Download - Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda
![Page 1: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/1.jpg)
Auditing and Identifying Contamination Points for Listeria
in Food Plants
Presented by:
Graham Monda
![Page 2: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/2.jpg)
Canadian Recalls
• Mitchell’s Gourmet Foods, Saskatoon: Wieners
• JM Schneider, Kitchener, Ont. sliced luncheon meats
• Golden Valley Farms, Arthur, Ont.: Fletcher’s smoked chicken and smoked turkey breast
• Maple Leaf Foods, Ont. Deli meats, sausage, Canada wide recall
![Page 3: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/3.jpg)
Listeria monocytogenes
• Named for Joseph Lister
• Non-spore forming, Gram-positive rod
• Grows aerobically and anaerobically
• Grows between -0.4 and 50C• Grows at pH 4.4 to 9.6
• Grows at 10% NaCl
• Studies suggest up to 10% of human gastrointestinal tracts may be colonized
![Page 4: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/4.jpg)
Lm is unique
• Grows (slowly) at refrigeration temperatures
• Difficult to inactivate
• RTE contaminated post processing
• Can survive vacuum packaging
• Is ubiquitous
![Page 5: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/5.jpg)
Lm Policy - Canada
(1) RTE foods linked to listeriosis 0/50g
(2) RTE foods, support growth, 0/25g SL>10 days
(3) RTE foods, SL<10days or RTE <100/g foods not supporting growth
![Page 6: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/6.jpg)
CDC Estimated Food-Related Deaths*:
5 Pathogens = 90% of Total
0%
5%
10%
15%
20%
25%
30%
35%
Est. Food-Related Deaths
Salmonella
Listeria
Toxoplasma
Norwalk-likeviruses
Campylobacter
E.coli 0157:H7*Approximately 5,000/year 100/week
![Page 7: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/7.jpg)
What are we dealing with?
• Listeria is the clean plant organism
• To manage Listeria requires change, not only in actions but to our thought process
• This includes, Sanitation Management Training SSOP’S HACCAP
![Page 8: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/8.jpg)
Conduct a Listeria Audit
• Data driven management decisions
• Objective risk assessment
• Identify areas for improvement
• Assess equipment & personnel
• Vehicle for training
• Demonstrate compliance
![Page 9: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/9.jpg)
Purpose of a Listeria Audit
• Evaluate the effectiveness of the environmental sanitation program
• Assist in implementing the QA/QC program– QA - Are we doing the right things? – QC - Are we doing things right?
• Confirm the area’s compliance with procedures
• Identify opportunities for improvement
![Page 10: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/10.jpg)
Stages in a Listeria Audit
![Page 11: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/11.jpg)
Environmental: Floors
DrainsWalls (cracks)
Ceilings, overheadsCat walks
Condensation (bio-aerosols)Wet insulation Standing water
Equipment moving from raw to finished
Sources of Product Contamination
![Page 12: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/12.jpg)
Sources of Product Contamination
Equipment:
Trolleys, forklifts
Cleaning tools
Maintenance tools
Pallets
![Page 13: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/13.jpg)
Sources of Product from raw materials
Raw Materials
Ingredients: MeatsSpices Water BeefSweeteners PorkConcentrates Poultry
Turkey
1) Keep ingredients, raw materials, and products as cool as possible; (below 7 C) during processing, storage, and distribution.
![Page 14: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/14.jpg)
Sources of Product Contamination
Packaging Materials:
Cartons
Cans
Films
Combo’s
Tape
Plastic coverings
![Page 15: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/15.jpg)
Sources of Product Contamination
•Engineering Design– Dead Ends– Cross Connections– Improper Welds– Difficult to Clean Areas– Exposed Insulation – Sandwiched Materials - Niches
![Page 16: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/16.jpg)
Sources of Product Contamination
• Processing Equipment– Smokehouses– Cookers– Coolers– Freezers (Spiral -Blast)– Refrigeration Units– Air handling Units– Seals & Gaskets– Flexible Hosing– Air Baggers
![Page 17: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/17.jpg)
Sources of Product Contamination
• Employees
– Orientation– Operators – Mechanics– Employee traffic
patterns
![Page 18: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/18.jpg)
Sources of Product Contamination
•Employees - GMP’S– Bathroom practices– Washing & sanitizing hands– Footwear
![Page 19: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/19.jpg)
Identify Growth Areas
Limit Microbes Food/Water
Store trash properlyDrains should be properlycleaned and sanitized
![Page 20: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/20.jpg)
Identify Growth Areas
Find the organism’s growth nichesWorn GasketsUnsealed Equipment Areas
![Page 21: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/21.jpg)
Identify Growth Areas
Maintain Air Handling Systems
![Page 22: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/22.jpg)
Identify Growth Areas
Beware of Temporary Repairs!!
