Postpackage pasteurization of ready-to-eat deli meats by submersion heating for reduction of Listeria monocytogenes

Effect of Biltong Dried Beef Processing on the Reduction of Listeria monocytogenes, E. coli O157:H7, and Staphylococcus aureus, and the Contribution of the Major Marinade Components

Biltong is a dry beef product that is manufactured without a heat lethality step, raising concerns of whether effective microbial pathogen reduction can occur during biltong processing. Raw beef inoculated with 4-strain cocktails of either E. coli O157:H7, Listeria monocytogenes, or Staphylococcus aureus, and processed with a standard biltong process, were shown to incur a >5-log reduction in 6−8 days after marination by vacuum-tumbling for 30 min in vinegar, salt, spices (coriander, pepper) when dried at 23.9 °C (75 °F) at 55% relative humidity (RH). Pathogenic challenge strains were acid-adapted in media containing 1% glucose to ensure that the process was sufficiently robust to inhibit acid tolerant strains. Internal water activity (Aw) reached < 0.85 at 5-log reduction levels, ensuring that conditions were lower than that which would support bacterial growth, or toxin production by S. aureus should it be internalized during vacuum tumbling. This was further confirmed by ELISA testing for staphylococcal enterotoxins A and B (SEA, SEB) after marination and again after 10 days of drying whereby levels were lower than initial post-marination levels. Comparison of log reduction curves obtained for E. coli O157:H7, L. monocytogenes, S. aureus, and Salmonella (prior study) showed that microbial reduction was not significantly different (p < 0.05) demonstrating that even without a heat lethality step, the biltong process we examined produces a safe beef product according to USDA-FSIS guidelines.

Novel Approaches to Environmental Monitoring and Control of Listeria monocytogenes in Food Production Facilities

Listeria monocytogenes is a serious public health hazard responsible for the foodborne illness listeriosis. L. monocytogenes is ubiquitous in nature and can become established in food production facilities, resulting in the contamination of a variety of food products, especially ready-to-eat foods. Effective and risk-based environmental monitoring programs and control strategies are essential to eliminate L. monocytogenes in food production environments. Key elements of the environmental monitoring program include (i) identifying the sources and prevalence of L. monocytogenes in the production environment, (ii) verifying the effectiveness of control measures to eliminate L. monocytogenes, and (iii) identifying the areas and activities to improve control. The design and implementation of the environmental monitoring program are complex, and several different approaches have emerged for sampling and detecting Listeria monocytogenes in food facilities. Traditional detection methods involve culture methods, followed by confirmation methods based on phenotypic, biochemical, and immunological characterization. These methods are laborious and time-consuming as they require at least 2 to 3 days to obtain results. Consequently, several novel detection approaches are gaining importance due to their rapidness, sensitivity, specificity, and high throughput. This paper comprehensively reviews environmental monitoring programs and novel approaches for detection based on molecular methods, immunological methods, biosensors, spectroscopic methods, microfluidic systems, and phage-based methods. Consumers have now become more interested in buying food products that are minimally processed, free of additives, shelf-stable, and have a better nutritional and sensory value. As a result, several novel control strategies have received much attention for their less adverse impact on the organoleptic properties of food and improved consumer acceptability. This paper reviews recent developments in control strategies by categorizing them into thermal, non-thermal, biocontrol, natural, and chemical methods, emphasizing the hurdle concept that involves a combination of different strategies to show synergistic impact to control L. monocytogenes in food production environments.

A Microplate Growth Inhibition Assay for Screening Bacteriocins against Listeria monocytogenes to Differentiate Their Mode-of-Action

Lactic acid bacteria (LAB) have historically been used in food fermentations to preserve foods and are generally-recognized-as-safe (GRAS) by the FDA for use as food ingredients. In addition to lactic acid; some strains also produce bacteriocins that have been proposed for use as food preservatives. In this study we examined the inhibition of Listeria monocytogenes 39-2 by neutralized and non-neutralized bacteriocin preparations (Bac+ preps) produced by Lactobacillus curvatus FS47; Lb. curvatus Beef3; Pediococcus acidilactici Bac3; Lactococcus lactis FLS1; Enterococcus faecium FS56-1; and Enterococcus thailandicus FS92. Activity differences between non-neutralized and neutralized Bac+ preps in agar spot assays could not readily be attributed to acid because a bacteriocin-negative control strain was not inhibitory to Listeria in these assays. When neutralized and non-neutralized Bac+ preps were used in microplate growth inhibition assays against L. monocytogenes 39-2 we observed some differences attributed to acid inhibition. A microplate growth inhibition assay was used to compare inhibitory reactions of wild-type and bacteriocin-resistant variants of L. monocytogenes to differentiate bacteriocins with different modes-of-action (MOA) whereby curvaticins FS47 and Beef3, and pediocin Bac3 were categorized to be in MOA1; enterocins FS92 and FS56-1 in MOA2; and lacticin FLS1 in MOA3. The microplate bacteriocin MOA assay establishes a platform to evaluate the best combination of bacteriocin preparations for use in food applications as biopreservatives against L. monocytogenes.

