P2-142 Optimizing Sample Plans to Improve Microbiological Safety in a Food Processing Plant

Tuesday, August 5, 2014
Exhibit Hall D (Indiana Convention Center)
Hassan Masri, Virginia Tech, Blacksburg, VA
Joseph Eifert, Virginia Tech, Blacksburg, VA
Renee Boyer, Virginia Tech, Blacksburg, VA
Hengjian Wang, Virginia Tech, Blacksburg, VA
Ivan Volonsevich, Virginia Tech, Blacksburg, VA
Introduction: Salmonella and Cronobacter sakazakii are two leading causes of foodborne illness associated with low-moisture foods, including infant formula. Both causative organisms can persist in food manufacturing environments and contaminate finished product if programs are not in place to limit their introduction and control their spread. Microbial sampling and testing of the process environment and finished product are valuable for identifying and preventing contamination.

Purpose: An environmental sampling and monitoring program is an important tool that food manufacturers use to determine the effectiveness of their sanitation practices and pathogen control efforts. The objective of this research was to develop guidance for initiating and evaluating an environmental sampling plan for an infant formula process.

Methods: An interactive spreadsheet tool for designing sampling monitoring plans for Salmonella (qualitative) and Enterobacteriaceae (quantitative) was developed using Microsoft Excel and Visual Basic for Applications (VBA). Microbiological environmental sampling plans (9) were based on the answers to a series of questions related to product hazards, processing risks and controls, and knowledge of appropriate microbiological sampling and testing protocols. Furthermore, these initial sampling plans were related to the volume of product and size of the processing facility.  Guidelines were designed to support the instructions for selecting and modifying a sampling plan.

Results: Additionally, the tool could be used to record qualitative and quantitative sample test results, and to alert the user to adjust the sampling plan, if necessary, based on monthly test summaries. The sampling tool provides a simple method for selecting an appropriate environmental sampling plan (samples per zone per month) based on product and process risk level and production volume, and provides a rationale and guidance for modifying these plans.  

Significance: Effective, well-designed sampling plans and trend analysis of sample test results support food processors’ decisions for implementing controls to enhance food safety.