Principles of Microbiological Troubleshooting in the Industrial Food
Contents
1. Editor Kornacki Microbiology Solutions Inc P O Box 163 McFarland WI 53558 USA A Springer Editor Jeffrey L Kornacki Kornacki Microbiology Solutions Inc P O Box 163 McFarland WI 53558 USA JLKORN731 gmail com ISBN 978 1 4419 5517 3 e ISBN 978 1 4419 5518 0 DOI 10 1007 978 1 4419 5518 0 Springer New York Dordrecht Heidelberg London Library of Congress Control Number 2010921492 Springer Science Business Media LLC 2010 All rights reserved This work may not be translated or copied in whole or in part without the written permission of the publisher Springer Science Business Media LLC 233 Spring Street New York NY 10013 USA except for brief excerpts in connection with reviews or scholarly analysis Use in connection with any form of information storage and retrieval electronic adaptation computer software or by similar or dissimilar methodology now known or hereafter developed is forbidden The use in this publication of trade names trademarks service marks and similar terms even if they are not identified as such is not to be taken as an expression of opinion as to whether or not they are subject to proprietary rights Printed on acid free paper Springer is part of Springer Science Business Media www springer com Preface This book is borne out of many experiences with many people in hundreds of food processing facilities mainly in North America The principles of food safety and food qual2. positive yield different CAMP reactions Table 2 3 Typical L monocytogenes isolates fer ment rhamnose dextrose esculin and maltose but not xylose and mannitol Datta 2003 The CAMP reaction and key biochemical reactions have been traditionally used to confirm cultures However numerous Listeria identification test kits are now available that greatly expedite this process without the use of the CAMP reaction 2 3 2 Cost Approximately 2 518 cases of foodborne listeriosis including 500 fatalities occur annually in the United States at an estimated cost of 2 3 billion making liste riosis the second most costly foodborne illness after salmonellosis which some have estimated at 2 33 billion dollars Mead et al 1999 Buzby and Roberts 1996 Consequently foodborne listeriosis has been targeted by many public heath programs most notably Healthy People 2010 a comprehensive nationwide health promotion and disease prevention program developed by the Department of Health and Human Services to reduce bacterial infections and enhance life expectancy quality 2 3 3 Disease Syndromes Two types of listeriosis are recognized a an invasive form that can be life threatening in newborn infants the elderly and immunocompromised adults and b a less common self limiting gastrointestinal illness In the gastrointestinal form flu like symptoms e g diarrhea vomiting fever may occur 18 24h after inges tion of the contaminated
3. 1 45 C optimum at 35 37 C makes control of this organism in the process ing environment challenging Eradication of this organism from ready to eat meat and poultry processing environments is unlikely given current technology Tompkin et al 1999 Hence implementation of rigorous controls is essential to prevent processed food contamination 2 3 1 The Organism L monocytogenes is a gram positive short 0 4 0 5x0 5 2 um non spore forming rod shaped microaerobic bacterium that exhibits tumbling motility The organism appears translucent with a characteristic blue green sheen when observed under oblique lighting However some technicians are better than oth ers at visualizing this phenomenon It is typically weakly hemolytic on horse blood agar and exhibits a characteristic CAMP reaction on sheep blood agar when streaked perpendicularly to S aureus enhanced hemolysis and Rhodococcus equi hemolysis not enhanced Other than Listeria seeligeri the remaining Listeria spp 12 R G Behling et al Table 2 3 Key reactions of Listeria Camp reaction enhanced hemolysis Species Staphylococcus streak Rhodococcus equi streak Rhamnose Xylose monocytogenes a ivanovii innocua Variable welshimeri Variable seeligeri grayi Variable Rare strains may show a region of enhanced hemolysis near both the Staphylococcus and the Rhodococcus streaks gt This species is mannitol
