evaluation of microbiological risks in the food industry ... · evaluation of microbiological risks...

2011-11-25

Evaluation of Microbiological Risks in the

Food Industry: Tools to support Safety

Assessments in NestléAFSCA Symposium, Brussels

p. 2FrD/FSM/QS/NRC 2011-11-25

Overview

• Quality and Safety at Nestlé

• Microbiological Risk Assessments in the food industry

• Nestlé tools/processes developed and used to support Safety

Assessments and to achieve our goal: (microbiological) product

quality and safety

• Examples of Nestlé Safety Assessments


Overview



• Nestlé tools/processes developed and used in to support Safety


quality and safety


Nestlé, the World’s Largest Food Company

and a very broad range of food products

449 factories in 83 countries

Sales of CHF 108 billion in 2009

280‘000 employees

93% of sales is food and beverages

Pharmaceutical

products

7%

Nestlé

Nutrition

9%Powd. & Liq.

beverages

18%

Prep. Dishes &

Cooking aids

16%Milk products & Ice Cream

18%

Nestlé Waters

8%

Confectionery

11%

PetCare

12%

2011-11-25 p. 4FrD/FSM/QS/NRC

Nestlé R&D worldwide

MinneapolisSolon

MarysvilleBakersfield St. Joseph

St.Louis+ NRCQueretaro

AmiensLisieux

BeauvaisToursVittel

York

Lausanne NRC

Fremont

CPW Orbe Innovation Ctr

Dehli

Singen

Abidjan

NRC Santiago

1 Science & Research Center

1 Nestlé Institute of Health Sciences

27 PTC and R&D Centres

320 Application Groups

Tokyo NRC

Beijing + NRC

Shanghai

Singapore

Konolfingen

Systems Centre Orbe

Orbe

Broc

NIHS LausanneSderot

Casa Buitoni


The Food Safety Microbiology network

Mission: Link our Nestle microbiology experts in R&D and Operations

to enhance information and competence transfer

and to assure microbiological safety, quality and compliance of our products.


Nestlé R&D worldwide

MinneapolisSolon

MarysvilleBakersfield St. Joseph

St.Louis+ NRCQueretaro

AmiensLisieux

BeauvaisToursVittel

York

Lausanne NRC

Fremont

CPW Orbe Innovation Ctr

Dehli

Singen

Abidjan

NRC Santiago

1 Science & Research Center

1 Nestlé Institute of Health Sciences

27 PTC and R&D Centres

320 Application Groups

Tokyo NRC

Beijing + NRC

Shanghai

Singapore

Konolfingen

Systems Centre Orbe

Orbe

Broc

NIHS LausanneSderot

Casa Buitoni


8

Early Warning Risk Assessment Analytical Science High PerformingTesting Labs

NRC Quality & Safety Department

The Competence Center for Quality and Safety Sciences 10 teams and 140 people working for

Consumer trust

in Nestlé brands and products.

one goal:

Food Safety First !

Early warning Packaging

Food Safety

Chemical Food

Safety

Food Safety

Microbiology

Chemical

contaminants

Functional

ingredients

Authenticity and

Adulteration

Microbiological

and Molecular

Analytics

Methods

Management

FrD/FSM/QS/NRC

Laboratory

performance

9

Early Warning Risk Assessment Analytical Science High PerformingTesting Labs

NRC Quality & Safety Department

The Competence Center for Quality and Safety Sciences 10 teams and 140 people

working for

Consumer trust

in Nestlé brands and products.

one goal:

Food Safety First !

Early warning Packaging

Food Safety

Chemical Food

Safety

Food Safety

Microbiology

Chemical

contaminants

Functional

ingredients

Authenticity and

Adulteration

Microbiological

and Molecular

Analytics

Laboratory

performance

Methods

Management

FrD/FSM/QS/NRC

Food Safety Microbiology (FSM)

p. 10FrD/FSM/QS/NRC

Emerging microbial issues

Address relevant microbiological issues by

understanding the impact of emerging pathogens on

the food chain and on human health and how to

prevent contamination of the food supply

Microbiological risk

assessmentProvide:

- Risk assessment methodologies & tools

- State of the art risk assessments to allow

science-based management

NRC Food Safety Microbiology team

Microbiological product quality and safety

2011-11-25


Overview





quality and safety


Microbiological Risk Assessment (MRA)


MRA as government bodies do

1• Hazard Identification

2• Exposure assessment

3• Hazard characterization

4• Risk Characterization

End point: Public health

statistics such as number

of case per million people

and per year

MRA as Nestlé (FSM) does /

“Safety Assessment”

Hazard identification: identification of biological hazard capable of causing adverse health

effect which may be present in particular food or group of food

Exposure assessments: assessing presence, survival and growth of pathogens in food

during and after production, in order to control the microbiological hazard until time of

consumption

End point: Safe Product and Process design… for the

safety of our Consumers

13

Microbiological Food Safety and Quality is truly a farm-to-folk

issue.

