| Possible causes of elevated microbial counts |
Suggested measures |
Use of microbiologically contaminated raw materials or ingredients: If the process does not include reliable inactivation steps, the foods produced from them may be potentially microbiologically contaminated (e.g. raw milk, meat, salad, …) |
- Check products at incoming goods for e.g. incoming or transport temperature, shelf life, packaging, deviations or abnormalities
- This also applies to the goods before they are used in production. If in doubt, do not use the food and ask supervisors
- Check microbiological specifications. If necessary, arrange laboratory testing of suspicious products or request results from the supplier
- Verification by follow-up testing
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Insufficient separation of “clean and unclean”: The consequence is unwanted contamination of clean work areas, equipment or low-microbe 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 corrective measures
- Verification by visual on-site inspections and follow-up testing
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Errors in cleaning and disinfection: The consequence is contamination of foods by, for example, microbiologically contaminated equipment, utensils, surfaces or machines |
- Review the execution of cleaning and disinfection:
- Hygiene plan
- Execution of cleaning and disinfection, e.g. dosing of the disinfectant, contact time, use of appropriate and clean materials and cleaning cloths
- Avoid moisture residues and biofilms. Ensure good drying of equipment, devices and surfaces
- Train staff regarding potential errors and corrective measures
- Repeat cleaning and disinfection
- Verification by visual on-site inspections, environmental testing and follow-up testing
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Errors in personal hygiene: This can lead to the transfer of (dangerous) microorganisms to e.g. product-contact utensils or foods. Possible errors include inadequate hand hygiene or glove changes, deficiencies in body hygiene, contaminated work clothing or incorrect behavior when ill (deficiencies in infection protection) |
- Train staff regarding potential errors and corrective measures
- Regular cleaning and disinfection of hands and regular glove changes
- Regular changing of work clothing. Ensure work clothing is clean
- Train employees regarding the requirements for infection protection
- Verification by visual on-site inspections and follow-up testing
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Deficiencies in infection protection: This creates the risk of transmission of pathogenic microorganisms from humans to product-contact surfaces or directly to foods
Examples:
Salmonella from excretors or ill employees
Staphylococcus aureus from employees with infected or purulent wounds or with colonization of the nasopharynx
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- Employees who are ill with or suspected of infections by Salmonella, EHEC/STEC, Shigella, cholera vibrios, hepatitis A or E viruses or other infectious gastroenteritis, or who excrete the above bacterial pathogens, must not work in food establishments handling perishable foods and kitchens according to the German Infection Protection Act (IfSG) (see IfSG § 42)
- The same applies to employees who suffer from infected or purulent wounds. Non-infected wounds must be hygienically properly covered
- Regular training/instruction of employees regarding the required infection protection measures
- Verification by visual on-site inspections, checks of training records and follow-up testing
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Errors during heating, hot holding or cooling: The consequence is insufficient inactivation of microorganisms due to inadequate heating or strong microbial growth due to too low hot-holding temperatures combined with excessively long cooling phases |
- 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, for example, in the respective information sheets (fact sheets)
- Check the 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)
- Verification by follow-up testing
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Faulty ripening and fermentation processes: The consequence can be undesired growth or insufficient inactivation of microorganisms |
- Check processes, environmental conditions, production protocols and documentation
- Verification by follow-up testing
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Errors in refrigeration or excessively long shelf life: The consequence is excessive microbial growth due to interruptions in the cold chain, too high storage temperatures or product over-age (excessively long shelf life) |
- Request traceability of the cold chain during transport or from the supplier
- Check incoming and storage temperatures
- Control refrigeration temperatures and cold chains during processing, transport and sale
- If over-age (or excessively long shelf life) is suspected, carry out appropriate shelf-life tests
- Verification by follow-up testing
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Errors in agricultural cultivation, harvesting or post-harvest processes: Contamination of plant-based foods (e.g. sprouts) in the field by animal excreta, contaminated water or fertilizers, or by personnel |
- Maintain distance to fields with animal husbandry; keep wildlife away from fields using, for example, fences or nets
- Water hygiene: contaminated water must not be used for irrigation. Irrigation and drainage systems must be suitable. Regular monitoring of microbiological water quality
- Do not use microbiologically contaminated fertilizers in crop production
- Personnel and work hygiene during harvest and post-harvest steps
- Remove soil and contaminations by washing
- Verification by follow-up testing
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