Implementation of ATP and Microbial Indicator Testing for Hygiene Monitoring in a Tofu Production Facility Improves Product Quality and Hygienic Conditions of Food Contact Surfaces: A Case Study

Before and After: Evaluation of Microbial and Organic Loads in Produce Handling and Packing Operations with Diverse Cleaning and Sanitizing Procedures

Inadequate cleaning and/or sanitation (C/S) of food contact surfaces (FCSs) has been frequently reported during Produce Safety Rule inspections; however, limited data are available evaluating the effectiveness of C/S processes in produce operations. Different C/S practices were evaluated in four fresh produce operations for their efficacy in reducing microbial and organic loads on various FCSs. Microbial (aerobic plate counts; APC) and organic (ATP) loads were quantified during production, after cleaning, and after sanitizing, if applicable. Operations included: a berry packinghouse (BerryPK; wet cleaning), a blueberry harvest contractor (BerryHC; cleaning + sanitizing, C+S), and two mixed vegetable packinghouses (MixedV1; C+S, and MixedV2; rinsing + sanitizing, R+S). Following wet cleaning, significant reductions in APCs (p < 0.05) were seen on high-density polyethylene (HDPE) storage trays (n = 50) in BerryPK (3.1 ± 0.9 to 2.5 ± 0.7 log CFU/100 cm2). In BerryHC, a greater reduction in APCs was seen on HDPE harvest buckets (n = 25) following C+S (3.8 ± 0.5 to 1.1 ± 0.4 log CFU/100 cm2), compared to wet cleaning only in BerryPK. Stainless steel and conveyor belt FCSs (n = 16) in MixedV1 were sampled, and a significant reduction in APCs (p < 0.05) was observed when comparing in-use (4.8 ± 1.3 log CFU/100 cm2) to post-C+S (3.9 ± 0.7 log CFU/100 cm2). When similar FCSs (n = 17) were sampled in MixedV2, R+S also led to significant reduction in APCs (3.3 ± 0.6 to 1.9 ± 0.6 log CFU/100 cm2) (p < 0.05). ATP testing in fresh produce settings yielded inconsistent results, with no correlation between organic and bacterial loads detected during production (R2 = 0.00) across four operations, and weak correlations observed after cleaning (R2 = 0.18) and after sanitation (R2 = 0.33). The results from this study provide the foundational basis for future research on practical and effective C/S methods tailored to the produce industry.

A Comprehensive Analysis of ATP Tests: Practical Use and Recent Progress in the Total Adenylate Test for the Effective Monitoring of Hygiene

ABSTRACT

Rapid hygiene monitoring tests based on the presence of ATP have been widely used in the food industry to ensure that adequate cleanliness is maintained. In this study, the practical applications and limitations of these tests and recent technological progress for facilitating more accurate control were evaluated. The presence of ATP on a surface indicates improper cleaning and the presence of contaminants, including organic debris and bacteria. Food residues are indicators of insufficient cleaning and are direct hazards because they may provide safe harbors for bacteria, provide sources of nutrients for bacterial growth, interfere with the antimicrobial activity of disinfectants, and support the formation of biofilms. Residues of allergenic foods on a surface may increase the risk of allergen cross-contact. However, ATP tests cannot detect bacteria or allergenic proteins directly. To ensure efficient use of commercially available ATP tests, in-depth knowledge is needed regarding their practical applications, methods for determining pass-fail limits, and differences in performance. Conventional ATP tests have limitations due to possible hydrolysis of ATP to ADP and AMP, which further hinders the identification of food residues. To overcome this problem, a total adenylate test was developed that could detect ATP+ADP+AMP (A3 test). The A3 test is suitable for the detection of adenylates from food residues and useful for verification of hygiene levels. The A3 test in conjunction with other methods, such as microorganism culture and food allergen tests, may be a useful strategy for identifying contamination sources and facilitating effective hygiene management.

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