4. GA USA eric line ars usda gov Mark Moorman Ph D The Kellogg Company Battle Creek MI USA mark moorman kellogg com Payton Pruett Ph D The Kroger Company Cincinnati OH USA payton pruett kroger com Roy Radcliff Ph D Department of Applied Sciences Marshfield Clinic Marshfield WI USA radcliff roy marshfieldclinic org Elliot T Ryser Ph D Michigan State University East Lansing MI USA ryser msu edu Bradley Stawick M S Stawick Laboratory Management Memphis TN USA brad stawick stawicklabmgt com Martin Weidman Ph D Department of Food Science Cornell University Ithaca NY USA mw16 cornell edu Zhinong Yan Ph D Mol Industries Grand Rapids MI USA zhinongy gmail com xi Chapter 1 Troubleshooting Costs Jeffrey L Kornacki Abstract Seventy six million cases of foodborne disease occur each year in the United States alone Medical and lost productivity costs of the most common pathogens are estimated to be 5 6 9 4 billion Product recalls whether from food borne illness or spoilage result in added costs to manufacturers in a variety of ways These may include expenses associated with lawsuits from real or allegedly stricken individuals and lawsuits from shorted customers Other costs include those associ ated with efforts involved in finding the source of the contamination and eliminating it and include time when lines are shut down and therefore non productive addi tional non routine tes
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6. OgIsDa S yodDN S unianunyday 5 viq S vi hj N u ui u h ui supa s1p111421U2 tunfof J uasoyjyed asaoyo odAq uvorxopy ypu pozuna sed yu pozuna sed ypu pozuna sed ypu poznased SISL A Anseg NBOA posoarypy swool1ysnu pouuep PULI yu pouurs Ju 9o90 spooz yua q ousese uowles pouurd s30p 10H Jong ayejosoyD ayejosoyD wey poors payood sIMI YOS ov NULIOJ JULJUT Wea 90 peres vuny ponpold UONRLUILUE UOD eLJUDUTUOITAUD 0 paque syeoiqino Jo sojdwexg TZ aquy 8 R G Behling et al Table 2 2 Estimated annual foodborne disease from selected pathogens Number of total Total illness Hospitalized Deaths Number Bacterium illness of deaths Campylobacter 2M 14 2 17 3 5 5 99 Salmonella non typhoidal 1 3 M 9 7 25 6 30 6 553 Listeria monocytogenes 2 493 0 0 3 8 27 6 499 E coli O157 H7 62 458 0 5 3 0 2 9 52 Clostridium perfringens 248 520 1 8 0 1 0 4 7 Staphylococcus 185 060 1 3 2 9 0 1 2 Shigella 89 648 0 6 2 0 0 8 14 Adapted from Mead et al 1999 M million 2 2 1 Salmonella The Organism Salmonella species are gram negative rod shaped usually motile members of the taxonomic family Enterobacteriaceae Despite great advances in molecular genetic approaches to identification and characterization these organisms are still serolog ically defined i e by their somatic O and usually flagellar H and sometimes capsular Vi antigens Over approximatel
7. Principles of Microbiological Troubleshooting in the Industrial Food Processing Environment Food Microbiology and Food Safety Series Food Microbiology and Food Safety publishes valuable practical and timely resources for professionals and researchers working on microbiological topics associated with foods as well as food safety issues and problems Series Editor Michael P Doyle Regents Professor and Director of the Center for Food Safety University of Georgia Griffith GA USA Editorial Board Francis F Busta Director National Center for Food Protection and Defense University of Minnesota Minneapolis MN USA Bruce R Cords Vice President Environment Food Safety amp Public Health Ecolab Inc St Paul MN USA Catherine W Donnelly Professor of Nutrition and Food Science University of Vermont Burlington VT USA Paul A Hall President AIV Microbiology and Food Safety Consultants LLC Hawthorn Woods IL USA Ailsa D Hocking Chief Research Scientist CSTRO Food Science Australia North Ryde Australia Thomas J Montville Professor of Food Microbiology Rutgers University New Brunswick NJ USA R Bruce Tompkin Formerly Vice President Product Safety ConAgra Refrigerated Prepared Foods Downers Grove IL USA For other titles published in this series go to www springer com series 7131 Principles of Microbiological Troubleshooting in the Industrial Food Processing Environment Jeffrey L Kornacki
8. age is discussed in Chapter 3 There are even economic consequences to otherwise acceptable foods wherein levels of selected quality indicators e g coliforms have been exceeded These sit uations may result in rejection of product by suppliers There are frequent disputes between companies over what is the correct number of non pathogenic contami nants in a sample Effective sampling is not as straightforward as taking a sample and testing it due to the potential for non homogeneous microbial populations in the product and there are added expenses to taking and testing the proper number of samples Sampling plans are addressed in Chapter 8 The cost associated with an effective quality assurance plan is well worth the effort to prevent the situations just described The savings in terms of maintenance and repair and increased revenues resulting from higher quality foods due to effec tive microbiological control efforts in processing facilities are often overlooked Consequently there is great need to understand how to locate and control micro bial contaminants in processed foods and in the environments in which they are produced That is what the main thrust of this book is about References Buzby JC Roberts T 1996 ERS updates US foodborne disease costs for seven pathogens ABI INFORM Global 3 20 25 http www ers usda gov publications foodreview sep 1996 sept96e pdf Accessed 17 July 2008 Mead PS Slutsker L Dietz V McCaig LF Br
