Thermal inactivation of Salmonella during hard and soft cookies baking process.

This study validated a simulated commercial baking processes for hard and soft cookies to control Salmonella, and determined D- and z-values of 7-serotype Salmonella (Newport, Senftenberg, Tennessee, Typhimurium, and three isolates from dry pet food) cocktail in cookie doughs. Cookie doughs were prepared using flour mist-inoculated with the Salmonella cocktail. Hard and soft cookies were baked at 185 °C for 16 min and 165.6 °C for 22 min, respectively, followed by 30 min of ambient air cooling. D-values of the cocktail in cookie doughs were determined using thermal-death-time disks. Studies were designed as randomized complete blocks with three replications as blocks (α = 0.05). Salmonella populations decreased by > 5 log CFU/g in hard and soft cookies at 11.5 and 20.5 min of baking, respectively. Salmonella was not detected in hard cookies at the end of baking (as determined by enrichment), whereas in soft cookies, 0.6 log CFU/g Salmonella was present at the end of baking and cooling. Salmonella D-values in hard cookie dough at 60, 65 and 70 °C were 59.6, 28.1 and 11.9 min, respectively; while in soft cookie dough they were 62.3, 28.6 and 14.4 min, respectively. The Salmonella z-values in hard and soft cookie doughs were 14.5 and 15.8 °C, respectively.

Evaluation of thermal inactivation parameters of Salmonella in whole wheat multigrain bread.

This study was conducted to validate a simulated commercial whole wheat multigrain bread baking process at 375 °F (190.6 °C) oven temperature for 35 min to inactivate Salmonella, and to determine the thermal inactivation parameters of a 7-serovar Salmonella cocktail in whole wheat multigrain bread dough. A ≥5-log CFU/g reduction in Salmonella population was achieved by 15 min, and no viable Salmonella was detected after enrichment plating by 16 min. The aw of the bread crumb (0.96) after baking and 60 min of cooling was similar to that of pre-baked bread dough, whereas the aw of bread crust decreased to 0.81 at the end of baking and cooling. The D-values of the Salmonella cocktail in bread dough were 59.6, 20.0 and 9.7 min at 50, 52 and 55 °C, respectively; and the z-value was 6.5 °C.

Validation of a Simulated Commercial Frying Process to Control Salmonella in Donuts.

This study validated a typical commercial donut frying process as an effective kill-step against a 7-serovar Salmonella cocktail (Newport, Typhimurium, Senftenberg, Tennessee, and three dry food isolates) when contamination was introduced through inoculated flour. The bread and pastry flour mix (3:1) was inoculated with the Salmonella cocktail, and subsequently dried back to original preinoculation moisture content, achieving a Salmonella population of 7.6 log CFU/g. Inoculated flour was used to prepare a typical commercial donut batter, which was fried using 375°F (190.6°C) oil temperature. No viable Salmonella was detected using an enrichment plating protocol in the donuts after 2 min of frying, resulting in >7-log reduction in Salmonella population. The internal donut temperature increased from ∼30°C to ∼119°C at the end of 2 min of frying. The water activities of the donut crumb and crust after 2 min of frying, followed by 30 min of ambient air cooling, were 0.944 and 0.852, respectively. The donut pH after ambient-air cooling was 5.51. The D- and z-values of the Salmonella cocktail in donut dough were determined using thermal-death-time disks and temperature-controlled water baths. The D-values of the cocktail were 8.6, 2.9, and 2.1 min at 55°C, 58°C, and 61°C, respectively, whereas the z-value was 10°C. This study validated that >7-log reduction could be achieved if donuts are fried for at least 2 min in the oil at 190.6°C, and calculated D- and z-values present the heat resistance of Salmonella in donut dough at the start of the frying processes. However, results from this study should not be extrapolated when donut composition and frying parameters are changed significantly.

Evaluating the Safety of Sous-Vide Cooking for Beef Products Inoculated with Single Strains of Salmonella enterica and Escherichia coli O157.