Microbiological Challenge Testing for Listeria Monocytogenes in Ready-to-Eat Food: A Practical Approach

Food business operators (FBOs) are the primary responsible for the safety of food they place on the market. The definition and validation of the product's shelf-life is an essential part for ensuring microbiological safety of food and health of consumers. In the frame of the Regulation (EC) No 2073/2005 on microbiological criteria for foodstuffs, FBOs shall conduct shelf-life studies in order to assure that their food does not exceed the food safety criteria throughout the defined shelf-life. In particular this is required for ready-to-eat (RTE) food that supports the growth of Listeria monocytogenes. Among other studies, FBOs can rely on the conclusion drawn by microbiological challenge tests. A microbiological challenge test consists in the artificial contamination of a food with a pathogen microorganism and aims at simulating its behaviour during processing and distribution under the foreseen storage and handling conditions. A number of documents published by international health authorities and research institutions describes how to conduct challenge studies. The authors reviewed the existing literature and described the methodology for implementing such laboratory studies. All the main aspects for the conduction of L. monocytogenes microbiological challenge tests were considered, from the selection of the strains, preparation and choice of the inoculum level and method of contamination, to the experimental design and data interpretation. The objective of the present document is to provide an exhaustive and practical guideline for laboratories that want to implement L. monocytogenes challenge testing on RTE food.

Study of the effect of post-packaging pasteurization and argon modified atmosphere packaging on the sensory quality and growth of endogenous microflora of a sliced cooked meat product

The objective of this work was to study the effect of post-packaging pasteurization on the sensory quality and growth of natural microorganisms during refrigerated storage (6 °C) of a cooked meat product considering two packaging atmospheres based on mixture of typical gases (CO(2)/N(2) (22/78%) and novel gases (CO(2)/Ar (17/83%)). Growth of lactic acid bacteria was significantly different between samples with and without post-packaging pasteurization, showing a growth rate >0.44 and equal to 0.28 log cfu/day, respectively. For samples with post-packaging pasteurization, atmosphere CO(2)/Ar resulted in a lower growth of lactic acid bacteria and a better sensory quality. Overall, samples without post-packaging pasteurization did not show a significant reduction of sensory quality during storage time (121 days) while samples with post-packaging pasteurization showed deterioration in their sensory quality. Further investigation is needed to obtain more definitive conclusions about the effect of post-packaging pasteurization and argon-based packaging atmospheres on cooked meat products.

Prediction of Listeria innocua survival in fully cooked chicken breast products during postpackage thermal treatment

The effectiveness of postpackage hot water thermal treatment on survival of Listeria innocua in fully cooked chicken breast products was investigated at 60, 70, 80, and 90°C. Primary models based on log-linear and Weibull models were used to fit bacterial survival curves at different temperatures. The prediction plot and fit statistics indicated that the Weibull model provided a better fit than the log-linear model and was selected as the primary model. A secondary model based on linear regression was developed to describe the effect of temperature on the kinetic parameters of Listeria innocua survival derived from the Weibull model. The root mean square error and coefficients of determination indicated a good fit of the secondary model. The models were validated by independent data from pilot plant tests, and the values of bias factor and accuracy factor fell into the acceptable range. The models developed in this study can assist poultry producers and risk managers in designing appropriate thermal treatment regimens to minimize the risk associated with Listeria in ready-to-eat poultry products.

Irradiation and additive combinations on the pathogen reduction and quality of poultry meat

Reduction of foodborne illnesses and deaths by improving the safety of poultry products is one of the priority areas in the United States, and developing and implementing effective food processing technologies can be very effective to accomplish that goal. Irradiation is an effective processing technology for eliminating pathogens in poultry meat. Addition of antimicrobial agents during processing can be another approach to control pathogens in poultry products. However, the adoption of irradiation technology by the meat industry is limited because of quality and health concerns about irradiated meat products. Irradiation produces a characteristic aroma as well as alters meat flavor and color that significantly affect consumer acceptance. The generation of a pink color in cooked poultry and off-odor in poultry by irradiation is a critical issue because consumers associate the presence of a pink color in cooked poultry breast meat as contaminated or undercooked, and off-odor in raw meat and off-flavor in cooked meat with undesirable chemical reactions. As a result, the meat industry has difficulties in using irradiation to achieve its food safety benefits. Antimicrobials such as sodium lactate, sodium diacetate, and potassium benzoate are extensively used to extend the shelf-life and ensure the safety of meat products. However, the use of these antimicrobial agents alone cannot guarantee the safety of poultry products. It is known that some of the herbs, spices, and antimicrobials commonly used in meat processing can have synergistic effects with irradiation in controlling pathogens in meat. Also, the addition of spices or herbs in irradiated meat improves the quality of irradiated poultry by reducing lipid oxidation and production of off-odor volatiles or masking off-flavor. Therefore, combinations of irradiation with these additives can accomplish better pathogen reduction in meat products than using them alone even at lower levels of antimicrobials/herbs and irradiation doses. Effects of irradiation and additive combinations on the pathogen reduction and quality of poultry meat will be discussed in detail.