9. diarrhea occasionally with mucous or blood Nausea and vomiting often occur but are rarely severe or protracted A fever of 38 39 C is common often after a chill In many instances the disease resolves within 48h However it can last with diarrhea and low grade fever for 10 14 days In severe cases dehydration may lead to hypotension cramps olig uria and uremia Symptoms are often more severe in infants and adults over 60 years of age Fatalities rarely exceed 1 of the affected population and are generally limited to infants elderly and debilitated individuals Hanes 2003 Nevertheless Salmonella infection accounts for more foodborne deaths 31 in the United States than any other foodborne pathogen Mead et al 1999 Furthermore multi drug resistant Salmonella DT104 has been associated with double the hos pitalization rate and ten times the case fatality rate of other foodborne Salmonella Hanes 2003 The presence of viable salmonellae in the gastrointestinal tract indicates that the organism survived a variety of non specific host defenses including lactoperoxi dase in saliva stomach acidity mucous secretions from intestinal goblet cells and sloughing of luminal epithelial cells In addition they must survive non specific phagocytic cells immune responses associated with specific T and B lymphocytes Peyer s patches and complement inactivation D Aoust 1991 Once they have survived these conditions they attach to inte
10. ellae are widespread in the natural environment and a number of these are host specific e g Salmonella serotype Pullorum in chickens Salmonella serotype Cholera Suis in pigs In many countries poultry remain the dominant reservoir although pork beef and mutton have served as vehicles of infection The eggborne pandemic of Salmonella serotype Enteritidis phage type 4 in Europe and phage type 8 in North America illustrates the importance of poultry products as vehicles of human salmonellosis 2 2 6 Foods Associated with Human Salmonella spp Infection Salmonella spp have a long history of food contamination and have caused illness from ingestion of a wide variety of foods These organisms have been a particular concern with foods of animal origin e g meat poultry eggs and dairy products Dry foods and fruit and vegetableborne outbreaks have also occurred One multi state cantaloupeborne outbreak affected more than 25 000 across 30 states Ries et al 1990 Major outbreaks have occurred with chocolate milk powder potato salad egg salad raw milk mustard dressing salad base cheddar cheese liver pate aspic glaze pasteurized milk egg drink cuttlefish cooked eggs cantaloupes fruit soup may onnaise paprika chips ice cream and alfalfa sprouts D Aoust 1997 In the 1994 frozen dessert associated outbreak mentioned above an estimated 224 000 people were infected with Salmonella serotype Enteritidis The source of the or
11. esee JS Shapiro C Griffin PM Tauxe RV 1999 Food related illness and death in the United States Emerg Infect Dis Online 5 5 607 625 http www cdc gov ncidod eid vol5noS mead htm Accessed 17 July 2008 MMWR 2003 Preliminary FoodNet data on the incidence of foodborne illnesses selected sites United States 2002 52 15 340 343 http www cdc gov mmwr preview mmwrhtml mm5215a4 htm Accessed 17 July 2008 Chapter 2 Selected Pathogens of Concern to Industrial Food Processors Infectious Toxigenic Toxico Infectious Selected Emerging Pathogenic Bacteria Robert G Behling Joseph Eifert Marilyn C Erickson Joshua B Gurtler Jeffrey L Kornacki Erick Line Roy Radcliff Elliot T Ryser Bradley Stawick and Zhinong Yan Abstract This chapter written by several contributing authors is devoted to discussing selected microbes of contemporary importance Microbes from three categories are described by the following 1 infectious invasive agents like Salmonella Listeria monocytogenes and Campylobacter 2 toxigenic pathogens such as Staphylococcus aureus Bacillus cereus and Clostridium botulinum and 3 toxico infectious agents like enterohemorrhagic Escherichia coli and Clostridium perfringens In addition emerging pathogens like Cronobacter Enterobacter sakazakii Arcobacter spp and Mycobacterium avium subspecies paratuberculosis are also described In most cases the discussion includes a description of the organism it
12. food In contrast invasive listeriosis has an onset time of 3 to as long as 70 days after which adults typically experience septicemia meningi tis or endocarditis whereas unborn fetuses develop abscesses in their liver lungs
