When it comes to food safety, there is no room for risk-taking. The challenge isn’t whether to protect products against pathogens; it’s to identify the best approach for your processing operations. There are many options available and technology is changing rapidly. In this white paper, you’ll learn a bit about the different approaches to pathogen control and a lot about one technology that is highly effective, versatile and lower cost than other options: applying antimicrobials to processed meats/poultry prior to packaging.

INTERVENTION OPTIONS

There are four equipment options for treating meat and poultry for pathogen protection and each relies on different technology.

SELECTING THE BEST ANTIMICROBIAL

Antimicrobials come in a variety of forms and options must be carefully evaluated. Factors such as ingredients, efficacy and handling, shelf life, clean labeling requirements, application requirements and cost can vary widely, and will drive the ultimate selection. Keep in mind that the application equipment can have a significant impact on the effectiveness of the antimicrobial. Be sure to closely consider how the equipment controls volume and placement.

Most antimicrobials are shipped in a concentrated form and require mixing on-site with water at a determined ratio. The storage temperature of the concentrate and mixed solution may differ so be sure to understand the requirements early in the evaluation process. Also, keep in mind that most antimicrobials have a shelf life after being mixed, usually one to five days.

Some antimicrobials must be listed on product labels; some do not. It depends on whether the antimicrobial is considered a processing aid. This classification is often dependent on the regulatory limits of the application level of the antimicrobial.

WHERE AND WHEN TO APPLY?

Throughout meat and poultry processing plants there are a number of locations where antimicrobials can be applied. The most common application points are just after slaughter and as close to packaging as possible.

While antimicrobial systems can be effective at various stages in the process, a very well-established application point is in the package. This process was developed and established by the United States Department of Agriculture/Agricultural Research Service (USDA/ARS). In May of 2006, the Food Safety and Inspection Service (FSIS) released the compliance guideline for Controlling Listeria Monocytogenes in Post-Lethality Exposed Ready-to-Eat Meat and Poultry. The Listeria Rule Alternatives 1 or 2 can be achieved depending on the antimicrobial agent. At the point the roll stock or whole muscle product is loaded, an antimicrobial is also dispensed into the package.

For other products, a variety of other locations for application of the antimicrobial can be targeted.

BEST PRACTICES IN SPRAYING ANTIMICROBIALS

• Applying antimicrobials in the package is ideal. The package is the last point of intervention after exposure to other potential sources of contamination, such as conveyors, tables and personnel
• If spraying just prior to packaging, choose a point where contact surfaces of the product are accessible. If the product comes in contact with other surfaces after the antimicrobial application, be sure those surfaces have been sanitized. For example, conveyors should be sanitized to eliminate potential contamination
• Trim and other products that are going to be ground should be sprayed with antimicrobial prior to grinding. Exposed product surfaces that could have potential contamination are lowest at this point. The antimicrobial is typically sprayed into a blender or mixer
• Any type of equipment that comes in contact with the products should be sprayed periodically with sanitizers to limit the spread of contaminants
• Consult with experts. Spraying antimicrobials requires a high-level of precision and is not attainable with workers using spray bottles or holes drilled in pipes

GUIDELINES FOR EQUIPMENT SELECTION

While spray systems may seem simple, they are not. Even slight problems can cause reductions in product produced, downtime, and excessive antimicrobial usage. Properly designed equipment will ensure the antimicrobial is applied properly and without waste.

DILUTION, MIXING AND DOSING

Nearly every antimicrobial comes in a concentrated form and requires dilution. Antimicrobials can be mixed manually. However, because manual mixing is operator dependent, it isn’t very precise or repeatable. Automated mixing/refill equipment eliminates the variations found in manual mixing and reduces the potential for contamination. When antimicrobials are exposed to airborne bacteria and surfaces such as containers, the opportunity for contamination exists.

Most processors run a variety of products on a single line. Each product may require a different volume of antimicrobial. Spray equipment should be able to easily and quickly accommodate different products. In fact, it should be as easy as a couple of taps on a touch screen. If physical changes to the equipment are required, quality control is typically compromised.

The efficacy of antimicrobials is based on the concentration and volume applied. As discussed earlier, an automated refill system can help ensure the proper concentration is achieved. The volume of antimicrobial applied is just as important. Applying the proper volume ensures the kill required for the process occurs.

OPERATION AND OPERATOR REQUIREMENTS

Understanding how the system operates before any decisions are made is important. Daily tasks and operation should be simple. Actions to change volume, change antimicrobials and calibration should be easy to learn. Wear parts and any other items that may require service should be easily accessible.

CONSTRUCTION

Consider the materials used in the system. Will they withstand wash down, high pressure fluid exposure, cold temperatures, high temperature shock, humidity, and corrosive chemicals? Be sure to check and make sure all components are stainless steel including electrical covers, caps, seals and lids and that sanitary connections are used throughout the system. Although some antimicrobials are capable of killing most undesirable bacteria, threads are difficult to clean and should be eliminated.

OVER-APPLICATION OF THE ANTIMICROBIAL CAN CAUSE A VARIETY OF NEGATIVE EFFECTS:

• Customer satisfaction may decrease as over-application can create unpleasant smells or liquid in packages
• Regulatory limits can be exceeded and result in fines or recalls
• Costs can spiral out of control. If a plant produces ten million pounds of product in a year, and the cost/lb of the antimicrobial is $0.01/lb, the annual cost of antimicrobials is approximately US$100,000. If antimicrobials are over applied by 20%, the annual cost of antimicrobials jumps to US$120,000

CONCLUSION

Determining the best approach to food safety is dependent, of course, on the types of products being processed, the processing facility and equipment, annual production and more. Applying antimicrobials with spray equipment offers many advantages over other technologies. Cost, ease-of-use and precision application are attractive to processors of all sizes. Depending on which antimicrobials are used, shelf-life extension, cleaner labels, improved customer satisfaction, Alternative Status 1 or Alternative Status 2 are also possible benefits.