Reduction of Salmonella spp. populations in Italian salami during production process and high pressure processing treatment: Validation of processes to export to the U.S

Growth and Non-Thermal Inactivation of Staphylococcus aureus in Sliced Dry-Cured Ham in Relation to Water Activity, Packaging Type and Storage Temperature

Dry-cured ham (DCH) could support the growth of Staphylococcus aureus as a halotolerant bacterium, which may compromise the shelf-stability of the product according to the growth/no growth boundary models and the physicochemical parameters of commercial DCH. In the present study, the behavior of S. aureus is evaluated in sliced DCH with different water activity (a_w 0.861-0.925), packaged under air, vacuum, or modified atmosphere (MAP), and stored at different temperatures (2-25 °C) for up to 1 year. The Logistic and the Weibull models were fitted to data to estimate the primary kinetic parameters for the pathogen Log₁₀ increase and Log₁₀ reduction, respectively. Then, polynomial models were developed as secondary models following their integration into the primary Weibull model to obtain a global model for each packaging. Growth was observed for samples with the highest a_w stored at 20 and 25 °C in air-packaged DCH. For lower a_w, progressive inactivation of S. aureus was observed, being faster at the lowest temperature (15 °C) for air-packaged DCH. In contrast, for vacuum and MAP-packaged DCH, a higher storage temperature resulted in faster inactivation without a significant effect of the product a_w. The results of this study clearly indicate that the behavior of S. aureus is highly dependent on factors such as storage temperature, packaging conditions and product a_w. The developed models provide a management tool for evaluating the risk associated with DCH and for preventing the development of S. aureus by selecting the most appropriate packaging according to a_w range and storage temperature.

Fate of Listeria monocytogenes, Salmonella spp., and Shiga Toxin-Producing Escherichia coli on Slices of an All-Beef Soppressata during Storage

Cells of Listeria monocytogenes, Salmonella spp., or Shiga toxin-producing Escherichia coli (STEC) were inoculated (ca. 4.0 log CFU/slice) onto slices (ca. 4 g each slice) of an all-beef soppressata (ca. pH 5.05 and a_w 0.85). The storage of vacuum-sealed slices of inoculated soppressata at 4 °C or 20 °C for 90 days resulted in reductions of all three pathogens by ca. 2.2 to 3.1 or ca. ≥3.3 log CFU/slice, respectively. When pathogen levels decreased to below detection (≤1.18 log CFU/slice) by direct plating, it was possible to recover each of the target pathogens by enrichment, albeit more frequently from slices stored at 4 °C (p < 0.05) compared to 20 °C. In summary, the slices of the commercially produced beef soppressata selected for this study did not provide a favorable environment for either survival or outgrowth of surface-inoculated cells of L. monocytogenes, Salmonella spp., or STEC during storage.

Assessing the Impact of Different Technological Strategies on the Fate of Salmonella in Chicken Dry-Fermented Sausages by Means of Challenge Testing and Predictive Models

Salmonella is the main relevant pathogen in chicken dry-fermented sausages (DFS). The safety of shelf-stable DFS must rely on the production process, which should not only prevent growth but promote inactivation of Salmonella. The aim of the study was to assess the behaviour of Salmonella during the production process of two types of low-acid chicken DFS. The impact of the use of starter culture, corrective storage and high-pressure processing (HPP) at different processing times was assessed through challenge testing, i.e., inoculating a cocktail of Salmonella into the meat batter (at 6 Log₁₀ cfu/g) used for sausage manufacture. Sausages of medium (fuet-type, FT) and small (snack-type, ST) calibre were elaborated through ripening (10-15 °C/16 d) and fermentation plus ripening (22 °C/3 d + 14 °C/7 d). Physico-chemical parameters were analysed and Salmonella was enumerated throughout the study. The observed results were compared with the simulations provided by predictive models available in the literature. In FT, a slight decrease in Salmonella was observed during the production process while in ST, a 0.9-1.4 Log₁₀ increase occurred during the fermentation at 22 °C. Accordingly, DFS safety has to be based on the process temperature and water activity decrease, these factors can be used as inputs of predictive models based on the gamma-concept, as useful decision support tool for producers. Salmonella lethality was enhanced by combining HPP and corrective storage strategies, achieving >1 and 4 Log₁₀ reductions for FT and ST, respectively.