13. ganism was traced to contaminated post pasteurized ice cream mix which had been shipped in tank trucks previously used to transport raw eggs Hennessy et al 1996 2 2 7 Dry Foods Dry products are not often associated with microbial contamination problems However salmonellae have been a particular concern with some dry foods and dry food production environments Control of these organisms is a priority among indus tries that produce dried foods such as dry milk infant formula chocolate dry soup mixes and rendered animal proteins an ingredient in animal feed and pet food Human outbreaks of disease have been reported with dry milk chocolate and even paprika potato chips dry cereal and peanut butter D Aoust et al 1975 Greenwood and Hopper 1983 Kapperud et al 1990 Lehmacher et al 1995 Weissman et al 1977 CDC 2007 2009 It is important to note that simply because a microbe can not grow in a low water activity food it may still survive for some time Factors that influence microbial growth survival and death are discussed in Chapter 5 2 Selected Pathogens of Concern to Industrial Food Processors 11 2 2 8 Food Processing Environments A wide variety of food factory environments may be contaminated with this microbe due to their widespread occurrence in the natural environment and likely presence in some raw ingredients which may enter factory environments In the author s experi ence birds which are frequent car
14. inong Yan 3 Solving Microbial Spoilage Problems in Processed Foods 63 Rocelle Clavero 4 Where These Contaminants Are Found 79 Jeffrey L Kornacki 5 What Factors Are Required for Microbes to Grow Survive and Die naaa aaa a 103 Jeffrey L Kornacki 6 Where Do I Start Beginning the Investigation 117 Jeffrey L Kornacki 7 How Do I Sample the Environment and Equipment 125 Jeffrey L Kornacki 8 How Many Samples Do I Take 137 Jeffrey L Kornacki 9 When Can I Start Up My Factory or Processing Line Again 147 Jeffrey L Kornacki 10 Value and Methods for Molecular Subtyping of Bacteria 157 Mark Moorman Payton Pruett and Martin Weidman AEX airs fo tk te Sah eed ete Sd Sa ain Zan Seah cee th cal i cet a Ade thee at 175 Contributors Robert G Behling B S Behling Food Safety Associates Madison WI USA rbehling msn com Rocelle Clavero Ph D Sara Lee Corporation Downers Grove IL USA rocelle clavero saralee com Joseph Eifert Ph D Department of Food Science and Technology Virginia Tech Blacksburg VA USA jeifert vt edu Marilyn C Erickson Ph D University of Georgia Griffin GA USA mericks uga edu Joshua B Gurtler Ph D USDA ARS Wyndmoor PA USA joshua gurtler ars usda gov Jeffrey L Kornacki Ph D Kornacki Microbiology Solutions Inc McFarland WI USA JLKORN731 gmail com Erick Line Ph D USDA ARS Athens
15. ity microbiology range from simple to complex as does the experience of those in charge of maintaining food safety and quality Many in our culture assume that the principles are simple like Wash your hands after using the rest room However in my experience the vast majority of companies that produce foods contaminated with pathogenic bacteria or spoilage organisms are not will fully negligent as some may think Rather companies often fail for other reasons which could include equipment inadequately designed for appropriate sanitation poorly constructed facilities and paradigms that prevent them from recognizing true microbiological risk Quality assurance food safety managers become the point persons to deal with food contamination situations It is a heavy burden that you bear and this book while useful to anyone wishing to investigate sources of contamination in food processing facilities is really written with you in mind This book is written in hopes that it makes your load lighter your confidence greater and the food your company produces safer McFarland WI Jeffrey L Kornacki Acknowledgments The technical editor of this book Dr Kornacki wishes to express his heartfelt thanks to a number of individuals who were instrumental in forming his perspectives on in plant microbiological investigations First I want to thank my father Thomas Kornacki a retired criminal investiga tor of 35 years whose investigations were q
16. lly pro cessed foods are contaminated Kornacki 2000 Allan et al 2004 Reij and Den Aantrekker 2004 Examples of post process contamination from the food process ing environment are illustrated in Table 2 1 In this book we refer to commercially processed foods as those which have been modified from the raw state into a ready to eat format in an industrial manufacturing environment Environmental contamination can come from ingredients used in processing whether directly or indirectly worker s hands shoes walls floors and a myriad of other sources This chapter is devoted to discussing selected microbes of contemporary importance These microbes fit into three categories which include 1 infectious invasive agents like Salmonella Section 2 2 Listeria mono cytogenes Section 2 3 Campylobacter Section 2 4 and enteroinvasive Escherichia coli 2 toxigenic pathogens like Staphylococcus aureus Section 2 5 Bacillus cereus Section 2 6 and Clostridium botulinum Section 2 7 The growth and pro duction of pre formed toxin in foods is a particular concern with enterotoxin producing strains of Staphylococcus B cereus and C botulinum 3 toxico infectious agents like enterotoxigenic and enterohemorrhagic E coli Section 2 8 and Clostridium perfringens Section 2 9 are described In addition emerging pathogens like Cronobacter Enterobacter sakazakii Section 2 11 Arcobacter spp Section 2 10 and Mycobacte
