Cook Chill Its not for Dills EHPA 2018 Food Forum Karen Ferres Manager, Food Safety & Audit, SA Health
Aim To highlight the risks associated with > The food service sector expansion to the realm of extended life cook chill processing > Further expanding the service to include sale of extended shelf life meals in supermarkets 2
Presentation Overview > Technical overview of cook chill process > Investigation of a food service businesses conducting extended shelf life cook chill processing an EHOs perspective > SA Health initiatives and outcomes 3
Cook-Chill Technical Overview 4
5 Cook Chill Humour
When should you be concerned? > Does the business Cook and chill potentially hazardous food (PHF) And Vacuum package (VP)/modified atmosphere package (MAP) and store refrigerated And Do they have more than 10 days shelf life? > Does the process comply with Cook Chill for Foodservice and Manufacturing Guidelines (The Blue Book)? 6
Risks from VP and MAP Foods > Thought to increase the shelf life of chilled foods Removes oxygen so spoilage M/O can t grow > Removing oxygen creates additional hazards Anaerobic M/O can grow without competition Clostridium botulinum - Toxin Listeria monocytogenes > Critical for vulnerable populations > Controls required throughout shelf life Cook and storage temp or ph < 5, water activity<0.97, NaCl >5.0% 7
Introduction > Target organisms > Cook chill classifications > Types of processes > Key parameters 8
Listeria monocytogenes > Environmental survivor forms biofilms > Grows at refrigeration temperatures 1 C and above (Psychrotrophic) > Facultative anaerobe Vacuum or modified atmosphere packaging creates ideal growth conditions > Broad ph range 4.4-9.4 > Serious illness Vulnerable population > Not all foods are a risk if not supporting growth FSANZ criteria Std 1.6.1 9
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Clostridium botulinum > Commonly found in the environment > C. botulinum cannot grow <3 C > Anaerobe Grow in low acid food in the absence of oxygen or anaerobic pockets with low oxygen > Produces a potent neurotoxin 3ng/g food > Toxin is heat sensitive Can be destroyed by boiling for 10 minutes > 2 types Non proteolytic C. botulinum Proteolytic C. botulinum 11
Clostridium botulinum > Non proteolytic C. botulinum Uses sugar breakdown as source of energy Psychrotrophic (grows in fridge >3 C) Toxin formed slowly, 10 days at 8 C, 20 days at 6 C, 36 days at 3.3. Minimal growth required for toxin formation Less heat resistant and won t survive 90 C for 10 mins Main hazard for extended shelf life cook chill foods (HTRF) > Proteolytic C. botulinum Uses protein breakdown as source of energy Not Psychrotrophic (grows at >=10 C) More heat resistant and survives 90 C for 10 mins Widespread in the environment Not main hazard if refrigeration controlled 12
Cook Chill Classifications > Two classifications cook chill processes (packaged only) 1. Short Shelf Life SSL 2. Heat Treated Refrigerated Food HTRF Extended shelf life > Two typical processes 6D for L.monocytogenes 6D for C.botulinum 13
14 What is 6D Processing
Cook Chill Processes > 6D for L.monocytogenes SSL (short) 75 C (time/temp equivalent) Vegetative pathogens destroyed Pre-formed toxins and spores not destroyed Potential germination of spore forming bacteria during chilling and storage > 6D for C.botulinum HTRF (extended) 90 C for 10 mins (time/temp equivalent) Vegetative pathogens destroyed Kills sufficient no s of non proteolytic C. botulinum spores Pre-formed toxins of C.botulinum destroyed 15
Cook Chill Processes Short Short Shelf Shelf Life Cook Life Cook Chill Chill 10 days 10 days refrigerated refrigerated shelf shelf life life Extended Shelf Life Cook Chill 10 days refrigerated shelf life Receival of raw materials and ingredients Receival of raw materials and ingredients Pre-cook/Batching/Thawing/ Preparation Pre-cook/Batching/Thawing/ Preparation Cooking Cooking/ Pasteurisation Filling Cooking/ Pasteurisation Rapid Cooling Non-aseptic filing/gas addition Sealing Non-aseptic filing Sealing Cooking/ Pasteurisation Aseptic filling Sealing Rapid cooling Rapid cooling Sealing Labelling Labelling Labelling Labelling Chill Storage & distribution Chill Storage & distribution Chill Storage & distribution Chill Storage & distribution Conventional Cook chill MAP Cook chill Tank Cooking & Sous Vide Kettle cooking & Hot Filling 16