Control of Listeria monocytogenes in chicken dry-fermented sausages with bioprotective starter culture and high-pressure processing

Listeria monocytogenes is one of the most relevant pathogens for ready-to-eat food, being a challenge for the food industry to comply with microbiological criteria. The aim of the work was to assess the behavior of L. monocytogenes in two types of chicken-based dry-fermented sausages during the fermentation and ripening, with or without a bioprotective starter culture (Latilactobacillus sakei CTC494). To complement the challenge testing approach, simulations with different predictive models were performed to better understand the role of contributing factors. The impact of post-processing strategies, such as high-pressure processing and/or corrective storage was assessed. The chicken meat was inoculated with a cocktail of three L. monocytogenes strains, mixed with other ingredients/additives and stuffed into small (snack-type) or medium (fuet-type) casings. Snack-type was fermented (22°C/3 days) and ripened (14°C/7 days), while fuet-type was ripened (13°C/16 days). At the end of ripening, HPP (600 MPa/5 min) and/or corrective storage (4 or 15°C/7 days) were applied. The suitability of HPP after fermentation was evaluated in the snack-type sausages. Pathogen growth (>3 Log₁₀) was observed only during the fermentation of the snack type without a starter. The bioprotective starter prevented the growth of L. monocytogenes in the snack-type sausages and enhanced the inactivation (1.55 Log₁₀) in fuet-type sausages, which could be related to the higher lactic acid production and consequent decrease of pH, but also the production of the antilisterial bacteriocin sakacin k. The gamma concept model allowed us to identify the main factors controlling the L. monocytogenes’ growth, i.e., the temperature during the early stages and a_w at the end of the production process. The earlier acidification linked with the addition of starter culture made the interaction with the other factors (undissociated lactic acid, a_w and temperature) to be the growth-preventing determinants. High-pressure processing only caused a significant reduction of L. monocytogenes in snack-type, which showed higher a_w. The application of HPP after fermentation did not offer a relevant advantage in terms of efficacy. Corrective storage did not promote further pathogen inactivation. The findings of the work will guide the food industry to apply effective strategies (e.g., fermentation temperature and bioprotective starter cultures) to control L. monocytogenes in chicken dry-fermented sausages.

Inactivating Food Microbes by High-Pressure Processing and Combined Nonthermal and Thermal Treatment: A Review

High-pressure processing (HPP) is a mild technology alternative to thermal pasteurization and sterilization of different food products. HPP has emerged to provide enormous benefits to consumers, i.e., mildly processed food and additive-free food. It effectively retains bioactive compounds and extends the shelf life of food commodities by inactivating bacteria, yeast, mold, and virus. The limitation of HPP in inactivating spores can be overcome by using other thermal and nonthermal processing sequentially or simultaneously with HPP. This review summarizes the applications of HPP in the fruits and vegetables, dairy, meat, fish, and poultry sector. It also emphasizes microbial food safety and the effectiveness of HPP in the load reduction of microorganisms. Comprehensive information about the synergistic effect of HPP with different techniques and their effectiveness in ensuring food safety is reported. The summarized data would be handy to interested researchers and industry personnel.

Emerging Trends for Nonthermal Decontamination of Raw and Processed Meat: Ozonation, High-Hydrostatic Pressure and Cold Plasma

Meat may contain natural, spoilage, and pathogenic microorganisms based on the origin and characteristics of its dietary matrix. Several decontamination substances are used during or after meat processing, which include chlorine, organic acids, inorganic phosphates, benzoates, propionates, bacteriocins, or oxidizers. Unfortunately, traditional decontamination methods are often problematic because of their adverse impact on the quality of the raw carcass or processed meat. The extended shelf-life of foods is a response to the pandemic trend, whereby consumers are more likely to choose durable products that can be stored for a longer period between visits to food stores. This includes changing purchasing habits from “just in time” products “for now” to “just in case” products, a trend that will not fade away with the end of the pandemic. To address these concerns, novel carcass-decontamination technologies, such as ozone, high-pressure processing and cold atmospheric plasma, together with active and clean label ingredients, have been investigated for their potential applications in the meat industry. Processing parameters, such as exposure time and processing intensity have been evaluated for each type of matrix to achieve the maximum reduction of spoilage microorganism counts without affecting the physicochemical, organoleptic, and functional characteristics of the meat products. Furthermore, combined impact (hurdle concept) was evaluated to enhance the understanding of decontamination efficiency without undesirable changes in the meat products. Most of these technologies are beneficial as they are cost-effective, chemical-free, eco-friendly, easy to use, and can treat foods in sealed packages, preventing the product from post-process contamination. Interestingly, their synergistic combination with other hurdle approaches can help to substitute the use of chemical food preservatives, which is an aspect that is currently quite desirable in the majority of consumers. Nonetheless, some of these techniques are difficult to store, requiring a large capital investment for their installation, while a lack of certification for industrial utilization is also problematic. In addition, most of them suffer from a lack of sufficient data regarding their mode of action for inactivating microorganisms and extending shelf-life stability, necessitating a need for further research in this area.

