Chlorate
Intended Usage
To be fed the day prior to slaughter
Feed additive
No withdrawal
Regulatory Clearance (Food additive petition)
In progress, Pivotal study Summer 2010
Demonstrate efficacy on beef carcasses

22. Sodium Chlorate Challenge Study
Emerging Technology
Sodium Chlorate
Challenge Study
Experimentally challenged cattle with a 3-strain cocktail of E. coli O157:H7
Administered via water
24-hours prior to slaughter
Decreased E. coli O157
strains by 3 logs (106 to 103)
in fecal samples
Callaway et al. (2002) J. Anim. Sci. v.80 pp

23. Summary Objective: To lower pathogen contamination on beef carcasses
Hide On Carcass Washes are current technologies that can be implemented within a harvest facility.
Vaccines and Sodium Chlorate are emerging technologies to be utilized prior to arrival at a harvest facility.

24. A Few Words From Our Sponsor
WAYNE BENSON
Director, Sales and Marketing
For more information, visit us at
or call

26. Multiple Hurdle Interventions Slaughter Phase
Pre-Harvest
Mechanical
Antimicrobials
Procedures

27. Pathogen Control Of Beef Carcass Production – An INTEGRATED Approach
Executive Management
Plant / Corporate
Operations–Maintenance–Engineering-Safety
QA-HACCP-R&D
Procurement – Raw Materials
Cattle Buyers
Scheduling – Logistics
Sales Team [not Marketing]
Customers [domestic, export]
USDA

28. Interventions – Pre-Harvest
Seasonal [April-September; October-March]
Climate-Region [dry-arid, wet-humid]
Dust Management – Hide & Air [summer]
Pen Washing/Cleaning
Hide Wetting/Washing
Water [water troughs, sprinklers, cleaning]
Mud Scores ?
Bacteriophage
Other

29. Interventions – Mechanical I
Air Flows [positive-negative differential pressures & alarms; clean-to-dirty; roof, floor, doors, drains]
Traffic Patterns [clean-to-dirty, inside/outside traffic]
Hide Wetting/Washing – [pre-slaughter; post- slaughter]
Hide Removal [physical; aerosols]
Hide/Viscera to Carcass Preventions
PECS – on/off; water only; hot water [recirc-validation]; antimicrobials – see later slide ]

30. Interventions – Mechanical II
Head Wash [water only; temp-time-nozzles, antimicrobials?]
Steam Vacs & Knife Trimming
Dual Knives & Dual Equipment [i.e., weasand, etc]
Sterilizers [water temp; time-dwell, flow-thru/overflow]
Equipment Wash [water temp; splash]
Cross-Contamination Potentials [rub; drip; splash; air]
Flaps & Folds – Carcass Trimming

31. Interventions – Mechanical III
Carcass Wash [engineered cabinet or hand wash]
Carcass Thermal – Steam; Hot Water [freeflow or recirc]; temps, dwell time, validations]
Maintenance of Wash-Steam Cabinets [nozzles, flows-patterns, water temp/volume/pressure, exhausts, drains, doors, over-heads, rub points]
Coolers – chill rate, spacing, spray chill water temp; cooler cleanout [routine/periodic], cooler fogging, condensation, drains [floor & roof]; spray chill antimicrobial [PAA~30ppm]

32. Interventions – Antimicrobials I
PECS – hot water >160F carcass surface; lactic mist ~4%; full flow PAA-peroxyacetic ~175ppm, ….]
Head Wash [post wash spray – lactic mist~4%, PAA~175ppm]
Offals [head, cheek, weasand, hearts] – PAA~175ppm; lactic mist~4%, N60 lot tested]
Carcass Wash [water only; bromous acid ~230ppm]
Carcass Thermal [>160F carcass surface; dwell time; top- to-bottom mapping; validation]
Carcass PreChill – [ASCpH/ppm; lactic~4%; PAA~175ppm]

33. Interventions – Antimicrobials II
Validations & On-Going Applicatons
academic / plant data;
operating paramaters –
Range vs Target Concentrations
Flow Rates
Water temperature / quality
Dwell times
Other
Mechanical Performance of Equipment During Routine and Non-Routine operations

34. Interventions – Procedural I
Hygienic Carcass Dress Procedures
Conditional Chain Speed Management
Air Balance Controls & Alarm Procedures
In-Process Controls - Slaughter Dress [fecal]
Zero Tolerance on Carcass & Offals
HACCP/SSOP programs
QA support systems
BioMap system analysis – micros

35. Poll Question:
N60-Trim testing by the slaughter plant is best defined as:
Verification of production systems
Verification of process controls
Validation of HACCP programs
A Waste of Time and Money

36. Interventions – Procedural II
N60 Testing of Offals for System Verification
N60 Testing of 100% Trim for System Verification
Equipment SOPs & PMs
Event Procedures [trim test data]
Emergency Evisceration Procedures
Downed Carcass & Red Beef Procedures
Construction/Deconstruction Procedures
Incident Investigation – each incident requires investigation; corrective action and further preventive actions when root cause identified.

