Tag Archives: disinfection

Tyson Foods

Report: 22% of Tyson Workers at Iowa Pork Plant Positive for COVID-19, Facility to Temporarily Shut Down

By Food Safety Tech Staff
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Tyson Foods

Yesterday Tyson Foods, Inc. announced that it would temporarily close its pork plant located in Storm Lake, Iowa following a significant number of employees testing positive for coronavirus. According to Reuters, an Iowa state official placed the positive COVID-19 count at 555 workers at the facility—this accounts to 22% of employees.

Attend the on-demand complimentary webinar: “Is Your Plant COVID-19 Safe?”The company stated that it would reopen next week after “deep cleaning and sanitizing the entire facility.”

The meat industry has been struggling with worker safety during the COVID-19 pandemic for months. While there have been calls for more transparency in the number of COVID-19 cases among facility workers, the information has not been freely flowing. For example, this week Sarah Reisetter, deputy director of the Iowa Department of Health, told the media the following: “Businesses are not currently required to report an outbreak to the Iowa Department of Public Health. Additionally, Iowa law allows confirmation of outbreaks only when necessary to protect the health of the public.”

Frank Meek, Orkin, Rollins
Bug Bytes

How to Keep Pathogen-Spreading Pests Out of Your Business

By Frank Meek
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Frank Meek, Orkin, Rollins

As food processors and retailers work tirelessly to feed the public during the current global health pandemic, pests continue to work overtime to keep their food supply on track. Filth flies, cockroaches and rodents, in particular, pose a threat to the food supply chain, especially with concerns of the transmission of pathogens at an all-time high. The last thing your business needs is an avoidable food safety incident that threatens your reputation and bottom line.

When it comes to food safety, pathogen-spreading pests have no place in your facility and pose a major public health risk. Not only can these filthy pests become a nuisance within your facility, they can also contaminate your products and spread foodborne bacteria such as Salmonella, E. coli and Listeria, which can cause illnesses.

Knowing what attracts these pests to your facility and the dangers they pose is important for effective removal. Let’s dive into the signs of cockroaches, filth flies and rodents, and the specific concerns they can cause.

Register to attend “Integrated Pest Management: Protect Food Safety and Prevent the Spread of Pathogens” | A complimentary virtual conference | Tuesday, June 30 at 12 pm ETCockroaches

Cockroaches seek four things that food processing facilities provide in abundance—food, shelter, proper temperatures and water. With the ability to squeeze through tiny gaps and cracks, these dirty pests enjoy crawling under equipment, in cabinets and through drains to find their next meal. Cockroaches can be found in and around almost any place within your facility. They’re capable of carrying harmful bacteria that they can spread from one location to another. Look out for droppings, cast skins or egg cases, which might signal a cockroach problem.

Filth Flies

You may think these types of flies have no desire to be inside, but they are in fact happy to go wherever the conditions are right. The most common filth fly is the housefly. These winged pests can carry and spread more than 100 disease-causing pathogens including bacteria, fungi and viruses. These can cause illnesses such as cholera, dysentery and infantile diarrhea. Filth flies in your facility can lead to a major public health issue if your food becomes contaminated.

Rodents

One of the filthiest pests around, rodents can contaminate your food supply, destroy or consume products and cause structural damage to your facility. Like cockroaches, mice and rats can fit through relatively small spaces to find food and water. With sightings on the rise during the COVID-19 pandemic, you’ll want to keep an eye out for rodents near your food products. These mighty chewers pose a public health threat as they can transmit diseases such as hantavirus and lymphocytic choriomeningitis (LCM) via their urine and droppings.

The presence of these vermin in your facility threatens public health. Additionally, an infestation can slow down the supply chain by causing businesses to recall contaminated foods.

A rigorous sanitation routine is one of the most effective ways to proactively manage pests like cockroaches, rodents and filth flies. Regularly sanitizing and disinfecting your facility can help eliminate any pathogens left behind on hard surfaces and remove the attractants for which they search. While cleaning removes dirt and buildup, sanitization and disinfection kill bacteria and pathogens, reducing the risk of a food safety issue.

Including the following tips in your cleaning routine can help keep your products and reputation safe from harm.