Cook Chill - SSL > Cooked to 75 C or equivalent (Lm cook) > Can be Cooked, chilled & packaged Cooked, packaged & chilled > Cooled 60 C 21 in 2 hrs & 21 5 in another 4 hrs > Stored at 5 C > Shelf life <10 days Unless aseptic packaging, stored at 3 C, & validated 17
18 Time - Temp Equivalence - Lm
Cook Chill - HTRF > Cooked 90 C for 10 mins or equivalent > Kettle cooked, cook tank, or MAP Aseptic filling Packaged hot (80-90 C) to prevent microbial recontamination during filling Cooked in pouch/bag > Cooled 60 21 in 2 hrs & 21 5 in another 4 hrs (can be stricter) > Stored at 5 C > Shelf life can be validated > 10 days NB if only cooked to 75 C must be stored at <3 C 19
20 Time - Temp Equivalence - Cb
Cook Chill - HTRF Alternative methods (whole of shelf life) > ph ph 5 + Lm Cook + Aseptic Packing or ph 4.4 (if post cook non aseptic packaging) > aw (water activity) 0.97 (salt) 0.94 (glycerol) > NaCl (Salt concentration) 5.0% > Lysozyme Eggs, crab meat, broccoli, cauliflower) Need to consider extra heat process 21
22 Skills & Knowledge
Cook Chill Processes - Overview > Types of cook chill processes 1. Cook chill serve - Food service Not considered cook/chill manufacturing 2. Cook chill package - SSL Not likely to have shelf life greater than 10 days 3. Cook package chill - SSL/HTRF Can validate a shelf life greater than 10 days if > Hot fill or chill/store <3 C 4. Package cook chill HTRF Can validate a shelf life greater than 10 days if > Lm cook & chill/store <3 C > Cb cook & chill/store <5 C *Refer to Blue book pg. 40 for flow diagram 23
Cook Chill Key Parameters > Shelf life Practical/validated (SSL or HTRF) > Cook process What temp/time target M/O Process tank, sous vide, kettle > Chill process FSS requirements or <3 C > Storage temperature 3 C or 5 C > Type of packaging Prior to cook/ Aseptic After cook > Hurdles ph, aw, Salt 24
Cook-chill - an EHOs perspective local councils working together to protect the health of the community local councils working together to protect the health of the community
Cook-Chill Manufacturing local councils working together to protect the health of the community
Case Study 1 local councils working together to protect the health of the community
Routine Inspection Identified the processing of ready-to-heat meals at routine inspection Information obtained only after extensive open questioning Warning signs Extended shelf life (14-21 days) Products vacuum packed Packaged after food is cooled local councils working together to protect the health of the community
Floorplan Continental Deli Seafood Butcher Cook-chill Chilling and packing Cooking and preparation Scullery local councils working together to protect the health of the community
What we found Cooking Food is cooked to 75 C The type of extended shelf life processing required 90 C for 10 min cook local councils working together to protect the health of the community
What we found Cooling Roast Pork Blast chiller available. Cooling temperature did not always achieve 60 C to 21 C or 21 C to 5 C. 60 C 21 C 3 hours 21 C 5 C 5 hours local councils working together to protect the health of the community
What we found Packing Food is assembled by hand to enhance presentation Filling technique non-aseptic. Post-processing contamination Sealing Prevents growth of spoilage organism. Improved freshness, presentation Favourable environment for anaerobic bacteria such as Listeria and Clostridium local councils working together to protect the health of the community
5 C or below stops growth of spoilage organisms Listeria and Clostridium can grow at 3 C What we found Storage Distribution Display Fraudulent labelling identified Unable to rely on consumers and supermarkets strictly to maintain 3 C. local councils working together to protect the health of the community
