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Growth and Case Studies: Listeria in Chicken Products

Explore research on Listeria growth in chicken roll, bacon, and sausages from Tegel, NZ's largest cooked chicken producer. Discover case studies, incidents, conclusions, monitoring strategies, and valuable insights.

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Growth and Case Studies: Listeria in Chicken Products

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  1. Growth and Case Studies Roy Biggs Tegel Research and Case Studies • Research on growth of Listeria in products; chicken roll, chicken bacon and pre-cooked sausages • Tegel experience – case studies

  2. Background - NZ • Tegel is the largest producer of cooked chicken products in NZ – over 150 tonnes per week, up to one third of this is chilled, long shelf life products • Last Tegel recall for micro contamination was in January 2000

  3. The Research - 1 • Objective – to test our assumptions (models) on consequences if contamination occurred. • 3 products • Sliced chicken roll • Chicken bacon • Pre-cooked sausages

  4. The Research - 2 • Innoculate them with <100 per g of Listeria • Incubate at 2oC & 10oC and test fortnightly • Plot the growth • Be scared, be very, very scared!

  5. The Results – Chicken Roll

  6. The Results - Bacon

  7. The Results - Sausages

  8. The Research - Conclusions • If we have a low level of contamination it is serious • Need to concentrate our efforts on prevention and monitoring • Be scared, be very, very scared!

  9. The Incidents - 1 • Product – chicken tenders • Dedicated cook plant with excellent separation & facilities • Isolation 1 – shift changeover – repair • Isolation 2 – shift changeover – wash • Isolations 3 & 4 – intermediate washes • Conclusions – conveyor, mandated wash

  10. The Incidents - 2 • Product – shredded chicken • Dedicated cook plant with excellent separation but poor entry facilities • Isolation 1 – product produced on nightshift • Isolation 2 – 6 days later on same shift • Isolation 3 – over next 7 days 37/160 • Conclusion – shaft seal on dicer

  11. The Incidents - 3 • Dedicated cook plant with excellent separation & entry facilities • Poor maintenance led to Lm isolations from floors over a period of months, shutdown planned in 3 months • No product isolations and product testing increased to 5 per line per day • NZFSA instruction to cease processing

  12. The incidents – 3 - continued • Negotiated continuation of processing for most products with increased sampling and supervision by Tegel technical staff • Maintenance shutdown 2 weeks later • Sporadic incidents over the next few months followed by “deep” cleans • DNA typing • No isolations for the following 2 years

  13. The Current Monitoring Regime • Pre-start physical check daily & ATP monitoring • First product off the line for all sliced and shredded products • Product samples and PC swabs at start up, 25%, 50% and 75% of the production run and during the last hour. • Non PC swabs (up to 20 locations) during last 2 hours of production • Any Intermediate cleans followed by product samples, PC and non-PC swabs • Escalation response

  14. Guidance • Control of Listeria monocytogenes in the Food Processing Environment – R. B. Tompkin (2002)Journal of Food Protection, vol 65 No4, pages 709-725 • Listeria Guidelines MAF

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