  • Clean out drains routinely with an enzymatic cleaning solution that can break down the organic grime.
  • Disinfect high-touch hard surfaces with a proper and low-toxicity disinfectant to kill bacteria and pathogens that can cause food illnesses.
  • Move dumpsters away from your building to reduce flies being attracted to and then gaining easy entry into your facility.
  • Wipe spills as soon as they occur to prevent them from becoming a sticky paradise for flies and cockroaches.
  • Practice good hygiene in your work environment and ensure employees are washing their hands regularly and keeping break rooms free of trash and leftovers.

Implementing exclusion practices such as sealing cracks, gaps and holes in walls with a proper sealant can also help you keep pests out. Budget allowing, consider investing in insect light traps and mechanical traps to help reduce flying insects inside.

Communication with your suppliers and distributors is also important to ensure food safety. If your partners implement similar measures, you’re more likely to protect the public from harmful diseases. Furthermore, customers will continue to trust your business.

While following these tips can help reduce the chances of a pest infestation, it’s not always possible to keep pests and the pathogens they spread out of your food processing facility. Work with a trained pest control specialist to develop a customized prevention program for your business as each type of pest requires specific treatment. They can also help you schedule inspections to identify conditions in and around your facility that may attract flies, cockroaches and rodents, among other pests.

FDA

FDA, USDA Reach MOU to Prevent Disruptions in FDA-Regulated Food Facilities

By Food Safety Tech Staff
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FDA

This week the USDA and FDA signed a Memorandum of Understanding (MOU) in an effort to prevent disruptions at FDA-regulated food facilities, including fruit and vegetable processing locations. The agencies are also trying to prepare for the peak harvesting seasons that involve freezing and canning fruits and vegetables. The MOU provides a process by which the agencies can determine the instances when USDA would exercise authorize under the Defense Production Act (DPA) related to food resource facilities that manufacture, process, pack or hold foods.

“While the FDA will continue to work with state and local regulators in a collaborative manner, further action under the DPA may be taken, should it be needed, to ensure the continuity of our food supply. As needed, the FDA will work in consultation with state, local, tribal and territorial regulatory and public health partners; industry or commodity sector; and other relevant stakeholders (e.g. Centers for Disease Control and Prevention, Occupational Safety and Health Administration) to chart a path toward resuming and/or maintaining operations while keeping employees safe,” stated FDA Deputy Commissioner for Food Policy and Response Frank Yiannas in an agency press release. “We are working with our federal partners who have the authority and expertise over worker safety to develop information on protecting worker health. We are also working with other federal partners to assist the food and agriculture industry in addressing shortages of personal protective equipment (PPE), cloth face coverings, disinfectants and sanitation supplies.”

FDA

FDA on How to Return Refrigerated Transport Vehicles and Storage Units to Food Use After Holding Human Remains

By Food Safety Tech Staff
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FDA

The increase in deaths during the COVID-19 pandemic has pushed funeral homes and morgues beyond capacity, and other measures have been taken to store the bodies of victims. As a result, refrigerated food transport vehicles and food storage units have been temporarily used for this purpose. Now, FDA has released the guidance document, “Returning Refrigerated Transport Vehicles and Refrigerated Storage Units to Food Uses After Using Them to Preserve Human Remains During the COVID-19 Pandemic” because when those additional storage units are no longer needed to store bodies, “industry may wish to return the trailers and storage units to use for food transport and storage”.

Returning these vehicles and storage units to use for food is possible—but only with thorough cleaning and disinfection. The agency recommends the use of EPA-registered disinfectants that are suitable for the material being disinfected. It also recommends these disinfectants be effective against SARS-CoV-2 and foodborne pathogens. When disinfecting, it is important to adhere to the instructions for use for guidance on how many times application is required, the contact time needed, and effectiveness at refrigeration temperatures. For instances in which the interior surfaces have been in direct contact with blood or bodily fluids, the FDA guidance provides the scenarios in which the vehicles and storage units should not be returned to use for transporting or storing food for humans or animals.

OSHA has also stated that compressed air or water sprays should not be used to clean contaminated surfaces due to the risk of aerosolizing infectious material.