A predictive model for the inactivation of Listeria innocua in cooked poultry products during postpackage pasteurization

Contamination of Listeria monocytogenes in ready-to-eat poultry products poses potential risk of listeriosis to the public. To control the level of Listeria contamination, attention has been focused on the postpackage pasteurization of fully cooked poultry products. In this study, we sought to develop a model to predict the thermal inactivation of L. monocytogenes in chicken drumettes during postpackage hot water pasteurization. Fully cooked chicken drumettes were inoculated with Listeria innocua as a surrogate microorganism for Listeria monocytogenes, vacuum packaged, and treated in hot water baths at 60, 70, 80, and 90°C for different heating times. Experimental results showed that a 7-log CFU/g reduction of L. innocua occurred at 54, 28, 18, and 10 min at 60, 70, 80, and 90°C, respectively. The Weibull model was used to fit the survival curves of L. innocua at each heating temperature. The root mean square errors and residual plots indicated good agreements between the predicted and observed values. The predictive model was further validated by predicting a new data set generated in the pilot-plant tests. Model performance was evaluated by the acceptable prediction zone method, and the results indicated that the percentages of acceptable prediction errors were 100, 100, 82.4, and 87.5% at 60, 70, 80 and 90°C, respectively, which were all greater than the threshold acceptable value of 70% , indicating good performance of the model. The developed predictive model can be used as a tool to predict thermal inactivation behaviors of L. monocytogenes in ready-to-eat chicken drumettes products.

Effect of inhibitory extracts derived from liquid smoke combined with postprocess pasteurization for control of Listeria monocytogenes on ready-to-eat meats

Surface pasteurization was examined in combination with low-phenolic antimicrobial extracts derived from liquid smoke to inhibit and prevent the growth of Listeria monocytogenes during the shelf life of ready-to-eat meats. In preliminary trials with retail frankfurters, one smoke derivative (2-min dip) produced a 0.3-log reduction of L. monocytogenes and a 1-min in-bag pasteurization (73.9 degrees C) produced a 2.9-log reduction, whereas a combination of the two treatments produced a 5.3-log reduction that resulted in no detectable Listeria by week 3 under accelerated shelf-life conditions (10 degrees C). In trials with frankfurters manufactured without lactate or diacetate that were treated with a shortened 1-s dip, this smoke extract and one with reduced smoke flavor and color both produced a > 4.5-log reduction of L. monocytogenes on frankfurters when heated at 73.9 degrees C for 1 min, with no recoverable Listeria detected for 10 weeks when stored at 6.1 degrees C. When deli turkey breast chubs manufactured without lactate, diacetate, or nitrite were treated with a 1-s dip in combination with radiant-heat pasteurization (270 degrees C), growth of L. monocytogenes was retarded but not prevented. However, in a similar study in which smoke extract treatment of deli turkey breast was combined with in-bag postpackage pasteurization (water submersion at 93.3 degrees C), a 60-, 45-, or even 30-s heat treatment resulted in a 2- to 3-log reduction of L. monocytogenes, with no growth on the meat during 10 weeks of storage at 6.1 degrees C. These findings indicate that reduced-acid low-phenolic antimicrobial liquid smoke derivatives combined with surface pasteurization are capable of reducing or preventing growth of L. monocytogenes to meet the criteria for the U.S. Department of Agriculture Food Safety and Inspection Service Alternative 1 process for ready-to-eat deli meat products manufactured without lactate or diacetate.

Microplate fluorescence assay for measurement of the ability of strains of Listeria monocytogenes from meat and meat-processing plants to adhere to abiotic surfaces

Listeria monocytogenes is a significant food-borne pathogen that is capable of adhering to and producing biofilms on processing equipment, making it difficult to eliminate from meat-processing environments and allowing potential contamination of ready-to-eat (RTE) products. We devised a fluorescence-based microplate method for screening isolates of L. monocytogenes for the ability to adhere to abiotic surfaces. Strains of L. monocytogenes were incubated for 2 days at 30 degrees C in 96-well microplates, and the plates were washed in a plate washer. The retained cells were incubated for 15 min at 25 degrees C with 5,6-carboxyfluorescein diacetate and washed again, and then the fluorescence was read with a plate reader. Several enzymatic treatments (protease, lipase, and cellulase) were effective in releasing adherent cells from the microplates, and this process was used for quantitation on microbiological media. Strongly adherent strains of L. monocytogenes were identified that had 15,000-fold-higher levels of fluorescence and 100,000-fold-higher plate counts in attachment assays than weakly adherent strains. Strongly adherent strains of L. monocytogenes adhered equally well to four different substrates (glass, plastic, rubber, and stainless steel); showed high-level attachment on microplates at 10, 20, 30, and 40 degrees C; and showed significant differences from weakly adherent strains when examined by scanning electron microscopy. A greater incidence of strong adherence was observed for strains isolated from RTE meats than for those isolated from environmental surfaces. Analysis of surface adherence among Listeria isolates from processing environments may provide a better understanding of the molecular mechanisms involved in attachment and suggest solutions to eliminate them from food-processing environments.

Effect of preinoculation growth media and fat levels on thermal inactivation of a serotype 4b strain of Listeria monocytogenes in frankfurter slurries

Preinoculation growth conditions and fat levels were evaluated for effects on the heat resistance of Listeria monocytogenes strain MFS 102 in formulated frankfurter slurries and on frankfurter surfaces. Comparison of linear inactivation rates (D-values) for cells heated in frankfurter slurry showed that growth conditions were significant (P<0.05) factors affecting subsequent thermal resistance. The average D(60 degrees C)-values for the five preinoculation growth media tested from most resistant to least heat resistant were: tryptic soy broth with 0.6% yeast extract (TSBYE) (2.2 min) and 8.5% fat slurry (2.2 min), followed by 23% fat slurry (1.7 min) and 11% fat slurry (1.7 min), and then TSYBE with quaternary ammonium compounds added (TSBYE+Q) (1 min). The fat level in the frankfurter heating media also had a significant (P<0.05) effect on the thermal death rate of L. monocytogenes. Cells heated in 8.5% fat slurry had a significantly higher (P<0.05) D(60 degrees C)-value (2.2 min) than those heated in 11% fat (1.0 min) and 23% fat slurry (0.9 min). Growth media (TSBYE, 8.5% fat slurry, and TSBYE+Q), and fat level (15% and 20%), however, were not significant factors (P>0.05) affecting thermal inactivation rates on frankfurter surfaces. Heat inactivation rates were consistently higher on frankfurter surfaces compared to similar treatments done in frankfurter slurry. On frankfurter surfaces, a 2.3- to 5.1-log(10) reduction was achieved after 15 min depending on frankfurter surface type. The time necessary to achieve a 3-log(10) reduction using post-processing pasteurization of frankfurters in a hot water-bath at 60 degrees C almost doubled for cells grown in TSBYE and heated in 23% fat frankfurter slurry (19.6 min) versus cells grown and heated in 8.5% fat frankfurter slurry (10.8 min).