17. ns of the authors of this book and the fine example and encouragement of many other professional colleagues through the years this book would not have been possible I would be remiss to omit the fine contribution of the authors that contributed to Chapter 2 many of whom are of national and international reputations I wish to recognize the fine contributions of Robert Behling Bacillus cereus Joseph Eifert Arcobacter Marilyn Erickson Clostridium botulinum Joshua Gurtler Cronobacter sakazakii Erick Line and Bradley Stawick Campylobacter Roy Radcliff Mycobacterium paratuberculosis Elliot Ryser Listeria monocytogenes viii Acknowledgments and Drs Ryser and Yan Staphylococcus aureus and Clostridium perfringens I am also very grateful for the fine work of Drs Moorman Pruett and Weidman with Chapter 10 May you all be kings Proverbs 25 2 Thanks also to Mr Dwight Clough for his considerable assistance with many of the nuts and bolts of putting this book together McFarland WI Jeffrey L Kornacki September 9 2009 Contents 1 Troubleshooting Costs 040 1 Jeffrey L Kornacki 2 Selected Pathogens of Concern to Industrial Food Processors Infectious Toxigenic Toxico Infectious Selected Emerging Pathogenic Bacteria 5 Robert G Behling Joseph Eifert Marilyn C Erickson Joshua B Gurtler Jeffrey L Kornacki Erick Line Roy Radcliff Elliot T Ryser Bradley Stawick and Zh
18. on of their food manufacturing factory and redesign and install some of the processing equipment in the aftermath of a national food infection and recall Settlements outside of the court room can also be in millions of dollars Serious damage to a company s brand name can and has occurred even in instances when the company issuing the recall is not at fault e g in cases where a product has been contaminated by a supplier s ingredient Some companies have resorted to changing their name as a result Damage to a company s reputation and profit margin can also result in loss of jobs and salary reductions In some instances a recall from a competitor has even resulted in market losses due to brand confusion Food safety is in everyone s best interest 1 1 3 Costs Associated with Spoilage and Foods with Microbial Indicators of Unacceptable Quality Many of the same costs listed above apply to spoiled food products Spoiled foods are not necessarily hazardous but are organoleptically unacceptable Consequently these foods may be perceived as dangerous resulting in expenses associated with product recalls lawsuits from allegedly stricken individuals and shorted customers 1 Troubleshooting Costs 3 efforts to find and eliminate the source s of the contamination non productive lines additional testing consultant fees lost market share to competitors and the costs associated with redesign of the facility and or equipment Food spoil
19. riers of this organism may find roosts on factory roofs or roof associated structures e g air intakes for air handling units Most food processing facilities have flat roofs and many are not adequately sloped to drains resulting in collection of standing water Standing water on roof tops will permit the growth of salmonellae to high numbers Entry of salmonellae in the factory environment may occur through inappropriately sealed roof top associated penetrations Other routes of entry are described in Chapter 4 In the author s expe rience it is rare that the post cook side of a factory is contaminated with more than one serotype of Salmonella Most often the Salmonella serotype found on the finished side of the facility is its signature organism or house bug It appears that each environment selects for the strain which has likely adapted to its environ ment However exceptions to this observation have been noted and the presence of multiple serotypes suggests multiple sources for the microbe The author has observed sporadic detection of a specific serotype of Salmonella in some dry product processing environments for 10 or more years 2 3 L monocytogenes an Infectious Invasive Agent The very widespread some say ubiquitous distribution of this organism in the natural environment coupled with its resistance to freezing growth in the pres ence of 10 salt survival in concentrated brine solutions and its ability to grow at
