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Undercooking may allow the survival of pathogens leading to several unintentional but potentially hazardous conditions: 1) direct contamination of a ready-to-eat product with pathogens, 2) elimination of other less heat resistant microorganisms that, if present, may suppress pathogen growth or cause spoilage prior to significant pathogen growth, and 3) thermal conditioning of pathogens and increasing their heat resistance to any subsequent cooking or reheating step. It is also possible for a sublethal heating step to trigger bacterial spores to germinate, producing vegetative cells that are more hazardous than spores, but also far more vulnerable to subsequent reheating (Rippen, 1998).
This section on killing pathogens by cooking excludes fish and fishery products processed by pasteurizing (covered in Chapter 5), retorting (covered by the low acid canned foods regulations, 21 CFR 113), smoking (covered in Chapter 7), acidified shelf stable fish and fishery products (covered by the acidified foods regulations, 21 CFR 114), and acidified refrigerated fish and fishery products (covered in Chapter 1).
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Controlling pathogen survival through the cook step is accomplished by:
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Expert knowledge of thermal process calculations and the dynamics of heat transfer in processing equipment is required to establish such a cooking process. Education or experience, or both can provide such knowledge.
Establishing cooking processes requires access to suitable facilities and the application of recognized methods. The cooking equipment should be designed, operated, and maintained to deliver the established process to every unit of product. In some cases, thermal death time, heat penetration, temperature distribution, and inoculated pack studies will be required to establish the minimum process. In many cases, establishing the minimum process may be simplified by repetitively determining the process needed to reach an internal product temperature that will assure the inactivation of all vegetative pathogens of public health concern (e.g., 82.2ºC [180°F]) under the most difficult heating conditions likely to be encountered during processing. In other instances, existing literature or federal, state, or local regulations establish minimum processes or adequacy of equipment. Characteristics of the process, product, and/or equipment that affect the ability of the established minimum cooking process should be taken into consideration in the establishment of the process. A record of process establishment should be maintained (FDA, 1998).
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Death of bacteria subjected to moist heat is logarithmic. A D-value (decimal reduction time) is the time required to kill 90% of the spores or vegetative cells of a given microorganism at a specific temperature in a specific medium. A 90% reduction in bacteria is equivalent to a reduction from 10,000 bacteria/g to 1,000 bacteria/g or 1 log cycle.
D-values can be determined from survivor curves when the log of population is plotted against time ( Figure 3-1), or by the formula:
Where T = time of heating, a = the initial number of microbial cells, and b = the number of surviving microbial cells after heating time T (Stumbo, 1965; Rippen et al., 1993).
For example, if a suspension containing 10,000 microbial cells/ml is heated for 4 min at 140ºF (60ºC) and only 293 microbial cells survive:
Harrison and Huang (1990) determined D-values for L. monocytogenes (Scott A) in crabmeat (Table 3-2).
Table 3-2. D-values for L. monocytogenes (Scott A) in blue crabmeat.
Temperature |
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40.43 |
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12 |
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2.61 |
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Where T 1 and T2 are temperatures and D1 and D2 are D-values at temperatures T1 and T2 (Rippen et al., 1993).
For example, using the D values (D122ºF = 40.43 min and D140ºF = 2.61 min) for L. monocytogenes:
z = 15.1ºF
Z-values are used to determine D-values at different temperatures using the formula:
Where:
D1 = Known D-value at temperature T1
D2 = Unknown D-value at temperature T2
Using the known D-values for L. monocytogenes (Scott A) in blue crabmeat and the z-value, D-values can be calculated for any given temperature. For example, substituting D and z values for Listeria in blue crabmeat (D140 = 2.61 min, z = 15.1ºF) from the Harrison and Huang (1990) study, the equivalent D-value at 185ºF is 0.16 s.
D185 = 0.0027 min or 0.16 s
D-values vary with product type and pubished D-values are rarely determined at the temperatures encountered during commercial processing.. Equivalent D-values should not be calculated for temperatures far hotter or cooler than those used in the original laboratory studies or errors may result due to the non-linerarity of some survivor curves (Rippen, 1998).
Adequate cooking processes are generally 6-D to 7-D processes at the geometric center of the thickest product or container being processed. Table 3.3 gives 1D-, 6-D, and 7-D-values for L. monocytogenes (Scott A) calculated from the Harrison and Huang (1990) study with blue crabmeat.
