Microbiology and HACCP For Surimi Seafood

2. Microbiology and HACCP For Surimi Seafood OSU Surimi Technology School April 11-13, 2000

3. Surimi Seafood Microbiology Production and storage Microbial quality Microbial safety Pasteurization studies Non-thermal processing HACCP Microbial standards Packaging Fermented products Rapid test kits

4. Microbiology of Surimi During Production and Storage

5. Microbial Quality and Safety of Surimi Seafood Depends On: Microbial load in the raw surimi Microbial load in ingredients Processing time/temperature abuse Equipment sanitation Employee hygiene Microbiology of Surimi Seafood During Production and Storage. Microbial Quality and Safety of Surimi Seafood Depends On: Microbial load in the raw surimi Microbial load in ingredients Processing time/temperature abuse Equipment sanitation Employee hygiene Microbiology of Surimi Seafood During Production and Storage. Microbial Quality and Safety of Surimi Seafood Depends On: Microbial load in the raw surimi Microbial load in ingredients Processing time/temperature abuse Equipment sanitation Employee hygiene

6. a = surimi b = surimi plus ingredients c = first cook/rope formation d = color addition e = second cook f = flaking or chopping g = packaging h = “pasteurization” Microbiological data on surimi seafood production are variable. Changes in Aerobic Plate Count at processing steps in the production of surimi seafood. High initial counts from the raw surimi and ingredients Some reduction in APC during the initial cook Further reduction during second cook Flaking, chopping, packaging add bacteria “Pasteurization” reduces APC to low levels. Pasteurization does not kill all bacteria, e.g., spores of Bacillus and Clostridium. 2. JR Matches, E Raghubeer, IH Yoon, RE Martin. Microbiology of surimi-based products. In: DE Kramer, J Liston, ed. Seafood Quality Determination. Amsterdam: Elsevier Science Publ, 1987, pp 373-387. Microbiological data on surimi seafood production are variable. Changes in Aerobic Plate Count at processing steps in the production of surimi seafood. High initial counts from the raw surimi and ingredients Some reduction in APC during the initial cook Further reduction during second cook Flaking, chopping, packaging add bacteria “Pasteurization” reduces APC to low levels. Pasteurization does not kill all bacteria, e.g., spores of Bacillus and Clostridium. 2. JR Matches, E Raghubeer, IH Yoon, RE Martin. Microbiology of surimi-based products. In: DE Kramer, J Liston, ed. Seafood Quality Determination. Amsterdam: Elsevier Science Publ, 1987, pp 373-387.

7. a = surimi b = surimi plus ingredients c = first cook/rope formation d = color addition e = second cook f = flaking or chopping g = packaging h = pasteurization Coliforms and fecal Coliforms, present in surimi and ingredients or contributed through handling, are generally low to absent in pasteurized surimi seafood.Coliforms and fecal Coliforms, present in surimi and ingredients or contributed through handling, are generally low to absent in pasteurized surimi seafood.

8. a = surimi b = surimi plus ingredients c = first cook/rope formation d = color addition e = second cook f = flaking or chopping g = packaging h = pasteurization

9. Equipment Sanitation Belt conveyor 1,800,000/cm2 Container of mixed paste 25,000/cm2 Inner wall of mixer 540/cm2 Bacterial biofilms or improperly cleaned and sanitized equipment and utensils can add bacteria to the product, causing quality problems and potential safety problems. These results were found on crab leg kamaboko processing equipment (3). The color paste can be a reservoir for bacteria and can result in higher bacteria counts after the thermal gelling step. 3. M Yokoyama. Packaging of surimi-based products. In: TC Lanier, CM Lee, ed. Surimi Technology. New York: Marcel Dekker, 1992, pp 317-334. Bacterial biofilms or improperly cleaned and sanitized equipment and utensils can add bacteria to the product, causing quality problems and potential safety problems. These results were found on crab leg kamaboko processing equipment (3). The color paste can be a reservoir for bacteria and can result in higher bacteria counts after the thermal gelling step. 3. M Yokoyama. Packaging of surimi-based products. In: TC Lanier, CM Lee, ed. Surimi Technology. New York: Marcel Dekker, 1992, pp 317-334.