Due to the public health emergency, the guidance has been issued without the agency’s usual 60-day comment period.

FDA

As States Look to Reopen, FDA Releases Best Practices for Retail Food Establishments

By Food Safety Tech Staff
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FDA

Across the country, many restaurants have been closed for at least two months, while others have been partially closed and offering take-out or delivery to customers during the COVID-19 pandemic. As states begin their strategy to reopen the economy, many restaurants have already opened, and others are preparing for when this day comes. To better help food retail establishments during this uncertain time, the FDA has issued the checklist, “Best Practices for Re-Opening Retail Food Establishments During the COVID-19 Pandemic”, along with a two-page infographic.

The checklist offers guidance in several key areas related to food safety practices, including:

  • Facility Operations
  • Water, Plumbing and Ice
  • Food Contact and Non-food Contact Surfaces (clean, disinfect, sanitize)
  • Food Temperature Control
  • Product Inspection, Rotation
  • Dishwashing Equipment
  • Handwashing Stations
  • Employee Health/Screening
  • Social Distancing

While the food safety checklist covers a lot of ground, the FDA has stated that the list is not comprehensive. “We encourage retail food establishments to partner with local regulatory/health authorities to discuss the specific requirements for their retail food establishment prior to re-opening,” the agency states.

Coronavirus, COVID-19

Worker Safety a Concern as COVID-19 Affects U.S. Meat Plants, Supply Chain Uncertain

By Maria Fontanazza
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Coronavirus, COVID-19

Employees at meat processing plants across the nation aren’t reporting to work as they fear for their health during the coronavirus pandemic. Hundreds of workers have become infected with COVID-19, and several deaths have been reported. There is no official count on the infection rate or how many employees have succumbed to the novel coronavirus, but the information released thus far is alarming. Demands for more protective equipment, along with hazard pay, may not be enough to keep workers safe; concerns over a meat shortage loom.

Tyson Foods

On March 31, Tyson Foods posted on “The Feed Blog” (the company’s blog) that it would be taking additional measures to protect and reward its frontline workers and truckers during the COVID-19 crisis: Protection in the form of “protective facial coverings for production workers who request them” and a reward in the form of a “one-time $500 bonus” to be paid the first week in July “based on their work attendance in accordance with our relaxed COVID-19 attendance policy during the months of April, May and June”.

Last week Tyson Foods issued a news release about the steps it is taking to further handle the COVID-19 problem at U.S. plants: At all facilities, workers are having their temperatures taken (temporal thermometers or infrared temperature scanners, depending on the location) prior to entering the plants; the company has increased deep cleaning and sanitizing, some of which will require the shutdown of at least one day of production. The release also states that Tyson Foods is implementing more social distancing measures, which includes putting up dividers between workstations and increasing space between workers on the plant floor.

The company’s measures come among serious concerns about the presence of outbreaks at various facilities. The New York Times reported about the deaths of three workers at a Tyson poultry plant in Camilla, Georgia, one of whom was allegedly told to return to work even after feeling symptoms of COVID-19. In Columbus Junction, Iowa, a Tyson pork plant closed after more than 24 employees tested positive for COVID-19. And according to the Benton-Franklin (Washington state) health district COVID-19 Case Count page, 30 people linked to the Tyson Fresh Meats plant have been diagnosed with the coronavirus as of April 13.

Cargill, Inc.

Last week Cargill closed a meat production facility in Hazleton, PA due to the high concentration of COVID-19 cases in the area. The facility has 900 employees, and it has been reported that some workers were staying home as a result of testing positive for coronavirus or out of concerns for their own safety.

JBS

JBS shut down its plant in Pennsylvania for two weeks; it shuttered its beef plant in Greeley, Colorado after at least 36 employees tested positive for the virus, and at least one death was reported. One representative for union workers stated 50 employees have tested positive and an additional worker has died. JBS issued a statement on Friday that it is offering free COVID-19 tests to all workers at the Greeley beef plant. The company also lists its policy on prioritizing team member health and safety on its website.

Smithfield Foods, Inc.