Pathogen kinetics and heat and mass transfer-based predictive model for Listeria innocua in irregular-shaped poultry products during thermal processing

The increasing demand of ready-to-eat poultry products has led to serious concerns over product safety, and more emphasis has been placed on thorough cooking of products. In this study, processing conditions and thermal inactivation of Listeria innocua in chicken breast meats were evaluated during convection cooking in a pilot-plant scale air-steam impingement oven. A predictive model was developed by integrating heat and mass transfer models with a pathogen kinetics model to predict temperature, water content, product yield, and bacterial inactivation during air-steam impingement cooking. Skinless boneless chicken breasts were cooked at oven air temperatures of 177 and 200 degrees C for 2 to 10 min at a humidity of 70 to 75% (moisture by volume) and an air velocity of 1 m/s at the exit of the nozzles. The reduction in Listeria in chicken breasts after 2 to 5 min of cooking was from 0.3 to 1.4 log CFU/g and from 0.8 to 1.8 log CFU/g at 177 and 200 degrees C, respectively. After cooking for 10 min at both temperatures, no survivors were detected in any of the cooked chicken breasts from an initial bacterial concentration of 10(6) CFU/g. The standard errors of prediction for the endpoint center temperatures after 2 to 10 min of cooking were 2.8 and 3.0 degrees C for air temperatures of 177 and 200 degrees C, respectively. At 177 and 200 degrees C, the median relative errors of prediction for water content were 2.5 and 3.7% and those for product yield were 5.4 and 8.4%, respectively. The developed model can be used as a tool to assist in evaluating thermal processing schedules for poultry products cooked in an air-steam impingement oven.

Use of octanoic acid as a postlethality treatment to reduce Listeria monocytogenes on ready-to-eat meat and poultry products

The antilisterial efficacy and organoleptic impact of an octanoic acid (OA)-based treatment for ready-to-eat (RTE) meat and poultry products were investigated. Whole-muscle and comminuted RTE products were inoculated with a five-strain mixture of Listeria monocytogenes. The OA treatments were applied to the surface of RTE products by dispensing a specific volume of solution directly into the final package prior to vacuum sealing. Once sealed, the vacuum-packaged RTE products containing OA were immersed in water heated to 93.3 degrees C (200 degrees F) for 2 s to effect adequate film shrinkage. Extending the time at which the packaged, treated RTE products were exposed to water heated to 93.3 degrees C was also evaluated with a commercial cascading shrink tunnel fitted with a modified drip pan. Once treated, RTE products were examined for survivor populations of L. monocytogenes after 24 h of storage at 5 degrees C. Sensory evaluation was conducted with a 60-member trained panel on 11 uninoculated, treated RTE products. The OA treatment of RTE products reduced L. monocytogenes numbers to between 0.85 log CFU per sample (oil-browned turkey) and 2.89 log CFU per sample (cured ham) when compared with controls. The antilisterial activity of OA was improved by increasing the duration of the heat shrink exposure. Specifically, reductions of L. monocytogenes ranged from 1.46 log CFU per sample (oil-browned turkey) to 3.34 log CFU per sample (cured ham). Results from the sensory evaluation demonstrated that 10 of the 11 treated RTE products were not perceived as different (P < or = 0.05) from the untreated controls. Panelists detected reduced (P < or = 0.05) smoke flavor intensity with treated mesquite turkey, although the treated product was viewed as acceptable. Results demonstrate the effectiveness of OA as a postlethality treatment meeting U.S. Food Safety and Inspection Service regulatory guidelines for RTE meat and poultry products with minimal impact on sensory quality.

Heat inactivation of Listeria monocytogenes and Salmonella enterica serovar Typhi in a typical bologna matrix during an industrial cooking-cooling cycle

The heat resistance of Salmonella enterica serovar Typhi PF-724 and Listeria monocytogenes 2812 was determined in a commercial bologna batter. The heat inactivation of the two bacterial species was also studied in a semiautomatic pilot smokehouse under cooking conditions that reproduced an industrial bologna process. S. enterica serovar Typhi PF-724 was less heat resistant than L. monocytogenes 2812. The D-values (times required to reduce the population by 1 logarithmic cycle) for S. enterica serovar Typhi PF-724 ranged from 10.11 to 0.04 min for temperatures of 50 to 70 degrees C, while for L. monocytogenes 2812, the D-values were 2.5-, 4.9-, 3.8-, 3.3-, and 2-fold higher at 50, 55, 60, 65, and 70 degrees C, respectively, than for S. enterica serovar Typhi PF-724. However, the z-value (temperature required to reduce log D by 1 logarithmic cycle) for S. enterica serovar Typhi PF-724 (5.72 degrees C) was not significantly different from the z-value for L. monocytogenes 2812 (7.04 degrees C), indicating that a given increase in temperature would have a similar effect on the decimal reduction time for both bacterial species in that meat emulsion. Our data on experimentally inoculated batter also showed that processing bologna at a cooking-cooling cycle commonly used in the industry resulted in a minimum 5-log reduction for both S. enterica serovar Typhi PF-724 and L. monocytogenes 2812.

