February 2013

Technical information note

Listeria monocytogenes management in dairy factories
This technical information note explains why Listeria monocytogenes is a concern for dairy manufacturers, and offers practical measures to prevent product contaminations, or manage them should they occur. of contamination and improving operational aspects or processes within production.

An environmental monitoring program

Evidence shows that a basic environmental monitoring program can be cost-effective when compared to the costs incurred due to an L. monocytogenes detection in product.3 Environmental monitoring will usually provide a forewarning as to whether Listeria is present within the manufacturing site before it can contaminate product. The National Guidelines Pathogen Management document contains useful information on how to implement an environmental monitoring program.4

What is the risk?

There are six known Listeria species, however, only Listeria monocytogenes has been confirmed as pathogenic (diseasecausing). The detection of any Listeria species in either the processing environment or a dairy product may be considered a warning, as L. monocytogenes is often found following earlier detections of other Listeria species. Consumers of product containing L. monocytogenes may contract listeriosis which is a disease that can have varying effects, depending on the level of bacteria present, the quantity of product consumed and the susceptibility of the consumer. Listeriosis is rare, but the consequences of infection can be severe. For individuals categorised as high risk, (infants, pregnant women, the elderly, and the immuno-compromised), it is estimated that up to 30% will die if they contract the illness.1 In Australia in 2009, 14 Listeria infections identified in pregnant women resulted in two fatal materno-foetal cases, and 74 Listeria infections in elderly or immunocompromised individuals resulted in 10 deaths.2 Although these illnesses were not linked to dairy foods, it demonstrates the serious effects the disease can have on susceptible consumers.

Premises design
Flaws in the design or construction of a dairy premise may favour the growth of Listeria. In such cases, where it is impractical to fix these faults, extra vigilance will be required to monitor hot spots and maintain these areas in a sanitary condition. The following references provide practical detail in design and construction aspects: The Australian Code of Practice for Dairy Factories5 Operational Guideline: Design and Construction of Dairy Premises and Equipment.6 Plans for any new premises must be reviewed by DFSV.7

How can contamination be prevented?

Although regular product testing results may show an excellent history with respect to indicator organisms such as coliforms, Enterobacteriaceae or staphylococci, testing for these organisms will usually provide no indication that Listeria may be present in the plant or product. Listeria species often live and breed in different environments to these other contaminants. They are widespread in the general environment in soil and water, and can be carried by animals. They are most commonly found in moist damp environments, and are hardy survivors. There are various strategies that can be adopted to help prevent Listeria contaminations occurring. These include: implementing an environmental monitoring program, designing the manufacturing plant to reduce the risk

Operational aspects
Staff training is an important aspect of managing the risks associated with L. monocytogenes contamination. Each staff member must be adequately trained in hygienic practice related to their job. Having the best of systems and equipment in place does not eliminate the risk of contamination if there is inadequate understanding of how contamination can occur. Resources such as external training bodies or information from DFSV can be utilised. In-house training sessions, or mentoring of inexperienced staff should also be considered.

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Restricting the entry of personnel into high-risk production areas will assist in reducing the risk of contamination. Reinforcing the reasons why access is limited can also aid in operator understanding of the impact of contamination. Tanker drivers, maintenance, laboratory and administration staff, as well as visitors, are all capable of unknowingly transferring Listeria into a clean facility. Similarly, equipment can also transfer Listeria into production areas. Trolleys, forklifts, pallets, containers (particularly cardboard) are all possible contamination sources.8 below of how and where Listeria can contaminate a factory environment. Drains: Listeria is regularly found in external drains. To ensure these microorganisms do not enter the manufacturing area, drainage flow should be checked that it does not pass back through production areas. Open drains should be contained within each specific manufacturing section, not running under dividing walls, or to outside the premises. Drains need to be included in any cleaning and sanitising program. Drain cleaning needs to be done carefully, and not while production is still running. Never wash drains with water using high pressure, particularly while product or clean processing equipment is exposed, as the aerosols (tiny moisture droplets) created can disperse bacteria extraordinary distances. Appropriate attention needs to be paid to minimise the potential for contamination of the boots and clothing of the person doing the cleaning. Brushes used to clean drains should be clearly identified and only used for that purpose. Floors: Effective floor sealing is essential, particularly where equipment is or has been mounted on the floor. Any damage must be repaired promptly in order to prevent bacterial colonisation.