Microbiological Testing Product name Retail store Temp ( o C) ph Standard Plate Count (org/g) Satisfactory <10 3 Marginal 10 3-10 5 Unsatisfactory >10 5 E.coli (org/g) Satisfactory <3 Marginal 3 - <10 2 Unsatisfactory >10 2 Bacillus Cereus (org/g) Satisfactory <10 2 Marginal 10 2 <10 3 Unsatisfactory 10 3 - <10 5 Scotch Fillet & Veg Supermarket 3.8 5.1 >30,000,000 <3 500 Cannelloni Supermarket 3.8 5.2 16,000,000 <3 <100 Scotch Fillet & Veg Supermarket 9.2 5.33 >30,000,000 <3 <100 Cannelloni Supermarket 9.2 5.64 >30,000,000 <3 <100 Barramundi & Veg Supermarket 3.4 6.44 6,900,000 21 <100 Cannelloni Supermarket 3.4 5.44 12,000 36 <100 Yellow Chicken Curry In-store n/a 6.28 2,400,000 38 <100 Spaghetti and Meatballs In-store n/a 5.27 2,300 <3 <100 Yellow Chicken Curry In-store n/a 6.28 2,400,000 38 <100 Alla panna sauce (ingredient) In-store n/a 6.39 4,200,000 <3 31,000 local councils working together to protect the health of the community
Outcomes Further controls implemented: Shelf life changed to 10 days ph testing Hot filling techniques trialled Clostridium cook (90 C/10min) Process flow diagram and procedures developed. Validation required Facility not fit for purpose local councils working together to protect the health of the community
Learnings Business did not understand the risks or process controls Assumed cook chill process was audited by PIRSA and recognised in their HACCP Plan Not aware of Clostridium or associated cases Facility not suitable for HR processes (Flow & Structure) Failure to follow the process in the cook-chill guidelines Business believed that microbiological testing alone assured safety of their product. Business took the approach of focusing on competitors Difficultly in requiring business to change shelf life local councils working together to protect the health of the community
SA Health Initiatives and Outcomes 37
Cook Chill Products Survey Background > Council identification of potentially unsafe Ready to Heat meals prepared in food service environment and sold in supermarkets. Purpose > Verify that manufacturing process is controlled Telephone interview and site visit > Assess microbiological integrity of extended shelf life (>10 days) packaged convenience meal and prioritise the visits to manufacturers. Scope > Only SA based manufacturers or food service > Manufacturing convenience meal products with extended shelf life (Vac or MAP). 38 SA Health Home/About us/health statistics/food Safety Survey Reports http://www.sahealth.sa.gov.au/wps/wcm/connect/public%20content/sa%20health%20internet/abo ut%20us/health%20statistics/food%20safety%20survey%20reports/food%20safety%20survey%2 0reports
Summary of Results Microbiological Test No. of Samples Microbiological Quality (%) Satisfactory Marginal Unsatisfactory Potentially Hazardous Standard Plate Count 98 56 (57%) 16 (16%) 26 (27%) - Escherichia coli 98 95 (97%) 3 (3%) - - Bacillus cereus 98 94 (96%) 3 (3%) 1 (1%) - Salmonella 98 98 (100%) - - - Coagulase +ve Staphylococci Clostridium perfringens Listeria monocytogenes 98 98 (100%) - - - 98 97(99%) 1(1%) - - 98 98 (100%) 39
Survey Outcomes > 3 businesses improved their process controls By working collaboratively with SA Health & LG > 1 producer changed their process recipes Reduced the ph below 5 to ensure extended shelf life product safety > 1 business was shutdown and facility was served a prohibition notice by Council. They relocated to another premises with improved infrastructure and reduced shelf life 40
Survey Conclusion > Small operators of convenience meal products in SA have gaps in skills and knowledge. > Shelf life validation is inadequate. > Market trend of convenience meals is expected to grow more rapidly and, so is the potential risk. It is intended to continue to monitor and educate the businesses producing extended shelf life meals by continuing the survey for the next year. 41
Future Plans > Prepare HR Food Communication Cook chill meal processing > Survey results published in Food Act Report > SA Health Home/About us/health statistics/food Safety Survey Reports > Continued identification of businesses by EHOs Producing RTH meals (shelf life > 10 days) > Continued SA Health technical support > Review the risk classification of cook chill manufacturers 42
43 Questions
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