All cooking processes are product and equipment specific and must be evaluated independently. Any changes in the critical aspects of processes will effect the adequacy of the cook.
Conducting an in-plant process establishment study may result in a lower temperature process resulting in improved quality or yields. A process authority can usually identify alternative cook schedules that achieve equivalent pathogen kill (Rippen, 1998).
Table 3-3. 1-D and 7-D values for L. monocytogenes (Scott A) in blue crabmeat.
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60 | 140 | 2 | 37 | 15 | 40 | 18 | 16 |
60.56 | 141 | 2 | 14 | 13 | 27 | 15 | 41 |
61.11 | 142 | 1 | 55 | 11 | 33 | 13 | 28 |
61.67 | 143 | 1 | 39 | 9 | 55 | 11 | 34 |
62.22 | 144 | 1 | 25 | 8 | 31 | 9 | 56 |
62.78 | 145 | 1 | 13 | 7 | 19 | 8 | 32 |
63.33 | 146 | 1 | 3 | 6 | 17 | 7 | 20 |
63.89 | 147 | - | 54 | 5 | 24 | 6 | 18 |
64.44 | 148 | - | 46 | 4 | 38 | 5 | 24 |
65.00 | 149 | - | 40 | 3 | 59 | 4 | 38 |
65.56 | 150 | - | 34 | 3 | 25 | 3 | 59 |
66.11 | 151 | - | 29 | 2 | 56 | 3 | 25 |
66.67 | 152 | - | 25 | 2 | 31 | 2 | 56 |
67.22 | 153 | - | 22 | 2 | 10 | 2 | 31 |
67.78 | 154 | - | 19 | 1 | 51 | 2 | 10 |
68.33 | 155 | - | 16 | 1 | 36 | 1 | 52 |
68.89 | 156 | - | 14 | 1 | 22 | 1 | 36 |
69.44 | 157 | - | 12 | 1 | 11 | 1 | 22 |
70.00 | 158 | - | 10 | 1 | 1 | 1 | 11 |
70.56 | 159 | - | 9 | - | 52 | 1 | 1 |
71.11 | 160 | - | 7 | - | 45 | - | 52 |
71.67 | 161 | - | 6 | - | 38 | - | 45 |
72.22 | 162 | - | 5 | - | 33 | - | 38 |
72.78 | 163 | - | 5 | - | 28 | - | 33 |
73.33 | 164 | - | 4 | - | 24 | - | 28 |
73.89 | 165 | - | 3 | - | 21 | - | 24 |
74.44 | 166 | - | 3 | - | 18 | - | 21 |
75.00 | 167 | - | 3 | - | 15 | - | 18 |
75.56 | 168 | - | 2 | - | 13 | - | 15 |
76.11 | 169 | - | 2 | - | 11 | - | 13 |
76.67 | 170 | - | 2 | - | 10 | - | 11 |
77.22 | 171 | - | 1 | - | 8 | - | 10 |
77.78 | 172 | - | 1 | - | 7 | - | 8 |
78.33 | 173 | - | 1 | - | 6 | - | 7 |
78.89 | 174 | - |
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- | 5 | - | 6 |
79.44 | 175 | - |
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- | 5 | - | 5 |
80.00 | 176 | - |
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- | 4 | - | 5 |
80.56 | 177 | - |
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- | 3 | - | 4 |
81.11 | 178 | - |
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- | 3 | - | 3 |
81.67 | 179 | - |
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- | 2 | - | 3 |
82.22 | 180 | - |
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- | 2 | - | 2 |
82.78 | 181 | - |
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- | 2 | - | 2 |
83.33 | 182 | - |
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- | 2 | - | 2 |
83.89 | 183 | - |
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- | 1 | - | 2 |
84.44 | 184 | - |
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- | 1 | - | 1 |
85.00 | 185 | - |
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- | 1 | - | 1 |
85.56 | 186 | - |
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- | 1 | - | 1 |
86.11 | 187 | - |
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- | 1 | - | 1 |
86.67 | 188 | - |
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- | 1 | - | 1 |
87.22 | 189 | - |
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- | 1 | - | 1 |
87.78 | 190 | - |
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- | <0.5 | - | 1 |
88.33 | 191 | - |
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- | <0.5 | - | <0.5 |
88.89 | 192 | - |
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- | <0.5 | - | <0.5 |
89.44 | 193 | - |
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- | <0.5 | - | <0.5 |
90.00 | 194 | - |
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- | <0.5 | - | <0.5 |
90.56 | 195 | - |
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- | <0.5 | - | <0.5 |
91.11 | 196 | - |
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- | <0.5 | - | <0.5 |
91.67 | 197 | - |
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- | <0.5 | - | <0.5 |
92.22 | 198 | - |
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- | <0.5 | - | <0.5 |
92.78 | 199 | - |
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- | <0.5 | - | <0.5 |
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F-values and D-values are related in that a process F-value usually represents multiple D-values. If a research study determined that an organism’s D-value was 1 min at 185ºF (D185 = 1 min), then a process with a F185 = 10 min would achieve 10 decimal reductions for the target microorganism, or a 99.99999999 % kill (Rippen, 1998).
