Analysis Critical Control Point Plan Research Articles

Microbial Quality Evaluation of Seafood Samples from the Vishakhapatnam Coast, Andhra Pradesh, India

Consumption of seafood has increased, resulting in the production and productivity of aquaculture in the past few years. Since, seafood is crucial in human nutrition, providing essential nutrients and proteins. However, their perishable nature and vulnerability to microbial contamination make them prone to spoilage and foodborne illnesses. Therefore, the microbiological analysis of fish samples is paramount to ensure their quality and safety for consumption. In this study, microbiology of fish samples, encompassing various aspects such as microbial load assessment, and pathogen detection. Isolation and identification of pathogenic bacteria viz., Total plate count, Escherichia coli, Total coliforms, Vibrio spp, Staphylococcus aureus, and Salmonella spp. These pathogens pose severe health risks to consumers and highlight the necessity of effective monitoring and control measures throughout the seafood supply chain. Proper handling, storage, and processing practices minimise microbial contamination and preserve fish quality. Implementing Hazard Analysis Critical Control Point (HACCP) plans and Good Manufacturing Practices (GMP) helps ensure the safety of fish products and prevent outbreaks of foodborne illnesses.

Environmental Monitoring of Food Manufacturing Facilities for Listeria: A Case Study

Environmental monitoring programs (EMPs) for food production facilities are useful for verifying general sanitation controls and are recommended as verification measures to ensure that the Hazard Analysis Critical Control Point plan is working effectively. In this study, EMPs for Listeria were conducted at three food production facilities to assess the efficacy of sanitation control and establish effective sanitation control methods. In Facility A, L. monocytogenes was detected in the clean area although in Zone 3, non–food-contact surfaces. To prevent contamination from dirty areas, the cleaning practices in the preparation room were investigated. Normal cleaning combined with disinfection with carbonated hypochlorite water (chlorine concentration, 150 ppm) proved effective. At Facility B, a salad product and its ingredients (pastrami and salami) were positive for L. monocytogenes serotype 3b. The bacterial count was <10/g in all samples. However, when inoculated with L. monocytogenes isolates, the growth of approximately 2 log cfu/g was observed on pastrami after 48 h of incubation at 10°C. The ingredients were commercially purchased blocks that were sliced in a slicer at Facility B and used as salad toppings. Because both unopened blocks were negative for L. monocytogenes, contamination of the slicer was suspected. Sampling of the slicer revealed that contamination by L. monocytogenes serotype 3b was more extensive after use than before use. Therefore, the slicer was disassembled, cleaned, and disinfected thoroughly. In Facility C, L. monocytogenes serotype 4b (4e) was detected in all the dirty, semiclean, and clean areas. The strain was also isolated from the wheels of a smoking cart transported across the zones. Therefore, efforts were made to frequently clean and disinfect the cart. EMPs revealed the presence of Listeria in each facility and allowed remedial measures to be undertaken. Continued monitoring and Plan-Do-Check-Act cycles were considered desirable.

Salmonella spp., Escherichia coli and Enterobacteriaceae Control at a Pig Abattoir: Are We Missing Lairage Time Effect, Pig Skin, and Internal Carcass Surface Contamination?

To provide meat safety and consumer protection, appropriate hygiene control measures at an abattoir are required. This study aimed to evaluate the influence of visual fecal contamination level (VFCL) and lairage time (LT) on pig skin (PS) and external (ECS) and internal (ICS) carcass surfaces. The presence of Enterobacteriaceae, Escherichia coli (E. coli) and Salmonella in PS, ECS, and ICS were evaluated. A total of 300 paired samples were collected from 100 pigs. Results underlined the importance of the skin (Enterobacteriaceae: 3.27 ± 0.68 log CFU/cm2; E. coli: 3.15 ± 0.63 log CFU/cm2; Salmonella: 21% of samples) as a direct or indirect source of carcass contamination. Although VFCL revealed no significant effect (p > 0.05), the increase of LT had a significant impact (p < 0.001) on Enterobacteriaceae and E. coli levels across all analysed surfaces, and Salmonella presence on ICS (p < 0.01), demanding attention to LT. Also, the ICS showed a higher level of these bacteria compared to ECS. These results highlight the need of food business operators to consider ICS as an alternative area to sample for Salmonella, as a criterion for process hygiene based on EC Regulation No. 2073/2005, and as a potential contamination source to be integrated in the hazard analysis critical control point (HACCP) plans.