Smithfield Foods is the world’s largest pork processing company, employing 40,000 people in the United States. The company shut down its plant in Sioux Falls, SD indefinitely after more than 80 workers tested positive for COVID-19 (this particular accounts for 4–5% of pork production domestically and employs an estimated 3700 workers). “The closure of this facility, combined with a growing list of other protein plants that have shuttered across our industry, is pushing our country perilously close to the edge in terms of our meat supply,” said Kenneth M. Sullivan, president and CEO of Smithfield Foods in a news release. “It is impossible to keep our grocery stores stocked if our plants are not running. These facility closures will also have severe, perhaps disastrous, repercussions for many in the supply chain, first and foremost our nation’s livestock farmers.”

Several Smithfield Food workers in poultry plants across Alabama, Georgia and Tennessee have also tested positive for the virus.

“We have a stark choice as a nation: we are either going to produce food or not, even in the face of COVID-19,” said Sullivan.

Colleen Costello, VitalVio
FST Soapbox

Shining New Light on Preventing Food Recalls

By Colleen Costello
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Colleen Costello, VitalVio

Recalls have become an unfortunate reality for the food and beverage industry. It seems every month, another grocer pulls inventory from its shelves due to contaminated products that are potentially harmful for consumers.

Last month, it was Kroger that was forced to remove beef products from stores in Ohio, Kentucky and Indiana as part of Aurora Packing Company’s recall of more than 62,000 pounds of meat that may have been infected with E. coli. Not only do these situations hurt the reputation and bottom line of companies across the food supply chain—from the manufacturer to the retail store—there is the potential for these issues to become deadly.

The CDC counts 3,000 deaths, 128,000 hospitalizations and 48 million foodborne illness cases every year. While the food industry has put stricter guidelines into place for recalling contaminated products, the key to preventing illness is to take an even more proactive stance toward making food free of harmful pathogens before it reaches consumers’ plates.

Unfortunately, this is easier said than done.

The 2019 Food Safety Consortium Conference & Expo features an entire track on sanitation | October 1–3 | Schaumburg, ILComplexities of the Food Supply Chain

The food industry faces unique supply chain challenges. First, consider that the industry is dealing with products that come from the ocean or earth. Once obtained, these products are boxed, sent, in many cases long distances, to a facility via truck or cargo ship, where our foods undergo a number of processing mechanisms before being put back in a shipping container and sent off to a store. When they finally make it in-store, they’re moved from the backroom to the store floor. After all this, these products go into our mouths and through our digestive systems.

There are often many complex steps food has to go through before it makes it into our homes—and with each level of the food supply chain comes a new opportunity for things to go wrong and contamination to happen. What makes the food supply chain even more frightening is that pinpointing the root cause of harmful pathogens—such as E. coli or Listeria—by retracing all the potential contacts points is very challenging given their microscopic nature. All in all, the germs are beating us.

Old Disinfection Techniques Aren’t Cutting It

To mitigate the issue of contamination and avoid those dreaded recalls, food companies have prioritized disinfection. Most often, techniques include manually washing processing equipment with chemicals to keep them sanitized, and even spraying food products with antibiotics to directly kill harmful germs. However, these solutions have many limitations and are either intermittent in their use or insufficient to tackle the complexity of challenges associated with the food processing environment.

First, the tide is beginning to turn on the use of chemicals on food products, with consumers having growing concerns with introducing antibiotics in their food. There’s heightened and justified skepticism over the use of antibiotics and fears over the potential impact on resistance through overuse. In other words, consumers are afraid of the potential side effects from ingesting these chemicals on a daily basis and the alternative resistance bacteria they promote.

The truth is that the excessive use of antibiotics makes them less effective. This is due to frequently exposed bacteria developing resistance to antibiotics over time. The result is that antibiotics are no longer as effective at killing these germs, which is at the heart of great concern for the public’s health.

Resistant bacteria can be passed from food-producing animals to humans in a number of ways. If an animal is carrying resistant bacteria, it can be passed on through meat that is not handled or cooked properly. Plus, food crops are regularly sprayed with fertilizers, which can contain animal manure with resistant bacteria. Once spread to humans, resistant bacteria can stay in the human gut and spread between individuals. The consequences of the introduction of these germs and the subsequent consumption of them include infections that would not have happened otherwise.