Example of contamination source trolley wheels

The production process

Products or ingredients that are introduced into the production process without an adequate microbial kill step may result in a Listeria contamination. Raw milk may contain L. monocytogenes or other pathogens. Segregation of raw and processed products needs to be ensured to prevent any possible cross-contamination. All ingredients that are not heat-treated, or are added after pasteurisation, should be purchased from approved suppliers, who should provide an assurance that they are free of Listeria. Also be aware of the handling process associated with ingredients, with the potential for contamination coming from the packaging. Be wary of purchasing discounted ingredients, such as cheese to be used for shredding, or similar processes. Examples have been recorded of cheese known to be contaminated with Listeria being sold to an unsuspecting manufacturer, resulting in their plant and products becoming contaminated.

Example of contamination source damaged flooring

Possible sources of contamination

Like other pathogens, L. monocytogenes is destroyed by pasteurisation, therefore any contamination in product would occur post-pasteurisation. Based on a combination of research and experience, some examples are listed

Walls: Dangers exist when walls are in direct contact with the floor in wet environments. Solid dwarf or nib walls incorporated into the flooring are recommended to raise panel walls above floor level. If damaged, particularly in production areas where product can fall, splash or be washed in, walls can become contaminated with Listeria, and will continually seed the environment until the damage is replaced and properly sealed. Footbaths or shoe change areas: Where provided, these facilities must be used by all who enter restricted production areas. Footbaths must be regularly emptied and cleaned, and adequate sanitiser strengths maintained.

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Traffic: If possible, eliminate wheeled devices such as forklifts, pallet jacks or trolleys from entering high-risk production areas. Consider using un-powered conveyor systems instead. Trolley wheels: Often overlooked in cleaning, trolley wheels can combine product, grease, moisture and soil, becoming a breeding ground for Listeria. Do not use high pressure water if cleaning them in production areas, as aerosols will be produced. Second-hand or refurbished equipment: Be aware that second-hand or refurbished equipment could contain contaminants, so ensure it has been thoroughly cleaned outside your premises before installation. Jacketed vats: Jacketed vats can be damaged or pitted on internal surfaces and holes may not be visible to the naked eye. Leak detection dyes are useful in such cases. External corrosion of vats can also allow contamination with product and organisms, which may be difficult to trace and remove. required in hard to access areas. Over-lubrication may also contribute to contamination from inside the stem housing. Enclosed support frames and other hollow equipment: When damaged or ineffectively sealed, enclosed support frames can become impossible to clean if internally contaminated. They have been known to cause on-going intermittent contamination through leakage onto exposed product. Avoid this tube structure where possible. Alternatively, ensure it is totally sealed, or can be effectively cleaned and drained. Any other equipment that is of hollow construction can similarly be a potential site for microbial contamination, such as conveyor rollers, agitator shafts and manual equipment with hollow handles.

Example of contamination source enclosed structures

Example of contamination source damaged vat

Out of sight product build-up: Get a floor-upward and ceiling-down perspective of the production area. Product and bacterial accumulation on the under surfaces of equipment has the potential to fall or come into contact with objects that may contaminate product. Uncleaned areas above production can allow contaminants to fall directly into product, onto product contact surfaces, or be circulated through the environment by air currents such as air conditioning or opening or closing doors. A regular inspection will highlight areas of concern. Powered conveyors: In wet areas, particularly where product can come into contact with them, powered conveyors can be problematic for cleaning and sanitising due to access difficulties. Sanitiser sprays or passing the belt through sanitiser solution is often used as a preventative measure. Mechanical seals: Seals can wear or become damaged, and on equipment such as reciprocating pneumatic devices, or on other locations that are not regularly subject to cleaning, can become a problem. Routine maintenance should prevent this occurring, and careful manual cleaning may be

Air line moisture traps: Listeria has been isolated from air line moisture traps. Once inside the traps, distribution can become widespread. These sites should be included in an environmental monitoring program. Control panels: Perished or damaged seals in wet production areas can support Listeria growth, either in the seal, or inside the panel. They should be inspected routinely. Ventilation/refrigeration: Vents and air-conditioning units can gather dust in some production circumstances. Condensate collection must be managed effectively. Regular inspection is recommended. Exposed product: Take extra care in how product postpasteurisation is stored prior to packaging, particularly when left in cool rooms or maturing rooms. Exposed product can become contaminated through the air currents of the recirculation systems. Listeria is an organism that can continue to multiply slowly at refrigeration temperatures. Cleaning and sanitising: Review the program efficacy, and ensure adequate contact with all surfaces is occurring. Listeria species have the ability to form biofilms which are difficult to remove once they attach to a surface. Consult with your chemical and equipment suppliers to assist with this.