37. Poll Question:
Direct contamination from hide-to-carcass is the primary vector for E. coli O157:H7?
Agree
Disagree
Don’t Know

38. Integration Elements
Worker Training and Hygiene Methods Implementation
Multiple Hurdles – mechanical, antimicrobial, procedures
Pre-Harvest – Hide Wetting-Washing; Phage Live Animal]
Steam Vacuums to Treat Pattern Marks
Pre-Evisceration Carcass [PECS] & Offal Treatments
Equipment Sanitation – Dual Knife/Equipment
Carcass Cleansing – Final Carcass Wash
Final Carcass Intervention (Thermal, Acidified Sodium Chlorite; Bromous Acid]
Environmental Controls – Differential Pressure, Air Flows, Air Treatments
On-Going System Review – HACCP/SSOP; GMP
Verification Testing - N60 Trim and Offal Testing
Incident Investigation & Event Program

39. A Few Words From Our Sponsor
WAYNE BENSON
Director, Sales and Marketing
For more information, visit us at
or call

41. Poll Question:
Do you think that pasteurizing carcasses is the key to solving the E. coli problem?
Yes No
Don’t know

42. Carcass Pasteurization
The theory behind carcass pasteurization is to eliminate pathogen contamination at the one point in the process where it is limited to a single site – the surface of the carcass – “The Cantaloupe Theory”
After the carcass is cut into subprimals and trimmings, it is much more difficult to eliminate microbiological contaminants

43. Carcass Pasteurization
Technologies for Pasteurizing Chilled Carcasses:
E-Beam Irradiation – Not Approved
Advanced Oxidation – Exposure to Oxidative gases – H2O2 and O3
Treatment using Ammonia Gas - ?
Chemical Treatments – PAA; Sanova and Bromous Acid

44. Carcass Pasteurization
Options are Limited
Research on Advanced Oxidation Technologies is promising – 2-3 Log reduction
Exposure to Reactive Oxygen Species can be accomplished during the chilling process – hours

45. Environmental Management System (EMS)
EMS uses electricity to produce low levels of oxidative gases, including H2O2 and O3
Levels are very low and do not pose a risk to employees
EMS has applications for controlling airborne and vapor borne contaminants during the slaughter process and fabrication

46. Environmental Management System (EMS)
EMS also has applications for carcass pasteurization
Since the antimicrobials – O3 and H2O2 are in gas form, they reach every exposed surface
EMS also prevents recontamination of carcasses during chilling from environmental sources

47. Environmental Management System (EMS)
KSU Study on Inoculated Beef Carcass Tissue
One hour of exposure to EMS resulted in a 2.1 log reduction in E. coli O157:H7 and a 2.2 log reduction in Salmonella
Research is continuing to evaluate exposure times up to 24 hours

48. Environmental Management System (EMS)
Chemical treatments also provide a 2-3 log reduction in E. coli O157:H7 and Salmonella
Future research will evaluate combining EMS with a UV treatment and with PAA, Bromous Acid and Sanova
Carcass pasteurization objective: 5 log reduction in E. coli O157:H7 and Salmonella

49. Objective: Beef Carcasses that are Visually and Microbiologically Clean
Summary
Beef safety is a continuum that requires a commitment from producers, packers, processors and consumers
Technologies are available that allow for the production of beef carcasses that are visually and microbiologically clean
Microbiological sampling and testing systems provide verification that the systems are working 49

50. Objective: Beef Carcasses that are Visually and Microbiologically Clean
An integral part of the solution to the problem of E. coli O157:H7 in ground beef is to produce pasteurized beef carcasses that are virtually free of enteric contamination – This includes E. coli O157:H7 and Salmonella
Extraordinary measures are required n order to eliminate E. coli O157:H7 and Salmonella from beef carcasses and consumer beef products 50

51. Objective: Beef Carcasses that are Visually and Microbiologically Clean
Ideally, the slaughter process should employ interventions that result in a minimum 5 log reduction in these pathogens.
In the December Webinar, technologies were discussed that provide for a > 2 log reduction in E. coli O157:H7 and Salmonella during processing.
The universal implementation of these interventions combined with consumer education on proper handling and cooking will go a long way to a real solution to the problem 51

53. For More Information: Dr. James Marsden: jmarsden4741@aol.com
Dan Schaefer:
Dean Danilson:
Bill McDowell:
Tom Johnston:
Webinar recording and PowerPoint presentation available at: