WAGENINGEN UR

Enhancing Hygiene Performance in the Food Production System of CMC(Research topic 01)
Assignment -03/PDQ -35806 Kahawe palliya Gurunnanse KTG Reg. no 770125416060
3/9/2012

Contents
Chapter 1 From problem feeling to problem framing ................................................................................. 3 1.1. Quality problem situation: ........................................................................................................... 3

1.2 Formulation of problem feeling: ........................................................................................................ 4 1.3 Demarcation of study object ............................................................................................................. 4 1.3.1. Literature ................................................................................................................................... 4 1.3.2. Demarcated study object ............................................................................................................... 6 Chapter 2 From problem framing to problem definition ............................................................................ 7 2.1. Formulation of problem definition ................................................................................................... 7 2.1.1 Major T and M factors ................................................................................................................ 7 2.2. Problem definition .......................................................................................................................... 11 2.3. Hypothesis....................................................................................................................................... 12 2.4. Study aim ........................................................................................................................................ 12 Chapter 3From problem definition to techno-managerial research instrument ...................................... 13 3.1.Formulation of indicators and reference situation.......................................................................... 13 3.2. Visual representation of research instrument ................................................................................ 16 3.3. Summery table ................................................................................................................................ 18 3.4. Refined hypothesis.......................................................................................................................... 22 Reference ................................................................................................................................................... 23 Appendix: ................................................................................................................................................... 25

Chapter 1 From problem feeling to problem framing

1.1. Quality problem situation:
CMC is a ready to eat chill meal producing company which produce products containing meat, vegetables and spices. Those products are rich in carbohydrates and proteins. The pH (nearly neutral) and water activity (aw) of these products are highly desirable for growth of wide range of micro-organisms hence the effective control of hygienic performance in CMC is highly critical to maintain the constant quality of product. CMC has many suppliers of ingredients both from European and non-European companies. The ultimate quality of the product is depend on both, all the activities at primary production chain(meat and vegetable production), as well as inside the company. The major steps involved in production process of chill meal are receiving inspection, pre-treatment and chilled storage, preparation and assembly, packaging and labelling, chilled storage and transportation which contribute to the final quality of the product. The quality management system in CMC is based up on the guidelines and standards of PRP and GM codes for food industry, the HACCP guidelines of codex Alimentarius, ISO 9001 standards, BRC criteria and specific legislative requirements on chilled food. The Operation Department is mainly responsible for meeting the final quality specification. Recently, the company is dealing with food safety and quality issues in their product and production facilities. By looking at their problems and conditions inside the organisation, I have found out some technological and managerial issues. CMC Products at chill storage, at retailer and at catering were contaminated with some spoilage bacteria which cause gas formation and off-flavour. In addition to that they have found out that some product samples were contaminated with pathogenic bacteria such as Listeria monocytogenes (a common bacteria that can found in food production environment) , S.aureus ( the principle habitat is skin, skin glands and mucous membrane of warm blood animal including human) and campylobacter( very common in poultry products) cause food safety problems.Vegetables can be contaminated with wide range of bacteria through cultivation, harvesting and also processing because of high water activity and high pH range (5 6). Contamination of animal products can occur any stage of production chain, animal rearing, slaughterhouse as well as processing. The minimal processing conditions are not strong enough to destroy all the pathogenic and spoilage microbes in final chill meal and also the production process is not highly automated and high degree of manual handling taking place. The quality control functions ( measuring, testing regulating and corrective actions) in production is not performing well. The commitment for procedures and task of operators and supervisors seems to be poor. Since the chill meals normally stored at temperature below 5 C, bacteria like Listeria monocytogenes grow at chilled conditions leading high safety risk if the inactivation process are not controlled well.Sanitation activities at company is not sufficient and their production equipment (slicing and mixing machines, conveyor belt, weighing scales, packaging and filling machines) were not clean well. Contaminated production equipment can cause cross contamination of pasteurized products with pathogenic bacteria like Listeria monocytogenes which is common in foodproduction environment. The workers in production do not have clear understanding about microbial safety issues and hygiene practices. the knowledge of operators about CCP is questionable. Employer training regarding hygiene and
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sanitation look like inadequate or not given. Inside the organisation the records of knowledge and information is not well organised hence those data cannot use in effective way in quality control activities. In addition company does not maintain good relationship with their suppliers so the knowledge about the raw materials (vegetables and meat) is not available for the company. All these managerial and technological issues indicate that effectiveness of quality control activities at CMC is inadequate to ensure the constant quality of their products.

1.2 Formulation of problem feeling:

What could be the reasons for presence of pathogenic microbes increasing of microbial growth in chill meals (fresh cut vegetables) leading to food safety issues? Are they performing quality control activities (decision making and technology dependent activities) effectively in production? Is the cleaning and disinfection program performs as it means to be? Is that the personal hygienic behaviour of food handlers satisfactory? Do they received adequate training and do they have enough knowledge about their influence for food safety? Do they have positive attitude toward administrative conditions?

