1. Muscle Foods Safety Presented by: Dana J. Hanson, Ph.D. NCSU Extension Meat Specialist

2. Foodborne Disease Annual Case Estimates 76 Million Cases Annually - United States Campylobacter2,435,926 Salmonella1,412,498 Clostridium perfringens 248,520 Staphylococcus aureus 185,060 Yersinia enterocolitica 96,368 Escherichia coli O157:H7 73,480 Listeria monocytogenes 2,518 Clostridium botulinum58

3. Foodborne Disease Annual Cost Estimates $8.4 Billion Salmonella$2,853,400,000 Listeria monocytogenes$2,333,200,000 Staphylococcus aureus$1,500,000,000 Campylobacter$1,215,300,000 Escherichia coli O157:H7 $329,700,000 Clostridium perfringens $123,000,000 Clostridium botulinum $87,000,000

4. Sources of contamination

5. Feed & Equipment Insects Domestic Animals Rodents Wild Birds SoilAir Water Humans Wild Animals

6. Location of Bacteria on a Live Animal Surface Hair Hide/Skin Feet Gastrointestinal tract * Muscle tissue - “essentially sterile”

7. Bacteria on Carcass Skin scalded/dehair or remove Clean surface Freshly inoculated with bacteria

8. Contamination During Cutting Sterile Interior Knife Exterior bacteria

9. Contamination During Cutting Sterile Interior Knife Exterior bacteria

10. Contamination During Grinding Ground Meat Contamination throughout

11. Salmonella spp. Salmonellosis Illness usually occurs 6 to 72, usually 12-36 hours after ingestion of contaminated foods It is estimated that 2 to 4 million cases occur annually in the U.S. Acute symptoms –Nausea –Vomiting –Abdominal cramps –Diarrhea –Fever

12. Listeria monocytogenes Listeriosis Onset ranges from a few days to 3 weeks There are at least 1600 cases of listeriosis with 415 deaths per year in the U.S. Symptoms (preceded by flu-like symptoms) –Septicemia –Meningitis –Encephalitis –Spontaneous abortion or stillbirth –Intrauterine or cervical infections (pregnant women)

13. Yersinia enterocolitica Yersiniosis Illness usually occurs 24 to 48 hours after ingestion of contaminated food Approximately 17,000 cases occur annually in the U.S. Symptoms: –Gastroenteritis –Diarrhea and/or vomiting –Fever and abdominal pain are hallmark symptoms

14. Campylobacter jejuni/coli Campylobacteriosis It is estimated that 2-4 million cases occur every year in the U.S. Illness usually occurs 2 to 7 days after ingestion of contaminated food Symptoms –Diarrhea –Fever –Abdominal pain –Nausea –Headache –Muscle pain

15. Staphylococcus aureus Intoxication by consumption of heat stable, preformed toxin in food Symptoms –vomiting (“projectile”) –nausea –abdominal cramps –and diarrhea 1-6 hours after eating food contaminated with toxin –“Two-bucket disease” Bacteria killed by mild heat. Toxins are very heat stable. Will grow with or without air; toxin not usually produced in acid food; bacteria are resistant to high salt (up to 15%)

16. Clostridium perfringens Perfringens food poisoning Toxin production in the digestive tract during sporulation following ingestion of vegetative cells in food. Heat resistant spore Spores survive normal cooking procedures, including boiling Grows well without oxygen Optimum temperature for growth is 110-120 o F Symptoms occur 6-24 hours and is generally self-limiting (24 hrs) : –intense abdominal cramps –diarrhea (“explosive”)

17. Prevention of Foodborne Disease Salmonella Campylobacter Escherichia coli O157:H7 Yersinia enterocolitica Listeria monocytogenes Clostridium perfringens Staphylococcus aureus enterotoxin *Reduction in levels of contamination *May reduce risk *No guarantee of absence Extreme care in slaughter and processing - Strict sanitation

18. Prevention of Foodborne Disease Salmonella Campylobacter Escherichia coli O157:H7 Yersinia enterocolitica Listeria monocytogenes Clostridium perfringens Staphylococcus aureus enterotoxin *Elimination of heat- sensitive organisms *Cross contamination must be controlled Sufficient heating during cooking step

19. Prevention of Foodborne Disease Salmonella Campylobacter Escherichia coli O157:H7 Yersinia enterocolitica Listeria monocytogenes Clostridium perfringens Staphylococcus aureus enterotoxin *Prevents growth to high numbers *Prevent toxin production Proper handling and storage (cooling)

20. Most Common Problem Areas Undercooking Cross-contamination Temperature Abuse

21. Most Common Problem Areas Undercooking Human pathogens may be part of the natural flora of the live animal If raw products of animal origin are not properly cooked, held, cooled, and stored, they can cause foodborne illness.

