General Session: Process Management

Transcription

1 General Session: Process Management DEFINING PRIORITY PROCESS MANAGEMENT AREAS THROUGH EMP SPATIAL MAPPING IN RAC OPERATIONS DEFINING PRIORITY PROCESS MANAGEMENT AREAS THROUGH EMP SPATIAL MAPPING IN RAC OPERATIONS General RAC Facility Challenges Case examples Lm swab athon key outcomes WGS, spatial mapping, and making some FCS to NFCS links Trevor Suslow 1

2 For your business sustainability, having a well managed cleaning and sanitization program AND environmental testing program for harvest and field packing equipment and implementation of prerequisite programs in packing facilities should be a very high priority Zones generally refer to Food Contact Surfaces and Non Contact Surfaces Considerations for frequency of cleaning and sanitizing Likelihood of harborage Likelihood of cross contamination Frequency and depth of EMP, PMP GMP Process Control Areas may include all four Zones in an intimate space tvsuslow@ucdavis.edu 2

3 5 Many Challenges in Uncontained to Enclosed Environments pole barn with roof but no side walls May be within cropping area Not generally built with deep cleaning or sanitation in mind Materials not amenable to cleaning Perimeter and Internal Pest Control insects, birds rodent vectors May be remote from sanitation services Packing staff also cleaning and sanitizing crew 3

4 High care areas may not be internal with RAC Dump and Transport Precooling operations 1 Quality treatment Pre grade and sort Pre pack conditioning or storage Packing Pre shipping cooling 1 3,4 1,2, Equipment and foot traffic tvsuslow@ucdavis.edu 4

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8 How does facility layout influence food safety programs? Solid cleanable floors sloped toward drains Drains preferable located away from walls Sanitary joint between floors and walls Cooler condensate does not drain to floor Doesn t drain onto product or contact surfaces Prevent harborage area on door thresholds Cracked and broken epoxy floor coatings Degraded concrete with areas of exposed aggregate tvsuslow@ucdavis.edu 8

9 Bin dump Pallet Bin Cull Line Incoming Fruit Hydro Cool Wax & Treat Dry Carton Assembly Sort and Grade Palletizing Hand pack Palletizing Packing Lines Stickering Catwalk Lunch/Break Area Rest Rooms Shipping Area Preferences for Product flow directions (from Troller, Sanitation in Food Processing) Poor Poor Better Best Best 9

10 Create an environment that is easy to maintain in the required sanitary condition Specify materials that are easy to clean Design for the expected life cycle of the facility Especially flooring Start planning for sanitation at the property line Often necessary to look to adjacent activities 19 4 images omitted tvsuslow@ucdavis.edu 10

11 Replace conveyance contact points of concern Injury Entrapment and potential bio burden foci Pervasively cracked belts Frayed and exposed edges Clean ability Points of entrapment in rollers Reduce number of brush beds to essential for quality 11

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13 Accumulated Peach Fuzz 13

14 Fix rough welds Fix all transition and entrapments points 14

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16 2 images omitted qrtpcr virulence confirmation and serotyping Primary Postenrichment Screen Presumptive Lm colonies PFGE Facility & Temporal Diversity Mapping T. Suslow et.al., unpublished WGS source tracking 16

17 DETAILED SPATIAL MAPPING CAN REVEAL PRIORITY AREAS FOR RESIDENT ESTABLISHMENT Fans 1,2,3 4,5,6 7,8 Cold rooms Pre pack Staging Rooms Shipping Area 10 BIN DUMP BIN DUMP 37, Drain 2 Drain 1 Drain Stairs , 35, ,26,27 5 Drain Drain 23,24 Drain 44 Drain 45 Drain Drain Entrance ,22 Wax Dry 49 Drain Drain 48 Drain 50 Green only Listeria sp. Office 13,14 15 Culls Red Listeria sp. + L.mono Receiving Product DETAILED SPATIAL MAPPING CAN REVEAL RESIDENT ESTABLISHMENT Entrance Office 44 Bin Washer Bin Drier Bin Dumper Drain UV Sorting Room HPW HF Receiving Room Wax Listeria spp. Listeria monocytogenes Both together 20 Drier Drain Drain Packing Room Cold Room A Cold Room B Shipping Area tvsuslow@ucdavis.edu 17

