tyson foods - how are we applying what we've learned
TRANSCRIPT
Tyson Foods
How Are We Applying What We’ve Learned?
Scott Stillwell
Vice President
Food Safety and Quality Assurance
Arkansas Association for Food Protection
September 14, 2011
Jim LochnerChief Operations Officer
Hal CarperGVP R&D, Technical Services
SVP Science & Regulatory Affairs
EnvironmentalCompliance –
Health & Safety
Dir. of Food Safety & Regulatory Compliance
Dr. Kellye PfalzgrafSr. Dir. Animal Welfare
Dr. Neal AppleVP Lab & Research
Services
Dr. Dean DanilsonVP Food Safety & Q.A.
Fresh Meats
Scott StillwellVP Food Safety & Q.A.
Poultry & Prepared Foods
Dr. Dan ZelenkaSr. Dir. Statistical Process
Design
Research and Development
InformationServices
Logistics and Supply Chain
Donnie SmithPresident & CEO
DistributionAviation
Consumer Relations Manager
Dir. International FSQASr. Dir. Animal Welfare
VP Lab & Research Services
VP Food Safety & Q.A. Fresh Meats
VP Food Safety & Q.A. Poultry & Prepared Foods
Sr. Dir. Statistical Process Design
Tyson’s Food Safety Organization
Food Safety Scope
Food Safety & Quality Assurance Manual Table of Contents
Detailed within the Tyson Foods’ FSQA Policies and Procedures
Involves a Step-Wise Approach:1) Policy / Program Development;2) Training;3) Monitoring – Process Control;4) Auditing; and5) Verification.
Food Safety Philosophy
• Assure production of safe, high quality products in large volumes at competitive prices;
• Collaborate with academic institutions on applied research -- Conduct applied research;
• Work closely with regulators and customers to develop meaningful and reliable standards;
• Develop technologies to reduce risk;• Validate efficacy of technology;• Training and education of team members; and• System implementation and verification (audit oversight).
“Quality is expected, Food Safety is required…”
Food Safety Scope
Involves a Step-Wise Approach:1) Policy / Program Development;2) Training;3) Monitoring – Process Control;4) Auditing; and5) Verification.
That’s all great and good, but if we’re not doing the right thing – it
won’t matter that we do it well!
Policy and Program Development
"We want to do those things that will truly impact public health and prevent
foodborne illnesses… we have to work smarter, more efficiently with our
resources.”
~ Elizabeth Hagen, MD USDA Undersecretary for Food Safety
American Farm Bureau Annual Meeting January 2011
Policy and Program Development
“Evolution is the law of policies: Darwin said it, Socrates endorsed it, Cuvier
proved it and established it for all time in his paper on The Survival of the Fittest.
These are illustrious names, this is a mighty doctrine: nothing can ever remove
it from its firm base, nothing dissolve it, but evolution.”
~ Mark TwainWhen in Doubt, Tell the Truth
Policy and Program Development
So – How do we make sure our policies and programs are founded on a solid base and modified as necessary in response to evolutionary pressure?
Applied Research Services and Research and Development
• Diversified Team Organizing and Directing Applied Research in Food Safety and New Technologies
• Coordinating Research on Microbiological Intervention Strategies
• Validation of Intervention Technologies• Designing and Conducting Field and Laboratory Testing
Collaboration with Academic Researchers
Through Industry Trade Associations• American Meat Institute Foundation
– Monday September 12: Salmonella spp. Research Proposals– Tuesday September 13: Listeria monocytogenes Research
Proposals– Wednesday September 13: E. coli O157:H7 and other STEC
Research Proposals
• Other Trades: NCC, USPEA, NTF, etc.
Through Direct Collaboration• University of Arkansas• Iowa State University• USDA, ARS, MARC
Collaboration with Other Researchers
Research Labs and Corporations• The National Food Lab
– Research Project # RES SERV-000004, “In-plant Thermal Process Validation Study Using a Non-Pathogenic Surrogate Microorganism to Determine Cross-Contamination Potential for Poultry Products with an Internal Temperature below 160F”, October 22-26, 2001.
• Deibel Labs– James N Bacus, Ph.D. Technical Ingredient Solutions, LLC
“Evaluation of a Commercial Starter Culture as a Potential Surrogate for Enteric Pathogens in Fermented Sausage Validation Studies”, June 2011
• Individual Corporate Interests– Project #: RES SERV-61 “Evaluation of Efficacy of Megan™
Vac 1 Vaccine in Broiler Chickens”, February – May, 1999.