Thermal inactivation studies of Escherichia coli O157:H7, Salmonella, and Listeria monocytogenes in ready-to-eat chicken-fried beef patties

Thermal inactivation studies were used to determine the D- and z-values of Escherichia coli O157:H7, Salmonella, and Listeria monocytogenes in ready-to-eat chicken-fried beef patties. Inoculated meat was packaged in sterile bags, which were immersed in a circulated water bath and held at 55, 57.5, 60, 62.5, 65, 67.5, and 70 degrees C for different lengths of time. D- and z-values were determined with a linear regression model. Average D-values at temperatures 55 to 70 degrees C were 27.62 to 0.04 min for E. coli 0157:H7, 67.68 to 0.22 min for Salmonella, and 81.37 to 0.31 min for L. monocytogenes. The z-values were 5.2 degrees C for E. coli O157:H7, 6.0 degrees C for Salmonella, and 6.1 degrees C for L. monocytogenes. The results of this study can be used by food processors to validate their processes and help eliminate pathogenic bacteria associated with chicken-fried beef products.

Surface pasteurization of vacuum-sealed precooked ready-to-eat meat products

Pathogens may contaminate ready-to-eat meat products after cooking but before packaging. Listeria monocytogenes is a formidable contaminant in the food processing environment and is relatively heat resistant compared with other non-spore-forming pathogens. As a consequence, this microorganism is commonly chosen for evaluation in postpackage pasteurization studies. The aim of this study was to review information on the thermal surface pasteurization of vacuum-sealed precooked ready-to-eat meat products, bearing in mind the conditions of commercial production lines, and to formulate a guideline for pasteurization intensity. Review of the literature revealed that fewer microorganisms were killed at the product surface than would be expected based on the results of volumetric thermal resistance studies. Mathematical modeling studies indicated that this low kill might be due to surface imperfections that shield bacteria from the heat. More information on contamination with L. monocytogenes (and other possible pathogens) in process lines and their potential migration into product surface irregularities is urgently required. Studies involving destructive sampling (surface shaving) methods and inoculation with pathogens, both at realistic and inflated levels, should be performed with various product types. Published reports suggest that postpackage pasteurization of fully cooked meat products (weighing up to 9 kg) by water submersion (96 degrees C) for about 10 min should achieve a 2- to 4-log destruction of L. monocytogenes on the product surface. If heating at this temperature and duration is not feasible for product quality or logistic reasons, the inherent bacteriological stability of the product should be increased so that the intensity of surface pasteurization can safely be reduced.

Combining organic acid treatment with steam pasteurization to eliminate Listeria monocytogenes on fully cooked frankfurters

An organic acid solution of 2% acetic, 1% lactic, 0.1% propionic, and 0.1% benzoic acids was combined with steam surface pasteurization to treat frankfurters during vacuum packaging to eliminate potential postcook contamination with Listeria monocytogenes. The thermal lethality of L. monocytogenes from steam was evaluated at an inoculation concentration of 1 to 6 log CFU/cm2. About 3-log reductions of L. monocytogenes were achieved when frankfurters were treated by steam for 1.5 s. Combining organic acid treatment with steam pasteurization further inhibited the growth of surviving L. monocytogenes cells for 19 and 14 weeks when the packaged frankfurters were stored at 4 and 7 degrees C, respectively. The results from this study provide meat processors with useful information for controlling L. monocytogenes on ready-to-eat meats.

Hot water postprocess pasteurization of cook-in-bag turkey breast treated with and without potassium lactate and sodium diacetate and acidified sodium chlorite for control of Listeria monocytogenes

