New Surrogates in Low-moisture Food/Petfood Process Validation , Are - - PowerPoint PPT Presentation

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New Surrogates in Low-moisture Food/Petfood Process Validation , Are - - PowerPoint PPT Presentation

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New Surrogates in Low-moisture Food/Petfood Process Validation , Are We Ready to Use Them? Dr. Pablo Alvarez-Martin R&D Manager 13/05/2016 May 2016 New Surrogates in Low-moisture Food/Petfood Process Validation, Are We Ready to Use Them?

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SLIDE 1

New Surrogates in Low-moisture Food/Petfood Process Validation,

Are We Ready to Use Them?

  • Dr. Pablo Alvarez-Martin

R&D Manager 13/05/2016

May 2016

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SLIDE 2

New Surrogates in Low-moisture Food/Petfood Process Validation,

Are We Ready to Use Them?

Foodborne Outbreaks

Herbs, Spices and Nuts ≈ 20% PetFood Increasing market

2 May 2016

From 2007 to 2015:

(WHO, Foodborne disease burden epidemiology reference group, 2015)

 600 million cases of foodborne illnesses  Resulting in 420 000 deaths Annually costing $15.6 billion in US:

(Buzby J.C. et al., USDA, 1996)

 Salmonella ($3.6 billion)  Campylobacter ($1.9 billion)

http://www.ers.usda.gov/media/755624/aer741_1_.pdf WHO Estimates of the global burden of foodborne diseases, 2015.

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SLIDE 3

Main problems LMF

 Few bacteria could cause illness  Salmonella persisting up to 5 years (Uesugi et al., 2007)  Able to grow in optimal conditions  Low amount of bacteria in the product Low moisture food category: d herbs

  • Spices and dried herbs
  • Dried fruits and vegetables
  • Cereals and grain
  • Dried protein products
  • Confections and snacks
  • Nuts and nuts products

The joint FAO/WHO expert meeting on microbiological hazard in spices and dried aromatic herbs, 2014, Preliminary Report FAO/WHO expert consultation on ranking of low moisture foods in support pf microbiological risk management, 2014, Part I Main report

New Surrogates in Low-moisture Food/Petfood Process Validation,

Are We Ready to Use Them?

3 May 2016

problem of detection

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SLIDE 4

Harvesting Transportation to manufacturing site Storage and product processing Packing and distribution

Sources of pathogen contamination

New Surrogates in Low-moisture Food/Petfood Process Validation,

Are We Ready to Use Them?

4 May 2016

Cross contamination

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SLIDE 5
  • HACCP: Hazard Analysis Critical Control Point
  • Microbiological Sampling Plan

Food Safety Plan

Routine sampling plans are not likely to be sufficient for validation studies.

ICMSF, 2011, Microorganisms in Foods 8

New Surrogates in Low-moisture Food/Petfood Process Validation,

Are We Ready to Use Them?

5 May 2016

Hazard identification Monitoring and verification procedure Critical limits

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SLIDE 6

Need of Preventing Controls

True Prevalence in a Sample Population Based on the Number of Negative Samples Number of Samples Testing Negative Probability

New Surrogates in Low-moisture Food/Petfood Process Validation,

Are We Ready to Use Them?

6 May 2016

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SLIDE 7

The most sweeping reform of US food safety laws in more than 70 years, was signed into law by President Obama on January 4, 2011.

Final Rule: Sanitary Transportation of Human and Animal Food. April 2016 Final Rule: Accredited Third-Party Certification. November 2015 Final Rule: Standards for the Growing, Harvesting, Packing, and Holding of Produce for Human Consumption. November 2015 Final Rule: Food Supplier Verification Programs (FSVP) for Importers of Food for Humans and Animals. November 2015 Final Rule: Current Good Manufacturing Practice and Hazard Analysis and Risk-Based Preventive Controls for Human Food. September 2015

REACTION PREVENTION

New Surrogates in Low-moisture Food/Petfood Process Validation,

Are We Ready to Use Them?

7 May 2016

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SLIDE 8

Process Validation

Obtaining and evaluating scientific and technical evidence that a control measure, combination of control measures, or the food safety plan as a whole, when properly implemented, is capable of effectively controlling the identified hazards.” – 21 CFR 117.3

Hazard Analysis and Risk-Based Preventive Controls (HARPC). Sec 103

  • Hazard Analysis
  • Preventive Controls
  • Corrective Actions
  • Verification
  • Recordkeeping
  • Written Plan and Documentation

New Surrogates in Low-moisture Food/Petfood Process Validation,

Are We Ready to Use Them?

8 May 2016

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SLIDE 9

Validation establishes the scientific basis for process preventive controls in the Food Safety Plan May include:

  • Using scientific principles and data
  • Use of expert opinion
  • Conducting in-plant observations or tests
  • Challenging the process at the limits of its operating controls

Process Validation SURROGATES

New Surrogates in Low-moisture Food/Petfood Process Validation,

Are We Ready to Use Them?