Power ultrasound in the meat industry (freezing, cooking and fermentation): Mechanisms, advances and challenges

High intensity ultrasound (HIUS) has a wide range of applications in different sectors of food processing. It is a promising and emerging technology demonstrating the potential to promote food processes without or at least damage to the quality of products. Among the processes of the meat industry, freezing, thawing, cooking and fermentation are very sensitive and important, because they have significant effects on product quality and are also very energy and time consuming. This review paper provides an interpretation of high intensity ultrasound (HIUS) applications, a summary of recent outstanding published research and an overview of the freezing/thawing, cooking/frying and fermentation processes in meat and its products assisted by HIUS. The effects, benefits and drawbacks as well as the challenges ahead in the commercialization of this technology in the meat industry are studied. The research results confirmed that the use of HIUS in the meat freezing/thawing, cooking/frying and fermentation in combination with the corresponding processing methods demonstrates a great potential to promote the process, improve the general quality of the final product and reduce the time and energy required. However, many issues remain that require further research to address these challenges. These challenges and subsequent research that is useful for developing and increasing the efficiency of this technology have been reviewed. After the literature review, it is concluded that HIUS may be a useful technology for meat processing because of its significant effects on the quality factors and related process variables that leads to the preservation of the initial nutritional and sensory properties of meat and its products. Of course, research must be continued to eliminate the disadvantages or minimize the undesirable effects of this technology on the final product and to remove barriers to commercialization and optimization of this method.

Inactivation of Listeria monocytogenes and Salmonella spp. in Milano-Type Salami Made with Alternative Formulations to the Use of Synthetic Nitrates/Nitrites

During the manufacture of Italian salami, a traditional meat product, a sequence of hurdles like meat fermentation, air-drying, and long ripening processes are generally sufficient to inhibit the growth of most pathogens. Furthermore, Italian salami are traditionally produced by adding synthetic nitrates/nitrites to raw meat with safety and technological aims, even if controversial opinions about their use still remain, particularly in relation to the consumer demand for natural food products. In this context, the aim of the study was to investigate the inactivation of Listeria monocytogenes and Salmonella spp. during the manufacturing process of Milano-type salami made with different formulations to evaluate the contribution of the hurdles and the vegetable or synthetic additives on the inactivation of pathogens. Thus, a challenge study was performed dividing ca. 400 kg of Milano-type salami batter into three batches: Batch (A) without nitrates/nitrites; Batch (B) with vegetable nitrates, and Batch (C) with synthetic nitrates/nitrites. The batches were separately inoculated with L. monocytogenes and Salmonella spp. and the pathogens’ survival was evaluated during the fermentation, draining, and 70-day ripening of the Milano-type salami. The pathogen counts decreased in all tested conditions, even though the highest inactivation of L. monocytogenes and Salmonella spp. (p < 0.05) was observed when nitrates or nitrites were added to the batter. This study shows how the safety of these products cannot exclude the aspect of the hurdle technology during the process, which plays a major role in the reduction of pathogens, but additives like nitrates and nitrites allow for a greater margin of safety. Thus, further studies are needed to validate the use of natural compounds as alternatives to conventional preservatives in meat products. These results may provide new information to support food business operators in producing traditional foods with alternative preservatives and competent authorities in verifying the safety of the products made with natural compounds, and to control the process parameters responsible for the synergistic effect against pathogens such as L. monocytogenes and Salmonella spp.

A systematic review of clean-label alternatives to synthetic additives in raw and processed meat with a special emphasis on high-pressure processing (2018-2021)

The meat industry is continuously facing challenges with food safety, and quality losses caused by thermal processing. This systematic review reports recent clean label approaches in high-pressure production of meat. A literature search was performed using Scopus, Web of Science, PubMed, and Springer databases for studies published in 2018-2021. In this regard, 69 articles were assessed out of 386 explored research articles in the identified stage. The findings indicate that most of the earlier work on high-pressure processing (HPP) focused on physicochemical and sensorial meat quality rather than providing nutritional aspects and clean-label solutions. However, few advanced studies report effective and innovative solutions to develop low salt/fat, and reduced nitrite for raw and cured meat products. HPP could help on increasing the shell life by five times in meat products; however, it depends on the formulation and packaging, etc. HPP can also preserve nutrients by using this non-thermal technology and reduce food waste as once the shelf life of products is known, it easily reduces the shrinkage in the marketplace. This review explores the latest trend of experimental research in high-pressure processing alone, or multi-hurdle techniques employed to increase the effect of clean-label ingredients for enhanced meat safety/quality.

