Policy on Microbiology Testing at American Pop Corn Company
American Pop Corn Company is the manufacturer of the Jolly Time Popcorn brand. The company, based in Sioux City, IA, produces over 100 million bags of microwave popcorn a year (4). American Pop Corn Company is the third largest maker of microwave popcorn in the country. The Jolly Time brand is exported to many countries around the world. Its workhorse, Blast O Butter, is the largest selling heavy butter microwave popcorn product in the world. The company is committed to delivering a quality product every time. American Popcorn Company does not have a program in place to test for microbes in their products.
Microbiological testing has become a critical component in many food manufacturing facilities. The testing for bacteria is a necessary part of a company’s food safety program. The Food and Drug Administration and the American Institute of Baking have programs in place to make sure compliant companies all have microbiology testing as part of their food safety programs. These testing programs could be the last defense for an unknowing public. Congress passed the Public Health Security and Bioterrorism Preparedness and Response Act of 2002, also known as the Bioterrorism Act of 2002 (1). Title III of this Act deals directly with protecting the safety of food and drugs manufactured in the United States (1). The events of September 11, 2001 have opened our eyes to the fact that our food manufacturing facilities are potential points of entry for any possible bioterrorism agents. This realization is another reason microbiology testing at food manufacturing plants is critical to the safety of the public.
Bacteria have the ability to adapt and/or evolve to make sure that the species survives. They have the ability to copy plasmids, circular segments of DNA, and pass that information on to other bacterium ensuring that the species will continue. It was found in one study that if bacteria are exposed to low pH, high salt, or high temperatures they will adapt. The study exposed Escherichia coli, Salmonella enteric serovar Typhimurium, and Staphylococcus aureus. The bacteria were exposed to various stresses. They were put in high and low temperatures, acidic conditions, and high salt conditions. Then they tested the bacteria for any antibiotic resistance. Here is the conclusion:
This study demonstrates that some common food preservation processes (i.e., those which employ low pH or high NaCl to prevent or reduce pathogen growth rate) can lead to the development of populations or subpopulations of pathogens with decreased susceptibility to a range of currently used antibiotics. (3)
The production process at the microwave popcorn facility of American Pop Corn Company is closely related to the environmental conditions used in the study. The oils used are kept above their melting points, above 125 F, for use in the manufacturing process. The flavor slurries are high salt environments, typically. Most flavors used are at 2 – 3% salt by weight. According to the study, these factors could be contributing to an increase in antibiotic resistance.
It is believed in the microwave popcorn industry that the extreme temperatures reached in the microwave during popping would kill all bacteria present in the products. Temperatures in the microwave floor can reach 145 degrees F (2). Also, for popcorn to pop, the moisture in the kernels must reach at least 212 F. The starches in the corn then begin to melt and at an internal temperature of 347 F and an internal pressure of 135 pounds per square inch the outer shell of the kernel gives out (5). The starches then expand and cool quickly giving the popcorn its classic shape. These high temperatures would lead a person to believe that all bacteria in the bag, in the flavor slurry, or on the corn would be killed. No data to confirm or deny the idea could be found in researching a need for a bacteria testing policy. Therefore, American Pop Corn Company will set up a policy to test various parts of the production system for any pathogenic bacteria activity and confirm or deny a need for microbial testing.
I. Policy
A. Quality Control of the Microwave Pop Corn Plant will take swabs of low lying areas after the production equipment has been washed and sanitized. The swabs will then be tested for various types of pathogenic bacteria.
B. Quality Control of the Microwave Pop Corn Plant will test all flavor slurries used in production for any pathogenic bacteria.
C. Quality Control of the Microwave Pop Corn Plant will pop random bags of production and test the contents for any bacterial activity.
D. All data collected will be kept, reviewed and analyzed regularly by the Lab Manager.
Looking at the possible threats to food safety and the results of the study on antibacterial resistance, one can say without a doubt that microbiological testing is necessary in all food manufacturing facilities. American Pop Corn Company will take an active role in gathering and analyzing microbial data on their products. The data will be used to see if the popping process does in fact kill all bacteria present. The new policy will take the products of American Pop Corn Company to a new level and will ensure the safety of its many loyal customers.
References
1. Food and Drug Administration. Public Health Security and Bioterrorism Preparedness and Response Act of 2002. http://www.fda.gov/oc/bioterroism/PL107-188.html#title3, accessed 9-23-2009
2. US Patent #US4219573. http://www.freepatentsonline.com/4219573.pdf , accessed 9-23-2008
3. McMahon, Xu, Moore, Blair, and McDowell, “Environmental Stress and Antibiotic Resistance in Food-Related Pathogens”. Applied and Environmental Microbiology, Jan. 2007 p 211-217
4. Interview. Mike Carr, Lab Director at American Pop Corn Company. 9-23-2008.
5. Popcorn Board. http://www.popcorn.org/frames.cfm?main=encyclopedia, accessed 10-5-2008.