Comprehensive evaluation of abattoirs with no Hazard Analysis Critical Control Point plan in Tucumán, Argentina

This work focused on the comprehensive study of two provincial transit abattoirs in Tucumán, Argentina, with no Hazard Analysis Critical Control Point (HACCP) plan. Visits (n=20) were conducted between 2016 and 2018 during the operational and post-operational processes. Risk was estimated and the bacteriological analysis of carcass and environmental samples was performed. Risk estimation showed the predominance of high risk in both abattoirs. The main deviations from the HACCP plan were: deficient building conditions, deficient workflow, lack of sectorization of changing rooms and bathrooms, lack of implementation of Standardized Sanitary Operational Procedures, and no food safety training of workers. The counts of indicator microorganisms from both abattoirs were not significant. Salmonella spp. was isolated from 7.5% carcass and 7.3% environmental samples. The Salmonella serovars identified were Cerro, Corvallis, Havana and Agona. Shiga toxin (stx) genes were detected in 24.4% carcass and 30.9% environmental samples. The isolates were characterized as Escherichia coli O8:H7/stx1, O116:H49/stx2 and O136:H40/stx2. Based on these results, it would be possible to implement an improvement plan in Tucumán abattoirs together with the local health authorities. Still, the need to work jointly with the sanitary authority in search of a unique sanitary standard for Argentina remains unaddressed.

Study of Good Handling Practices and Critical Control Point Determination of Dried Fermented Cocoa Bean in Gunung Kidul Regency, Yogyakarta

The Hazard Analysis Critical Control Point is needed to improve the quality and competitiveness of cocoa beans. The objectives of this research were to study of Good Handling Practices at cocoa beans fermentation and determination of critical control point as the first step in making Hazard Analysis Critical Control Point plan. The research was conducted at Processing Product Unit Ngudi Raharjo II, Gunung Kidul Regency, Yogyakarta. The method used in this research were interview, observation, recording of cocoa quality, temperature and pH during fermentation, drying temperature and water content reduction in cocoa beans during drying, while determination of critical control point by answering the question from decision tree associated with the risk assessment matrix. The results shown that Good Handling Practices there were 26 of 76 elements that have not been applied, so it needs to be improved. The average temperature of cocoa beans fermentation on the surface for five days is 38.5 °C, in the middle section is 42.3°C and in the bottom was 34.8°C. The average pH of cocoa beans fermentation for 5 days was 3.2. Temperature and pH of fermentation are lower than they should be, this is due to too much cocoa bean pulp. The average temperature in sun drying for four days was 30.3 °C. The average drying temperature with drying machine for three days was 39.2 °C. The drying process should be carried out at 55-60 °C for 40-50 hours. Of the nine stages of the process, drying was a critical control point.

Precooking as a Control for Histamine Formation during the Processing of Tuna: An Industrial Process Validation

An experiment to validate the precooking of tuna as a control for histamine formation was carried out at a commercial tuna factory in Fiji. Albacore tuna (Thunnus alalunga) were brought on board long-line catcher vessels alive, immediately chilled but never frozen, and delivered to an on-shore facility within 3 to 13 days. These fish were then allowed to spoil at 25 to 30°C for 21 to 25 h to induce high levels of histamine (>50 ppm), as a simulation of "worst-case" postharvest conditions, and subsequently frozen. These spoiled fish later were thawed normally and then precooked at a commercial tuna processing facility to a target maximum core temperature of 60°C. These tuna were then held at ambient temperatures of 19 to 37°C for up to 30 h, and samples were collected every 6 h for histamine analysis. After precooking, no further histamine formation was observed for 12 to 18 h, indicating that a conservative minimum core temperature of 60°C pauses subsequent histamine formation for 12 to 18 h. Using the maximum core temperature of 60°C provided a challenge study to validate a recommended minimum core temperature of 60°C, and 12 to 18 h was sufficient to convert precooked tuna into frozen loins or canned tuna. This industrial-scale process validation study provides support at a high confidence level for the preventive histamine control associated with precooking. This study was conducted with tuna deliberately allowed to spoil to induce high concentrations of histamine and histamine-forming capacity and to fail standard organoleptic evaluations, and the critical limits for precooking were validated. Thus, these limits can be used in a hazard analysis critical control point plan in which precooking is identified as a critical control point.