Strategies for Nitrite Replacement in Fermented Sausages and Effect of High Pressure Processing against Salmonella spp. and Listeria innocua

The development of nitrite-free meat products is a current industrial concern. Many efforts have been attempted to replace the nitrite effect in cured meats colour formation and pathogens control. Our previous work evidenced that lactic acid and a cold ripening were the best hurdle technologies for nitrite-free fermented sausages from metabolomics. In the first part of this work, we investigated the effect of lactic acid compared with both two alternative additives (glucono-D-lactone and a mix of sodium di-acetate/sodium lactate) and with low-nitrite sausages, all of them following either cold or traditional ripening. For this purpose, microbiological analysis, pH, water activity (aw), and a sensory study were performed. All nitrite-free sausages (cold or traditional ripened) showed quality and safety traits similar to low-nitrite traditionally ripened ones used as control. In addition, sensory study revealed that sausages with lactic acid were the most preferred cold ripened samples, supporting that this is an optimal strategy for the production of nitrite-free sausages. We selected this product for further studies. Indeed, in the second part, we evaluated the impact of ripening, and other hurdle technologies as High Pressure Processing (HPP) and under-vacuum storage against Listeria innocua and Salmonella spp. by a challenge test. Maximal declines were obtained for ripening along with HPP (i.e., 4.74 and 3.83 log CFU/g for L. innocua and Salmonella spp., respectively), suggesting that HPP might guarantee nitrite-free sausages safety. Although the quality of raw materials remains essential, these hurdle strategies largely contributed to nitrite-free sausages safety, offering a promising tool for the meat industry.

Aspects of high hydrostatic pressure food processing: Perspectives on technology and food safety

The last two decades saw a steady increase of high hydrostatic pressure (HHP) used for treatment of foods. Although the science of biomaterials exposed to high pressure started more than a century ago, there still seem to be a number of unanswered questions regarding safety of foods processed using HHP. This review gives an overview on historical development and fundamental aspects of HHP, as well as on potential risks associated with HHP food applications based on available literature. Beside the combination of pressure and temperature, as major factors impacting inactivation of vegetative bacterial cells, bacterial endospores, viruses, and parasites, factors, such as food matrix, water content, presence of dissolved substances, and pH value, also have significant influence on their inactivation by pressure. As a result, pressure treatment of foods should be considered for specific food groups and in accordance with their specific chemical and physical properties. The pressure necessary for inactivation of viruses is in many instances slightly lower than that for vegetative bacterial cells; however, data for food relevant human virus types are missing due to the lack of methods for determining their infectivity. Parasites can be inactivated by comparatively lower pressure than vegetative bacterial cells. The degrees to which chemical reactions progress under pressure treatments are different to those of conventional thermal processes, for example, HHP leads to lower amounts of acrylamide and furan. Additionally, the formation of new unknown or unexpected substances has not yet been observed. To date, no safety-relevant chemical changes have been described for foods treated by HHP. Based on existing sensitization to non-HHP-treated food, the allergenic potential of HHP-treated food is more likely to be equivalent to untreated food. Initial findings on changes in packaging materials under HHP have not yet been adequately supported by scientific data.

Risk management tool to define a corrective storage to enhance Salmonella inactivation in dry fermented sausages

The resistance of Salmonella to the harsh conditions occurring in shelf-stable dry fermented sausages (DFS) poses a food safety challenge for producers. The present study aimed to model the behaviour of Salmonella in acid (with starter culture) and low-acid (without starter culture) DFS as a function of a_w and storage temperature in order to build a decision supporting tool supporting the design of a corrective storage strategy to enhance the safety of DFS. Salmonella spp. were inoculated in the raw meat batter at ca. 6 Log cfu/g with a cocktail of 3 strains (CTC1003, CTC1022 and CTC1754) just before mixing with the other ingredients and additives. After stuffing, sausages were fermented and ripened following industrial processing conditions. Different drying-times were applied to obtain three batches with different a_w (0.88, 0.90 and 0.93). Afterwards, DFS were stored at 4, 8, 15 and 25 °C for a maximum of three months and Salmonella spp. were periodically enumerated. The Weibull model was fitted to Log counts data to estimate inactivation kinetic parameters. The impact of temperature and a_w on the primary inactivation parameters was evaluated using a polynomial equation. The results of the challenge tests showed that Salmonella spp. levels decreased during storage at all the assayed conditions, from 0.8 Log (in low-acid DFS at 4 °C) up to 6.5 Log (in acid DFS at 25 °C). The effect of both a_w and temperature was statistically significant. Delta (δ) parameter decreased by decreasing a_w and increasing temperature, while the shape (p) parameter ranged from above 1 (concave) at 10 °C to below 1 at 25 °C (convex). A common secondary model for the p parameter was obtained for each type of DFS, acid and low-acid, indicating that acidification during the production of DFS affected the time for the first Log reduction (δ) during the subsequent storage, but not the overall shape (p parameter) of the inactivation. The developed models covered representative of real conditions, such as Salmonella contamination in the raw materials and its adaptation to the harsh processing conditions. The good predictive performance shown when applying the models to independent data (i.e. up to 80% of the predictions within the 'Acceptable Simulation Zone' for acid sausages) makes them a suitable and reliable risk management tool to support manufacturers to assess and design a lethality treatment (i.e. corrective storage) to enhance the Salmonella inactivation in the product before DFS are released to the market.

