Survival of Salmonella enterica and Enterococcus faecium on Abiotic Surfaces During Storage at Low Relative Humidity

Currently, there is limited knowledge on the survival of bacteria on surfaces during postharvest handling of dry products such as onions. Extended survival of microorganisms, coupled with a lack of established and regular, validated cleaning or sanitation methods could enable cross-contamination of these products. The aim of the study was to evaluate the survival of a potential surrogate, Enterococcus faecium, and Salmonella enterica on typical onion handling surfaces, polyurethane (PU), and stainless steel (SS), under low relative humidity. The influence of onion extract on the survival of E. faecium and Salmonella on PU and SS was also investigated. Rifampin-resistant E. faecium NRRL B-2354 and a five-strain cocktail of Salmonella suspended in 0.1% peptone or onion extract were separately inoculated onto PU and SS coupons (2 × 2 cm), at high, moderate, or low (7, 5, or 3 log CFU/cm2) levels. The inoculated surfaces were stored at ∼34% relative humidity and 21°C for up to 84 days. Triplicate samples were enumerated at regular intervals in replicate trials. Samples were enriched when populations fell below the limit of detection by plating (0.48 log CFU/cm2). Scanning electron microscopy was used to observe the cell distribution on the coupons. Reductions of E. faecium of less than ∼2 log were observed on PU and SS over 12 weeks at all inoculum levels and with both inoculum carriers. In 0.1% peptone, Salmonella populations declined by 2 to 3 log over 12 weeks at the high and moderate inoculum levels; at the low inoculum level, Salmonella could not be recovered by enrichment at 84 days. Survival of E. faecium and Salmonella was significantly (P < 0.05) enhanced over 84 days of storage when suspended in onion extract, where cells were covered by a layer of onion extract. E. faecium might have utility as a conservative surrogate for Salmonella when evaluating microbial survival on dry food-contact surfaces.

Bootstrapping for Estimating the Conservative Kill Ratio of the Surrogate to the Pathogen for Use in Thermal Process Validation at the Industrial Scale

A surrogate is commonly used for process validations. The industry often uses the target log cycle reduction for the test (LCRTest) microorganism (surrogate) to be equal to the desired log cycle reduction for the target (LCRTarget) microorganism (pathogen). When the surrogate is too conservative with far greater resistance than the pathogen, the food may be overprocessed with quality and cost consequences. In aseptic processing, the Institute for Thermal Processing Specialists recommends using relative resistance (DTarget)/(DTest) to calculate LCRTest (product of LCRTarget and relative resistance). This method uses the mean values of DTarget and DTest and does not consider the estimating variability. We defined kill ratio (KR) as the inverse of relative resistance.The industry uses an extremely conservative KR of 1 in the validation of food processes for low-moisture foods, which ensures an adequate reduction of LCRTest, but can result in quality degradation. This study suggests an approach based on bootstrap sampling to determine conservative KR, leading to practical recommendations considering experimental and biological variability in food matrices. Previously collected thermal inactivation kinetics data of Salmonella spp. (target organism) and Enterococcus faecium (test organism) in Non-Fat Dried Milk (NFDM) and Whole Milk Powder (WMP) at 85, 90, and 95°C were used to calculate the mean KR. Bootstrapping was performed on mean inactivation rates to get a distribution of 1000 bootstrap KR values for each of the treatments. Based on minimum temperatures used in the industrial process and acceptable level of risk (e.g., 1, 5, or 10% of samples that would not achieve LCRTest), a conservative KR value can be estimated. Consistently, KR increased with temperature and KR for WMP was higher than NFDM. Food industries may use this framework based on the minimum processing temperature and acceptable level of risk for process validations to minimize quality degradation.

Surface inoculation method impacts microbial reduction and transfer of Salmonella Enteritidis PT 30 and potential surrogates during dry sanitation

