Salmonella in low Aw Foods A paradigm shift

1. Salmonella in low Aw FoodsA paradigm shift Brian A. Nummer, PhD.

2. Salmonella risk Which would you choose as the greatest risk … last year / this year?

3. SalmonellaThe paradigm shift Yesterday: Growth Today: Survival Survives Aw to below 0.3 Survives in acid foods Resistant to heat Resistant to drying Known to survive many months or more • Water activity below 0.9 • pH below 4.6 • Heat to approx 140-150◦F. (pasteurization) • Drying

4. Salmonellosis outbreaks in low Aw foods • chocolate • dry infant formula • raw almonds • toasted oat cereal • dry seasonings • paprika-seasoned chips • dried coconut • infant cereals • peanut butter

5. Few outbreaks, but high no. illnesses • Although Salmonella outbreaks from low-moisture products are relatively rare, they often impact large numbers of people. • >200 cases were attributed to toasted oat cereal in 11 states between April and June 1998, • >600 cases were attributed to peanut butter in 47 states between August 2006 and May 2007, • >600 cases have been attributed to peanut butter and peanut butter-containing products in 43 states between September 2008 and January 2009. • Due to the large number of unreported cases of salmonellosis for all types of products, the actual number of cases was likely much higher.

6. Current outbreak

7. …and more Salmonella is pervasive!

8. …and more, still March 30, 2009 -- Stop eating pistachio nuts, the FDA says. They may carry food-poisoning salmonella bacteria. The nuts came from a large shipment of 1 million pounds of pistachio nuts sold to 36 different wholesalers nationwide, more recalls are expected, says FDA.

9. Soils Where are they coming from? Birds Processing Environment Drains On ingredients

10. Heat So, why do they survive in the plant and in inhospitable foods? Acid High Sugar Low Aw

11. Biochemistry Lesson I

12. Biochemistry Lesson II • Polymerase transcribes DNA to mRNA • Sigma factors assist polymerase binding to genes • Several sigma factor groups (the stress sigma factor increases transcription of all genes that it binds to: heat, acid, drying, etc)

13. So, what exactly do we do?

14. No. 1. Get Management Support Dear Mr. or Ms. CEO, CFO, COO, EiEiO: There were 175 manufacturers of candy listed on the latest recall list of peanut butter products. Assuming a cost of 1-10 million dollars per company, that adds up to 175 million dollars to 1.7 billion dollars lost to the industry. Where does your bottom line meet food safety?

15. GMA Salmonella control plan • Prevent ingress or spread of Salmonella in the processing facility. • Enhance the stringency of hygiene practices and controls in the Primary Salmonella Control Area. • Apply hygienic design principles to building and equipment design • Prevent or minimize growth of Salmonella within the facility • Establish a raw materials/ingredients control program. • Validate control measures to inactivate Salmonella. • Establish procedures for verification of Salmonella controls and corrective actions.

16. My Salmonella control plan • Prevent ingress of Salmonella • Establish a raw materials & ingredients control program • Prevent spread of Salmonella in plant • Create Salmonella Control area to confine high risk ingredients within the facility • Enhance sanitation in the Salmonella Control Area. Apply hygienic design principles to building and equipment design • Prevent survival of Salmonella in foods using HACCP • Apply control measures to inactivate Salmonella. • Verify inactivation using sound science • Keep excellent records of all CCP’s

17. Salmonella controls1. Prevent ingress of Salmonella = • Identify ingredients with risk • Replace high risk ingredients (e.g. irradiated nuts) • Create new HACCP Prerequisite program

18. Salmonella controls2. Prevent spread of Salmonella Create Salmonella control area

19. Salmonella controlsEnhance sanitation and controls in the Salmonella Control Area • Enhanced Sanitation • Redesign plant / equipment (Use “wet” process mentality) • Rethink “dry only” sanitation • Sanitation audits (internal and external) • In-house monitoring **simple! • Remove bad news barriers • Create a Salmonella action plan for positives

20. Salmonella controlsRe-apply sanitation design

21. In-house monitoring

22. Salmonella controls3. Prevent survival of Salmonella in foods using HACCP • Review HACCP flow chart and identify step(s) where 1 or more control measures can be instituted • Consider adding control measures as CCP’s • E.g. Add spice to water and pasteurize before mixing into high sugar product

23. Salmonella controls3. Prevent survival of Salmonella in foods using HACCP • E.g. Add spice or high risk ingredient to water and pasteurize before mixing into high sugar product • Salmonella lethality in Aw >.95 is minutes at 150oF • Salmonella lethality in Aw <.65 is may be as much as 260 minutes at 150oF

24. Salmonella controls3. Prevent survival of Salmonella in foods using HACCP • Establish process control measures to inactivate Salmonella • Validate using U.S.U. Food Safety program pathogen lab or similar resource • FDA said during the peanut butter recall – “all products are considered adulterated unless scientific evidence exists demonstrating a 5-log reduction of Salmonella”

25. Salmonella controls3. Prevent survival of Salmonella in foods using HACCP • Verify process has required lethalities • Verify HACCP records are adequate and are produced • Self audit the new HACCP plan • Will it withstand an FDA voluntary recall request? • Consider an outside audit of the new HACCP Plan

26. Salmonella controlsPlan for a recall! • Revisit your recall and crisis management prerequisite program • Insert materials that would support your Salmonella Control Program, especially lethality measures • Encourage management to revisit insurance, legal assistance, etc. for crisis management • Understand new pass along recall fees from major retailers • Consider strengthening lot coding or tracing methods to minimize recall impact

27. Food Safety Program 8700 Old Main Hill Logan, UT 84322 brian.nummer@usu.edu