1.3 Demarcation of study object

1.3.1. Literature

FDA (U.S. Food and Drug Administration)Guide to Minimize Microbial Food Safety Hazards of Fresh-cut Fruits and Vegetables (2008) is provide guide to fresh cut fruits and vegetables industry describing fresh-cut produce production and processing controls from product specification to storage and transport. In recent past few years the consumption of fresh product is remarkably increased and the foodborne illness outbreak associated with fresh production also considerably higher hence my study mainly focus on fresh cut vegetable shredded lettuce. Processing fresh produce into fresh-cut products increases the risk of bacterial growth and contamination by breaking the natural exterior barrier of the produce. Hence, if pathogens are present when the surface integrity of the fruit or vegetable is broken, pathogen growth can occur and contamination may spread. The processing of fresh produce without proper sanitation procedures in the processing environment increases the potential for contamination by pathogens. In addition, the degree of handling and product mixing common to many fresh-cut processing operations can provide opportunities for contamination and for spreading contamination through a large volume of product. The potential for pathogens to survive or grow is increased by the high moisture and nutrient content of freshcut fruits and vegetables, the absence of a lethal process (e.g., heat) during production to eliminate pathogens, and the potential for temperature abuse during processing, storage, transport, and retail display. Importantly, however, fresh-cut produce processing has the capability to reduce the risk of contamination by placing the preparation of fresh-cut produce in a controlled, sanitary facility. The usefulness of this literature is, it provide guidance to consider which aspect of fresh cut vegetable production process should pay attention to increase the food safety. Tompkin (2002), has presented the data gathered from the several research peppers related to L. monocytogenes out brake and the causes for those out brakes. Most of outbreaks
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associated with ready to eat products were contaminated with contaminated processing environments. Hence it is clear that the food safety problems at CMC may be caused by poor sanitary conditions and the focuses will be on the cleaning and disinfection at CMC. Adams and Moss (2010) chapter 11 gives insight into the sources that cause the contamination of food product through processing. The food processing equipments soiled with food residues can act as a source of microbiological contamination therefore hygienic processing of food requires that both premises and equipment are cleaned frequently and thoroughly to restore them to the desired degree of cleanliness. However what appears to be clean visually can still harbour lager number of viable micro-organisms which may contaminate the product thus the proper disinfection after cleaning also crucial. Moreover higher standards of personal hygiene avoid the contamination of food with bacteria the food handlers may harbour as part of body flora. From these two literature I get insight that sanitation activities inside the production process ( cleaning and disinfection and personal health and hygiene) is very crucial in fresh-cut vegetable production hence my attention is mainly focuses to control activities at cleaning and disinfection and personal health and hygiene at CMC. Alzamora et.al (2000) describes all the aspects of minimally processed fruits and vegetables processing and safety concerns. I referred this literature to get insight into which pathogenic microorganisms associated with fresh-cut vegetables and which microbes are highly crucial from food safety aspect. C hence psychrotrophic bacteria are very important group that has to pay attention. Among the bacteria that can grow and survive in this temperature range Listeria monocytogenes has high rate of fatality. Its widespread distribution in environment and its ability to grow on most non acidic foods offer L. monocytogenes plenty of opportunity to enter the vegetable food chain and multiply. It has been reported several L.monocytogenes outbreaks associated with vegetables and they have refers to several studies in this book and confirmed the frequency of finding L.monocytogenes in fresh cut vegetable is relatively high. By considering all the facts I decided to focused my study mainly on Listeria monocytogenes in this assignment. More over this literature is very useful to find all the processing steps and importance of those to reduce and eliminate the growth and contamination of microorganisms in minimally processed vegetable products; by referring to all processing steps I have got insight that pre washing and washing after cutting or peeling is the main steps to reduce or eliminate the initial microbial count. Hence my focuses is control activities at washing step.

