| Possible causes of elevated microbial counts |
Suggested measures |
Faults in personnel hygiene: This can lead to transfer of (dangerous) microorganisms to e.g. product-contact utensils or foods. Possible faults include insufficient hand hygiene or glove changes, deficiencies in personal hygiene, contaminated work clothing or incorrect behavior when ill (deficiencies in infection control) |
- Train staff regarding potential faults and improvement measures
- Regular cleaning and disinfection of hands and regular glove changes
- Regular change of work clothing. Ensure work clothing is kept clean
- Train staff on the requirements for infection control
- Effectiveness control by visual on-site inspections and follow-up testing
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Deficiencies in infection control: This creates the risk of transmission of pathogenic microorganisms from people to product-contact surfaces or directly to food
Examples:
Salmonella from excretions or infected employees
Staphylococcus aureus from employees with inflamed or purulent wounds or colonization of the nasopharynx
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- Employees who are ill with or suspected of infections with Salmonella, EHEC/STEC, Shigella, Vibrio cholerae, hepatitis A or E viruses or other infectious gastrointestinal diseases, or who excrete the aforementioned bacterial pathogens, must not work in food businesses handling perishable foods and in kitchens according to the Infection Protection Act (IfSG) (see IfSG § 42)
- The same applies to employees who have inflamed or purulent wounds. Non-infected wounds must be hygienically and properly covered
- Regular training/instruction of employees regarding required infection control measures
- Effectiveness control by visual on-site inspections, checks of training documentation and follow-up testing
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Faults in agricultural production, harvesting or downstream processes: Contamination of plant-based foods during cultivation by animal excretions, contaminated water or fertilizers, or by personnel |
- Maintain distance from fields with animal husbandry; keep wild animals away from fields using e.g. fences or nets
- Water hygiene: do not use contaminated water for irrigation. Irrigation and drainage systems must be suitable. Regular monitoring of microbiological water quality
- No microbially contaminated fertilizers may be used in crop production
- Personnel and work hygiene during harvest and downstream steps
- Remove soil and contamination by washing
- Effectiveness control by follow-up testing
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Use of microbiologically contaminated raw materials or ingredients:
If no reliable inactivation steps are present in the process, the foods produced may be microbiologically contaminated (e.g., raw vegetables or seafood …)
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- Check products at goods receipt for e.g. incoming/transport temperature, shelf life, packaging, deviations or abnormalities
- The same applies to goods before use in production. In case of doubt, do not use the food and consult supervisors
- Check microbiological specifications. If necessary, arrange laboratory testing of suspicious products or request results from the supplier
- Effectiveness control by follow-up testing
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Insufficient separation of "clean and unclean": The result is unwanted contamination of clean work 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 faults and improvement measures
- Effectiveness control by visual on-site inspections and follow-up testing
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Faults in heating, holding or cooling: The result is insufficient inactivation of microorganisms due to inadequate heating or strong microbial growth due to too low holding temperatures combined with excessively long cooling phases |
- Review processes, production protocols and documentation
- Inactivation of the viruses from a core temperature of +85 °C for at least 2 minutes
- Check correctness of processes and temperatures
- In general, 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)
- Effectiveness control by follow-up testing
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Faults in refrigeration or excessive shelf life: The result is excessive growth of microorganisms due to interruptions in the cold chain, too high storage temperatures or product overripening (excessively long shelf life) |
- Require traceability of the cold chain from transport or supplier
- Check incoming and storage temperatures
- Monitor refrigeration temperatures and cold chains during processing, transport and sale
- If overripening (or excessive shelf life) is suspected, carry out appropriate storage tests
- Effectiveness control by follow-up testing
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Faults in refrigeration or excessive shelf life: The result is excessive growth of microorganisms due to interruptions in the cold chain, too high storage temperatures or product overripening (excessively long shelf life) |
- Require traceability of the cold chain from transport or supplier
- Check incoming and storage temperatures
- Monitor refrigeration temperatures and cold chains during processing, transport and sale
- If overripening (or excessive shelf life) is suspected, carry out appropriate storage tests
- Effectiveness control by follow-up testing
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Faulty ripening and fermentation processes: The result can be unwanted growth or insufficient inactivation of microorganisms |
- Review processes, environmental conditions, production protocols and documentation
- Effectiveness control by follow-up testing
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