10. Surimi Seafood Shelf Life Days at: 15oC 10oC 5oC 0oC 59oF 50oF 41oF 32oF Surimi crab legs 4 14 >28 >28 Flaked surimi crab meat <3 <4 <7 14 Only a few shelf life studies have been conducted for surimi seafood. These studies show that product form affects shelf life as the overall bacterial growth rates are more rapid for flaked surimi crab meat than for surimi crab leg at each storage temperature. Handling and product size reduction increase microbial contamination and enhance microbial growth. Storage temperature directly effects the shelf life of surimi seafood products. The shelf life for vacuum packaged surimi crab legs is >28 days at 32°F, and for vacuum packaged flaked surimi crab meat about 14 days at 32°F. Only a few shelf life studies have been conducted for surimi seafood. These studies show that product form affects shelf life as the overall bacterial growth rates are more rapid for flaked surimi crab meat than for surimi crab leg at each storage temperature. Handling and product size reduction increase microbial contamination and enhance microbial growth. Storage temperature directly effects the shelf life of surimi seafood products. The shelf life for vacuum packaged surimi crab legs is >28 days at 32°F, and for vacuum packaged flaked surimi crab meat about 14 days at 32°F.

11. Increasing storage temperature for surimi seafood, increases the rate of bacterial growth.Increasing storage temperature for surimi seafood, increases the rate of bacterial growth.

12. More rapid growth with flaked surimi seafood products than with unflaked products. More surface available for rapid growth.More rapid growth with flaked surimi seafood products than with unflaked products. More surface available for rapid growth.

13. Microbial Quality of Surimi Seafood: Bacillus Species and Other Gram-positive Bacteria

14. Pasteurization Has no effect on bacterial spores, i.e., Clostridium and Bacillus species Bacillus species are prime spoilers in air-packaged surimi seafood II. Microbial Quality of Surimi Seafood: Bacillus species and Other Gram-Positive Bacteria. Bacillus can produce volatile fatty acids (lactic and acetic) and alcohols (butabediol and ethanol) from sucrose and sorbitol (cryoprotectants). Slime formation and sour odors are also theorized to occur from Bacillus growth on cryoprotectants. A major source of Bacillus is starch, which may contain 10,000 spores/gram.II. Microbial Quality of Surimi Seafood: Bacillus species and Other Gram-Positive Bacteria. Bacillus can produce volatile fatty acids (lactic and acetic) and alcohols (butabediol and ethanol) from sucrose and sorbitol (cryoprotectants). Slime formation and sour odors are also theorized to occur from Bacillus growth on cryoprotectants. A major source of Bacillus is starch, which may contain 10,000 spores/gram.

15. Vacuum packaged, surimi flaked crabmeat stored at 22°C (71.6°F) is predominated by Gram-positive bacteria.Vacuum packaged, surimi flaked crabmeat stored at 22°C (71.6°F) is predominated by Gram-positive bacteria.

16. At 15°C (59°F), spoilage is still primarily by Bacillus species.At 15°C (59°F), spoilage is still primarily by Bacillus species.

17. Below 10°C (50°F), Pseudomonas start to grow better or faster than Bacillus species.Below 10°C (50°F), Pseudomonas start to grow better or faster than Bacillus species.

18. At 5°C (41°F) and 0°C (32°F), Pseudomonas predominate in spoilage.At 5°C (41°F) and 0°C (32°F), Pseudomonas predominate in spoilage.

19. Microbial Safety of Surimi Seafood: Listeria monocytogenes, Clostridium botulinum and Other Bacteria

20. L. monocytogenes 1988 surimi survey found 29% of samples positive 1988 U.S. Class I recall of imitation crab meat produced in Japan and distributed in three states

21. Table 1. Surimi Seafood Recalls Due to L. monocytogenes Imitation crab meat products 7/28/99 Imitation crab spread 9/17/97 Imitation king crab legs 8/6/97 Imitation crab meat chunks 6/12/96 Imitation crab meat salad 9/30/92 Seafood salad 7/2/92 III. Microbial Safety of Surimi Seafood: Listeria monocytogenes, Clostridium botulinum, and other bacteria. In the first published survey of Listeria in surimi seafood in 1988, 29% of the samples were contaminated with L. monocytogenes. In the U.S., FDA has established a zero tolerance for L. monocytogenes in ready-to-eat seafood because the infective dose has not been established. The first reported FDA recall of surimi seafood for Listeria occurred in 1988 for imitation crabmeat manufactured in Japan and distributed in three states. Additional recalls for L. monocytogenes have occurred in 1992, 1996, 1997, and 1999. A small (2 people) outbreak of food poisoning from Listeria monocytogenes in imitation crab meat was reported in 1997, but other recent research reports have found no Listeria in surimi seafood.III. Microbial Safety of Surimi Seafood: Listeria monocytogenes, Clostridium botulinum, and other bacteria. In the first published survey of Listeria in surimi seafood in 1988, 29% of the samples were contaminated with L. monocytogenes. In the U.S., FDA has established a zero tolerance for L. monocytogenes in ready-to-eat seafood because the infective dose has not been established. The first reported FDA recall of surimi seafood for Listeria occurred in 1988 for imitation crabmeat manufactured in Japan and distributed in three states. Additional recalls for L. monocytogenes have occurred in 1992, 1996, 1997, and 1999. A small (2 people) outbreak of food poisoning from Listeria monocytogenes in imitation crab meat was reported in 1997, but other recent research reports have found no Listeria in surimi seafood.