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1 = thin liquid
2 = thick liquid
3 = soft gel
4 = firm gel
Note: gelatin-raw fat mixture should have a texture = 1; plain gelatin should have a texture = 4, and should serve as a reference when checking for lack of enzyme activity
For example,
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*Minimum cook time required to eliminate enzymes.
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CHEF Test with Charm LUM-T meter
[Used to identify undercooked fish] |
Phosphatase measurement | 5 min | Charm Sciences, Inc.
36 Franklin St. Malden, MA 02148-4120 Phone: 781/322-1523 E-mail: charm1@charm.com Web: www.charm.com |
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Table 3-1. Temperature changes in lobster claw and tail muscle during cooking in boiling water.
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Lobster #1 | ||||
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11.9 | 53 | 12.7 | 55 |
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54.9 | 131 | 55.4 | 132 |
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86.4 | 188 | 81.7 | 179 |
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94.2 | 202 | 97.4 | 207 |
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95.9 | 205 | 100.5 | 213 |
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97 | 207 | 103.7 | 219 |
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98.2 | 209 | 105.1 | 221 |
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98.8 | 210 | 105.6 | 222 |
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99.3 | 211 | 105.7 | 222 |
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14.7 | 59 | 16.7 | 68 |
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52.1 | 126 | 67.2 | 153 |
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67.7 | 154 | 79.4 | 175 |
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84.2 | 184 | 88.2 | 191 |
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91.2 | 196 | 93.6 | 201 |
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94.6 | 202 | 98.1 | 209 |
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95.5 | 204 | 100.5 | 213 |
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96.7 | 206 | 101.4 | 215 |
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98.1 | 209 | 101.7 | 215 |
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17.1 | 63 | 19.5 | 67 |
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61.5 | 143 | 60.3 | 141 |
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78.6 | 174 | 84.3 | 184 |
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90.3 | 194.5 | 94.9 | 203 |
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95.5 | 204 | 100.0 | 212 |
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97.4 | 207 | 102.2 | 216 |
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99.6 | 211 | 103.1 | 218 |
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100.4 | 213 | 103.4 | 218 |
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100.8 | 213 | 103.4 | 218 |
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16.6 | 62 | 17.1 | 63 |
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53.3 | 128 | 69.1 | 156 |
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62.9 | 145 | 79.9 | 176 |
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70.5 | 159 | 97.4 | 207 |
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88.7 | 192 | 101.5 | 215 |
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94.4 | 202 | 104.4 | 220 |
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96.7 | 206 | 105.7 | 222 |
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97.8 | 208 | 106.1 | 223 |
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98.5 | 209 | 106.2 | 223 |
Note: LD50 is an abbreviation for the dose (expressed in milligrams per kilogram of body weight of the test animal) that is lethal to 50 per cent of the group of test animals (Ali, 1995).
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Ali, S. (Ed.). 1995. Pesticide toxicity, hazard and risk. http://itsd-s3.agric.gov.ab.ca/pests/pestcide/toxicity.html#LD50 (25 June, 1998).
Babbitt, J.K. 1981. Improving the Quality of Commercially Processed Dungeness Crab. SG 65, Oregon State University, Extension Marine Advisory Program, Corvallis, OR.
Barnett and Nelson, 1966. Recent technological studies of Dungeness crab processing. Part 4 – Preliminary report on salt uptake and heat penetration in whole cooked crab. Fishery Industrial Research 3(3):13-16.