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Personnel: The estimated carriage rate of Listeria monocytogenes of healthy people is estimated at 26%.1 The likelihood of direct product contamination by personnel is therefore probably low. However, failure to follow basic good manufacturing practices may result in the spread and possible contamination from Listeria. The poor work practices of factory personnel, particularly related to water aerosol production, has been identified as a significant reason for the spread of organisms throughout dairy factory environs.9

References
1. P Sutherland, D Miles & D Laboyrie, Listeria monocytogenes In AD Hocking (ed) Foodborne microorganisms of public health significance, 6th edn, AIFST, NSW Branch, Food Microbiology Group, Waterloo, NSW 2003, p. 393. 2. OzFoodNet. Monitoring the Incidence and Causes of Diseases Potentially Transmitted by Food in Australia, Annual Report of OzFoodNet Network 2009, Department of Health and Ageing, Canberra 2010. <http://www.ozfoodnet.gov.au/internet/ozfoodnet/ publishing.nsf/Content/reports-1> 3. I Haynes and D Eddy, Economic Impact of Monitoring the Dairy Manufacturing Environment, Aust. J. Dairy Tech, vol. 59, no. 2, 2004, pp. 149-151. 4. Dairy Food Safety Victoria, National Guidelines Pathogen Management, DFSV, Melbourne, 2011. <http://www.dairysafe.vic.gov.au/resource-library/ regulations-material> 5. Department of Primary Industry (superseded), Australian Code of Practice for Dairy Factories, Commonwealth of Australia, Canberra, 1986. <http://www.dairysafe.vic.gov.au/resource-library/ historical-documents> 6. New Zealand Food Safety Authority, Operational Guideline: Design and Construction of Dairy Premises and Equipment, NZFSA, Wellington, 2006. <http://www.foodsafety.govt.nz/elibrary/industry/ Operational_Guideline-Standards_Bulk.pdf> 7. Dairy Food Safety Victoria, Code of Practice for Dairy Food Safety, Section 5.2.4: Dairy Manufacturing Premises and Equipment, DFSV, Melbourne 2002. <http://www.dairysafe.vic.gov.au/resource-library/ regulations-material> 8. Biosecurity South Australia, Fact Sheet: Listeria Food Safety Issues for Dairy Manufacturers, Dairy Authority of South Australia, Adelaide, 2007. <http://www.pir.sa.gov.au/__data/assets/word_doc/0008/ 163565/info_sheet_for_listeria_and_dairy_211111.doc> 9. Australian New Zealand Dairy Authorities Committee. Australian Manual for Control of Listeria in the Dairy Industry Section 4.4. Occurrence of Listeria in Dairy Factory Environments, ANZDAC, Melbourne, 1999. <http://www.dairysafe.vic.gov.au/resource-library/ historical-documents>

What if there is a product contamination?

If Listeria species is found in a dairy food, further testing to confirm whether it is L. monocytogenes, should be undertaken promptly. The National Guidelines Pathogen Management4 document describes the procedures to follow in regards to product clearance, cleaning and environmental sampling in cases where L. monocytogenes is detected. Part of the clearance program will involve environmental testing to try to trace the source of the contamination. Initial environmental testing may pinpoint locations that appear to be the obvious cause, however experience has shown that there may be multiple sites that are not immediately detected. This can result in intermittent positive detections in product even after a clearance program has concluded. In such cases, additional environmental swabbing, line surveys or plant dismantling and inspection are suggested to trace the root source and cause of the contamination. Sometimes even extensive testing can fail to identify the source, which then places greater emphasis on the need to have an effective system of controls in place to prevent further contaminations, and to control affected product should a contamination occur.

Key points to consider

There are numerous ways that Listeria monocytogenes can colonise a factory environment and potentially cause product contamination. Careful consideration of factory design, construction, cleaning and maintenance will minimise the risk of contamination occurring. Staff training, ingredient control, and effective processing will further reduce this risk. Implementing an environmental monitoring program is perhaps the best strategy available to alert a manufacturer of potential dangers before product contamination with Listeria monocytogenes can occur.

Further information
Further food safety technical information is available at www.dairysafe.vic.gov.au Or contact Dairy Food Safety Victoria on (03) 9810 5900 or [email protected]
Dairy Food Safety Victoria 2013

This document is intended to be used as a general guide only and is not a comprehensive statement of all the relevant considerations with respect to this food safety topic or your particular circumstances, nor does it comprise, or substitute for, legal or professional advice. DFSV does not guarantee the accuracy, reliability, currency or completeness of the information. Links to other websites are provided as a service to users and do not constitute endorsement, nor are we able to give assurances of the accuracy of their content. DFSV accepts no legal liability arising from, or connected to, any reliance on this document.

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