Validation of brownie baking step for controlling Salmonella and Listeria monocytogenes

Demonstration of Inappropriate Validation Method for a Cracker Baking Process Using Predictive Modeling

Validation of baking processes for the inactivation of Salmonella is complicated by the combined effects of product heating and drying. The goal of this study was to quantitatively evaluate a previously disseminated approach to validating baking processes utilizing a predictive model developed using only isothermal and single-moisture inactivation data for the initially formulated dough. A simple cracker dough was formulated using flour inoculated with a five-strain cocktail of Salmonella. Side-by-side isothermal and baking experiments were performed to estimate Salmonella inactivation kinetics and to quantify survivors in a dynamic environment, respectively. Isothermal, single-moisture inactivation experiments were performed with cracker dough (water activity, aw = 0.956 ± 0.002; moisture content = 0.50 ± 0.01 dry basis) at three temperatures (56, 60, or 63°C) with ≥6 time intervals. Baking experiments were performed in a convection oven at 177°C with samples pulled every 30 s up to 360 s, with an endpoint product aw (25°C) of 0.45. The Salmonella isothermal, single-moisture inactivation kinetics in cracker dough resulted in D60°C and z-values of 4.6 min and 4.9°C, respectively; this model was then integrated over the dynamic product temperature profiles from the baking experiments. In the baking experiments, an average of 5-log reductions of Salmonella was achieved by 150 s of treatment; however, >100-log reductions were predicted by the dough-based models at that time point. This fail-dangerous overestimation of Salmonella lethality in crackers explicitly demonstrated that single-level moisture-based prediction models are inappropriate for describing inactivation in a process with both dynamic temperature and moisture, and that model-based validations must incorporate moisture/aw. Furthermore, end-users should exercise caution when utilizing unvalidated models to validate preventive control processes.

Validation of a Simulated Commercial English Muffin Baking Process to control Salmonella Contamination

A validation study was conducted to investigate the effect of the English muffin baking process to control Salmonella contamination and to study the thermal inactivation kinetic parameters (D- and z-values) of Salmonella in English muffin dough. The unbleached bread flour was inoculated with 3 serovar Salmonella cocktail (Salmonella serovars viz., Newport, Typhimurium, and Senftenberg), and dried back to its preinoculated water activity levels with 7.46 ± 0.12 log CFU/g of Salmonella concentration. The Salmonella inoculated flour was used to prepare English muffin batter and baked at 204.4°C (400°F) for 18 min and allowed to cool at ambient air for 15 min. The English muffins reached 99 ± 0°C (211.96 ± 0.37°F) as their maximum mean internal temperature during baking. The pH and aw of English muffin dough were 5.01 ± 0.01 and 0.947 ± 0.003, respectively. At the end of the 18-min baking period, the Salmonella inoculated English muffins recorded a more than 5 log CFU/g reduction on the injury-recovery media. The D-values of 3 serovar cocktails of Salmonella at 55, 58.5, and 62°C were 42.0 ± 5.68, 15.6 ± 0.73, and 3.0 ± 0.32 min, respectively; and the z-value was 6.2 ± 0.59°C. The water activity (aw) of the English muffin crumb (0.947 ± 0.003 to 0.9557 ± 0.001) remained statistically unchanged during baking, whereas the aw of the muffin crust decreased significantly (0.947 ± 0.003 to 0.918 ± 0.002) by the end of 18 min of baking. This study validates and documents the first scientific evidence that baking English muffins at 204.4°C (400°F) for 18 min acts as an effective kill step by controlling Salmonella population by >5 log CFU/g.

Validation of baking as a kill-step for controlling Shiga toxin-producing Escherichia coli during traditional crust pizza baking process

A study was conducted to validate a simulated traditional crust pepperoni pizza baking process to control Shiga toxin-producing Escherichia coli (STEC) and to determine the heat resistance characteristics of STEC in pizza dough. Pizza dough and pepperoni slices were inoculated with 7 strains STEC cocktail and baked at 500°F (260°C) for 12 min using a conventional kitchen oven followed by 15 min of ambient air cooling. The mean internal temperature of the pizza reached 209.32 ± 1.94°F by the end of 12 min of baking and dropped to 137.90 ± 2.88°F after the 15 min ambient air cooling. The a_w and pH of the traditional crust pizza did not alter significantly during the baking process. The STEC population decreased by >5 log CFU/g in traditional crust pizza after 12 min of baking. Where pepperoni slices were used as a source of STEC introduction, a reduction of >6.5 log CFU/g was observed. The D-values of STEC cocktail in pizza dough at 55, 58, 61°C were 49.5 ± 4.10, 15.3 ± 0.68, and 2.8 ± 0.31 min, respectively. The z-value of STEC was 4.8 ± 0.16°C. This study validated that a typical traditional crust pizza baking process with ~209°F internal temperature for at least 12 min will result in 5 log reductions in STEC population.