Second, cleaning equipment with chemicals and disinfectants is important, but only intermittently effective. While someone working in a food processing plant uses chemicals to clean off a surface or container before food touches it, there’s still an opportunity for harmful bacteria to land on the space in between washes from many sources including the air, packaging, other food, etc. Not to mention there is a wide variety of different surfaces and nodes that food touches as it moves throughout a plant and across the supply chain. Every single surface is a distinct and new opportunity for germs to live, and simply scrubbing these areas a few times a day (or once a day in some cases) simply isn’t enough to keep these germs away. By solely relying on the intermittent use of chemicals to sanitize, it seems virtually impossible to ensure contamination is not ever introduced along the way to your table.

The Introduction of Continuous Disinfection Using Light

Intermittent sanitization hasn’t been disproven to be a wholly effective way to kill germs—it’s simply not a strong enough line of defense in and of itself. Perhaps, one of the best ways to protect our food from harmful bacteria and prevent expensive recalls altogether is to introduce and layer in a new breed of “continuous disinfection” technology using bacteria-killing visible LED lighting directly into the process.

Going back to more than a century ago, scientists have known that certain wavelengths of light are highly effective at destroying bacteria. Ultraviolet (UV) light is extremely powerful, but it is also especially dangerous to humans and causes things like plastics to become brittle and crack. UV light directly impacts the DNA in people, animals and plants, along with bacterial cells.

There is, however, a very human-friendly frequency of light (405 nanometers), which is in the visible spectrum of light, that is completely harmless to humans, but just as devastating to bacteria. It activates the porphyrin molecules that exist only within unicellular organisms such as bacteria and fungi. Humans, animals and plants do not have these particular molecules. Exposure to 405 nm light directly activates these molecules and essentially rusts bacteria from the inside out destroying any bacteria that is exposed to this human-friendly light. The ability of this new LED tool to be safely used around the clock allows for it to be acting continuously. This continuous nature goes above and beyond the existing limitations of intermittent cleaning.

With the advent of LED lighting, it is now possible to “tune” the frequency of light with extreme precision. The significant breakthrough of isolating light to this specific frequency of violet-blue light has now begun to enter the food processing industry. It is taking its place as a critical component to the layered defenses against harmful bacteria entering the food chain. When left on, this light continuously kills bacteria, preventing any germ colonies from forming and replicating. This has now become the perfect complement to the proper cleaning and sanitizing of all surfaces used in food processing and preparation—intermittent chemical cleaning working together with continuous disinfection from light.

In short, avoiding outbreaks and infection crises is all about smart prevention. Recalls are a reactionary solution to the problem. The key to preventing these potentially deadly (and costly) situations is to make sure that all facilities that process and handle food are continuously disinfected. The good news is that tech startups are at the helm of developing these new tools for killing germs before they even have a chance to have a seat at our tables.

Alert

Flooding and Food Safety: A Two-Part Plan for Extreme Weather Season

By Paula Herald
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Alert

The spring of 2019 saw record rain fall across North America, causing historic, severe flooding in the Great Plains, parts of the Midwest, and the Southern United States. That above-normal precipitation doesn’t look to be ending, either. The National Oceanic and Atmospheric Administration’s Climate Prediction Center predicts that wide swaths of the United States could face above normal precipitation for the remainder of 2019.

In addition to disrupting power to critical equipment and damaging property, when food businesses flood, food safety is put at risk. Flood waters can be contaminated with debris, sewage, chemicals, pests and more. In a restaurant or foodservice operation, any product, object or surface that flood waters touch becomes contaminated.

Pre-Flood Preparation

Having a documented flood emergency plan in place can give location staff a step-by-step course of action to follow in times of increased stress and panic. It can also help minimize losses for a business.

For national chains in particular, it can be harder to ensure that all locations have the resources and tools available in their area. Corporate operations can assist by identifying vendors and resources ahead of time.

