Onsite Microorganism Hub

Companies can prevent problems before any complications and hazards arrive by taking a solid and proactive approach to onsite microorganism and pathogen testing. Effective testing protocols can avoid contamination by acting as an early warning before they affect products.

Notably, having a robust environmental monitoring plan and structured process for eliminating dangers is also essential for adhering to guidelines such as the BRC Global Standards for Food Safety (BRCGS) in the food industry.

What is microorganism testing, and why is it important?

Microorganism and pathogen testing are incorporated into environmental monitoring programs to allow continual assessment of cleaning protocols at a microbial level. Target organisms and pathogens are established based on the risks presented in the environment, then a sampling and testing plan is determined based on this assessment.

These may include specific pathogens (e.g. Listeria spp in wet environments or Enterbacteriaceae in dry environments), specific spoilage organisms (e.g. yeast or mould) or indicator organisms (e.g., total plate count, total coliforms). Testing is commonly conducted through onsite testing and environmental swabs, which are then sent offsite to an external laboratory for analysis.

Identifying hazards at a microbial level helps mitigate potential food safety risks in production, allowing them to be appropriately managed to prevent product contamination, product recalls that waste time and money and ensure the safety of both the consumer and the workforce.

How can I ensure our environmental monitoring is to the best standard for microorganism testing?

There is no universal blueprint for an environmental microorganism monitoring program. Individual companies design and structure their programs based on their own specific manufacturing environment and hazard analysis.

To ensure that your environment monitoring successfully prevents hazards, mapping out the production process is essential along with, highlighting zones and specific areas within the equipment that are a higher risk. Once completed, test points can be defined throughout to monitor cleanliness and control the risks of potential contamination.

Areas can be broken down into different zones to easily identify the risks they pose based on their proximity to the food and cross-contamination risks, the ease of cleaning and the condition of the surface being tested.

• High-risk food contact areas (e.g., slicers, hoppers, conveyor belts, knives, drains, condensate from chillers and freezers)
• Proximity non-direct food contact areas (e.g., equipment control panels, chiller door handles, equipment framework)
• Remote non-food contact areas (e.g., hand carts, forklift trucks, floors, walls)
• Outside areas (e.g., staff rooms, canteens, warehousing for finished product)

Assessing the risks of surfaces, the material, porosity, age, accessibility, damage (scratches and marks) and overall condition must be taken into consideration. Limitations are also dependent on whether the surface is in an area considered to be clean processing or sterile food contact.

Through a hazard risk analysis that considers these areas, you can use onsite microorganism testing to monitor potential risks and make proactive changes to reduce them. Each company will have its own prerogative based on the raw materials and end products being produced.

It is vital to implement into your routine established test locations based on their proximity to food preparation areas, locations that are difficult to clean and ensure that your team is regularly checking areas that previously tested positive. Regular inspections and sample tests can also eliminate any potential contamination from being missed in areas you may not be aware are contaminated initially.