Defining the food microbiome for authentication, safety, and process management

Under intense scrutiny for safety and authenticity, our food supply encompasses probiotic supplementation, fermentation organisms, pathogenic bacteria, and microbial toxins—in short, the microbiome and metabolome of food. Recent claims regarding probiotic supplements, additives, and cultured foods highlight the need for widely accepted protocols for evidence-based oversight of such products, as well as specific methods to assess their safety and authenticity. Rapid improvements in high-throughput sequencing technologies, curated and annotated reference databases of whole genome sequences, bacterial strain banks, and novel informatics techniques coupled to a scalable computing platform are poised to provide a robust solution extendable to encompass systematic authentication of the microbiome and its variations up and down the supply chain. Members of the Sequence the Food Supply Chain Consortium are working to characterize and quantify the microbiome at a baseline and after processing. They are also working to create reference databases and develop a Metagenomics Computation and Analytics Workbench, capable of verifying the effectiveness of good manufacturing practices and monitoring control measures highlighted in a site's Hazard Analysis Critical Control Point plan. In this paper, we propose how microbial ecology, evolvability, and phylogenetic diversity exhort the application of new molecular techniques to assure safety, authenticity, and traceability for wholesome food.

Environmental (Saprozoic) Pathogens of Engineered Water Systems: Understanding Their Ecology for Risk Assessment and Management.

Major waterborne (enteric) pathogens are relatively well understood and treatment controls are effective when well managed. However, water-based, saprozoic pathogens that grow within engineered water systems (primarily within biofilms/sediments) cannot be controlled by water treatment alone prior to entry into water distribution and other engineered water systems. Growth within biofilms or as in the case of Legionella pneumophila, primarily within free-living protozoa feeding on biofilms, results from competitive advantage. Meaning, to understand how to manage water-based pathogen diseases (a sub-set of saprozoses) we need to understand the microbial ecology of biofilms; with key factors including biofilm bacterial diversity that influence amoebae hosts and members antagonistic to water-based pathogens, along with impacts from biofilm substratum, water temperature, flow conditions and disinfectant residual—all control variables. Major saprozoic pathogens covering viruses, bacteria, fungi and free-living protozoa are listed, yet today most of the recognized health burden from drinking waters is driven by legionellae, non-tuberculous mycobacteria (NTM) and, to a lesser extent, Pseudomonas aeruginosa. In developing best management practices for engineered water systems based on hazard analysis critical control point (HACCP) or water safety plan (WSP) approaches, multi-factor control strategies, based on quantitative microbial risk assessments need to be developed, to reduce disease from largely opportunistic, water-based pathogens.

Developing a time and effort-effective, highly sensitive TaqMan probe-based real-time polymerase chain reaction protocol for the detection of Salmonella in milk, yoghurt, and cheese

A time- and effort-effective, highly sensitive method combining brief pre-enrichment for only 4 h in a non-selective broth and TaqMan probe-based real-time PCR was developed for the detection of different concentrations of a cocktail of 8 Salmonella Typhimurium strains in milk and dairy products. As few as 1 cfu 25 mL−1 of Salmonella in milk was detectable, and sensitivity was not influenced by the presence of contaminating microflora or using milk containing different combinations of fat and solids-not-fat. The method could be also successfully used for detecting Salmonella during the preparation and cold storage of yoghurt and soft cheese. It was able to detect injured cells in cheese prepared from 10% and 12% salted milk after 3 months of cold storage. Given that the method generates quantitative data related to the numbers of the pathogen in these products, it is recommended for use in microbial risk assessments, and hazard analysis critical control point (HACCP) plans.

