microbiological risk mitigation in the primary processing ...microbiological risk mitigation in the...
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Microbiological risk mitigation inthe primary processing of plant-based raw materials
Matteo Campagnoli
Nestlé Research, Switzerland
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Outline
Inactivation studies• Washing
• Drying
• Steaming
Mild technologies & scientific challenges
Should we consider the microbiological risk for plant-based raw materials?
Guidance booklets overview
Supply chain & microbiological risk
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2
3
4
5
Creation of shared value 6
Conclusions 7
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Why we must consider the microbiological risk for plant-based raw materials
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Supply chain & microbiological risk
GAP
7 Routes of microbial
contamination• Growing field and adjacent land
• Animals
• Manure-based soil amendments
• Agricultural water
• Hygiene and human health
• Worker harvesting practices
• Equipment, premises and transportation
GMP
Mild processing
• Washing
• Drying
• Steaming
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Supply chain & microbiological risk
HarvestingGrowing ConsumerMild
processingNestlé
Control
measure, e.g.
GAP
Washing Candying /
drying
NO control
measure (RTE)
NO control
measure
e.g.
pasteurization
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Upstream supply chain & microbiological riskmanagement
Supplier Nestlé
• GFSI approved certification
• Nestlé technical audits
improve internal technical expertise
• Supplier continous improvement
voluntary training
Development of
guidance booklets and
auditing tools on mild
processing
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Translation of science into application
Scientific studies
External experts
Internal experts
Guidance booklets & auditing tools
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Mild technologies: scientific challenges
• Technologies with limited heat load (no official guidelines available)
• Product changes in moisture throughout
processing
• Dynamic microbial behaviour towards heat
resistance
• Impossibility to run prediction models
• Understand microbial inactivation at lab and pilot plant scale
• Identify suitable surrogate microorganisms
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Raw materials selection
Onion (air-drying)
Basil (air-drying)
Blueberry (candying)
Raisin (air-pasteurization)
Freeze-dried basil (steaming)
Black pepper (steaming)
Herbs & spices
Vegetables Fruits
Selection criteria:
• Volumes
• Processing at supplier
• Risk assessment for Nestlé finished products
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Inactivation studies: washing
• Collaboration with Ghent University
• Literature review on processing and inactivation
• Expert opinion on safe processing for 4 chemicals
• Delivery of one fact sheet for each chemical
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Washing booklet: content
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Inactivation studies: drying
• Definition of process conditions delivering 4 log10 reduction
• Identification of surrogate for process validations
aw 0.99
aw 0.95
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Microorganisms
• Sourced from national culture
collections
• Linked to previous outbreaks
• Linked to the specific raw material
• Known for high heat resistance
PATHOGENS
Salmonella spp
STEC
Listeria monocytogenes
Hepatitis A Virus (HAV)
SURROGATES
Enterococcus faecium ATCC
8459
Escherichia coli P1 ATCC BAA 1427
Listeria innocua
Murine Norovirus (MNV)
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Drying booklet: content
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Drying booklet: content
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Drying booklet: content
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Inactivation studies: steaming
Inoculation 1%
w/w + holding at
22°C / 4 days
PATHOGENS
Salmonella spp
STEC
Listeria monocytogenes
SURROGATES
Enterococcus faecium
ATCC 8459
Escherichia coli P1 ATCC BAA
1427
Listeria innocua
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Steaming booklet: content
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Steaming booklet: content
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Auditing tools
• 1 checklist for each technology
• Presence of scoring system
• Used as pre-audit assessment tool
• Can be used for continous
improvement at supplier level
• Booklets to support checklists
• Used for training of auditors and
suppliers
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Communication
Internal Corporate Quality
Supplier Quality Assurance Network
Procurement
External Product Associations
Health Authorities
Private companies
Corporate website:
https://www.nestle.com/aboutus/suppliers
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Shared value creation
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Conclusions In the supply chain of mildly processed raw materials, it is keyto minimize microbiological contamination and maximizeinactivation.
The R&D work done provides clear guidance on the microbialsurrogates to use on each technology for process validationsand the key process parameters to control for maximizingmicrobiological inactivation.
Mild technologies (e.g. air-drying) tipically applied for qualityobjectives and not food safety, could also be considered controlpoints for microbiological hazards.
In the abscence of globally recognized guidelines, mild processconditions need a validation study to prove safety.
Acknowledgments
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University of Gent, Belgium:
Prof. Mieke Uyettendaele
Prof. Frank Devlieghere
Prof. Imca Sampers
Zijin (Cece) Zhou
Bühler:
Nicolas Meneses
Nestlé Research:
Sophie Zuber
Françoise Julien-Javaux
Matteo Campagnoli
Frederique Cantergiani
Laurence Blayo
Thierry Putallaz
Sophie Butot
Lise Michot
Xi Bai
Yingyi Zhang
Adrianne Klijn
Mireille Moser
Questions…
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