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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

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Page 1: Tyson Foods - How Are We Applying What We've Learned

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

Page 2: Tyson Foods - How Are We Applying What We've Learned

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

Page 3: Tyson Foods - How Are We Applying What We've Learned

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.

Page 4: Tyson Foods - How Are We Applying What We've Learned

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…”

Page 5: Tyson Foods - How Are We Applying What We've Learned

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!

Page 6: Tyson Foods - How Are We Applying What We've Learned

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

Page 7: Tyson Foods - How Are We Applying What We've Learned

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

Page 9: Tyson Foods - How Are We Applying What We've Learned

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

Page 10: Tyson Foods - How Are We Applying What We've Learned

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

Page 11: Tyson Foods - How Are We Applying What We've Learned

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.

Page 12: Tyson Foods - How Are We Applying What We've Learned

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

Page 13: Tyson Foods - How Are We Applying What We've Learned

Proprietary ResearchListeria monocytogenes

• High Pressure Pasteurization

Page 14: Tyson Foods - How Are We Applying What We've Learned

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

Page 15: Tyson Foods - How Are We Applying What We've Learned

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

Page 16: Tyson Foods - How Are We Applying What We've Learned

Proprietary ResearchListeria monocytogenes

FSIS Average = 0.89%

Page 17: Tyson Foods - How Are We Applying What We've Learned

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

Page 18: Tyson Foods - How Are We Applying What We've Learned

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

Page 19: Tyson Foods - How Are We Applying What We've Learned

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

Page 20: Tyson Foods - How Are We Applying What We've Learned

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

Page 21: Tyson Foods - How Are We Applying What We've Learned

Proprietary Research

1/1/

2004

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2004

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2004

10/1

/200

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/200

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/201

0

0.00%

2.00%

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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)

Page 22: Tyson Foods - How Are We Applying What We've Learned

How Are We Doing?

http://www.cdc.gov/foodborneburden/PDFs/FACTSHEET_B_TRENDS.PDF

Page 23: Tyson Foods - How Are We Applying What We've Learned

How Are We Doing?

http://www.cdc.gov/foodborneburden/PDFs/FACTSHEET_B_TRENDS.PDF

Page 24: Tyson Foods - How Are We Applying What We've Learned

“…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

Page 25: Tyson Foods - How Are We Applying What We've Learned

Tyson’s Commitment

Ensuring Safe, Quality Food from Farm to

Fork

Questions?