Surface pasteurization and food-grade chemicals were evaluated for the ability to control listeriae postprocess on cook-in-bag turkey breasts (CIBTB). Individual CIBTB were obtained directly from a commercial manufacturer and surface inoculated (20 ml) with a five-strain cocktail (ca. 7.0 log) of Listeria innocua. In each of two trials, the product was showered or submerged for up to 9 min with water heated to 190, 197, or 205 degrees F (ca. 87.8, 91.7, or 96.1 degrees C) in a commercial pasteurization tunnel. Surviving listeriae were recovered from CIBTB by rinsing and were then enumerated on modified Oxford agar plates following incubation at 37 degrees C for 48 h. As expected, higher water temperatures and longer residence times resulted in a greater reduction of L. innocua. A ca. 2.0-log reduction was achieved within 3 min at 205 and 197 degrees F and within 7 min at 190 degrees E In related experiments, the following treatments were evaluated for control of Listeria monocytogenes on CIBTB: (i) a potassium lactate-sodium diacetate solution (1.54% potassium lactate and 0.11% sodium diacetate) added to the formulation in the mixer and 150 ppm of acidified sodium chlorite applied to the surface with a pipette, or (ii) a potassium lactate-sodium diacetate solution only, or (iii) no potassium lactate-sodium diacetate solution and no acidified sodium chlorite. Each CIBTB was inoculated (20 ml) with ca. 5 log CFU of a five-strain mixture of L. monocytogenes and then vacuum sealed. In each of two trials, half of the CIBTB were exposed to 203 degrees F water for 3 min in a pasteurization tunnel, and the other half of the CIBTB were not; then, all CIBTB were stored at 4 degrees C for up to 60 days, and L. monocytogenes was enumerated by direct plating onto modified Oxford agar. Heating resulted in an initial reduction of ca. 2 log CFU of L. monocytogenes per CIBTB. For heated CIBTB, L. monocytogenes increased by ca. 2 log CFU per CIBTB in 28 (treatment 1), 28 (treatment 2), and 14 (treatment 3) days. Thereafter, pathogen levels reached ca. 7 log CFU per CIBTB in 45, 45, and 21 days for treatments 1, 2, and 3, respectively. In contrast, for nonheated CIBTB, L. monocytogenes levels increased from ca. 5 log CFU per CIBTB to ca. 7 log CFU per CIBTB in 28, 21, and 14 days for treatments 1, 2, and 3, respectively. Lastly, in each of three trials, we tested the effect of hot water (203 degrees F for 3 min) postprocess pasteurization of inoculated CIBTB on the lethality of L. monocytogenes and validated that it resulted in a 1.8-log reduction in pathogen levels. Collectively, these data establish that hot water postprocess pasteurization alone is effective in reducing L. monocytogenes on the surface of CIBTB. However, as used in this study, the potassium lactate-sodium diacetate solution and acidified sodium chlorite were only somewhat effective at controlling the subsequent outgrowth of this pathogen during refrigerated storage.

Evaluation of small-scale hot-water postpackaging pasteurization treatments for destruction of Listeria monocytogenes on ready-to-eat beef snack sticks and natural-casing wieners

This study was conducted to evaluate small-scale hot-water postpackaging pasteurization (PPP) as a postlethality (post-cooking) treatment for Listeria monocytogenes on ready-to-eat beef snack sticks and natural-casing wieners. Using a commercially available plastic packaging film specifically designed for PPP applications and 2.8 liters of boiling water (100 degrees C) in a sauce pan on a hot plate, an average reduction in L. monocytogenes numbers of > or = 2 log units was obtained using heating times of 1.0 min for individually packaged beef snack sticks (three brands) and 4.0 min for packages of four sticks (two brands) and seven sticks (three brands). Average product surface temperatures, measured as soon as possible after PPP and opening the package, were 47 to 51.5, 58 to 61.5, and 58.5 to 61 degrees C for the beef snack sticks packages of one, four, and seven sticks per package, respectively. A treatment of 7.0 min for packages of four natural-casing wieners (three brands) achieved L. monocytogenes reductions of > or = 1.0 log unit and average product surface temperature of 60.5 to 63.5 degrees C. Cooked-out fat and moisture resulting from tested treatments ranged from 0.2 to 1.1% by weight for beef snack sticks and from 0.4 to 1.2% by weight for natural-casing wieners. For natural-casing wieners, PPP had no detrimental effect on overall product desirability to consumers; results suggested that PPP may significantly enhance appearance of this product. However, for beef snack sticks the cooking out of fat and moisture during PPP had a significant negative effect on consumer opinions of product appearance.

Achieving continuous improvement in reductions in foodborne listeriosis--a risk-based approach

Listeria monocytogenes is a foodborne pathogen that can cause listeriosis, a severe disease that can lead to septicemia, meningitis, and spontaneous abortion. Ongoing efforts are needed to further reduce the incidence of listeriosis, due to its high mortality rate. The focus of this report is the use of a risk-based approach to identify strategies that will have the greatest impact on reducing foodborne listeriosis. A continuum of risk for listeriosis is observed in the human population, ranging from exquisitely sensitive groups, who are highly immunocompromised and at very high risk of listeriosis, through the normal healthy population younger than 65 years of age, who appear to have a minimal risk for listeriosis. In addition, unique subpopulations may exist; for example, pregnant Latina women appear to have a higher risk of listeriosis than pregnant women of other ethnic groups, most likely due to consumption of contaminated soft cheeses such as queso fresco and queso blanco. The International Life Sciences Institute Risk Science Institute Expert Panel concluded that certain foods pose a high risk for causing listeriosis. High-risk foods have all of the following properties: (1) have the potential for contamination with L. monocytogenes; (2) support the growth of L. monocytogenes to high numbers; (3) are ready to eat; (4) require refrigeration; and (5) are stored for an extended period of time. Control strategies are needed in the food chain from preharvest through consumption to minimize the likelihood that food will become contaminated by L. monocytogenes and to prevent the growth of the organism to high numbers. The Expert Panel identified three main strategies for ensuring continuous improvement in reducing foodborne listeriosis: (1) preventing contamination of foods with L. monocytogenes; (2) preventing growth of L. monocytogenes to high numbers in foods; and (3) science-based education messages targeted to susceptible populations and their caregivers. Of these strategies, the Expert Panel concluded that preventing growth of L. monocytogenes to high numbers would have the greatest impact in reducing cases of listeriosis. Dose-response models predict that the risk of listeriosis increases as the number of organisms in a food increases and can be used as a scientific basis for a target level below which the organism should be reduced to minimize the likelihood of listeriosis in high-risk populations. This requires implementation of effective food safety control measures and ensuring that these control strategies are consistently met. Most effective strategies to control L. monocytogenes in high-risk foods include (1) good manufacturing practices, sanitation standard operating procedures, and hazard analysis critical control point programs to minimize environmental L. monocytogenes contamination and to prevent cross-contamination in processing plants and at retail; (2) an intensive environmental sampling program in plants processing high-risk foods and an effective corrective action plan to reduce the likelihood of contamination of high-risk foods; (3) time and temperature controls throughout the entire distribution and storage period, including establishing acceptable storage times of foods that support growth of L. monocytogenes to high numbers; (4) reformulating foods to prevent or retard the growth of L. monocytogenes; and (5) using postpackaging treatments to destroy L. monocytogenes on products. Science-based education and risk communication strategies aimed at susceptible populations and focused on high-risk foods should be delivered through health care providers or other credible sources of information. Exquisitely sensitive consumers may become ill when exposed to low numbers of L. monocytogenes or other opportunistic pathogens, so reducing the risk to this population could be achieved by maintaining them on restricted low-microbe diets during those periods when they are most severely immunocompromised. High-risk individuals (i.e., the elderly, pregnant women, and most immunocompromised individuals) should be provided with guidance on healthy eating, including specific information on high-risk foods that they should avoid, and strategies to reduce their risk, such as thorough cooking, avoidance of cross-contamination, and short-term refrigerated storage of cooked perishable foods. Those at low risk for listeriosis should receive information on safe food handling practices, preferably starting at a preschool age.