20. rium avium sub species paratuberculosis Section 2 12 are also described Infectious vs toxigenic bacterial pathogens In general infectious pathogens may enter the body and invade or colonize host tissues This requires some time e g usually greater than 8 h for onset of illness Toxigenic pathogens create food poisoning situations by producing an enterotoxin in the food Incubation times for onset of disease from toxigenic microbes are often shorter than for invasive pathogens and can be as little as 1 h as in the case of staphylococcal enterotoxin induced illness The short incubation time in compar ison to the infectious pathogens results because the agent of illness the toxin is pre formed in the food and ingested Illness is not contingent upon the organism migrating to the intestinal tract implanting and growing Selected examples of inva sive and infectious foodborne pathogens and their importance in various foods follow 2 2 Salmonella an Infectious Invasive Agent Salmonella spp are an example of an invasive infectious pathogen and are second only to the thermophilic Campylobacter spp e g jejuni coli in the number of foodborne disease cases per year attributed to bacteria Table 2 2 2 Selected Pathogens of Concern to Industrial Food Processors T007 ASOT Pur p007 JaPeauey pue foy woy padepy JUSWUOIIAUS SuUIssad0l1d Iy W017 UONeUTURUOD uonNeUrUteyUOS ssad01d jsog yuourdinbs Zupa OUT SUIT
21. self eco nomic impact of the organism due to disease loss of market share etc disease syndromes infectious process infectious dose reservoirs where the organism orig inates in the food processing chain foods associated with the organism and the occurrence of the organism in food processing environments 2 1 Introduction This chapter will not address all the pathogenic microbes that are of concern in all foods or all food processing environments However selected pathogens will be described which illustrate typical organism types i e infectious toxigenic toxico infectious of common concern in food manufacturing environments A few selected emerging foodborne pathogens will also be discussed Detailed reviews and descrip tions of foodborne pathogens can be found in a number of references Doyle 1989 Jay et al 2005 Doyle et al 1997 The later part of this chapter will address selected emerging microbial pathogens of concern R G Behling amp Behling Food Safety Associates Madison WI USA e mail rbehling msn com J L Kornacki ed Principles of Microbiological Troubleshooting in the Industrial 5 Food Processing Environment Food Microbiology and Food Safety DOI 10 1007 978 1 4419 5518 0_2 Springer Science Business Media LLC 2010 6 R G Behling et al Post process contamination from the factory environment is a very common and in this authors opinion the most common means by which commercia
22. stinal tissues and mesenteric lymph follicles resulting in enterocolitis Endotoxin is produced leukocytes move into the infected tissues and increased mucous secretion occurs Mucosal inflamma tion results from the release of prostaglandins by leukocytes which also activates adenyl cyclase in intestinal epithelial cells causing increased fluid secretion into the intestinal lumen and resulting in diarrhea Septicemia and other chronic conditions result when host defenses fail to keep these invasive Salmonella in check D Aoust 1991 2 2 4 Infectious Dose The infectious dose appears to be very low as evidenced by some foods implicated in foodborne disease with only a few cells recovered An example of this occurred in a 1994 frozen dessert associated outbreak wherein the level of Salmonella serotype Enteritidis was reported to have a most probable number MPN range of 4 cells per 1 000 g to 46 cells per 100 g with a median of 93 cells in 1 000 g Vought and Tatini 1998 The 95 confidence interval for these MPN values was from lt 1 cell per 1 000 g to 2 4 cells g The number of Salmonella serotype Enteritidis cells per serving was estimated at 25 cells In this study the infective dose appeared to be less than 28 cells Evidence from other studies indicates that from to 10 cells may constitute an infectious dose in some circumstances D Aoust et al 1985 and Kapperud et al 1990 10 R G Behling et al 2 2 5 Reservoirs Salmon
23. ting consultant fees time and personnel required to overhaul the entire food safety system lost market share to competitors and the cost asso ciated with redesign of the factory and redesign or acquisition of more hygienic equipment The cost associated with an effective quality assurance plan is well worth the effort to prevent the situations described 1 1 The Cost of Food Contamination 1 1 1 The Extent of Microbial Foodborne Illness in America Many have argued that the US food supply is the safest in the world Nevertheless the Centers for Disease Control and Prevention CDC have estimated that approx imately 5 200 deaths 325 000 hospitalizations and 76 million cases of foodborne disease occur each year in the United States Mead et al 1999 Known pathogens account for an estimated 14 million illnesses 60 000 hospitalizations and 1 800 deaths annually MMWR 2003 The Foodborne Disease Outbreak Surveillance System of the CDC indicates that over 1 000 outbreaks occur each year No one can J L Kornacki amp Kornacki Microbiology Solutions Inc McFarland WI USA e mail JLKORN731 gmail com J L Kornacki ed Principles of Microbiological Troubleshooting in the Industrial 1 Food Processing Environment Food Microbiology and Food Safety DOI 10 1007 978 1 4419 5518 0_1 Springer Science Business Media LLC 2010 2 J L Kornacki estimate the human cost in terms of suffering resulting from illness and death of lo