Effect of ultrasound on proteolysis and the formation of volatile compounds in dry fermented sausages

Ultrasound (US) is an emerging technology capable of affecting enzymes and microorganisms, leading to the release of amino acids and the formation of volatile compounds. The effect of different exposure times (0, 3, 6, and 9 min) of US (25 kHz, 128 W) on the proteolysis and volatile compounds of dry fermented sausages during processing (day 0 and 28) and storage (day 1 and 120) was investigated. Lower alanine, glycine, valine, leucine, proline, methionine, and tyrosine levels were observed at the beginning of manufacture for the sample subjected to 9 min of US (p < 0.05) when compared to the control. During the storage period, the samples subjected to US exposure for 3 and 6 min exhibited higher free amino acid levels. A greater formation of hexanal, pentanal, and hexanol was observed in the US-treated samples when compared to the control (p < 0.05), as well as other derivatives from the oxidation reactions during the storage. The use of US (25 kHz and 128 W) in the manufacture of dry fermented sausages can affect the proteolysis and the formation of compounds derived from lipid oxidation during the storage.

Modeling the behavior of Listeria innocua in Italian salami during the production and high-pressure validation of processes for exportation to the U.S

A model describing Listeria innocua evolution according to process parameters of 51 Italian salami processes and HPP in 31 companies was developed. A total of 51 challenge tests were performed. During processing a L. innocua reduction of 0.34-4.32 Log10 CFU/g was observed and HPP further reduced the count of 0.48-3.47 Log10 CFU/g; an overall reduction of 1.04-5.68 is reached. PH after acidification/drying process, a_w after seasoning, duration of the seasoning and caliber resulted associated (p < 0.05) with L. innocua decrease. HPP efficacy was associated (p < 0.05) with a_w and pH of the product: higher the pH and a_w after the acidification/drying and seasoning phases, higher resulted the L. innocua reduction after HPP. No significant association was observed between L.innocua and salt, nitrate and starter content and other characteristics of process. The model meets companies and Authorities needs and represents a useful tool to predict L. monocytogenes lethality, giving recommendations to food business operators interested in exportation to the U.S.

Effect of production process and high-pressure processing on viability of Salmonella spp. in traditional Italian dry-cured coppa

The aim of the study was to investigate the combined effect of the manufacturing process followed by HPP treatment on the inactivation of Salmonella spp. in artificially contaminated coppa samples, in order to verify the ability of the combined processes to achieve the objective of a 5-log reduction of Salmonella spp. needed for exportation to the U.S. Fresh anatomical cuts intended for coppa production were supplied by four different delicatessen factories located in Northern Italy. Raw meat underwent experimental contamination with Salmonella spp. using a mixture of 3 strains. Surface contamination of the fresh anatomical cuts was carried out by immersion into inoculum containing Salmonella spp. The conditions of the HPP treatment were: pressure 593 MPa, time 290 seconds, water treatment temperature 14°C. Surface and deep samples were performed post contamination (T0), end of the cold phase (T1), end of process (Tend), and after HPP treatment (postHPP) and Salmonella spp. Enumerated. The results of this study show a significant reduction of Salmonella spp. all through the production process (P<0.01) for all companies, followed by an additional reduction of bacterial counts due to HPP treatment (P<0.01), both in superficial and deep contaminations (P<0.01). The superficial overall reduction resulted of 1.58 to 5.04 log CFU/g during the production process. HPP treatment resulted in a significant (P<0.01) superficial and deep decrease in Salmonella spp. enumeration varying from 0.61 to 4.01 log and from 1.49 to 4.13 log. According to the data presented in this study, only the combined approach of coppa manufacturing process followed by HPP treatment always led to a 5-log reduction of Salmonella spp. required by USDA/FSIS guidelines.