Each part of the food chain poses different risks and must be taken into account

Microbiological Safety Assessments

Farm practices Raw materials

Suppliers management

Processing Retailers and

consumers

2011-11-25FrD/FSM/QS/NRC

Microbiological Risk Assessment (MRA)


MRA as government bodies do

1• Hazard Identification

2• Exposure assessment

3• Hazard characterization

4• Risk Characterization

End point: Public health

statistics such as number

of case per serving or

number of case per million

people and per year

MRA as Nestlé (FSM) does /

“Safety Assessment”

Hazard identification: identification of biological hazard capable of causing adverse health

effect which may be present in particular food or group of food

Exposure assessments: assessing presence, survival and growth of pathogens in food

during and after production, in order to control the microbiological hazard until time of

consumption

End point: Safe Product and Process design… for the

safety of our Consumers


Overview





quality and safety


Tools to support Safety Assessments


Early Warning System

Surveillance plan

Hazard Prevalence in raw materials

Food Safety Briefs

Predictive Microbiology

Guidelines on microbiological storage challenge testing

The principle and process of the Nestlé Early

Warning


Process to detect and evaluate EMERGING ISSUES and hence

minimize the number or impact of incidents and crises

Principle: Detect issues

before they arrive….

FrD/F

SM/Q

S/NR

C

Identification of new potential issues

comes from 3 main sources

Web Scouting • Web is used as a source of information

• A special tool is used to follow topics of interests :

DIGIMIND

B

Inte

rnet

Trend Analysis

• Study of past analytical data to detect abnormal

deviating trends that could lead to an issue

• Act before the issue happen

C

Data

Early Warning Network• Nestlé Worldwide Network of people

• From different field of interest (RA, QM, R&D, Agri, …)

• Personal network outside Nestlé (e.g. ILSI, EFSA, …)

A

People

2011-11-25 p. 18

FrD/F

SM/Q

S/NR

C

The Early Warning needs to cover all potential

sources of issues

• Early Warning covers

– Food safety issues

– Compliance issues

– Issues linked to nutrition

– Cover all Nestlé businesses

– On a worldwide basis

REAL PERCEIVED

2011-11-25 p. 19

Surveillance plan for raw materials


• Demonstrate that QA process is under control.

• Routine monitoring

Verification programs / activities

• Develop new knowledge.

• Gather data on contamination levels

Investigation programs / activities

Program for the Surveillance of Chemical and Microbiological

Contaminants

Early Warning

system, new

issues/priorities,

regulatory

developments…

Adapt suppliers selection, control measures, pathogen

monitoring, …(e.g. viruses, STEC)

Hazard prevalence in raw materials


• ~ 500 Nestlé factories

• Over 200 000 analyses per day (FP, Env., Lines, RM)

• Global system to collect the data (GLOBE – SAP)

• TIC: database on prevalence of hazard in RM = Tools for Identification of Contaminants

Food safety Briefs


Predictive Microbiology


Models are simplified simulations of microbial behavior based on a representation of data

using statistics and mathematics.

Most models try to predict the number of viable cells (or their products) within an

environment.

Public and in house softwares

Workshops and training

Developing new models

Microbiological storage and challenge testing


Guidelines for assessing safety and stability of food products: description on WHEN

and HOW to carry out storage and challenge tests

Storage tests

• Finished product

• Effectiveness of applied hurdles in the product formulation against spoilage microorganisms is investigated

• Quality Shelf-life

• Naturally contaminated products

Product challenge test

• Product or ingredients

• Growth and Reduction of spoilage and/or pathogenic microorganisms in a product is investigated

• Several questions can be addressed

• Inoculation

Process Challenge test

• Product or ingredient

• Reduction of spoilage and/or pathogenic microorganisms in a defined process is investigated

• Several questions can be addressed

• Inoculation

Product• Sample amount

• Sample size

Storage

• Storage temperature

• Storage time

• Examples

Testing

• Methods

• Test parameters

• Sampling frequency …e addressed

Test organisms

• Strains selection (origin, number, maintenance…)

• Inoculation (inoculum, stress, innoc. Method…)

Experimental design


Overview



• Nestlé tools/processes developed and used in the frame of Safety

Assessments to achieve our goal: (microbiological) product quality

and safety


Safety Assessment: Product innovation(Nick Johnson)


New culinary product

• Fermenta--tion

Process

• Fermentation from pH 6.5 to pH below 4

• Sterilization

Safety Assessment: hazard identification

• B. cereus and S. aureus heat stable toxins

• Done based on literature, TIC and surveillance data

• Growth must be controlled to avoid toxin production

Safety Assessment: exposure assessment

• 1E+03 cfu/g is the maximum tolerable level

• Modeling of pathogens growth under different fermentation profiles (pH) at static temperature and water activity conditions

Outcome:

From the model the optimum

profile was obtained

(balancing fermentation effects and maximum allowable growth of

pathogens)

Salmonella and nuts (V. Soni)

Almonds Peanuts PistachiosSesame Seeds

Hazelnuts Pecans Walnuts

p. 27FrD/FSM/QS/NRC

OutbreaksRecalls

2011-11-25

Usage of nuts and associated risk (raw vs

processed)

Finished Product

Nestlé Factory

Supplier

Farm Nuts

Raw

No Treatment

Further Treatment

Processed

No Treatment

Further Treatment

p. 282011-11-25FrD/FSM/QS/NRC

Risk associated with processed nuts: factory level

Risk Level

CoA &/or ‘S’ analysis

Supplier’sCompliance

No Further Treatment Processed Nuts

Complying

Yes

Low

Complying with

reservations

Yes

High

Not Complying

Yes

High

Not audited

Yes

High

Audit Results Not

available

Yes

High


Conclusion

30

Nestlé Policy: Use only processed nuts in Nestlé products

For factories using processed

nuts:

Work only with suppliers who are complying (i.e. CCP

and PRPs under control).

Include Salmonella testing in supplier specifications

Implement regular 'S' testing at receiving in all

factories using nuts to verify the performance of the

supplier.

2011-11-25FrD/FSM/QS/NRC

Acknowledgements


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