22. Most Common Problem Areas Cross-contamination General sanitation »equipment, utensils, and surfaces »raw foods »environment Personal hygiene Pest Control

23. Most Common Problem Areas Temperature abuse Cold storage »Smaller, flat containers »32-40 o F »environment Hot holding »130 o F or above

24. Hazard Analysis Critical Control Point (HACCP) Approach

25. Origin of HACCP -Food for the Space Program- Concept was Developed in 1959 –Dr. Howard Bauman Pillsbury, under contract from NASA –1 st Concern: Food crumbs in zero gravity –2 nd Concern: Microbiological safety

26. HACCP A systematic approach to the identification, evaluation, and control of food safety hazards.

27. “Food Safety Hazards Might be Expected to Arise from the Following” Bacteria Viruses Parasites Chemicals Pesticides Drug Residues Natural Toxins Zoonotic Diseases Decomposition Unapproved Food or Color Additives Physical Hazards

28. Pathogen Reduction; HACCP Final Rule All plants must adopt and follow, written Standard Operating Procedures for Sanitation (SSOP’s) As of January 25, 2000 all Federally Inspected Meat Processing facilities must have adopted HACCP (a system of process controls to prevent food safety hazards)

29. Total Mgmt Commitment Cleaning & Sanitation Personnel Hygiene Pest Control Bio,chem, phys hazards HACCP Education & Training Temperature Control …….support programs provide a good foundation for HACCP to be built on……….without a good foundation it is like building a skyscraper in a swamp…….

30. HACCP Support Programs Pre-requisite programs Good Manufacturing Practices (GMP’s) Standard Operating Procedures (SOP’s) Sanitation Standard Operating Procedures (SSOP’s)

31. 9 CFR Part 416—Sanitation Grounds and Facilities –Grounds and Pest Control –Construction –Walls, Floors, Ceilings, Doors and Windows –Rooms and Compartments (processing, handling and storage) –Lighting –Ventilation –Plumbing –Sewage Disposal –Water/Ice Supply –Dressing Rooms

32. SSOP’s 9 CFR Part 416—Sanitation (cont.) Equipment and Utensils Sanitary Operations Employee Hygiene Tagging Insanitary Equipment, Utensils, Rooms or Compartments

33. Corrective Action for SSOP’s Prevent Adulterated Product From Entering Commerce Ensure Facility and Equipment Sanitation is Restored Establish Procedures to Prevent Recurrence

34. Product Movement Move inedible product away from edible product Avoid floor splash Avoid working on the floor Minimize contact with equipment and building Assure carcass spacing in coolers and monitor Minimize opportunities for pathogens to be transferred from one area of the plant or one stage of production to another area of the plant or another stage of production

35. 7 Principles of HACCP 1. Conduct a Hazard Analysis 2. Identify Critical Control Points 3. Establish Critical Limit 4. Establish Monitoring Procedures 5. Establish Corrective Action Procedures 6. Verification 7. Record Keeping

36. HACCP Principle #1 Conduct a Hazard Analysis

37. HACCP Principle #2 Identify Critical Control Points

38. Critical Control Point (CCP) Critical Control Point Any step in the process at which biological, chemical, or physical factors can be controlled.

39. HACCP Principle #3 Establish Critical Limits

40. Critical Limits Critical Limit A maximum and/or minimum value to which hazards must be controlled at a CCP… To prevent, eliminate or reduce to an acceptable level, the occurrence of a food safety hazard Deviation Failure to meet a critical limit

41. HACCP Principle #4 Establish Monitoring Procedures and Frequency

42. Purpose of Monitoring Allows Management to Follow HACCP Operation Determine loss of control if and when it occurs Provides written documentation for verification--proves that you did what you said you were going to do

43. HACCP Principle #5 Corrective Action

44. Identify and Eliminate the Source of the Deviation Ensure CCP is Under Control Following Corrective Action Establish Procedures to Prevent Recurrence Prevent Adulterated Product From Entering Commerce

45. HACCP Principle #6 Establish Verification Procedures

46. Verification …..on-going activities designed to ensure that the HACCP plans is being implemented properly (e.g. compliance checks and audits). Verification of Prerequisite programs periodic (annual) review of written procedures and quality systems) Records of monitoring records Evaluation of day--to-day activities at each CCP Calibration of instrumentation;review of records; independent check of monitoring activity

47. Performance Standards RAW carcasses and ground: Salmonella spp. - carcasses, some ground product generic Escherichia coli - carcasses E. coli O157:H7 - in raw beef RTE products and environment: Listeria monocytogenes, Salmonella spp. and E.coli O157:H7 (patties) - zero tolerance RTE Environmental testing for Listeria spp. in order to verify SSOP’s

48. HACCP Principle #7 Record Keeping

49. Recordkeeping ……if you didn’t write it down……..it didn’t happen!!! temperature monitoring records - cook; chill; room; product; water…..etc. cook charts thermometer calibration records oven prove calibration records pH meter records oven validation records metal detector corrective actions ………………..