Dry sanitation methods are often limited to physical removal strategies such as brushing or wiping with sanitary cleaning tools. However, the relative efficacy of these approaches to remove microbiota on surfaces, and the risk of transferring cells to other surfaces via the cleaning tool, is unclear. The effect of dry wiping with a single-use towel on the removal of four different bacteria (Salmonella Enteritidis, Enterococcus faecium, Listeria innocua, Escherichia coli) was investigated. We also quantified the number of cells transferred to the towel itself during dry cleaning. Three different surface inoculation methods (spot, glass bead, contaminated milk powder) were assessed and significantly impacted initial surface microbial load. Higher initial counts corresponded to lower transfer coefficients (e.g., proportion of transferred cells). The effect of bacterial identity was significant on reduction after dry wiping for all three inoculation methods. Moreover, both bacterial identity and inoculation method had significant effects on the number of cells transferred to the towel. In most scenarios, dry wiping resulted in a reduction <1.0 log CFU/coupon. Although, on surfaces inoculated via contaminated milk powder, reductions of up to 1.6 ± 0.3 log CFU/coupon were obtained. Overall, E. faecium transferred more readily to the towel. These results may help guide experimental design for future research on dry sanitation.

Evaluation of Various Lactic Acid Bacteria and Generic E. coli as Potential Nonpathogenic Surrogates for In-Plant Validation of Biltong Dried Beef Processing

Validation studies conducted within a food processing facility using surrogate organisms could better represent the manufacturing process than controlled laboratory studies with pathogenic bacteria on precision equipment in a BSL-2 lab. The objectives of this project were to examine potential surrogate bacteria during biltong processing, conduct biltong surrogate validation lethality studies, and measure critical factors and intrinsic parameters during processing. Beef pieces (1.9 cm × 5.1 cm × 7.6 cm) were inoculated with four-strain mixtures of Carnobacterium divergens/C. gallinarum, Pediococcus acidilactici/P. pentosaceous, and Biotype 1 E. coli ATCC BAA (-1427, -1428, -1429, and -1430), as well as a two-strain mixture of Latilactobacillus sakei and other commercially available individual bacterial cultures (P. acidilactici Saga200/Kerry Foods; Enterococcus faecium 201224-016/Vivolac Cultures). Inoculated beef was vacuum-tumbled in marinade and dried in a humidity-controlled oven for 8−10 days (24.9 °C; 55% relative humidity). Microbial enumeration of surviving surrogate bacteria and evaluation of intrinsic factors (water activity, pH, and salt concentration) were performed post inoculation, post marination, and after 2, 4, 6, 8, and 10 days of drying. Trials were performed in duplicate replication with triplicate samples per sampling time and analyzed by one-way RM-ANOVA. Trials conducted with E. faecium, Pediococcus spp., and L. sakei never demonstrated more than 2 log reduction during the biltong process. However, Carnobacterium achieved a >5 log (5.85 log) reduction over a drying period of 8 days and aligned with the reductions observed in previous trials with pathogenic bacteria (Salmonella, E. coli O157:H7, L. monocytogenes, and S. aureus) in biltong validation studies. Studies comparing resuspended freeze-dried or frozen cells vs. freshly grown cells for beef inoculation showed no significant differences during biltong processing. Carnobacterium spp. would be an effective nonpathogenic in-plant surrogate to monitor microbial safety that mimics the response of pathogenic bacteria to validate biltong processing within a manufacturer’s own facility.

Recent developments in low-moisture foods: microbial validation studies of thermal pasteurization processes

Outbreaks associated with low-moisture foods (e.g., wheat flour, nuts, and cereals) have urged the development of novel technologies and re-validation of legacy pasteurization process. For various thermal pasteurization processes, they share same scientific facts (e.g., bacterial heat resistance increased at reduced water activity) and guidelines. However, they also face specific challenges because of their different heat transfer mechanisms, processing conditions, or associated low-moisture foods' formulations. In this article, we first introduced the general structural for validating a thermal process and the shared basic information that would support our understanding of the key elements of each thermal process. Then, we reviewed the current progress of validation studies of 7 individual heating technologies (drying roasting, radiofrequency-assisted pasteurization, superheated steam, etc.) and the combined treatments (e.g., infrared and hot air). Last, we discussed knowledge gaps that require more scientific data in the future studies. We aimed to provide a process-centric view point of thermal pasteurization studies of low-moisture foods. The information could provide detailed protocol for process developers, operators, and managers to enhance low-moisture foods safety.

