| Possible causes of elevated counts |
Suggested measures |
Errors in cleaning and disinfection: The result can be contamination of foods by, for example, microbiologically contaminated equipment, utensils, surfaces or machines |
- Check the implementation of cleaning and disinfection:
- Hygiene plan
- Execution of cleaning and disinfection, e.g. dosing of disinfectant, contact time, use of suitable and clean materials and cleaning cloths
- Avoid moisture residues and biofilms. Ensure thorough drying of equipment, tools and surfaces
- Train staff regarding potential errors and improvement measures
- Repeat cleaning and disinfection
- Verify effectiveness by visual on-site inspections, environmental testing and follow-up analyses
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Insufficient separation of "clean" and "unclean": The result is unwanted contamination of clean working areas, equipment or low-microbial foods with microorganisms originating from "unclean" activities or foods with high microbial loads (cross-contamination) |
- Review work organization in the facility
- Separate work areas, equipment and utensils for raw and processed foods
- Separation of "clean" and "unclean" areas and activities
- Train staff regarding potential errors and improvement measures
- Verify effectiveness by visual on-site inspections and follow-up analyses
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Errors in personnel hygiene: This can lead to transfer of (hazardous) microorganisms to, for example, product-contact utensils or foods. Possible errors include inadequate hand hygiene or glove changes, deficiencies in personal hygiene, contaminated work clothing or improper behavior when ill (deficiencies in infection control)
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- Train staff regarding potential errors and improvement measures
- Regular cleaning and disinfection of hands and/or regular changing of gloves
- Regular change of work clothing. Ensure work clothing is clean
- Train employees on infection control requirements
- Verify effectiveness by visual on-site inspections and follow-up analyses
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Errors in refrigeration or excessive shelf-life: The result is excessive growth of microorganisms due to interruptions of the cold chain, too high storage temperatures or storage beyond the recommended shelf-life |
- Ensure traceability of the cold chain during transport or request documentation from the supplier
- Check incoming and storage temperatures
- Monitor cooling temperatures/cold chain during processing, transport and sale
- If over-aging (or excessive shelf-life) is suspected, perform appropriate storage tests
- Verify effectiveness by follow-up analyses
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Errors in heating, hot-holding or cooling: The result is insufficient inactivation of microorganisms due to inadequate heating or strong microbial growth due to too low hot-holding temperatures combined with prolonged cooling phases
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- Check processes, production protocols and documentation
- Inactivation of most bacteria at a core temperature of +72 °C for at least 2 minutes. Exceptions include heat-stable spores and toxins. In these cases significantly higher temperatures and exposure times are required. Further information can be found in the respective information sheets (fact sheets)
- Verify correctness of processes and temperatures
- In general, hot-holding temperatures above +60 °C are required
- Rapid cooling: after 3 hours a core temperature of at least +7 °C must be reached (special caution is required for large quantities)
- Verify effectiveness by follow-up analyses
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Use of microbiologically contaminated raw materials or ingredients: If the process does not include reliable inactivation steps, the resulting foods may be microbiologically contaminated |
- Check products on receipt for e.g. incoming/transport temperature, shelf-life, packaging, deviations or abnormalities
- This also applies to goods before use in production. In case of doubt, do not use the food and consult supervisors
- Review microbiological specifications. If necessary, arrange laboratory testing of suspicious products or request results from the supplier
- Verify effectiveness by follow-up analyses
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Faulty maturation and fermentation processes: The result can be e.g. unwanted growth or insufficient inactivation of microorganisms |
- Check processes, environmental conditions, production protocols and documentation
- Verify effectiveness by follow-up analyses
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