The quality control function model(Luning and Marcelis, 2009) describes the decision-making process where quality control objectives are translated into product quality within acceptable tolerances by measuring product and process properties, by comparing the measurement results with target values and tolerances, and by taking corrective actions when necessary. The objective of quality control is to keep product properties, production process and human process between certain acceptable tolerances. If all the quality control activities are executed well the process could be run without familiar and product should meet the specifications. The quality control at CMC is mainly executed at three points in production process i.e.
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incoming materials, in production and in sales and distribution. Although they have a quality management system based on all well recognised guidelines and standards CMC have safety issues in their products and process. Hence the quality problems at CMC could be caused by failure at any quality control functions. It is possible that operators and supervises at CMC are not compliance with procedures and task structure, or the capability of measuring equipments and/or process capability are inadequate, or managers commitment for control activities are not strong enough. Moreover Luning and Marcelis, (2009, p202) describe the possible quality control decisions that can influence on quality. It is utmost important to make the correct decisions to keep the food behaviour and human behaviour at acceptable tolerance. It is understandable that the importance of monitoring quality control activities to obtain a microbial safe food product. Luning and Marcelis, (2009) describe four quality control activities in quality control process and activities model. Mainly measuring, testing, regulating and corrective actions are the basic quality control activities. In this study the focus is on decision making processing the quality control activities, measuring, testing, and corrective actions in CMC in order to control the process. The operators control decisions in measuring process parameters, comparing the resulted values with set target and the taking of corrective actions if deviation from set targets according to the procedures as well as the management decisions on out of tolerance of peoples action, deviation from requirements on personal, procedures and information system and taking corrective action are main focus. By considering all the facts from cited literature with respect to problem situation (high count of bacteria lading to food safety issues) at CMC it is clear that the quality control activities and control decision are crucial quality control functions that account for microbial count (food safety) in fresh cut vegetables. In addition, it is evident that in the processing of fresh cut vegetables, the washing step is the most important processing step to reduce the initial microbial count of vegetable ingredients. Moreover the cleaning and disinfection of both premises and equipments and also personal hygiene can cause cross contamination of product during processing. With respect to food safety concern L. monocytogenes is important pathogenic bacteria with high frequency of fatality. With the help of those literatures the study object is demarcated as in the section 1.3.2. 1.3.2. Demarcated study object CMC has several production lines and wide range of products, in this assignment I would like to demarcate my study object only to shredded lettuce production. Focused will be on quality control activities (measuring, testing and corrective action) and control decisions at shredded lettuce production mainly processing parameters of washing step and cleaning and disinfection at production line equipment (cutting, centrifugation, transformation and packaging) and personal hygiene standard in order to reduce the finalListeria monocytogenes count to enhance the food safety.

Chapter 2 From problem framing to problem definition

2.1. Formulation of problem definition
2.1.1 Major T and M factors

Food safety refer to the absence of hazards or the existence of hazard level with an expectable risk. From this perspective hazard is a potential source of danger that may contaminate food product during any stage of processing from farm to fork which can cause a health disorder if ingested by a consumer. With reference to food safety it can identify three different type of hazards i.e. biological, chemical and physical hazards.(Luning&Marcelis, 2009). With reference to CMC quality problem the safety problem in their shredded lettuce production is caused by biological hazard associatedListeria monocytogenes in product samples. Alzamora et.al (2000) describes all the fundamental aspects and applications related to minimally process fruit and vegetables. They have gathered information from all kind of researches and surveys done by varies researchers and almost all parts of the world and describe with regards to all the aspects in minimally process fruit and vegetables. Hence this literature is regard as reliable source and although this authors talk about referring to all type of minimally process fruits and vegetable I think it is more specific to CMC case since shredded lettuce is minimally process vegetable product. The main processing steps in shredded lettuce processing are initial (pre-washing) washing, shredding, Washing after shredding, centrifuging and packaging. Out of these processing steps washing step (before and after shredding) is the main steps that aim at reducing initial microbial load. Hence the washing step as demarcated in study object is mainly focusing in this study. The product properties, pH range and water activity (aw) are main reason of higher susceptibility of microbial growth in shredded lettuce. Since there is no any heat treatment or any other processing in shredded lettuce, (consume as fresh) it cannot control the affect product properties for the presence of L. monocytogenes in final product. The technological conditions that effect the reduction of listeria in shredded lettuce at washing step are the quality of washing water(hardness etc.), water temperature, amount of disinfection(free chlorine) and washing time. According to Alzamora et.al (2000) all these conditions are highly critical for the effectiveness of washing but water temperature and disinfectant concentration and washing time is the major ones. Optimum temperature and the disinfectant concentration effect the reduction of listeria from raw material and also it affects the sensory quality and the legal limitation (residual disinfectant) of the product hence it is very important to control those factors. On the other hand washing time is also very crucial because contact time effect to the lethality of listeria. From this the main technological factors that affect the washing quality of shredded lettuce by decreasing safety hazards from listeria are time-temperature and disinfectant concentration of washing water. Marriott and Gravani (2006) describe all the aspects in sanitation activities in food industry with respect to more general factors to any food producing industry and specifically to each type of food processing industry. In this literature chapter 19 is specific for sanitation program for fruit and vegetable processing facilities and chapter 22 is particular for effective management of sanitation activities. They have gathered all the information from early studies and analyzing all relevant aspects related to sanitation to the food industry hence this is a
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reliable and relevance literature for my study. Sanitation program is consisted of cleaning and subsequent disinfection. Aim of cleaning is to remove the soil adhering to the food contact surfaces which can protect micro-organisms and serve as a source of nutrients and disinfection is aim to reduce to an acceptable level the numbers of adhering micro-organisms which survive physical cleaning. The technological factors that effect on the effective and efficient sanitation program are design of facilities and equipment and use of appropriate concentration of cleaning compound and disinfectant. If the facility and equipment are hygienically designed, cleaning is easier and contamination is reduced. If the concentration of the cleaning compound is not high enough the effectiveness would be inadequate and; low concentration of disinfectant make adaptation of listeria to that disinfectant and they can survive ultimately making contamination of product at processing. As previously describe in demarcation of study object the variation in process parameters as well as decision making behaviour of people involved in production system affect the safety of the shredded lettuce. The main L. monocytogenes control point in shredded lettuce production in CMC are washing and cleaning and disinfection practices. Luning & Marcelis, (2007) have n q n n n n n and administrative (organisational) conditions to create the circumstances to prevent undesirable product properties and or people actions, and decisions on dynamics of the food and human systems to reduce actual variation. I used this model to get insight to the control decisions in CMC to reduce the L. monocytogenes in shredded lettuce. This is a general model for quality control decisions of any food production but it describe the factors that influence the decisions hence I think it is useful model to get insight in to CMC quality problem. The model schematically shows that human systems make decisions on, respectively, food and human dynamics, and technological and administrative conditions. Via these four factors decisions can influence food quality (include safety). Both Managers and operators take daily control decisions to keep the process in control. The management decisions based on food dynamics by putting requirements on product properties, to ensure adequate materials/products, and on the control of human dynamics by directing their actions through providing specific information, gaining commitment, and/or by giving detailed direct instructions. Food handlers typically take daily control decisions on out of tolerance situations of product properties and process conditions, and on subsequent corrective actions. As describe previously in the washing step the control should be focused on washing timetemperature regime and concentration of disinfectants (Alzamora et.al 2000). The actual washing can be control via different type of decisions. The people characteristics, that can affect the decision making of operators working in washing process are commitment to the procedures and their attitude. If the operators did not constrain to procedures and did not monitor the temperature or disinfectant concentration correctly final outcome would be the initial listeria count would not reduce as it assume to be and increase the listeria count in final product. The administrative conditions that can direct people decision making behaviour are giving correct instructions about washing temperature time and disinfectant concentration (i.e. correct procedures ) and correcting wrong behaviour(supervision). If the correct and specific procedures are not available for operates, the operation decision they made could be add-hock
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and not planed that leading to variation in product specification. From those, it is clear that n n n commitment to the procedures, correct procedures. The managerial factors that can affect for a successful sanitation program are adaptation of effective cleaning and disinfection procedures, Supervision and training. If an inappropriate sanitation procedures was adapted (incorrect selection of cleaning and disinfection chemicals, incorrect concentrations and frequency of cleaning and disinfection) target bacteria (L. monocytogenes) that can associated with the products (shredded lettuces) would not be completely eliminated and the product can contaminate with the contaminated equipment. If the cleaning operator did not have adequate training their knowledge about listeria is not enough to make the decisions. Supervisors should always be on the alert to identify unsafe practices that may creep into an operation. Thorough supervision should be reinforced, with a continuous training program to keep employees informed of their responsibilities. If the supervision is inadequate the performance of the employees could be reduced. The results of study of Kirby and Gardiner (1997)indicate that premises with high standards of food hygiene include food hygiene training as part of normal procedure and practice. Having adequate knowledge about importance hygienic behaviour and microbial risk associated with food production make food handlers to take correct decision at production and their hygienic behaviour. Luning&Marcelis, (2009) describe the aims and consequence of the quality control decisions using quality control process and activities model and control decisions. This literature is more general for food quality control process and I think the factors describe there are relevant for CMC to get insight in to the current safety issues they facing. The control decisions making in process are mainly associated with control activities, measuring, testing, regulating and corrective actions. As demarcated in study object this study is focus on Measuring is aiming at monitor the actual process parameters with the procedures (ex. Temperature, disinfectant concentration); testing intend to compare the outcome of measurements or analysis result with the establish target and tolerances, regulating is the process of determining which corrective action is required based upon the result of the comparison with the target value and tolerances; The aim of the corrective action is taking actual v n n n n.