Bushway, A.A. and Bayer, R. 1996. Lobster processing temperature recordings needed for HACCP plans. MSG-E-96-11. Maine/New Hampshire Sea Grant College Program and the Lobster Institute, 5715 Coburn Hall #22, University of Maine, Orono, ME.
Crawford, D.L. 1980. Meat yield and shell removal functions of shrimp processing. Special Report 597, Oregon State University, Extension Marine Advisory Program, Seafoods Laboratory, Astoria, OR.
FAO. 1976. Recommended international standard for quick frozen shrimps and prawns. CAC/RS 92-1976. Joint FAO/WHO Food Standards Programme, Codex Alimentarius Commission, Food and Agriculture Organization of the United Nations, World Health Organization, Rome.
FAO. 1978a. Recommended international standard for quick frozen lobsters. CAC/RS 95-1978. Joint FAO/WHO Food Standards Programme, Codex Alimentarius Commission, Food and Agriculture Organization of the United Nations, World Health Organization, Rome.
FAO. 1978b. Recommended international code of practice for shrimps and prawns. CAC/RCP 17-1978. Joint FAO/WHO Food Standards Programme, Codex Alimentarius Commission, Food and Agriculture Organization of the United Nations, World Health Organization, Rome.
FDA. 1998. Pathogen survival through cooking. Ch. 16. In Fish and Fishery Products Hazards and Controls Guide, 2nd ed., p. 189-196. Department of Health and Human Services, Public Health Service, Food and Drug Administration, Center for Food Safety and Applied Nutrition, Office of Seafood, Washington, DC.
FDA. 1999a. Destruction of organisms of public health concern: Cooking (raw fish). p. 53. Section 3-401.11(A)(1). 1995. Food Code, United States Public Health Service, Food and Drug Administration, Washington, DC.
FDA. 1999b. Destruction of organisms of public health concern: Cooking (comminuted fish). p. 54. Section 3-401.11(A)(2). 1995. Food Code, United States Public Health Service, Food and Drug Administration, Washington, DC.
FDA. 1999c. Destruction of organisms of public health concern: Cooking (stuffed fish). p. 54. Section 3-401.11(A)(4). 1995. Food Code, United States Public Health Service, Food and Drug Administration, Washington, DC.
Harrison M.A. and Huang, Y. 1990. Thermal death times for Listeria monocytogenes (Scott A) in crabmeat. J. Food Protect. 53:878-880.
Lee, J.S. and Hilderbrand, K.S. 1992. Hazard analysis & critical control point applications to the seafood industry. Oregon Sea Grant Publication ORESU-H-92-001. Oregon State University, Corvallis, OR.
Lind, J. 1965. Determination of activity of acid phosphatase in canned hams. Danish Meat Products Laboratory, The Royal Veterinary and Agriculture College, September 23, 1965.
Moody, M. 1999. The gelatin test. Louisiana State University, Baton Rouge, LA.
North Carolina. 1997. Handling, packing and shipping of crustacea meat. North Carolina Administrative Code, Title 15A, Department of Environment, Health and Natural Resources, Chapter 18, Environmental Health, Subchapter 18A - Sanitation, Section .0100 - (April, 1997).
Rippen, T.E. 1998. Personal communication. University of Maryland, Princess Anne, MD.
Rippen, T.E., Hackney, C.R., Flick, G.J., Knobl, G.M., Ward, D.R., Martin, R.E., and Croonenberghs, R. 1993. Seafood Pasteurization and Minimal Processing Manual. Virginia Cooperative Extension Publication 600-061 (1993), Virginia Sea Grant Publication VSG 93-09, Virginia Polytechnic Institute and State University, Blacksburg, VA. 173 p.
Stumbo, C.R. 1965. Thermobacteriology in Food Processing. Academic Press, New York, NY.
USDA. 1993. Internal cooking temperature determination (ICT1-2). In FSIS Analytical Chemical Laboratory Guidebook. Chemistry Division, Food Safety and Inspection Service, U.S. Department of Agriculture, Washington, DC.
Woodburn, M.J., Somers, E., Rodriguez, J. and Shantz, E.J. 1979. Heat inactivation rates of botulinum toxins A, B, E, and F in some foods and buffers. J. Food Sci. 44: 1658-1661.
Wojtowicz, M.B. 1974. Information on production of whole, frozen lobsters. New Series Circular No. 74. Environment Canada, Fisheries and Marine Service, Halifax Laboratory, Halifax, Nova Scotia.