PATHOGEN DISINFECTION TECHNOLOGIES, METRICS, AND REGULATIONS FOR RECYCLED ORGANICS USED IN HORTICULTURE

This report focuses on the efficacy of thermophilic and multi-stage treatment technologies in disinfecting generic E. coli, E. coli O157:H7, Salmonella spp., Listeria monocytogenes, parasites, and viruses in recycled organic residuals. Some recyclable organics can contain public health pathogens when delivered to a composting facility. Producing marketable soil amendments that meet high quality food safety standards for fresh produce commodities like leafy greens, tomatoes, onions, and cantaloupes requires diligent process management and record-keeping. Recent advances in composting and digestion technologies along with advances in knowledge of pathogen prevalence, survival, and susceptibility to treatments and natural attenuation provide a substantive foundation for improved sanitary quality of recycled organics for horticultural production. Establishment and use of Hazard Analysis Critical Control Point (HACCP) plans for facilities producing high quality soil amendments can aid process management for conventional and organic production systems. Use of HACCP approaches supports pathogen risk reduction metrics (e.g., E. coli O157:H7, Salmonella spp.) developed for targeted fresh and fresh-cut horticultural produce.

Hygienic-sanitary working practices and implementation of a Hazard Analysis and Critical Control Point (HACCP) plan in lobster processing industries

This study aimed to verify the hygienic-sanitary working practices and to create and implement a Hazard Analysis Critical Control Point (HACCP) in two lobster processing industries in Pernambuco State, Brazil. The industries studied process frozen whole lobsters, frozen whole cooked lobsters, and frozen lobster tails for exportation. The application of the hygienic-sanitary checklist in the industries analyzed achieved conformity rates over 96% to the aspects evaluated. The use of the Hazard Analysis Critical Control Point (HACCP) plan resulted in the detection of two critical control points (CCPs) including the receiving and classification steps in the processing of frozen lobster and frozen lobster tails, and an additional critical control point (CCP) was detected during the cooking step of processing of the whole frozen cooked lobster. The proper implementation of the Hazard Analysis Critical Control Point (HACCP) plan in the lobster processing industries studied proved to be the safest and most cost-effective method to monitor each critical control point (CCP) hazards.

Implementation of hazard analysis critical control point in jameed production

The average of standard plate count and coliforms, Staphylococcus aureus and Salmonella counts for three home-made jameed samples, a traditional fermented dairy product, before applying hazard analysis critical control point system were 2.1 × 10(3), 8.9 × 10(1), 4 × 10(1) and less than 10 cfu/g, respectively. The developed hazard analysis critical control point plan resulted in identifying ten critical control points in the flow chart of jameed production. The critical control points included fresh milk receiving, pasteurization, addition of starter, water and salt, straining, personnel hygiene, drying and packaging. After applying hazard analysis critical control point system, there was significant improvement in the microbiological quality of the home-made jameed. The standard plate count was reduced to 3.1 × 10(2) cfu/g whereas coliform and Staphylococcus aureus counts were less than 10 cfu/g and Salmonella was not detected. Sensory evaluation results of color and flavor of sauce prepared from jameed showed a significant increase in the average scores given after hazard analysis critical control point application.

Food safety objectives for Listeria monocytogenes in Spanish food sampled in cafeterias and restaurants.

To gain more insight into the context of food safety management by public administrations, food safety objectives must be studied. The Valencian administration quantified the prevalence of Listeria monocytogenes in cafeterias and restaurants in this region of Spain between 2002 and 2010. The results obtained from this survey are presented here for 2,262 samples of fish, salad, egg, cold meat, and mayonnaise dishes. Microbiological criteria defined for L. monocytogenes were used to differentiate acceptable and unacceptable samples; more than 99.9% of the samples were acceptable. These findings indicate that established food safety objectives are achievable, consumer health at the time of consumption can be safeguarded, and food safety management systems such as hazard analysis critical control point plans or good manufacturing practices implemented in food establishments are effective. Monitoring of foods and food safety is an important task that must continue to reduce the current L. monocytogenes prevalence of 0.1% in restaurant or cafeteria dishes, which could adversely affect consumer health.