Table 01 summarise what are the aims of each technological steps and managerial activities and how each major T and M factors influence the effectiveness of specific technological step and managerial activity.

Table 01:Aim and effect of each T and M factors for each processing step and final quality output.

Aim of Technological step

Washing (T) Mainly aim at reducing the initial L.monocytogenes count of raw vegetables (lettuces)

Aim of Main FQM functions and the activities Q. control functions at process focused on keeping product absence of L. monocytogenes in 0.01 g Washing (T) To ensure production and human processes are within acceptable tolerances by measuring process parameters (time- temperature and disinfectant concentration) and testing with set tolerances to identify the out of tolerances, determining direction in which the process must be corrected and to ensure the actual action is being carried out during wising of shredded lettuce products.

Effects of M or T factors on technological step and quality output

If the temperature of the washing water, were not controlled the intended reduction of L.monocytegence could not achieve. If the concentration of disinfectant were not controlled the intended reduction of L.monocytegence could not achieve. If the time were not controlled the quality and the safety of the product will be reduced. If the correct and specific procedures are not available for operates, the operation decision they make could be add-hock. I n procedures is not in line the decision they make in the quality control activity would not be correct

Combination of all this factors finally affect the effectiveness of washing process and if these factors were not control properly It will exceed the legal limit of L.monocytogenesin final product.
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Cleaning and disinfection (T) Cleaned and pathogens free food production equipment and environment Prevent contamination through the processing that ensure product safety

Cleaning and disinfection (T) To ensure cleaning and sanitation activities are within acceptable tolerances, the execution of control activities by measuring testing ,regulating and taking corrective actions on the deviation of process parameters, out of tolerance of people characteristics and deviation of administrative conditions. Hygienic design of equipment, disinfectant concentration, sanitation procedure and training of sanitation operators will be taken into account.

