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Tyson Foods - How Are We Applying What We've Learned



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  • 1. Tyson FoodsHow Are We Applying What We’ve Learned?
    Scott Stillwell
    Vice President
    Food Safety and Quality Assurance
    Arkansas Association for Food Protection
    September 14, 2011
  • 2. Tyson’s Food Safety Organization
    Donnie Smith
    President & CEO
    Jim Lochner
    Chief Operations Officer
    Hal Carper
    GVP R&D, Technical Services
    Compliance – Health & Safety
    Logistics and
    Supply Chain
    Research and
    SVP Science & Regulatory Affairs
    Dir. of Food Safety & Regulatory Compliance
    Dr. Neal Apple
    VP Lab & Research Services
    Dr. Dean Danilson
    VP Food Safety & Q.A. Fresh Meats
    Scott Stillwell
    VP Food Safety & Q.A. Poultry & Prepared Foods
    VP Lab & Research Services
    VP Food Safety & Q.A. Fresh Meats
    VP Food Safety & Q.A. Poultry & Prepared Foods
    Dr. Kellye Pfalzgraf
    Sr. Dir. Animal Welfare
    Dr. Dan Zelenka
    Sr. Dir. Statistical Process Design
    Consumer Relations Manager
    Dir. International FSQA
    Sr. Dir. Animal Welfare
    Sr. Dir. Statistical Process Design
  • 3. Food Safety Scope
    Involves a Step-Wise Approach:
    Policy / Program Development;
    Monitoring – Process Control;
    Auditing; and
    Detailed within the Tyson Foods’ FSQA Policies and Procedures
  • 4. Food Safety Philosophy
    “Quality is expected, Food Safety is required…”
    Assure production of safe, high quality products in large volumes at competitive prices;
    Collaborate with academic institutions on applied research -- Conduct applied research;
    Work closely with regulators and customers to develop meaningful and reliable standards;
    Develop technologies to reduce risk;
    Validate efficacy of technology;
    Training and education of team members; and
    System implementation and verification (audit oversight).
  • 5. Food Safety Scope
    Involves a Step-Wise Approach:
    Policy / Program Development;
    Monitoring – Process Control;
    Auditing; and
    That’s all great and good, but if we’re not doing the right thing – it won’t matter that we do it well!
  • 6. Policy and Program Development
    "We want to do those things that will truly impact public health and prevent foodborne illnesses… we have to work smarter, more efficiently with our resources.”
    ~ Elizabeth Hagen, MD
    USDA Undersecretary for Food Safety
    American Farm Bureau Annual Meeting January 2011
  • 7. Policy and Program Development
    “Evolution is the law of policies: Darwin said it, Socrates endorsed it, Cuvier proved it and established it for all time in his paper on The Survival of the Fittest. These are illustrious names, this is a mighty doctrine: nothing can ever remove it from its firm base, nothing dissolve it, but evolution.”
    ~ Mark Twain
    When in Doubt, Tell the Truth
  • 8. Policy and Program Development
    So – How do we make sure our policies and programs are founded on a solid base and modified as necessary in response to evolutionary pressure?
  • 9. Applied Research Services and Research and Development
    Diversified Team Organizing and Directing Applied Research in Food Safety and New Technologies
    Coordinating Research on Microbiological Intervention Strategies
    Validation of Intervention Technologies
    Designing and Conducting Field and Laboratory Testing
  • 10. Collaboration with Academic Researchers
    Through Industry Trade Associations
    American Meat Institute Foundation
    Monday September 12: Salmonella spp. Research Proposals
    Tuesday September 13: Listeriamonocytogenes Research Proposals
    Wednesday September 13: E. coli O157:H7 and other STEC Research Proposals
    Other Trades: NCC, USPEA, NTF, etc.
    Through Direct Collaboration
    • University of Arkansas
    • 11. Iowa State University
    • 12. USDA, ARS, MARC
  • Collaboration with Other Researchers
    Research Labs and Corporations
    The National Food Lab
    Research Project # RES SERV-000004, “In-plant Thermal Process Validation Study Using a Non-Pathogenic Surrogate Microorganism to Determine Cross-Contamination Potential for Poultry Products with an Internal Temperature below 160F”, October 22-26, 2001.
    Deibel Labs
    James N Bacus, Ph.D. Technical Ingredient Solutions, LLC “Evaluation of a Commercial Starter Culture as a Potential Surrogate for Enteric Pathogens in Fermented Sausage Validation Studies”, June 2011
    Individual Corporate Interests
    Project #: RES SERV-61 “Evaluation of Efficacy of Megan™ Vac 1 Vaccine in Broiler Chickens”, February – May, 1999.
  • 13. Proprietary Research
    Sentinel Site Program® (v12)
    Environmental Monitoring
    Search and Destroy
    Sanitation Standard Operating Procedures
    Master Sanitation Schedule and Equipment Design Reviews
    Existing Equipment Evaluations
    New Equipment Design task Force
    Validated Process Interventions or Product Formulations
  • 14. Proprietary Research
    High Pressure Pasteurization
  • 15. Proprietary Research
    Formulation / Intervention Chemicals
  • 16. Proprietary Research
    Inherent Product Characteristics
  • 17. Proprietary Research
    FSIS Average = 0.89%
  • 18. Proprietary Research
    Escherichia coli O157:H7 (and Other STECs)
    Pre-Slaughter Application of O157 Phage
    Pre-Harvest Interventions [probiotic, vaccine, phage, feedlot management practices]
    SPS Steam Pasteurization [post final rail]
    Hot Water Carcass Wash
    PECS [Pre-evisceration carcass spray w/ lactic/acetic acid or180F hot water]
    Hide Washing / Treatments
    Slaughter Process Control and Verification
    Carcass PREP™: Dressing and Hygiene
    Organic Acids; Halogens; Steam Pasteurization
    Tyson Total-N60™: Sampling Plan Design and Statistics [Prerequisite Program]
    Statistical Validation
  • 19. Proprietary Research
    Escherichia coli O157:H7 (and Other STECs)
    Residual Populations of Salmonella typhimurium and Escherichia coli (O157:H7) on Inoculated Carcass
  • 20. Proprietary Research
  • 21. Proprietary Research
    Salmonella spp. in Broilers
    Efficacy of Attenuated Broiler-Breeder Vaccine
    Effects of Water Treatments on Colonization of Broilers with Salmonella spp.
    Efficacy of Hot Water Dip vs Spray for Reduction of Salmonella and Campylobacter spp.
    Efficacy of Bio-Mapping for Evaluation of Multi-Hurdle Interventions for Reduction of the Salmonellae
  • 22. Proprietary Research
  • 23. How Are We Doing?
  • 24. How Are We Doing?
  • 25. Tyson’s FSQA Principle
    The Red Queen Principle- Leigh van Valen (evolutionary biologist, 1973)
    “…in this place it takes all the running you can do, to keep in the same place.“
    ~ Red Queen to Alice in Through the Looking Glass
  • 26. Tyson’s Commitment
    Ensuring Safe, Quality Food from Farm to Fork