  • Designate roles and responsibilities. Having a clearly outlined plan with designated roles and responsibilities can prevent confusion and extra work during the crisis. Have an updated phone contact list of key contacts available for those with designated roles and responsibilities.
  • Sandbags. Placing sandbags in front of doors or other openings may help limit flood damage.
  • Vital records. Both paper and digital/electronic records can be at risk. Businesses using electronic records should ensure that files are automatically backed up regularly. Businesses using paper records should ensure that vital records are secured in such a way that they can be quickly removed to a safe place or elevated to prevent damage.
  • Equipment. Flood waters can damage or destroy expensive equipment. Have a plan in place to remove equipment to a safe place.
  • Food storage. If flood waters contact food supplies, many may need to be destroyed. Arranging for food storage in a secure place away from flood waters can help minimize losses. This may require refrigeration storage.
  • Turn off electric and gas. Turning off natural gas lines can prevent devastating damage and contamination from occurring. Turning off and unplugging equipment that uses electricity can help protect the safety of rescue workers or staff returning for cleanup.
  • Refrigeration. If it is not possible to remove food, be certain that all refrigerated units are equipped with accurate thermometers. If possible, monitor the temperature in the units during the disaster situation.

Post-Flood Recovery

Even with a rock-solid pre-storm plan in place, Mother Nature’s extreme weather events can wreak havoc on facilities. In the wake of a storm, sorting out what needs to be done to restore order to operations can be a hefty task.

Post-storm recovery can be an extensive task, especially if flooding is involved. It may require work of many staff members or outside vendors, such as remediation specialists. Safety should be absolutely paramount. No one should enter a space that has been flooded without confirmation that there are no electrical shock hazards, gas leaks or debris that could harm people. Structural damage that could lead to collapse or other injury is possible. Mold is also a risk following floods. All personnel involved in flood clean-up must wear personal protective equipment—eye protection, gloves, disposable aprons, rubber boots, and masks or respirators, etc.

The following guidelines can help prioritize steps to ensure food safety won’t be a factor holding back a location from re-opening.

  • Safe water. Facilities cannot prepare food without a clean, potable water supply. If the water system was affected by flood or the local water supply was unsafe, the local health department should be involved in clearing re-opening.
  • Disinfection of equipment. Any food equipment that was exposed to flood water or other non-potable water must be disinfected prior to use, including ice machines, which are often overlooked. Discard any ice already present in a machine. Thoroughly clean and sanitize the machine before turning it on. Once the machine is running again, discard the first two cycles of ice.
  • Disinfection of surfaces. Any surface (countertops, walls, ceilings, floors, equipment surface, etc.) that was contacted by floodwaters must be disinfected before reopening.
    • Use a commercial disinfectant with effectiveness against norovirus or make a chlorine bleach solution to disinfect affected areas.
    • Use unscented bleach and wear gloves.
    • Make fresh bleach solutions daily.
    • Food contact surfaces that are disinfected must be rinsed with clean, potable water, and sanitized before use.
    • Discard any mop heads or absorbent materials used to clean flooded areas.
  • What to discard. Inevitably, there will be items that cannot be salvaged following a flood event. The following items should be discarded if they have come into contact with floodwater or non-potable water or were subjected to temperature abuse due to power outages. If there is any doubt, throw it out.
    • Unpackaged food (examples: fruits, vegetables)
    • Food in permeable packaging (examples: flour in bags, produce in cardboard boxes)
    • Food packaging materials
    • Refrigerated food in a refrigerated unit where the temperature rose above 41°F for more than four hours
    • Any refrigerated product that was not temperature-controlled for more than four hours
    • Frozen food product that has thawed to a temperature of above 41°F for more than four hours
    • Canned items with damaged seams, swelling or dents
    • Items with screw tops, twist-off caps, or other semi-permeable packaging
    • Single service/use items
    • Any linens that contacted floodwaters that cannot be laundered with bleach and dried in a mechanical dryer
  • What can be safely kept. Not everything will need to be discarded.
    • Canned foods free of dents or rust can be kept after labels are removed, they are disinfected, washed, rinsed in clean water, and sanitized; cans with any signs of bulging or leaking must be discarded; canned foods should be also be relabeled with the name of the food product, as well as the expiration date
    • Linens that can be safely laundered with bleach and dried in a mechanical dryer
    • Dishes, utensils, pots and pans, and other service items that are free of rust and can be disinfected, washed, and sanitized

As climate change continues to advance, the threat of extreme weather and flooding situations may soon be a reality for areas of the United States that have never experienced them before. In the Congress-mandated Fourth National Climate Assessment, compiled by the U.S. Global Change Research Program, the authors warn of the future of severe weather events.