If the equipment and the productions facilities are not hygienically design the effectiveness and efficiency of cleaning could be low. If the concentration of cleaning and disinfectant compounds are not high enough the cleaning could not be effective and L.monocytogenes could adapted to the disinfectant. If an inappropriate sanitation procedures was adapted, target bacteria (L.monocytogenes) that can associated with the products (shredded lettuces) would not be completely eliminated. If the cleaning operator did not have adequate training their knowledge about listeria is not enough to make the decisions. If the supervision is inadequate the performance of the employees could be reduced. Finally if all these factors were not control effectively the L.monocytogenes count in final product could de higher due to the contamination via inadequately clean equipment.

2.2. Problem definition

Is it possible to increase the efficiency of washing step by controlling technological factors temperature, washing time and concentration of disinfectant and the managerial factors i.e. commitment to the procedures, correct procedures and duty assigning? Is it possible to increase the efficiency of cleaning program by controlling technological factors, design of facilities and equipment and use of appropriate concentration of disinfectant and managerial factors selection of appropriate sanitation procedure, supervision and giving relevant training? Can increase the safety of shredded lettuce by improving efficiency of washing step and cleaning program?

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2.3. Hypothesis
If there were inadequate monitoring of temperature, disinfectant concentration of washing water and washing time in washing step as well as inadequate supervision, inadequate training and improper cleaning and disinfectant procedure in sanitation program will reduce the safety of shredded lettuce by presence of L. monocytogenes.

2.4. Study aim

The aim of this study is get insight in to the effect of controlling the technological factors as well as people related (managerial) factors at washing procedure and sanitation program to the food safety issues arise from presence of L. monocytogenes in ready to eat shredded lettuce.

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Chapter 3From problem definition to techno-managerial research instrument