Proprietary ResearchListeria monocytogenes
• Sentinel Site Program® (v12)– Environmental Monitoring– Search and Destroy
• Sanitation Standard Operating Procedures– Master Sanitation Schedule and Equipment Design
Reviews• Existing Equipment Evaluations• New Equipment Design task Force
• Validated Process Interventions or Product Formulations
Proprietary ResearchListeria monocytogenes
• High Pressure Pasteurization
Proprietary ResearchListeria monocytogenes
• Formulation / Intervention ChemicalsRTE Validation: Roasted Chicken
0
1
2
3
4
5
6
0 5 10 15 20 25 30 35 40
Days
Treated - Ional LC3 + Turbinado - UU
Treated - Ional LC3 + Splenda - VV
Treated - Mionix + Wild Flavor - WW
Treated - Mionix + Firmenich Flavor - XX
Control - YY
Proprietary ResearchListeria monocytogenes
• Inherent Product CharacteristicsRTE VALIDATIO N: PEPPERO NI
Complete
0.00
0.20
0.40
0.60
0.80
1.00
1.20
1.40
1.60
0 20 40 60 80 100 120
Days
Proprietary ResearchListeria monocytogenes
FSIS Average = 0.89%
Proprietary ResearchEscherichia coli O157:H7 (and Other STECs)
• Pre-Slaughter Application of O157 Phage• Pre-Harvest Interventions [probiotic, vaccine, phage,
feedlot management practices] • SPS Steam Pasteurization [post final rail]• Hot Water Carcass Wash• PECS [Pre-evisceration carcass spray w/ lactic/acetic
acid or180F hot water]• Hide Washing / Treatments• Slaughter Process Control and Verification
– Carcass PREP™: Dressing and Hygiene• Organic Acids; Halogens; Steam Pasteurization
– Tyson Total-N60™: Sampling Plan Design and Statistics [Prerequisite Program]• Statistical Validation
Proprietary ResearchEscherichia coli O157:H7 (and Other STECs)
5.0
2.7
0.4
5.0
2.7
0.5
0
1
2
3
4
5
Log10 cfu/ml
S. typhimurium E. coli (O157:H7)
Pre-Treatment Post-Water Wash Post-Treatment 1200 ppm ASC
Residual Populations of Salmonella typhimurium and Escherichia coli (O157:H7) on Inoculated Carcass
Proprietary Research
http://www.fsis.usda.gov/Science/Ecoli_O157_Summary_Tables/index.asp#2006
Table 6. Calendar Year 2009 through 2010
CY 2009 CY 2010*
Source Analyzed Positive Analyzed Positive
Federal Plants 12,065 36 11,616 29
Verification 11,573 35 11,291 26
Follow-up 492 1 325 3
Retail Stores 631 2 905 0
Verification 619 2 905 0
Follow-up 12 0 0 0
State Plants 0 0 0 0
Imports 101 3 29 1
Totals 12,797 41 12,550 30
Proprietary ResearchSalmonella spp. in Broilers
• Efficacy of Attenuated Broiler-Breeder Vaccine• Effects of Water Treatments on Colonization of
Broilers with Salmonella spp.• Efficacy of Hot Water Dip vs Spray for Reduction of
Salmonella and Campylobacter spp.• Efficacy of Bio-Mapping for Evaluation of Multi-Hurdle
Interventions for Reduction of the SalmonellaeSummary by Quarter MPN:
Months Salmonella % Positive
Average cfu per 400ml WBCR
Average log10 per 400ml WBCR
Jan - March 2007 15/18 = 83% + AVG = 36,131 AVG LOG = 3.28April - June 2007 23/24 = 96% + AVG = 48,881 AVG LOG = 3.70
July - September 2007 12/14 = 86% + AVG = 73,703 AVG LOG = 4.0
October - November 2007
11/16 = 69% + AVG = 24,523 AVG LOG = 2.84
February - March 2008 19/25 = 76% + AVG = 11,217 AVG LOG = 2.92
Apr-08 1/3 = 33% + AVG = 67 AVG LOG = 1.4
Proprietary Research
1/1/
2004
4/1/
2004
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2004
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/200
4
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/200
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/201
0
0.00%
2.00%
4.00%
6.00%
8.00%
10.00%
12.00%
14.00%
16.00%
18.00%
20.00%
Prevalence of Salmonella spp. Positive in Broiler WBCRs
C-8 Data Linear (C-8 Data) FSIS Data
Linear (FSIS Data) Tyson Data Linear (Tyson Data)
How Are We Doing?
http://www.cdc.gov/foodborneburden/PDFs/FACTSHEET_B_TRENDS.PDF
How Are We Doing?
http://www.cdc.gov/foodborneburden/PDFs/FACTSHEET_B_TRENDS.PDF
“…in this place it takes all the running you can do, to keep in the same place.“ ~ Red Queen to Alice in Through the Looking Glass
The Red Queen Principle - Leigh van Valen (evolutionary biologist, 1973)
Tyson’s FSQA Principle
Tyson’s Commitment
Ensuring Safe, Quality Food from Farm to
Fork
Questions?