Application of ISO 22000 and comparison with HACCP on industrial processing of common octopus (Octopus vulgaris) – Part I

SummaryCritical control points (CCPs) were identified in the risk assessment of octopus (Octopus vulgaris) processing and implemented in the hazard analysis critical control point (HACCP) plan. In the hazard analysis worksheet the different hazards were identified at each processing stage, whereas in the HACCP plan each CCP is identified and accompanied with the relevant significant hazard, critical limit, monitoring of the CCP and corrective actions. In this work comparison of ISO 22000 analysis with HACCP is carried out over octopus processing and packaging. ISO 22000 Analysis Worksheet was employed for determination of some prerequisite programmes (PrPs). Comparison between the two systems has been carried out using the hazard analysis worksheet. The PrPs are the main difference between the two systems. The incorporation of PrPs in the ISO 22000 made the system more flexible as a smaller number of CCPs was introduced.

HACCP plan proposal for a typical Brazilian peanut processing company

Peanuts are likely to be infested by fungi with consequent contamination by aflatoxin in post-harvest industries. A hazard analysis critical control point (HACCP) plan is proposed for a typical Brazilian post-harvest industry from raw in-shell reception to the unpeeled peanuts transportation. Codex Alimentarius Commission guidelines were followed, with four critical control points (CCP) for aflatoxin being identified. The process steps with highest probability of aflatoxin occurrence (risk) are the in-shell reception, the dried in-shell storage, and the unpeeled kernel storage. During the storage steps there is a lack of control of air moisture and temperature. Therefore, there is no option but to keep rigid monitoring and control over each CCP, and detour lots with high aflatoxin levels to either oil or seed production. Attempts to correlate the aflatoxin levels with the rainfall showed an irregular trend of the toxin level.

Listeria monocytogenes in Gorgonzola: Subtypes, diversity and persistence over time

L. monocytogenes represents a primary concern in the production of Gorgonzola, a Protected Designation of Origin (PDO) Italian blue-veined cheese produced only in the Piedmont and Lombardy regions. L. monocytogenes isolates ( N = 95) obtained from Gorgonzola rinds, paste, and production/ripening environments were serotyped and then genotyped using Pulsed Field Gel Electrophoresis (PFGE). The goal of this study was to investigate the variability of L. monocytogenes PFGE-types across different PDO Gorgonzola manufacturers ( N = 22). The majority of the strains (88%) were serotyped as 1/2a. PFGE identified 2 major pulse-types grouping 62 strains, detected from different plants and years, suggesting the presence of persistent and niche-adapted L. monocytogenes. In 9 plants, environmental strains shared the same pulse-types with strains from rinds or paste, suggesting a possible transmission pathway. Encouragingly, L. monocytogenes was retrieved from only 1 paste, indicating that production processes were under control in 21 plants. In the remaining plant, un-effective pasteurization or cross-contamination during production processes could be the cause of the contamination. Consequently, it is imperative that producers operate under the total respect of the Good Manufacturing Practices and following the principles of the Hazard Analysis Critical Control Point plans, in order to contain contamination throughout the whole processing.

Juice-Associated Outbreaks of Human Illness in the United States, 1995 through 2005

Outbreaks of illness associated with consumption of fruit juice have been a growing public health problem since the early 1990s. In response to epidemiologic investigations of outbreaks in which juice was implicated, the U.S. Food and Drug Administration implemented process control measures to regulate the production of fruit juice. The final juice regulation, which became effective in 2002, 2003, and 2004, depending on the size of the business, requires that juice operations comply with a hazard analysis critical control point (HACCP) plan. The Centers for Disease Control and Prevention (CDC) receives reports of food-associated outbreaks of illness. We reviewed fruit juice–associated outbreaks of illness reported to the CDC's Foodborne Outbreak Reporting System. From 1995 through 2005, 21 juice-associated outbreaks were reported to CDC; 10 implicated apple juice or cider, 8 were linked to orange juice, and 3 involved other types of fruit juice. These outbreaks caused 1,366 illnesses, with a median of 21 cases per outbreak (range, 2 to 398 cases). Among the 13 outbreaks of known etiology, 5 were caused by Salmonella, 5by Escherichia coli O157:H7, 2 by Cryptosporidium, and one by Shiga toxin–producing E. coli O111 and Cryptosporidium. Fewer juice-associated outbreaks have been reported since the juice HACCP regulation was implemented. Some juice operations that are exempt from processing requirements or do not comply with the regulation continue to be implicated in outbreaks of illness.