3.1.Formulation of indicators and reference situation
Delaquis et.al,(1999) have find out the effect of micro flora of shredded iceberg lettuce using experimental setup of different temperature and disinfectant concentration and describe the effect of washing in the processing of shredded iceberg lettuce. This literature is very reliable and specific because it is about shredded lettuce and they have studied previous scientific studies and also made their conclusion on scientific experiment. In this literature they have talk about washing efficiency as log reduction of initial microbial count. They measure the efficiency my analyzing log reduction of initial microbial lode and from that it is understandable that the crucial aspect of getting idea about the washing step is log reduction of initial microbial lode. Hence the indicator for good performance of washing in shredded lettuce processing is log reduction of initial microbial lode. Further Delaquis et.al,(1999) have found that the average reduction of initial microbial level at the washing step is 3 log cfu g-1 . hence the reference situation for log reduction of initial microbial is 3 log cfu g-1 reduction from initial count. Delaquis et. al,(2004) have studied the implication of wash water chlorination and temperature for the microbiological and sensory properties of fresh-cut iceberg lettuce. In their study they have get insight in to previous studies done by different researches and made their experimental plan based on scientific methodology hence this is reliable source and it is very specific literature for shredded lettuce. But it is general literature for any kind of microbiological reduction but they have used different time temperature and free residual chlorine concentrations conditions in their study to find the optimum conditions that affect the reduction of initial bacteria count within acceptable sensory characteristics. The time and the temperature of the water have significant impact on the reduction of Listeria monocytogenes. At the washing of shredded lettuce, the main technological factors that affect on the efficiency are temperature and disinfectant concentration of washing water and the washing time (Alzamora et.al 2000).To get insight in to the maximum efficiency of temperature control of this washing step, the optimum temperate is seems to be the crucial aspect. Delaquis et. al,(2004) find out from their study that the . Zhang and Farber (1996) have done their study on the effects of various disinfectants against Listeria monocytogenes on fresh-cut vegetables from that they have observed chlorine has the maximum efficiency to reduce the Listeria monocytogenes count and it is the widely used disinfectant in fresh-cut vegetable production approved by USFDA ( U.S. F.D.A. Guide to Minimize Microbial Food Safety Hazards of Fresh-cut Fruits and Vegetables 2008). Delaquis et. al,(2004) pointed out that the Hypochlorous acid, the more active antimicrobial form, reacts quickly with inorganic and organic matter in solution to form combined chlorine compounds that have limited activity. The amount of HOCl required to react with such materials defined as the chlorine demand of the water. Excess HOCl beyond the chlorine demand is referred to as free residual chlorine. Zhang and Farber (1996) mainly focused on initial concentration of chlorine in washing not on the Free residual chlorine concentrations. Since Free residual chlorine concentrations is more important the outcome of their study is not very specific to
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use as the reference situation although it is specific to Listeria monocytogenes. Free residual chlorine concentrations between 2 and 7mgkg1 are required to ensure complete destruction of micro-organisms in water. Hence Optimum range of Free residual chlorine concentrations is the indicator for disinfectant concentration since Free residual chlorine is the effective substance that affect the washing performance. And the reference situation is in between 2 and 7 mg kg1. The exposure time also have crucial impact on reduction of initial bacterial count since higher the contact more inactivation of bacterial cells. If the washing time is higher it could be higher destruction of bacteria but the higher time also affects the sensory quality of the product too. Hence the indicator of the washing time to get an idea about the status of this factor is optimum time. n n n n . The managerial factors are very important for successful quality control activities. The more important M-factors that affect the washing efficiency are commitment to the procedures and correct procedures. The operators commitments to the procedures are depend on their knowledge about importance of CCPs. Hence the indicator to get the idea about the statues of commitment is CCP knowledge of operators. The reference situation could be level of HACCP training they acquired. The selection of correct procedures is highly crucial to obtain the target outcome of that process. Hence the indicator of the correct procedure of washing step is optimum log reduction of Listeria monocytogenes and in this case the reference situation is 3 log cfu g-1. Marriott and Gravani (2006) has provide all the aspects of sanitation in food industry in general and specifically for different type of industries and also both technological and managerial perspective using previous relevant studies. Hence it is relevant and reliable source of literature to get insight to find the indicters to attribute the effectiveness of T and M factors in the Cleaning and disinfection. Cleaning and disinfection is aiming at preventing of the product contamination during processing The indicator for optimum performance of cleaning and disinfection is absence of Listeria monocytogenes in processing equipment and environment.. The reference situation is Reading of ATP bioluminescence test Less than one CFU per 10 ml when the equipment is rinsed or less than one colony-forming unit (CFU) per 25 square cm of equipment sampled. The technological factors that effect on the effective and efficient sanitation program are design of facilities and equipment and use of appropriate concentration of disinfectant. EHEDGE Update: (1993), describe the hygienic equipment design criteria for food industry; EHEDGE is the European organisation aiming at promote hygiene during the processing and packing of food products and offer certification hence this is reliable and relevant source.The affect of the design of facilities and equipment to effectiveness of cleaning is attributed by the hygienic design of the equipment so the indicator of the factor design of facilities and equipment is hygienic design of the equipment and facilities and the reference situation is use of EHEDG Certified equipment. The indicator for the concentration of disinfectant is the optimum range of concentration of disinfectant (chlorine).Taormina and Beuchat ( 2002) have studied lethal effect of different disinfectants and the optimum concentration for Listeria monocytogenes for effective cleaning in food processing equipments. They have found out through their experimental study the optimum lethal concentration of free chlorine for Listeria monocytogenes as 4 6 mg l-1. This is the reference situation.
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The managerial factors that can affect for a successful sanitation program are adaptation of effective sanitation procedure, Supervision and training. Adaptation of specific sanitation program is very important for effective cleaning outcome. The crucial aspect of sanitation procedure is specificity and the effectiveness of sanitation program for Listeria monocytogenes in equipment and processing environment. Tompkin et. al (1999) give Guidelines to prevent post-processing contamination from Listeria monocytogenes at ready to eat food production. It emphasise the important of using sanitation procedures designed for L.monocytogens. This is relevant and useful literature since it mainly target on L.monocytogens and reliable because it is published in scientific journal and builds up using relevant literature. It describe eleven criteria that have to include and pay consistent attention in the sanitation procedure to successful control of L. monocytogens.1. dry clean, 2. Pre-rinse the equipment, 3. Visually inspect the equipment, 4. Foam and scrub the equipment, 5. Rinse the equipment, 6. Visually inspect the equipment, 7. Clean the floors. 8. Sanitise the equipment, 9. Conduct post sanitation verification, 10. Dry the floors, 11. Clean and put away supplies. This is regard as reference situation for the specificity of sanitation program. The effectiveness of the cleaning and sanitation can measure by visual inspection and using ATP bioluminescence test. The reading of the test indicate the effectiveness of the cleaning and disinfection. . Less than one CFU per 10 ml when the equipment is rinsed or less than one colony-forming unit (CFU) per 25 square cm of equipment sampled can regard as reference situation. It is especially important to train sanitation employees in the basics of sanitation because nothing happens in a food establishment until the facility is clean ( Marriott and Gravani 2006).The indicator for measure the effectiveness of training of operators in sanitation program is knowledge. The reference situation is full compliance to the procedure. Although employees are properly trained, they must be supervised to ensure proper conduct of responsibilities. The indicator for proper supervision in cleaning and disinfection is cleaning efficiency. Reference situation is motivated cleaning employees. The quality output of this study is final product with absence of Listeria monocytogenes. The indicator of the quality output is the log count of Listeria monocytogenes in the final product. And the reference situation is not detectable/ 0.01 g.