Sous-videcooking is a growing trend among retailers and consumers. Foodborne pathogens may survive the cooking if nonvalidated parameters are used or if pathogens have enhanced thermalresistance. Pathogen inactivation from sous-vide cooking was determined when introduced directly to beef products or via contaminated spices, and with or without a finishing step. Beef products (ground beef, tenderized, and nontenderized steaks) were inoculated with pathogens (Salmonella Montevideo and Escherichia coli O157:NM) in three ways: 1) directly onto the meat 2) ground black pepper incorporated into the recipe 3) ground pepper equilibrated at 30% RH (4 d) prior to incorporation. Beef samples were vacuum-packaged and submerged in a 62.5°C water bath for 120 min. Samples were sampled at 5, 10, 20, and 120 min (recommended from a partner quality study), and a duplicate was grilled to a specific internal temperature (74°C for ground beef, 57°C for steaks) and sampled. Sous-vide cooking reduced pathogen populations by >5 log CFU/g after most treatment times, but less than grilled counterparts (ca. 1-2 log CFU/g difference; p < 0.05).There were no statistically significant differences between inoculation methods, but the tenderization of steaks resulted in significantly lower reductions of pathogens from sous-vide cooking (p < 0.05). Thisresearch challenged sous-vide cooking parameters (120 min, 62.5°C). It showed sous-vide alone lowered pathogens by >4 log CFU/g after most 20-min treatments, but 120-min sous-vide treatments or grilling would be needed for >5-log reductions.Contaminated pepper led to less consistent reductions during the cooking process, yet 2-h sous-vide still achieved a 5-log reduction. Sous-vide cooking instructions must be validated as more products and recipes are marketed.

Bootstrapping for Estimating the Conservative Kill Ratio of the Surrogate to the Pathogen for Use in Thermal Process Validation at the Industrial Scale.

A surrogate is commonly used for process validations. The industry often uses the target log cycle reduction for the test (LCRTest) microorganism (surrogate) to be equal to the desired log cycle reduction for the target (LCRTarget) microorganism (pathogen). When the surrogate is too conservative with far greater resistance than the pathogen, the food may be overprocessed with quality and cost consequences. In aseptic processing, the Institute for Thermal Processing Specialists recommends using relative resistance (DTarget)/(DTest) to calculate LCRTest (product of LCRTarget and relative resistance). This method uses the mean values of DTarget and DTest and does not consider the estimating variability. We defined kill ratio (KR) as the inverse of relative resistance.The industry uses an extremely conservative KR of 1 in the validation of food processes for low-moisture foods, which ensures an adequate reduction of LCRTest, but can result in quality degradation. This study suggests an approach based on bootstrap sampling to determine conservative KR, leading to practical recommendations considering experimental and biological variability in food matrices. Previously collected thermal inactivation kinetics data of Salmonella spp. (target organism) and Enterococcus faecium (test organism) in Non-Fat Dried Milk (NFDM) and Whole Milk Powder (WMP) at 85, 90, and 95°C were used to calculate the mean KR. Bootstrapping was performed on mean inactivation rates to get a distribution of 1000 bootstrap KR values for each of the treatments. Based on minimum temperatures used in the industrial process and acceptable level of risk (e.g., 1, 5, or 10% of samples that would not achieve LCRTest), a conservative KR value can be estimated. Consistently, KR increased with temperature and KR for WMP was higher than NFDM. Food industries may use this framework based on the minimum processing temperature and acceptable level of risk for process validations to minimize quality degradation.

The Use of Antimicrobial Washes to Inactivate Shiga Toxin-Producing Escherichia coli from In-Shell Pecans and Wash Water Contaminated by Different Inoculation Routes.