Microbial Levels in Michigan Apple Cider and Their Association with Manufacturing Practices

In recent decades, apple cider has been implicated in a series of outbreaks of foodborne illness. The objective of this study was to determine the presence and concentrations of pathogenic and indicator microorganisms in apple cider processed in Michigan and to evaluate the impact of thermal pasteurization, UV light radiation, and implementation of hazard analysis critical control point (HACCP) plans on these microbes. Cider samples were obtained from Michigan mills between 1997 and 2004 and analyzed for Escherichia coli O157:H7, Salmonella, generic E. coli, total coliforms, and aerobic bacteria. Neither E. coli O157:H7 nor Salmonella were detected in any tested cider samples, suggesting a very low frequency of pathogens in Michigan apple cider. The persistent and relatively high frequency of generic E. coli observed in samples obtained in all years indicates a continued risk of pathogen contamination in Michigan apple cider, especially when it is untreated. The use of thermal pasteurization or UV light radiation and reported implementation of HACCP plans were associated with lower frequency and counts of generic E. coli, total coliforms, and aerobic microorganisms. However, the relatively high counts of indicator organisms in some cider samples that were claimed to be treated according to these pathogen reduction measures indicates that some processors had inadequate practices, facilities, or equipment for pathogen reduction or did not consistently or adequately apply practices or pathogen-reduction equipment in an effective manner.

Validation of Time and Temperature Values as Critical Limits for the Control of Escherichia coli O157:H7 during the Production of Fresh Ground Beef

In order to provide beef processors with valuable data to validate critical limits set for temperature during grinding, a study was conducted to determine Escherichia coli O157:H7 growth at various temperatures in raw ground beef. Fresh ground beef samples were inoculated with a cocktail mixture of streptomycin-resistant E. coli O157:H7 to facilitate recovery in the presence of background flora. Samples were held at 4.4, 7.2, and 10°C, and at room temperature (22.2 to 23.3°C) to mimic typical processing and holding temperatures observed in meat processing environments. E. coli O157:H7 counts were determined by direct plating onto tryptic soy agar with streptomycin (1,000 μg/ml), at 2-h intervals over 12 h for samples held at room temperature. Samples held under refrigeration temperatures were sampled at 4, 8, 12, 24, 48, and 72 h. Less than one log of E. coli O157:H7 growth was observed at 48 h for samples held at 10°C. Samples held at 4.4 and 7.2°C showed less than one log of E. coli O157:H7 growth at 72 h. Samples held at room temperature showed no significant increase in E. coli O157:H7 counts for the first 6 h, but increased significantly afterwards. These results illustrate that meat processors can utilize a variety of time and temperature combinations as critical limits in their hazard analysis critical control point plans to minimize E. coli O157:H7 growth during the production and storage of ground beef.

Prevalence of Campylobacter and Salmonella Species on Farm, After Transport, and at Processing in Specialty Market Poultry

The prevalence of Campylobacter and Salmonella spp. was determined from live bird to prepackaged carcass for 3 flocks from each of 6 types of California niche-market poultry. Commodities sampled included squab, quail, guinea fowl, duck, poussin (young chicken), and free-range broiler chickens. Campylobacter on-farm prevalence was lowest for squab, followed by guinea fowl, duck, quail, and free-range chickens. Poussin had the highest prevalence of Campylobacter. No Salmonella was isolated from guinea fowl or quail flocks. A few positive samples were observed in duck and squab, predominately of S. Typhimurium. Free-range and poussin chickens had the highest prevalence of Salmonella. Post-transport prevalence was not significantly higher than on-farm, except in free-range flocks, where a higher prevalence of positive chickens was found after 6 to 8 h holding before processing. In most cases, the prevalence of Campylobacter- and Salmonella-positive birds was lower on the final product than on-farm or during processing. Odds ratio analysis indicated that the risk of a positive final product carcass was not increased by the prevalence of a positive sample at an upstream point in the processing line, or by on-farm prevalence (i.e., none of the common sampling stations among the 6 commodities could be acknowledged as critical control points). This suggests that hazard analysis critical control point plans for Campylobacter and Salmonella control in the niche-market poultry commodities will need to be specifically determined for each species and each processing facility.