18 Number of Samples Total Negatives Total Positives 0 Bin Dumper Bin Washer Bin Drying Sorting Room HPW HF Wax/Drier Packing Room Holding room Cold Room Shipping Room Outside Packing House Clean crates Conveyer Wash Room (before storage) Stage 1 Stage 2 Stage 3 Stage 4 Stage 5 Misc. Locations tvsuslow@ucdavis.edu 18

19 Hydrocooler system running Operation STOP 6 weeks Dry-Exposed Positive L. mono Positive Listeria sp. and L. mono 6 months 2.5 C Retest at start up 4 mo. later Positive L. mono 37 Last use of apple line Oct 31, 2014 FDA CORE samples Dec 23, 2014 WSU/UCD sampling Feb March, confirmed L. monocytogenes Multiple operational locations tvsuslow@ucdavis.edu 19

20 Listeria spp. Listeria monocytogenes Both together Change in Operational Process Results in Acute Lm Prevalence DATE: drain Receiving Product Bin 42 Washer Bin dumper Column 10 Offices Reception Main Office Shaded area Pre cooling Rooms Cold rooms Ethylene Rooms Linking isolates to spatial and traffic flow mapping More definitive source tracking Better resolve transient and resident Lm Data based evidence for a needed Correction or improved Best Management Practice tvsuslow@ucdavis.edu 20

21 Example from Facility Surveys: PFGE vs WGS: Listeria monocytogenes AscI ApaI PFGE 98% similarity WGS 88-90% similarity Five isolates from PFGE pulsotype 3 showed significant SNP difference Pulsotype 3 considered persistent in Facility 6 based on PFGE WGS results suggest reintroduction from a common source Appeared sporadically in other facilities over 3 seasons AscI ApaI PFGE 98% similarity Five isolates from PFGE pulsotype 22 had few SNP differences Isolated from 3 different facilities over two years Subtype 22 seems to be introduced to different facilities from an external source with limited diversification % tvsuslow@ucdavis.edu 21

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24 Not built with cleaning or sanitation in mind Spray on insulation common Frequently full of produce Cold moist environment Listeria friendly Pest Control insects, birds rodent vectors Storage bins and fork lifts bring contamination in to the environment Cooling coils hard to clean Air handling system is very effective at moving contamination around you facilityon 24

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30 Overview of Key Findings Understanding isolate diversity is critical to sound source tracking and corrective action plan Effective root cause assessment may depend on using molecular tools Focus too often on ancillary or secondary positives Miss persisters by giving equal weight to all sites The significance of Zone 2 3 positives to Zone 1 and product contamination needs further resolution 59 tvsuslow@ucdavis.edu 30

31 Position Incoming 1 Incoming 2 Conveyor 1 Roller 1 Conveyor 2 Roller 2 BrushBed 1 Brushed Bed 2 Under BB1 Under BB2 Drop 1 Drop 2 Waxer Brushes 1 Waxer Brushers 2 Polishing Brush 1 Polishing Brush 2 Singulator 1 Singulator 2 Cup Sizer 1 Cup Sizer 2 Grade 1 Belts Grade 2 Belts Grade 3 Belts Drop Rollers 1 Drop Rollers 2 Drop Rollers 3 Auto fill Chute 1 Auto fill Chute 2 Auto Fill Chute 3 Daily Swab United/PMA Listeria Workshop 90 days Not one factor Training Re training to data Replace uncleanables Eliminate practices Alter chemistries Six day TPC swab cycle 100 s 1,000 s 10,000 s In the absence of a primary Environmental Swab Assessment assume L. mono will be present in vulnerable non FCS areas Set corrective measures guidance for non FCS positives Prioritize zone Clean vs. Sanitize schedules Selection and rotation of sanitizer formulations tvsuslow@ucdavis.edu 31

32 Systems Can Fit Together Trevor Suslow 32