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3.2. Visual representation of research instrument

Equipment Design
hygienic design - EHEDG Certification of equipment

Training
knowledge- full compliance to the procedure

Supervision
cleaning efficiencymotivated cleaning employees

Procedures
Specificity and effectiveness of the sanitation program -

Concentration of disinfectant
optimum range of concentration of disinfectant (chlorine)- 4 6 mg l-1 free residual chlorine

Measuring

Testing

Regulating

Corrective Action (Q-control activities)

Microbial safety of Shredded lettuce

Washing
Shredding
log reduction of initial microbial- 3 -1 log cfu g

Mixing

Transforma tion

Packaging

Absence of Listeria monocytogenes in Shredded lettuce -not detectable / 0.01 g.

Shredded lettuce production process

Cleaning and disinfection

testing the food contact surfaces - L.monocytogenes Less than one CFU per25 square cm of equipment sampled

Measuring

Testing

Regulating

Corrective Action (Q-control activities)

Temperature
-

Concentration of disinfectant Free residual chlorine 1 concentrations-2 - 7 mg kg

Washing Time
optimum time - one minute at

Procedures
log reduction of L.monocytogenes3 log -1 cfu g

CCP knowledge -level of HACCP training

Washing and cleaning and disinfection of process equipment and facilities are the crucial technological step in shredded lettuce production line to eliminate Listeria monocytogenes from final product (Alzamora et.al 2000).Temperature, concentration of disinfectant and washing time has significant impact on efficiency of reduction of initial bacterial load of incoming raw material and it is assume that settin C, free chlorine 1 concentration at 2 - 7 mg kg and washing for one minute can achieve 3 log cfu g-1 reduction of initial bacterial count (Delaquis et. al,2004). To achieve this target the washing procedures and commitment of operators are very important factors. To prevent the contamination through processing and assure the safety of final product control of cleaning and disinfection activities have crucial impact (Marriott and Gravani 2006). To a successful cleaning outcome the controlling of disinfectant concentration hygienic design of equipment are utmost important if the well train operators and correct procedure is available with good supervision.

3.3. Summery table

Table 2: Aim and effect of each T and M factors for each processing step and final quality output with indicators and reference situation

Aim of Technological step

Aim of Main FQM functions and the activities Q. control functions at process focused on keeping product absence of L. monocytogenes in 0.01 g Washing (T) Washing (T) Mainly aim at reducing To ensure production the initial L. and human processes are monocytogenes count of within acceptable raw vegetables tolerances by measuring (lettuces) process parameters (time- temperature and disinfectant concentration) and testing with set tolerances to identify the out of tolerances, determining direction in which the process must be corrected and to ensure the actual action

Effects of M or T factors on technological step and quality output

Indicator for each T and M factors

Reference situation

If the temperature of the washing water, were not controlled the intended reduction of L.monocytegence could not achieve.

If the concentration of disinfectant were not controlled the intended reduction of L.monocytegence could not achieve.

Higher the temperate of washing water result in higher reduction of L.monocytegence in shredded lettuce but the temperature affect the sensory quality and the appearance of the product hence The indicator for the washing temperate is optimum temperate Optimum range of Free residual chlorine concentrations is the indicator for disinfectant concentration since Free residual chlorine is the effective substance that affect the washing performance.

Optimum temperature for higher reduction of

L.monocytegence by keeping quality attributes is C

reference situation is in 1 between 2 and 7 mg kg since it has to obey the legal limits for the acceptable Free residual chlorine concentrations.

is being carried out during wising of shredded lettuce products.

If the time were not controlled the quality and the safety of the product will be reduced.

For the washing Time the indicator is optimum time since longer time affect other quality attributes.

optimum washing time for maximum reduction of L.monocytegence while keeping other quality attributes within desirable level is C

If the correct and specific procedures are not available for operates, the operation decision they make could be add-hock.
If the operators commitment to procedures is not in line the decision they make in the quality control activity would not be correct

Optimum log reduction of Listeria monocytogenes is the indicator for correct and specific procedures

Reference situation is 3 log cfu g-1

The indicator for

operators commitment to procedures is Level of

level of HACCP training

CCP knowledge

Combination of all this factors finally affect the effectiveness of washing process and if these factors were not control properly It will exceed the legal limit of L. monocytogenes in final product.

Optimum log reduction of Listeria monocytogenes is the indicator for higher performance of washing process.

Reference situation is 3 log cfu g-1

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Cleaning and disinfection (T) Cleaned and pathogens free food production equipment and environment Prevent contamination through the processing that ensure product safety

Cleaning and disinfection (T) To ensure cleaning and sanitation activities are within acceptable tolerances, the execution of control activities by measuring testing ,regulating and taking corrective actions on the deviation of process parameters, out of tolerance of people characteristics and deviation of administrative conditions. Hygienic design of equipment, disinfectant concentration, sanitation procedure and training of sanitation operators will be taken into account.

If the equipment and the productions facilities are not hygienically design the effectiveness and efficiency of cleaning could be low. If the concentration of cleaning and disinfectant compounds are not high enough the cleaning could not be effective and L. monocytogenes could adapted to the disinfectant. If an inappropriate sanitation procedures was adapted, target bacteria (L.monocytogenes) that can associated with the products (shredded lettuces) would not be completely eliminated.

Level of hygienic design of the processing equipment.