“More frequent and intense extreme weather and climate-related events, as well as changes in average climate conditions, are expected to continue to damage infrastructure, ecosystems, and social systems that provide essential benefits to communities.” – Fourth National Climate Assessment

Even for businesses that have not had to consider flooding before, it may be time to sit down and develop a flooding and food safety plan of action. The time invested in training and educating staff members may help to protect investments and keep food safe in the event of flooding and weather emergencies.

Peas, UV light

Controlling and Mitigating Pathogens Throughout Production

By Troy Smith
1 Comment
Peas, UV light
Sampling
Product sampling

As the enforcement of rules, regulations and inspections get underway at food production facilities, we are faced with maintaining production rates while looking for infinitesimal pathogens and cleaning to non-detectible levels. This clearly sets demand on the plant for new and creative methods to control and mitigate pathogens pre-production, during production and post production.

As this occurs, the term clean takes on new meaning: What is clean, and how clean is clean? Swab and plate counts are now critically important. What method is used at the plant, who is testing, what sampling procedure is used, and how do we use the results? As we look at the process from start to finish, we must keep several key questions in mind: What are harboring points in the process, and what are the touch-point considerations to the product? Let’s review the overall processing progression through the factory (see Figure 1).

Figure 1.
Figure 1. The progression of processing of a food product through a facility.

Now consider micro pathogen contamination to the product, as we look deeper in the process for contamination or critical control points as used in successful HACCP plans. Consider contamination and how it may travel or contact food product. It is understood through study and research of both pathogens and plant operations that contamination may be introduced to the plant by the front door, back door, pallet, product, or by a person. In many cases, each of these considerations leads to uncontrolled environments that create uncontrolled measurements throughout, which lead to cleaning procedures based on time rather than science. This is certainly not to say that creating a preventive maintenance schedule based on a calendar is a bad thing. Rather, the message is to consider a deeper look at the pathogens and how they live and replicate. From the regulatory and control measures this should be a clear message of what food-to-pathogen considerations should be taken at the plant level as well as measurement methods and acceptable levels (which is not an easy answer, as each product and environment can change this answer). A good example to consider is public schools and children. Health organizations work to help the schooling system understand what immunizations children should have based on the current health risk tolerance levels. In food production, the consideration is similar in an everchanging environment. As we see contamination levels change the methods, techniques and solutions to proper food production must account for the pathogens of concern.

Contamination, Risk tolerance, Opportunity for Growth

Contamination, risk tolerance, and opportunity for growth are the considerations when looking at a plant design or a plant modification. Modification to modernization should be a top-of-mind critical quality control measure. If there are a few things we know, it is how to produce food at high rates of speed, measure and value production rates, and delays or failures can be measured by equipment and personnel performance. In the case of quality control, we must review, comprehend, and protect process risk. From a management or non-technical viewpoint, quality control can be very difficult to understand. When discussing pathogens, our concerns are not visible to the human eye—we are beyond a dirty surface, weare looking at risk tolerance based on pathogen growth in logarithmic measurement. When combining quality control and production, the measurement control and mitigation measures complement the effort. The use of quality control is expected and should coordinate with production to ensure the product is produced at the expected quality level.

Mike Hardegree, Proton Towels

Advancing Technology in Disinfection and Sanitation

By Food Safety Tech Staff
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Mike Hardegree, Proton Towels

“There is a lot of new technology that has taken place in sanitizers, [and] in practices, procedures and protocols to reduce the risk of foodborne illness,” said Mike Hardegree of Tietex International, Ltd at the Food Safety Consortium. “The cotton towel and the disinfecting and cleaning towels most often used are the same ones that have been used for many, many years.”

In the following video, Hardegree and Margaret Hearon, market development manager at Teitex share how the single-use towel technology is reducing the risk of cross contamination.