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

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

Tyson’s Food Safety Organization
Donnie Smith
President & CEO
Jim Lochner
Chief Operations Officer
Hal Carper
GVP R&D, Technical Services
Environmental
Compliance – Health & Safety
Information
Services
Logistics and
Supply Chain
Distribution
Aviation
Research and
Development
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

Food Safety Scope
Involves a Step-Wise Approach:
Policy / Program Development;
Training;
Monitoring – Process Control;
Auditing; and
Verification.
Detailed within the Tyson Foods’ FSQA Policies and Procedures

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).

Food Safety Scope
Involves a Step-Wise Approach:
Policy / Program Development;
Training;
Monitoring – Process Control;
Auditing; and
Verification.
That’s all great and good, but if we’re not doing the right thing – it won’t matter that we do it well!

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

“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

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?

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

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
Iowa State University
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.

Proprietary Research
Listeriamonocytogenes
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

High Pressure Pasteurization

Formulation / Intervention Chemicals

Inherent Product Characteristics

FSIS Average = 0.89%

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

Escherichia coli O157:H7 (and Other STECs)
Residual Populations of Salmonella typhimurium and Escherichia coli (O157:H7) on Inoculated Carcass

http://www.fsis.usda.gov/Science/Ecoli_O157_Summary_Tables/index.asp#2006

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

How Are We Doing?
http://www.cdc.gov/foodborneburden/PDFs/FACTSHEET_B_TRENDS.PDF

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

Tyson’s Commitment
Ensuring Safe, Quality Food from Farm to Fork
Questions?

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

by dedmark on Sep 19, 2011

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