EHEDG Certification of equipment

optimum range of concentration of disinfectant (chlorine)

free chlorine for Listeria monocytogenes is 4 6 mg l-1

Specificity of the sanitation program

Effectiveness of sanitation program

Include of eleven criteria describe by Tompkin et. al (1999) in Guidelines to prevent post-processing contamination from Listeria monocytogenes at ready to eat food production. Reading of ATP bioluminescence test
Less than one CFU per 10 ml when the equipment is rinsed or less than one colony-forming unit (CFU) per 25 square cm of equipment sampled

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If the cleaning operator did not have adequate training their knowledge about listeria is not enough to make the decisions. If the supervision is inadequate the performance of the employees could be reduced. Finally if all these factors were not control effectively the L.monocytogenes count in final product could de higher due to the contamination via inadequately clean equipment.

Level of hygienic knowledge

full compliance to the procedure

Level of cleaning efficiency

Reference situation is motivated cleaning employees.

The indicator for optimum performance of cleaning and disinfection is absence of Listeria monocytogenes in processing equipment and environment.

Reading of ATP

bioluminescence test
Less than one CFU per 10 ml when the equipment is rinsed or less than one colony-forming unit (CFU) per 25 square cm of equipment sampled

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3.4. Refined hypothesis

If the T factors of washing process i.e. the temperature of washing water Free residual chlorine concentrations, washing time , were not kept within the set requirement by controlling decision making process and administrative conditions and if the technological and managerial factors of cleaning and disinfection process i.e. concentration of disinfectant and , equipment hygienic design, execution of an effective and specific sanitation procedure, giving proper training and supervising cleaning operators properly, were not controlled, the count of Listeria monocytogenes in shredded lettuce product will higher than the acceptable limit (not detectable/ 0.01 g).

Reference
Adams, M.R., Moss, M.O., (2010). Food microbiology 3rd edition chapter 11: controlling microbiological Quality of Foods, p. 396-439, The Royal Society of Chemistry, Cambridge, UK. Alzamora, S.M., Tapia, M.S., Lopez-Malo, A., (2000) Minimally Processed Fruits and VegetablesFundamental Aspects and Applications, chapter 16, p.277-286, Aspen Publishers. Inc. USA. Amjadi, K. &Hussain, K. (2005) Integrating food hygiene into quantity food production. Systems Nutrition & Food Science, 35(3), p.169-183 Beuchat, L.R.andTaormina, P.J.,( 2002), Survival of Listeria monocytogenes in commercial food-processing equipment cleaning solutions and subsequent sensitivity to sanitizers and heat. Journal of Applied Microbiology, 92, p71-80 Delaquis, P.J., Stewart, S.,Toivonen, P.M.A., Moyls, A. L., (1999), Effect of warm, chlorinated water on the microbial flora of shredded iceberg lettuce, Food Research International32, p,7-14 Delaquis, P.J., Fukumoto, L.R., Toivonen, P.M.A., Cliff, M.A.,(2004) , Implications of wash water chlorination and temperature for the microbiological and sensory properties of fresh-cut iceberg lettuce, Postharvest Biology and Technology, 31, p 8191 EHEDGE Update: (1993), Hygienic equipment design criteria. Trends in Food Science and Technology, 4, 225-229. FDA, U.S. Department of Agriculture, and the Centers for Disease Control and Prevention, Guide to Minimize Microbial Food Safety Hazards in Hazards of Fresh-cut Fruits and Vegetables, February 2008. (accessed 28/02/12). Francis, G.A., Thomas, C., O'beirne, D., (1999), The microbiological safety of minimally processed vegetables International Journal of Food Science & Technology, 34, p1-22 Kirby, M.P., Gardiner, K., (1997),The effectiveness of hygiene training for food handlers. International Journal of Environmental Health Research 7, p,251258 Luning, P.A., Marcelis, W.J., 2007. A conceptual model of food quality management functions based on a techno-managerial approach, Trends in Food Science & Technology 18 p,159-166 Luning, P.A., Marcelis, W.J., 2009. Food Quality Management, Chapter 5: Quality control, p.199,202, 214,Wageningen Academic Publishers Marriott, N.G., Gravani, R.B., (2006), Principles of Food Sanitation. Fifth Edition chapter 19, chapter 22 p. 336-348,392-401, Springer Science+Business Media, Inc., the United States of America

Tompkin, R.B., Scott, V.N., Beranard, D.T., Sveum, W.H., and Gombas, K.S., (1999), Guidelines to

prevent post-processing contamination from Listeria monocytogenes, Dairy, Food and

Environmental Sanitation, 19, p, 551-562.

Tompkin, R.B., (2002) Control of Listeria monocytogenes in the Food-Processing Environment, Journal of Food Protection, 65, Pages 709725 Zhang, S., Farber, J.M., (1996), The effects of various disinfectants against Listeria monocytogenes on fresh-cut vegetables, Food Microbiology, 13, p,311321

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Appendix:

Figure 1. Quality Control Function by Luning and Marcelis, 2009.

Figure 2:Quality control process and activities model(Luning&Marcelis, 2009)

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