In-shell pecans are typically harvested after falling from trees to the ground, presenting a potential route of contamination of foodborne pathogens from soil contact. In-shell pecans are often subjected to various processing or washing steps prior to being shelled. This study determined Shiga toxin-producing Escherichia coli (STEC) reductions after treatment with antimicrobial washes on direct and soil-inoculated in-shell pecans and evaluated the cross-contamination potential of the spent pecan washes after treatment. Pecans were directly and soil-inoculated with an STEC cocktail (O157:H7, O157:NM, O121, O26). Direct inoculation was achieved by spraying the STEC cocktail on the pecans. For soil-inoculation pecans, autoclaved soil was sprayed with the STEC cocktail, homogenized for 2 min, and used to coat in-shell pecans. Inoculated pecans were washed in treatments of 2% lactic acid (LA), 1,000 ppm free chlorine (sodium hypochlorite; NaClO), hot water (HW; 85 ± 2 °C), or ambient water (C [control]; 18 ± 2 °C) for 2, 5, and 10 min and diluted to enumerate STEC populations. After treatments, 100 mL of the spent wash was vacuum filtered through a 0.45-µm membrane and plated on selective agar. HW significantly reduced STEC populations from pecans with and without soil regardless of treatment time (p < 0.05), NaClO reduced STEC populations more than the ambient control wash on directly inoculated pecans, but there were no significant differences between STEC reductions from ambient water (C), LA, and NaClO treatments on soil-inoculated pecans (p > 0.05). Larger STEC populations were enumerated from ambient water wash compared to the antimicrobial washes (p < 0.05). The HW, LA, and NaClO treatments were effective at maintaining the quality of the wash water, with STEC levels being generally at or below the detection limit (<1 CFU/100 mL), while HW was the most effective at reducing STEC from in-shell pecans with and without a soil coating (>5-log CFU/mL reductions).

Practice and Progress: Updates on Outbreaks, Advances in Research, and Processing Technologies for Low-moisture Food Safety.

Large, renowned outbreaks associated with low-moisture foods (LMFs) bring to light some of the potential, inherent risks that accompany foods with long shelf lives if pathogen contamination occurs. Subsequently, in 2013, Beuchat et al. (2013) noted the increased concern regarding these foods, specifically noting examples of persistence and resistance of pathogens in low-water activity foods (LWAFs), prevalence of pathogens in LWAF processing environments, and sources of and preventive measures for contamination of LWAFs. For the last decade, the body of knowledge related to LMF safety has exponentially expanded. This growing field and interest in LMF safety have led researchers to delve into survival and persistence studies, revealing that some foodborne pathogens can survive in LWAFs for months to years. Research has also uncovered many complications of working with foodborne pathogens in desiccated states, such as inoculation methods and molecular mechanisms that can impact pathogen survival and persistence. Moreover, outbreaks, recalls, and developments in LMF safety research have created a cascading feedback loop of pushing the field forward, which has also led to increased attention on how industry can improve LMF safety and raise safety standards. Scientists across academia, government agencies, and industry have partnered to develop and evaluate innovate thermal and nonthermal technologies to use on LMFs, which are described in the presented review. The objective of this review was to describe aspects of the extensive progress made by researchers and industry members in LMF safety, including lessons-learned about outbreaks and recalls, expansion of knowledge base about pathogens that contaminate LMFs, and mitigation strategies currently employed or in development to reduce food safety risks associated with LMFs.

Survivability and thermal resistance of Salmonella and Escherichia coli O121 in wheat flour during extended storage of 360 days.