22. Clostridium botulinum Strict anaerobe Grows above 38°F No instances reported from surimi seafood C. botulinum type E and nonproteolytic types B and F are the target bacteria for FDA’s pasteurization processes 6-D process = 90°C (194°F) for 10 minutes Strict anaerobe Grows above 38°F No instances reported from surimi seafood C. botulinum Type E and nonproteolytic Type B and F are basis for FDA “Pasteurization” 6-D process = 90°C (194°F) for 10 minutes used by EU Strict anaerobe Grows above 38°F No instances reported from surimi seafood C. botulinum Type E and nonproteolytic Type B and F are basis for FDA “Pasteurization” 6-D process = 90°C (194°F) for 10 minutes used by EU

23. Generation Times (Hours) for Pathogens in Surimi Seafood 15oC 10oC 5oC 0oC 59oF 50oF 41oF 32oF Aeromonas hydrophila 18 48 194 - Salmonella species 11 34 - - Staphylococcus aureus 29 46 - - Yersinia enterocolitica 11 26 77 166 Other pathogens have been shown to grow in surimi seafood, although no outbreaks have been reported. Psychrotrophic Aeromonas hydrophila and Yersinia enterocolitica grew slowly at 5°C (41°F) Other pathogens have been shown to grow in surimi seafood, although no outbreaks have been reported. Psychrotrophic Aeromonas hydrophila and Yersinia enterocolitica grew slowly at 5°C (41°F)

24. Pasteurization Studies for Surimi Seafood Inoculated pack studies with Enterococcus faecium 93°C (199.4°F) 5 minutes 85°C (185°F) for 15 minutes 75°C (167°F) for 15 minutes Yielded 6 log reduction of E. faecium Process also effective against C. botulinum Type E (85 and 93°C), L. monocytogenes, enteropathogenic E. coli, Salmonella, Yersinia entercolitica, and Vibrio Ineffective against C. botulinum Type B IV. Pasteurization Studies for Surimi Seafood. Inoculated pack studies with Enterococcus faecium 93°C (199.4°F) initial temperature Reduced to 75°C (167°F) for 15 minutes Yielded 6 log reduction of E. faecium Process also effective against L. monocytogenes, enteropathogenic E. coli, Salmonella, Yersinia entercolitica, and Vibrio Ineffective against C. botulinum IV. Pasteurization Studies for Surimi Seafood. Inoculated pack studies with Enterococcus faecium 93°C (199.4°F) initial temperature Reduced to 75°C (167°F) for 15 minutes Yielded 6 log reduction of E. faecium Process also effective against L. monocytogenes, enteropathogenic E. coli, Salmonella, Yersinia entercolitica, and Vibrio Ineffective against C. botulinum

25. Pasteurization Studies for Surimi Seafood Temperature Time D-Values (min.) L.m. C.b.(E) C.b.(B) 93°C (199.4°F) 5 16,200 52 0.7 85°C (185°F) 15 5,400 24 0.6 75°C (167°F) 15 350 2.2 0.1

26. Microbiological Implications of Novel Surimi Processing Technologies High pressure 200-400 MPa Effective against Vibrio, Listeria, Salmonella Ineffective against pressure resistant species and spore forming Bacillus and Clostridium species Electron beam Untested V. Microbiological Implications of Novel Surimi Processing Technologies. High pressure 200-300 MPa Effective against Vibrio, Listeria, Salmonella Less effective against Moraxella, Acinetobacter, Enterococcus, and Corynebacterium Ineffective against Bacillus, Clostridium Electron beam Untested V. Microbiological Implications of Novel Surimi Processing Technologies. High pressure 200-300 MPa Effective against Vibrio, Listeria, Salmonella Less effective against Moraxella, Acinetobacter, Enterococcus, and Corynebacterium Ineffective against Bacillus, Clostridium Electron beam Untested

27. HACCP and Surimi Seafood Preventive system of food safety control Based on Identified hazards Critical control points Monitoring records VI. Application of Hazard Analysis Critical Control Point (HACCP) System to Surimi Seafood Products VI. Application of Hazard Analysis Critical Control Point (HACCP) System to Surimi Seafood Products

28. Three steps can be used to control potential hazards: Metal fragments Pasteurization CoolingThree steps can be used to control potential hazards: Metal fragments Pasteurization Cooling