9 May 2016

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SLIDE 10

SURROGATES

Non-pathogenic organism which mimics process resistance

  • f target organism and is suitable for use in validation work.

 Similar or greater resistance compared to the pathogen  Scientifically reliable correlation need to be established  Non-pathogenic  Easy to detect and enumerate  Will not establish itself as a “spoilage”

  • rganism in the processing facility

New Surrogates in Low-moisture Food/Petfood Process Validation,

Are We Ready to Use Them?

10 May 2016

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  • E. faecium NRRL B-2354 strain well characterized
  • High thermal resistance
  • Widely used by Food companies and inter-professional associations

Enterococcus faecium as Salmonella surrogate Pediococcus acidilactici ATCC 8042

Evaluating Pediococcus acidilactici and Enterococcus faecium NRRL B-2354 as Thermal Surrogate Microorganisms for Salmonella for In-Plant Validation Studies of Low-Moisture Pet Food Products.

Ceylan et Bautista, 2015

PetFood Pantoea agglomerans SPS2F1 Dry Roasted Almonds

Guidelines for Validation of Dry Roasting Processes.

ABC, 2007

New Surrogates in Low-moisture Food/Petfood Process Validation,

Are We Ready to Use Them?

11 May 2016

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SLIDE 12

Universal Surrogates

Surrogate

Food Matrix Pathogen Intervention Strategy

New Surrogates in Low-moisture Food/Petfood Process Validation,

Are We Ready to Use Them?

12 May 2016

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SLIDE 13

Research and Development Surrogate Program

  • Qualification Surrogate Vs Pathogen
  • Intervention: temperature, pressure, etc.
  • Pathogen way of contamination
  • Physiological state

Surrogate behaviour

  • Surrogate strain Identification
  • BSL1 Status
  • BSL1 Certification

Recognition by authorities Lack of standard criteria

Studies could be done by laboratories, Universities and R&D Departments of Food Companies

New Surrogates in Low-moisture Food/Petfood Process Validation,

Are We Ready to Use Them?

13 May 2016

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Surrogate Nowadays Limits

 Surrogate concentration threshold

Inoculation technique

 Surrogate state standardization  Food Matrix diversity & inoculation protocol  Surrogate shelf-life and transport  Variation on food matrix physico-chemical characteristics

New Surrogates in Low-moisture Food/Petfood Process Validation,

Are We Ready to Use Them?

14 May 2016

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SLIDE 15

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New Surrogates in Low-moisture Food/Petfood Process Validation,

Are We Ready to Use Them?

Food Companies USE OF SURROGATES

  • BSL1 status and certification by an official agency
  • Introduction of bacteria in high concentration in a food facility
  • Specific surrogate detection and enumeration
  • Cleaning procedures

Ready for the shift of the paradigm

May 2016 15

Process Validation means less routine controls and batch release To validate a variety of processes for numerous products

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New Surrogates in Low-moisture Food/Petfood Process Validation,

Are We Ready to Use Them?

May 2016 16

Surrogate behaviour depending on process and food matrix parameters

Evaluating Pediococcus acidilactici and Enterococcus faecium NRRL B-2354 as Thermal Surrogate Microorganisms for Salmonella for In-Plant Validation Studies of Low-Moisture Pet Food Products. Ceylan and Bautista 2015 JFP

Objectives: Evaluation of potential surrogate against 7 Salmonella serovars in dry petfood at several temperature (60 to 87.8°C) and % moisture (9.1 to 27%)

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SLIDE 17

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New Surrogates in Low-moisture Food/Petfood Process Validation,

Are We Ready to Use Them?

May 2016 17

  • Steam pasteurization equipment, capacity of 1000kg/h of chilli powder
  • E. faecium NRRL B-2354 used as a surrogate of Salmonella

Comparison of validation study using liquid and dry surrogates:

  • Bacterial suspension sprayed on the chili powder,

and equilibrated

  • Pouches with Inoculated product 107cfu/g
  • Pouches are inserted in the equipment during a

production, among chilli powder

  • Recovered and enumerated

Liquid Surrogate Dry Surrogate

  • Treatment time is 6min
  • Equipment capacity is limited to 500kg/h
  • 110°C temperature to reach the 5 log reduction
  • Due to the limited heat penetration within the

pouch, treatment parameters are stabilised are

  • ver estimated
  • Surrogates produced industrially following a food

grade fermentation process

  • They reach high concentration of 1010 cfu/g
  • Ready to use surrogate is mixed with 1000kg of

chili powder

  • Inoculated powder is processed and sampled for

enumeration

  • Treatment time is 3 min
  • Equipment capacity reached 1000kg/h
  • 105°C temperature to reach the 5 log reduction
  • No heat penetration limitation allows a more

accurate validation

  • Better product and less energy consumption
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SLIDE 18

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New Surrogates in Low-moisture Food/Petfood Process Validation,

Are We Ready to Use Them?

May 2016 18

Take home message

Good Surrogates must be:

 Well Characterised and Controlled  Food Grade Quality Manufactured  Ready to Use and Flexible

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Thanks for your attention

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To be continued…

The surrogate company

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