Foodborne pathogens like Salmonella and Escherichia coli O121 can endure the harsh low water activity (aw) environment of wheat flour for elongated periods of time and can proliferate when hydrated for baking or other purposes. This study determined the survivability and thermal tolerance (D- and z-values) of Salmonella and Escherichia coli O121 in wheat flour and muffin batter (prepared from inoculated flour on the days of analyses) during the storage period of 360 days. The Salmonella and E. coli O121 studies were conducted as two independent experiments. Both studies were designed as randomized complete block with three replications as blocks. All experimental data were analyzed using one-way ANOVA and Tukey's test in Minitab® software, and P ≤ 0.05 was considered significant. The wheat flour was spray inoculated individually with 7-isolate Salmonella or 3-isolate E. coli O121 cocktail and then dried back to the original aw levels. On each analysis day, inoculated wheat flour (~5 g) or muffin batter (~2.5 g) was placed inside the TDT disks, heat treated at set temperatures in hot water baths, and sampled at predetermined time intervals for determining the survival microbial population. The population of E. coli O121 and Salmonella cocktails in wheat flour at day 1 were 7.6 ± 0.18 and 7.8 ± 0.07 log CFU/g, respectively, which decreased to 2.0 ± 0.40 and 2.8 ± 0.59 log CFU/g on day 360, respectively. The D-values of Salmonella and E. coli O121 cocktails in inoculated flour and muffin batter prepared from inoculated flour (on the day of analysis) were determined on days 1, 30, 90, 180, 270, and 360 [given enough surviving bacterial population (~3 to 4 log CFU/g) was present in the flour]. The population of Salmonella and E. coli O121 in wheat flour decreased by 5.0 and 5.6 log CFU/g, respectively, during the storage period of 360 days. The D70°C, D75°C, and D80°C values of Salmonella in wheat flour remained similar during the storage period. Whereas, for E. coli O157:H7 in wheat flour, the D70°C value decreased from 20.3 ± 2.82 to 7.1 ± 2.82 min, and D75°C decreased from 10.2 ± 2.14 to 2.7 ± 0.27 min, during the storage period of 180 days. The z-values of Salmonella or E. coli O157:H7 remained similar during the storage period. The D- and z-values from this research can be employed for validation of thermal process to ensure safety of wheat flour.

Evaluation of Listeria monocytogenes and Staphylococcus aureus Survival and Growth during Cooling of Hams Cured with Natural-Source Nitrite.

ABSTRACT: Growing consumer demand for clean-label "natural" products has encouraged more meat processors to cure meat products with natural sources of nitrate or nitrite such as celery juice powder. One challenge for these producers is to identify safe cooling rates in products cured with celery juice powder where extended cooling could allow growth of pathogens. The Food Safety and Inspection Service of the U.S. Department of Agriculture recently added guidelines for stabilization of meat products cured using naturally occurring nitrites based on control of Clostridium spp. However, a knowledge gap exists for safe cooling rates that prevent the growth of Listeria monocytogenes and Staphylococcus aureus, potential postlethality contaminants, in naturally cured ham. The study was conducted to investigate the temperature profiles of naturally cured hams of typical sizes during refrigerator cooling and to determine the behavior of S. aureus and L. monocytogenes on ham during these cooling periods. Whole hams (14 lb [6,300 g]), half hams (6 lb [2,700 g]), and quarter hams (3 lb [1,400 g]) were slowly cooked in a smokehouse until internal temperatures reached a minimum of 140°F (60°C) and then were immediately transferred into a walk-in cooler (38°F [3.3°C]). Cooling times for hams of all sizes were within the requirements for cured products but not for uncured products. Worst-case scenarios of postprocessing surface contamination were simulated by inoculating small naturally cured ham samples with S. aureus or L. monocytogenes. These inoculated hams were then cooled under controlled conditions of 130 to 45°F (54.4 to 7.2°C) for 720 to 900 min. By the end of cooling, small decreases (0.5 to 0.6 log CFU/g) were found for each inoculum. These findings may help small ham processors evaluating production and quality control methods to determine whether recommended concentrations of natural curing agents used to prevent growth of clostridial pathogens may also prevent growth of other pathogens during meat cooling.

Thermal Resistance of Single Strains of Shiga Toxin-Producing Escherichia coli O121:H19 and O157:H7 Based on Culture Preparation Method and Osmolyte-Reduced Water Activity.