Persistence of Salmonella enterica and Enterococcus faecium NRRL B-2354 on Baby Spinach Subjected to Temperature Abuse after Exposure to Sub-Lethal Stresses

The exposure of foodborne pathogens such as Salmonella enterica to a sub-lethal stress may protect bacterial cells against distinct stresses during the production of leafy greens, which can constitute potential health hazards to consumers. In this study, we evaluated how the prior exposure of S. enterica to sub-lethal food processing-related stresses influenced its subsequent persistence on baby spinach under cold (4 °C for 7 days) and temperature abuse (37 °C for 2 h + 4 °C for 7 days) conditions. We also compared the survival characteristics of pre-stressed S. enterica and Enterococcus faecium NRRL B-2354 as its surrogate on baby spinach. A cocktail of three S. enterica serovars, as well as S. Typhimurium ATCC 14028 wild type and its ΔrpoS mutant, and E. faecium NRRL B-2354, was first exposed to sub-lethal desiccation, oxidation, heat shock, and acid stresses. Afterward, baby spinach was inoculated with unstressed or pre-stressed cells at 7.0 log CFU/sample unit, followed by 7-day storage under cold and temperature abuse conditions. The unstressed S. enterica (fresh cells in sterile 0.85% saline) decreased rapidly within the first day and thereafter persisted around 5.5 log CFU/sample unit under both conditions. The desiccation-stressed S. enterica showed the highest bacterial counts (p < 0.05) compared to other conditions. The unstressed S. enterica survived better (p < 0.05) than the oxidation- and acid-stressed S. enterica, while there were no significant differences (p > 0.05) between the unstressed and heat-shocked S. enterica. Unlike the wild type, temperature abuse did not lead to the enhanced survival of the ΔrpoS mutant after exposure to desiccation stress, indicating that the rpoS gene could play a critical role in the persistence of desiccation-stressed S. enterica subjected to temperature abuse. E. faecium NRRL B-2354 was more persistent (p < 0.05) than the pre-stressed S. enterica under both conditions, suggesting its use as a suitable surrogate for pre-stressed S. enterica by providing a sufficient safety margin. Our results demonstrate the merit of considering the prior exposure of foodborne pathogens to sub-lethal stresses when validating the storage conditions for leafy greens.

Heating of milk powders at low water activity to 95°C for 15 minutes using hot air-assisted radio frequency processing achieved pasteurization

Salmonella persistence in milk powders has caused several multistate foodborne disease outbreaks. Therefore, ways to deliver effective thermal treatment need to be identified and validated to ensure the microbial safety of milk powders. In this study, a process of hot air-assisted radio frequency (HARF) followed by holding at high temperatures in a convective oven was developed for pasteurization of milk powders. Heating times were compared between HARF and a convection oven for heating milk powders to a pasteurization temperature, and HARF has been shown to considerably reduce the come-up time. Whole milk powder (WMP) and nonfat dry milk (NFDM) were inoculated with a 5-serotype Salmonella cocktail and equilibrated to a water activity of 0.10 to simulate the worst case for the microbial challenge study. After heating the sample to 95°C using HARF, followed by 10 and 15 min of holding in the oven, more than 5 log reduction of Salmonella was achieved in WMP and NFDM. This study validated a HARF-assisted thermal process for pasteurization of milk powder based on previously collected microbial inactivation kinetics data and provides valuable insights to process developers to ensure microbial safety of milk powder. This HARF process may be implemented in the dairy industry to enhance the microbial safety of milk powders.

Control of Salmonella in low-moisture foods: Enterococcus faecium NRRL B-2354 as a surrogate for thermal and non-thermal validation

Salmonella has been implicated in multiple foodborne outbreaks and recalls associated with low water activity foods (La_wF). To verify the effectiveness of a process against Salmonella in La_wF, validation using a nonpathogenic surrogate strain is essential. Enterococcus faecium NRRL B-2354 strain has been used as a potential surrogate of Salmonella in different processing of La_wF. However, the survival of Salmonella and E. faecium in La_wF during food processing is a dynamic function of a_w, food composition and structure, processing techniques, and other factors. This review assessed pertinent literature on the thermal and non-thermal inactivation of Salmonella and its presumable surrogate E. faecium in various La_wF and provided an overview of its suitibility in different La_wF. Overall, based on the D-values, survival/reduction, temperature/time to obtain 4 or 5-log reductions, most studies concluded that E. faecium is a suitable surrogate of Salmonella during La_wF processing as its magnitude of resistance was slightly greater or equal (i.e., statistical similar) as compared to Salmonella. Studies also showed its unsuitability which either does not provide a proper margin of safety or being overly resistant and may compromise the quality and organoleptic properties of food. This review provides useful information and guidance for future validation studies of La_wF.