Impact of antimicrobial ingredients and irradiation on the survival of Listeria monocytogenes and the quality of ready-to-eat turkey ham

Irradiation is an effective technology in eliminating Listeria monocytogenes, but it induces quality changes in meat products at or above specific radiation doses. To minimize irradiation-induced quality changes, only low irradiation doses are recommended. However, low-dose irradiation provides a chance for some pathogens to survive and proliferate during prolonged storage. To solve this problem, antimicrobial ingredients [2% sodium lactate (SL), 0.1% sodium diacetate (SDA), 0.1% potassium benzoate (PB)] and low-dose irradiation were combined and tested for their effects on the growth of L. monocytogenes and meat quality. The log10 reductions of L. monocytogenes in hams following exposure to 1.0 to 2.5 kGy of irradiation ranged from 2.0 to 5.0. The D10 values were 0.52 kGy for control ham or ham with PB, SL, or PB + SL; 0.49 kGy for ham with SL+SDA; and 0.48 kGy for ham with PB + SL + SDA (PSS). Addition of SL + SDA or PB + SL in combination with 1.0 kGy of irradiation was effective in suppressing the growth of L. monocytogenes for about 6 wk when stored at 4 degrees C, whereas 2.0 kGy of irradiation was listeriostatic. Ham irradiated with 1 kGy in combination with PSS was listeriostatic throughout storage. SL increased firmness of turkey hams, and sensory panelists noted that the saltiness was a little higher in products containing SL, but its overall impact on quality was minimal. Amounts of benzene were detected in irradiated hams with PB, showing PB was not fit as an antimicrobial ingredient for irradiated foods. In conclusion, 2% SL and 0.1% SDA in combination with low-dose irradiation were effective in ensuring the safety of ready-to-eat meat products against L. monocytogenes.

Eradicating Listeria monocytogenes from fully cooked franks by using an integrated pasteurization-packaging system

Surface pasteurization by applying steam or hot water before or after packaging of processed foods may be used to eliminate pathogens such as Listeria monocytogenes from ready-to-eat meat and poultry products. Surface pasteurization treatment with a mixture of pressurized steam and hot water was integrated into a continuous vacuum-packaging system to reduce L. monocytogenes from fully cooked franks. The franks (2.54 cm diameter by 15.24 cm length) were surface inoculated to contain up to 6 log CFU/cm2 L. monocytogenes. The inoculated franks were treated at 121 degrees C for 1.5 s in an arrangement of six franks per packaging chamber followed by immediate vacuum sealing of the top films of food packages in the same unit. A 3-log CFU/cm2 reduction of L. monocytogenes on fully cooked franks was obtained using the integrated pasteurization-packaging system. The pasteurization depth was 1.27 mm below the surfaces of the franks. This process provides a commercially applicable means of ensuring food safety by effectively eradicating L. monocytogenes from ready-to-eat meat and poultry products at the very last possible step of food packaging before reaching retail consumers.

Effect of prepackage and postpackage pasteurization on postprocess elimination of Listeria monocytogenes on deli turkey products

Surface pasteurization for inactivation of Listeria monocytogenes was evaluated for radiant heat prepackage pasteurization, submersed water postpackage pasteurization, and combinations of the two techniques on various types of ready-to-eat deli turkey products obtained from at least four different manufacturers. Products were inoculated either by in-package liquid inoculum or surface sponge-contact with approximately 10(9) CFU of L. monocytogenes. Additional testing of radiant heat pasteurization was performed with low-level inoculation of product undersides with approximately 100 CFU of L. monocytogenes followed by enrichment recovery after pasteurization. Prepackage pasteurization provided 2.0 to 2.8 log reductions when processed for 60 s and 2.8 to 3.8 log reductions when processed for 75 s. An improved radiant oven provided 3.53 (60 s) and 4.76 (75 s) log reductions of L. monocytogenes. No positive samples were detected after enrichment when 40 samples of deli turkey (4 to 4.5 kg) undersides were inoculated at low levels and processed for 75 s. Submersed water postpackage pasteurization provided 1.95 to 3.0 log reductions when processed for 2, 3, 4, or 5 min, and combinations of the two processes gave 3.0 to 4.0 log inactivation of L. monocytogenes using either 60 + 60 s or 60 + 90 s for the prepackage and postpackage pasteurization processes, respectively. These processes, either individually or in combination, can provide postprocess elimination of bacteria for the manufacture of safe ready-to-eat deli meats.