ABSTRACT: Bacterial exposure to stress, such as reduced water activity (aw), can increase thermal resistance. Pathogen thermal resistance studies on low-aw foods use a variety of methods to inoculate food, as well as strategies to reduce aw, which can influence observations. This study investigated effects of culture preparation method and osmolyte-induced aw on thermal resistance of two Shiga toxin-producing Escherichia coli (STEC) strains (O121:H19 and O157:H7) challenged with isothermal conditions, determining D- and z-values for each isolate (56, 59, and 62°C). Tryptic soy broth (TSB) and agar (lawn cultures) were compared. D-values of broth cultures were significantly and consistently larger than those of lawn cultures, and O121 was significantly more resistant than O157, but only at 56°C (P < 0.05). To compare potential effects of aw on STEC thermal resistance, cells were suspended in osmolyte solutions with varying aw: high (TSB, aw 0.99), intermediate (61% glycerol or 26% NaCl, aw 0.75), and low (82% glycerol, aw 0.5). In most instances, STEC strains in high-aw broth exhibited greater heat resistance compared to reduced-aw solutions, with the exception of the glycerol intermediate-aw solution (aw 0.75). Magnitudes varied with strain and temperature. The z-values of lawn cultures were significantly lower than those of broth cultures (P < 0.05), but there were few differences between high-aw and reduced-aw samples. There were no significant differences of z-values based on strain type. These results highlight that thermal resistance can be affected by culture preparation and that osmolyte-induced changes to aw influence thermal inactivation of STEC by varying magnitudes. These results emphasize the challenges of extrapolating results from laboratory inactivation kinetic experiments to determine the inactivation of low-aw foods, especially those considered dry in nature.

Comparison of survival and heat resistance of Escherichia coli O121 and Salmonella in muffins.

This study was conducted to validate a simulated commercial baking process for plain muffins against E. coli O121 (isolated from the recent illness outbreak associated with flour), and compare the thermal inactivation parameters (D- and z-values) of cocktails of four isolates of E. coli O121 and three serovars of Salmonella (Newport, Typhimurium, and Senftenberg) in muffin batter. Flour samples were spray inoculated with the E. coli O121 or Salmonella cocktails, dried back to the pre-inoculation weight to achieve ~7 log10 CFU/g, and used to prepare muffin batter. For the muffin baking validation study using E. coli O121, muffin batter was baked at 375 °F (190.6 °C) oven temperature for 21 min followed by 30 min of ambient cooling. The E. coli O121 population decreased by >7 log10 CFU/g in muffins by 17 min of baking, and was completely eradicated after 21 min of baking and ambient cooling. The D-values of E. coli O121 and Salmonella cocktails in muffin batter at 60, 65 and 70 °C were 42.0 and 38.4, 7.5 and 7.2, and 0.4 and 0.5 min, respectively; whereas the z-values of E. coli O121 and Salmonella were 5.0 and 5.2 °C, respectively.

Thermal inactivation of Salmonella, Shiga toxin-producing Escherichia coli, Listeria monocytogenes, and a surrogate (Pediococcus acidilactici) on raisins, apricot halves, and macadamia nuts using vacuum-steam pasteurization.

Salmonella, Shiga toxin-producing Escherichia coli (STEC), and Listeria monocytogenes have been isolated from low water activity foods (LWAF), where they may survive for extended periods. The ready-to-eat nature of many LWAF, such as dried fruits and nuts, warrants effective post-harvest thermal treatment for the reduction of pathogens such as low-temperature, saturated steam, also known as vacuum-assisted steam pasteurization. The objective of this study was to determine reductions of Salmonella, STEC, L. monocytogenes, and a possible surrogate (Pediococcus acidilactici) on dried apricot halves, whole macadamia nuts, and raisins after treatment with vacuum-assisted steam at three temperatures (62 °C, 72 °C, or 82 °C) and multiple time intervals. Bacterial inactivation was variable between commodities, with higher temperatures and longer times necessary to achieve comparable reductions of pathogens on apricot halves and macadamia nuts compared to raisins. Reductions of the tested pathogens were comparable; therefore, one species was not more resistant than the others. Pathogens were reduced by 5-log CFU/g on apricot halves after 20 min at 72 °C and after 5 min at 82 °C. Longer treatment times were necessary to achieve reductions of each pathogen on macadamia nuts. Pathogens were reduced by nearly 5 log CFU/g on macadamia nuts after 38 min at 72 °C (4.6-6.5 log CFU/g) and after 12 min at 82 °C (4.9-5.7 log CFU/g). Reductions of pathogens on raisins were achieved at lower temperatures than necessary for the other foods. A 5-log reduction for each of the pathogens (CFU/g) on raisins occurred after 20 min at 62 °C and after 5 min at 72 °C. Overall, the reductions of the pathogens exceeded those of P. acidilactici on both the dried fruits and macadamia nuts. Statistically significant differences, indicating greater confidence as a conservative surrogate, were observed at lower treatment temperatures. Inactivation kinetics were modeled for each pathogen on each food type and temperature. Bacterial survival was best described by the Weibull model for raisins and macadamia nuts, while the Gompertz model best described reductions on apricot halves according to Akaike information criterion (AIC) and root-mean-square error (RMSE) evaluations. Water activity and moisture content were increased due to the treatments, which could be addressed through implementation of drying steps. Thermal inactivation kinetic models and 5-log reduction parameters can help food processors design and evaluate similar vacuum-assisted steam interventions to comply with FSMA regulations and preventive control plans. However, results or model predictions should not be extrapolated to assume the safety of other types of foods.