24. uite a bit more dangerous but no less complex in their own way Thanks for your amazing example of observation logic and persistence you are one of a kind I hope some of your rigorous approach to problems has been passed down to me I also want to thank Emeritus Professor Wayne Becker who awakened me to a fascination with living cells and then Emeritus Professor Robert Deibel both of whom taught inspired courses that I attended in cell biology and Food Bacteriology respectively in the 1970s These courses created in me a passion to one day become a microbiological investigator and troubleshooter in the food industry Heartfelt thanks are due my graduate Major Professor the late Elmer Marth who very graciously allowed me to pursue graduate degrees under his guidance and lead ership How little I knew then the practical value of his insights vast contribution to the field of food microbiology and incredible example of diligence thoroughness and analysis I also owe a great debt of gratitude to Dr Damien Gabis and Dr Russell Flowers of Silliker Laboratories whose philosophy example and approaches matured me immensely as a microbiological troubleshooter through our many food processing plant visits together in the late 1980s and early 1990s Thanks are also due to Dave Evanson Dr Richard Smittle and Steve Decker also of Silliker for the same reason Apart from these individuals their insights and guidance the excellent contri butio
25. ved ones Other more quantifiable costs have been estimated Buzby and Roberts 1996 1 1 2 Overview of Costs Associated with Selected Foodborne Pathogens It is difficult to assess the costs associated with foodborne illness Buzby and Roberts 1996 estimated the costs of seven of these pathogens Campylobacter jejuni Clostridium perfringens Escherichia coli O157 H7 Listeria monocytogenes Salmonella Staphylococcus aureus and Toxoplasma gondii to be 5 6 9 4 billion in 1993 dollars in medical charges and lost productivity alone Selected foodborne pathogenic bacteria are discussed individually in Chapter 2 Product recalls whether from foodborne illness or spoilage result in added costs to manufacturers in a variety of ways These may include expenses associated with lawsuits from real or allegedly stricken individuals and lawsuits from shorted customers Other costs include those associated with efforts involved in finding the source of the contamination and eliminating it and include time when lines are shut down and therefore non productive additional non routine testing consultant fees time and personnel required to overhaul the entire food safety system lost market share to competitors and the cost associated with redesign of the factory and redesign or acquisition of more hygienic equipment This author is aware of one situation in the United States where a manufacturer in the late 1990s spent 11 million to remodel a porti
26. y 2 400 different serotypes are known to exist The nomenclature of this microbe has gone through a number of changes resulting in some confusion In this author s opinion it is easiest to refer to the serotype designation e g Salmonella serotype Typhimurium as opposed to other nomenclatural approaches e g Salmonella enterica serovar Typhimurium 2 2 2 Cost Costs that are difficult to measure include pain and suffering death and loss of a company s reputation Other costs may include lost market share lost jobs or reduced wages lawsuits from shorted customers the price to remanufacture prod ucts that have been destroyed the cost to recondition contaminated product if possible and allowed and lawsuits from stricken individuals or class actions see Chapter 1 The United States Department of Agriculture USDA estimated that 696 000 3 800 000 cases of non typhoid foodborne Salmonellosis occurs annually with an estimated cost of 0 9 12 2 billion dollars Buzby and Roberts 1996 2 2 3 Disease Syndromes Salmonella can cause a number of disease syndromes including typhoid fever from Salmonella typhi rarely found in foods produced in the United States However 2 Selected Pathogens of Concern to Industrial Food Processors 9 other strains of Salmonella cause gastroenteritis bacteremia and enteric or paraty phoid fever Hanes 2003 Onset times typically range from 18 to 36h IAFP 1999 Symptoms include abdominal pain
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