29. Metal Fragments Hard or sharp objects >7 mm in size are a potential hazard from laceration, perforation wound, and secondary infections Hard or sharp objects <7 mm in size are a possible hazard for high risk (e.g., infants, elderly) individuals Controls can include frequent inspections of cutting, portioning, blending, or other mechanical equipment for damage, or use of a metal detector Metal fragments Hard or sharp objects >7 mm in size are a potential hazard from laceration, perforation wound, and possibly a secondary infection Hard or sharp objects <7 mm in size are a possible hazard for high risk (e.g., infants, elderly) Controls can include frequent inspections of cutting, portioning, blending, or other mechanical equipment for damage, or use of a metal detector Metal fragments Hard or sharp objects >7 mm in size are a potential hazard from laceration, perforation wound, and possibly a secondary infection Hard or sharp objects <7 mm in size are a possible hazard for high risk (e.g., infants, elderly) Controls can include frequent inspections of cutting, portioning, blending, or other mechanical equipment for damage, or use of a metal detector

30. Pasteurization Eliminates targeted pathogenic bacteria and also extends product shelf life Pathogens in packaged products indicates inadequate pasteurization, or post pasteurization contamination, and time/temperature abuse Critical aspects: IT, temperature of heating medium, length of pasteurization cycle, package thickness, package integrity, product formulation, and microbial quality of the cooling medium

31. Cooling Rapid cooling prevents growth from Bacillus and Clostridium 60°C (140°F) to 21.1°C (70°F) in 2 hours To 4.4°C (40°F) within another 4 hours Rapid cooling prevents growth from Bacillus and Clostridium 60°C (140°F) to 21.1°C (70°F) in 2 hours To 4.4°C (40°F) within another 4 hours Rapid cooling prevents growth from Bacillus and Clostridium 60°C (140°F) to 21.1°C (70°F) in 2 hours To 4.4°C (40°F) within another 4 hours

32. Refrigerated Storage Refrigerated storage below 4.4°C (40°F) prevents growth of pathogens

33. Three CCPsThree CCPs

34. Microbial Recommendations for Ready-to-eat Seafood n c m M Aerobic plate count 5 2 105 106 E. coli 5 1 11 500 S. aureus 5 0 103 - V. parahaemolyticus 10 1 102 103 VII. Microbial Standards and Specifications n = Number of representative sample units. c = Maximum number of acceptable sample units with bacterial counts between m and M. m = Maximum recommended bacterial counts for good quality products. M = Maximum recommended bacterial counts for marginally acceptable quality products.VII. Microbial Standards and Specifications n = Number of representative sample units. c = Maximum number of acceptable sample units with bacterial counts between m and M. m = Maximum recommended bacterial counts for good quality products. M = Maximum recommended bacterial counts for marginally acceptable quality products.

35. FDA Tolerance Levels: Vacuum Packaged Ready-to-eat Seafood C. botulinum Presence of cells, toxin Enteropathogenic E. coli 103/g L. monocytogenes Presence Salmonella Presence S. aureus 104/g or toxin positive V. cholerae Presence V. parahaemolyticus 104/g V. vulnificus Presence FDA tolerance levels for vacuum packaged ready-to-eat seafood: C. botulinum Presence of cells, toxin Enteropathogenic E. coli 103/g L. monocytogenes Presence Salmonella Presence S. aureus 104/g or toxin positive V. cholerae Presence V. parahaemolyticus 104/g V. vulnificus Presence FDA tolerance levels for vacuum packaged ready-to-eat seafood: C. botulinum Presence of cells, toxin Enteropathogenic E. coli 103/g L. monocytogenes Presence Salmonella Presence S. aureus 104/g or toxin positive V. cholerae Presence V. parahaemolyticus 104/g V. vulnificus Presence

36. Microbiological Considerations in Packaging of Surimi Seafood Nitrogen and carbon dioxide packaging reduce fat and pigment oxidation and reduce spoilage bacterial growth Aseptic packaging requires a sterile product and may not be feasible

37. New Surimi Seafood Products Utilizing Fermentative Bacteria Fermented pollock kamaboko pH 4.5 Sour tasting Fermented chum salmon surimi Sensory studies have not been conducted

38. Reliability and Efficacy of Rapid Microbiological Procedures Traditional methods APC with petri dishes or PetriFilm ATP technology for sanitation Rapid test kits for L. monocytogenes 1-2 days instead of 5-7 days

39. Conclusion Surimi seafood Products are ready-to-eat Safety and quality concerns remain HACCP can help ensure a safe product The use of the term “pasteurization” should be discouraged or the process needs to be further studied