Validation of a nut muffin baking process and thermal resistance characterization of a 7-serovar Salmonella inoculum in batter when introduced via flour or walnuts.

This study was conducted to validate a commercial nut muffin baking process and to compare the survival of a 7-serovar Salmonella cocktail when contaminated via inoculated flour or walnuts. Enriched wheat flour or walnut pieces were mist inoculated with the Salmonella cocktail and dried back to the pre-inoculation weight, resulting in a Salmonella population level of 6.9 and 8.4 log CFU/g, respectively. Nut muffin batters were prepared separately using inoculated flour or walnuts, followed by baking at 375 °F (190.6 °C) oven temperature for 21 min and post-bake ambient air-cooling (B + C). During baking, >5-log CFU/g reductions in the Salmonella population in nut muffins was achieved in 17 min, and Salmonella was not detected by direct plating (<0.2 log CFU/g detection limit) but was recovered by enrichment at the end of 21 min of baking and B + C. In a separate baking study using an extended baking time (24 min) at 375 °F, Salmonella was detected after 24 and 22 min using enrichment plating of nut muffins prepared from inoculated flour and walnuts, respectively. The D-values of the Salmonella cocktail in nut muffin batters prepared from inoculated flour were 24.0, 4.0 and 0.6 min at 60, 65 and 70 °C; whereas, corresponding D-values in batters prepared from inoculated walnuts were 22.0, 3.6 and 1.7 min. The z-values of the Salmonella cocktail in nut muffin batters were 6.1 and 9.0 °C for inoculated flour and walnuts, respectively. This simulated commercial nut muffin baking study utilizing an oven temperature of 190.6 °C for at least 17 min validates that the process will eliminate Salmonella populations by ≥5 log CFU/g if pre-baking contamination occurs via flour or walnut ingredients.

Validation of the baking process as a kill-step for controlling Salmonella in muffins.

This research investigates the potential risk of Salmonella in muffins when contamination is introduced via flour, the main ingredient. Flour was inoculated with a 3-strain cocktail of Salmonella serovars (Newport, Typhimurium, and Senftenberg) and re-dried to achieve a target concentration of ~8logCFU/g. The inoculated flour was then used to prepare muffin batter following a standard commercial recipe. The survival of Salmonella during and after baking at 190.6°C for 21min was analyzed by plating samples on selective and injury-recovery media at regular intervals. The thermal inactivation parameters (D and z values) of the 3-strain Salmonella cocktail were determined. A ≥5logCFU/g reduction in Salmonella population was demonstrated by 17min of baking, and a 6.1logCFU/g reduction in Salmonella population by 21min of baking. The D-values of Salmonella serovar cocktail in muffin batter were 62.2±3.0, 40.1±0.9 and 16.5±1.7min at 55, 58 and 61°C, respectively; and the z-value was 10.4±0.6°C. The water activity (aw) of the muffin crumb (0.928) after baking and 30min of cooling was similar to that of pre-baked muffin batter, whereas the aw of the muffin crust decreased to (0.700). This study validates a typical commercial muffin baking process utilizing an oven temperature of 190.6°C for at least 17min as an effective kill-step in reducing a Salmonella serovar population by ≥5logCFU/g.