![Page 23: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/23.jpg)
The Problem with
High Pressure - Aerosols
Aerosols
Low pressureLow pressure High pressureHigh pressure
![Page 24: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/24.jpg)
Effects of Water Pressure - Aerosols
0102030405060708090
100
after15min
after30min
after45min
after60min
HighpressureLowpressure
Air samplingCounts of micro-organisms in filter on a vacuum system
A high pressure system still leaves more airborne contamination after 45 mins than low pressure after 15 mins
![Page 25: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/25.jpg)
Conclusion
•High Pressure
Not Recommended
Where Listeria is
an Issue
![Page 26: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/26.jpg)
Sanitary Design ofProcessing Equipment
![Page 27: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/27.jpg)
Transmission of Microbes
Brushes shouldbe properlystored
By Brushes/Hoses/Tools:
![Page 28: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/28.jpg)
Transmission of Microbes
By People:
> walking > moving carts> using tools
Moving from a ‘raw’ to‘finished’ area withouthandwashing, cleaningequipment, etc.
![Page 29: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/29.jpg)
Transmission of Microbes
By Vehicles:
Could this Hi-Lo move microbes around?
What is happening here?
![Page 30: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/30.jpg)
Transmission of Microbes
Condensation is a real threat!
Condensation
Exposed product
![Page 31: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/31.jpg)
Outside Factors
Black Mold enteringfrom leak in column
All cracks/gaps should be sealed
Not just open doors, but anyopenings that facilitate insect or rodent and ultimately microbial movement.
![Page 32: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/32.jpg)
“Bulls Eye” Approach to Control
Direct Product Contact• Filling or
packaging equipment
• Conveyors • Chilling solutions• Slicers, dicers,
shredders, blenders (after heating, before packaging)
• Collators• Racks• Hand tools • apparel • Spiral/blast freezers• Bins, tubs, or
baskets
![Page 33: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/33.jpg)
Secondary Level of Concern, Indirect Product Contamination
• Equipment framework and other equipment in the area
• Floors• Drains• Walls and ceilings,
especially if cracked
• Overhead structures, catwalks
• Condensate• Insulation in walls or
around pipes• Walkways• Cleaning tools• Maintenance tools
![Page 34: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/34.jpg)
Tertiary Level; Recontamination of
Processing Area
• Traffic in the processing and packaging areas• people• equipment such as trolleys and
forklifts
• Unscheduled equipment maintenance
![Page 35: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/35.jpg)
Niches, the Dark Holes of Lm Control
• Hollow conveyor rollers
• Slicers, dicers• On/off switches• Rubber seals around
doors• Damp insulation
• Fibrous or porous conveyor belts
• Conveyor scrapers, especially if in poor condition
• Open bearings in equipment
![Page 36: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/36.jpg)
More Niches
• Hollow implements, including box cutters
• Trash cans and other ancillary items
• Standing water in production areas
• Cleaning tools, including mops and sponges
• In-line air filters for compressed air
• Wet, rusting or hollow framework
• Motor housings• Walls/crevices of
spiral freezers;• Ice makers
![Page 37: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/37.jpg)
Lm Control in Niches
•Good control involves identifying the source or niche of the Listeria contamination and eliminating it.
![Page 38: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/38.jpg)
Some Conditions That Have Caused Problems
• Moving or significantly modifying a packaging line
• Installing used equipment brought from storage or another plant
• Equipment breakdown
![Page 39: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/39.jpg)
More “Red Flag” Situations
• Construction or major modifications in an RTE area.
• A new employee, unfamiliar with the operation and L. monocytogenes controls
in the RTE product area.
![Page 40: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/40.jpg)
Keep in Mind………….
• Initially most equipment is of a sanitary design; however, over time it has been welded, repaired, re-positioned to the extent that the sanitary design has now been lost...
![Page 41: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/41.jpg)
LISTERIAEnvironmental survey reported at the AMI List. workshop
• Drains & Trenches 355 samples 133 + 37%• Floors 269 samples 79 + 29%• Condensate 265 samples 19 + 7.0%• Walls & Ceilings 114 samples 6 + 5.0%• Exhaust Hoods 23 samples 5 + 22 %• Brine system 24 samples 2 + 8.0%• Cleaning Aids 86 samples 21 + 24%• Wash Areas 17 samples 4 + 24%• Potable water 25 samples 1 + 4.0%• Compressed air 25 samples 1 + 4.0%• Product contact surfaces 740 samples 152 + 20%• Others 333 samples 50 + 21%• TOTALS 2276 473* 21%
• ** 60% monocytogenes• 40% Other Listeria (All areas Post Processing)
![Page 42: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/42.jpg)
Top Ten
1. Drains, Floors.2. Cleaning equipment.3. Exhaust hoods.4. Condensation.5. Wash areas.
![Page 43: Auditing and Identifying Contamination Points for Listeria in Food Plants Presented by: Graham Monda](https://reader036.vdocument.in/reader036/viewer/2022062619/5518ac86550346b31f8b4d0c/html5/thumbnails/43.jpg)
Top Ten
6. Unsanitary welds and niches.7. Tools.8. Staff, operators, maintenance.9. Gaskets.10. Aerosols, high pressure
cleaning.