Combining pediocin (ALTA 2341) with postpackaging thermal pasteurization for control of Listeria monocytogenes on frankfurters

Frankfurters packaged in 1-link, 5-link, or 10-link packages were surface-inoculated with a five-strain mixture of Listeria monocytogenes (3.40 or 5.20 log CFU/g) after treatments with 3,000 arbitrary units (AU) or 6,000 AU pediocin (in ALTA 2341) per link. The frankfurters were vacuum packaged, after which the packages were heated in hot water at 71, 81, or 96 degrees C for 30, 60, or 120 s. L. monocytogenes was enumerated following the treatments. Selected treatments were subsequently evaluated during storage at 4, 10, and 25 degrees C for up to 12 weeks. L. monocytogenes was reduced by all treatments, but 81 degrees C or more for at least 60 s in combination with pediocin (Pdn-6000) was necessary to achieve a 50% reduction of initial inoculations. Heat treatments were most effective for 1-link packages and least effective for 10-link packages. Little or no growth of L. monocytogenes occurred on frankfurters for 12 weeks at 4 or 10 degrees C, and for 12 days at 25 degrees C. Generally, the treatments mentioned above did not significantly (P > 0.05) affect the sensory qualities of frankfurters. Therefore, pediocin (in ALTA 2341) in combination with postpackaging thermal treatment offers an effective treatment combination for improved control of L. monocytogenes on frankfurters.

Thickness and compositional effects on surface heating rate of bologna during in-package pasteurization

The surface heating rate (gamma) and final surface temperature (alpha) during in-package pasteurization were determined for different thickness levels of 2 types of bologna having different (13 and 18%) fat contents. Three thicknesses (4, 12, and 20 mm), corresponding to 1, 3, and 5 slices of bologna, were vacuum-packaged separately in a clear polymer pouch after placing a thermocouple on the surface. Refrigerated samples were immersed in a water bath set to 1 of 4 predetermined temperatures (60, 70, 80, and 90 degrees C), and time and temperature data were recorded for 10 min. Surface heating rate was fastest in the thinnest (4 mm) and slowest in the thickest (20 mm) samples for all 4 temperatures. Surface heating rate was slower in bologna with the higher fat content compared with the lower fat bologna. Final surface temperature attained after 3 min was lower with increased thickness levels for all temperatures. Thus, meat sample thickness and fat content significantly affect surface heating rate and final surface temperature during in-package pasteurization of bologna.

Thermal Inactivation of Salmonella and Listeria Monocytogenes in Ground Chicken Thigh/Leg Meat and Skin

Thermal inactivation D and z values of Salmonella and Listeria monocytogenes were obtained for chicken thigh and leg meat and skin. The D values of Salmonella at 55 to 70 degrees C were 43.33 to 0.07 min in the meat and 43.76 to 0.09 min in the skin. The D values of L. monocytogenes at 55 to 70 degrees C were 38.94 to 0.04 min in the meat and 34.05 to 0.05 min in the skin. The z value of Salmonella was 5.34 degrees C in the meat and 5.56 degrees C in the skin. The z value of L. monocytogenes was 5.08 degrees C in the meat and 5.27 degrees C in the skin. For Salmonella or L. monocytogenes, the z value of the meat was not different from that of skin. However, the z value of Salmonella in meat or skin was different from that of L. monocytogenes in meat or skin. The z value of Salmonella or L. monocytogenes in chicken thigh and leg meat was different from that in the skin. The results from this study are useful for predicting process lethality of Salmonella and L. monocytogenes in products that contain chicken thigh and leg meat or skin.

Effect of reheating on viability of a five-strain mixture of Listeria monocytogenes in vacuum-sealed packages of frankfurters following refrigerated or frozen storage

The purpose of this study was to assess consumer preferences for storing and reheating frankfurters and to use this information to assess the effect of product formulation and storage times and temperatures on the viability of Listeria monocytogenes after reheating of frankfurters. Individual links were inoculated with about 8.0 log CFU per package of a five-strain mixture of the pathogen, vacuum sealed, and stored at 4 degrees C for 3 and 15 days and at -18 degrees C for 30 days. Frankfurters formulated with and without 2% added potassium lactate were heated to a surface temperature of 60, 70, 80, or 90 degrees C for up to 8 min by submersing the packages in a thermostatically controlled circulating water bath. Surviving bacteria were recovered and counted by rinsing the contents of each package with sterile peptone water and plating this solution directly onto modified Oxford selective agar plates. In general, the results revealed that about a 5-log unit reduction was achieved by reheating to a surface temperature of 70 degrees C for about 2 min or 80 or 90 degrees C for about 0.6 min regardless of storage conditions or formulation. Product formulation did not appreciably affect the viability of the pathogen after heating; there was no appreciable difference in the number of cells surviving the heat treatment in product prepared with or without potassium lactate. These findings can be used to establish reheating guidelines for consumers to ensure that frankfurters, which may become contaminated with low levels of L. monocytogenes prior to packaging and after unpackaging, are adequately reheated prior to consumption.