Control of Listeria monocytogenes in a Poultry Processing Facility Using Sterilex PerQuatTM Technology

Abstract – Sterilex Drain Sanitation Program

The presence of Listeria monocytogenes biofilm in a drain in an RTE poultry processing facility quickly spreads to environmental and food contact surfaces due to an ineffective drain program consisting of scrubbing and the use of drain rings. Despite the use of chlorinated alkaline detergents, Quat, and Peracetic Acid sanitizers, the plant was unable to eliminate Listeria from their RTE room.

Utilizing Sterilex’s Drain Program, the foaming of Sterilex’s patented PerQuatTM chemistry into drain cavities in lieu of hand scrubbing, as well as the use of the Sterilex chemistry as a first rinse disinfectant during the foaming process, the plant was able to rapidly eradicate Listeria from the facility while saving time during the sanitation process.

Introduction

A 2004 USDA audit of food processing facilities found that nearly one in three federally inspected food plants had drains that tested positive for Listeria. As a wet surface with a constant food source, drains are a perfect breeding ground for organisms and the formation of resistant biofilm. Once biofilm form in drain cavities, they typically reside in cracks and crevices and are resistant to commonly used cleaners and sanitizers. Once in a drain, pathogens can easily find their way onto adjacent environmental surfaces and eventually food contact surfaces if not treated with a disinfectant with biofilm removal capabilities.

Recommended by top food safety experts, Sterilex PerQuatTM technology is the first and only chemistry approved by the US EPA for biofilm removal for both public health and industrial applications. As a hybrid disinfectant/cleaner, PerQuatTM technology can be used in a variety of food processing sanitation applications including environmental and food contact foaming, as a COP tank soak for belts and equipment parts, or for use as part of Sterilex’s drain sanitation program.

Issue

Large poultry processing plant consistently tested positive for Listeria monocytogenes in drains, floors, cooler doors and belts. Despite foaming the entire ready-to-eat room with heavy doses of chlorinated alkaline cleaner, quat sanitizer, and 1200 ppm of Peracetic Acid, Listeria positives continued to increase over a two week period. Drains were typically scrubbed using a black scrub brush and a chlorinated detergent daily followed by the addition of a Peracetic Acid sanitizer. The use of “Quat rings” was also in place in all plant drains. It was suspected that the presence of positives on contact surfaces was originally sourced from the formation of biofilm in a contaminated drain that were spread to other drains and environmental surfaces during the drain scrubbing process.

Sterilex Recommendation

Sterilex recommended that the plant initiate the following corrective actions:

1. Establish a comprehensive drain program without scrubbing. Hand scrubbing drains was determined to have been a critical factor in the spread of Listeria from the contaminated drain into nearby drains and environmental surfaces. Scrubbing drains did not guarantee the disinfection and removal of biofilm from all surfaces in the drain cavity as it is impossible to scrub into all cracks and crevices inside of the drain. In addition, it was determined that the quat ring simply treated the incoming water, did not come into contact with 90% of the drain surface and did not provide adequate contact time for the sanitizer to eliminate Listeria in the drain cavity. The Sterilex drain program involves the use of Sterilex Ultra Disinfectant Cleaner and Activator Solutions in a tank or wall foamer connected to a “drain foam attachment” to deliver thick “shaving-cream” quality foam to the drain cavity. Using the drain foam attachment, shown in Exhibit A, the plant is able to fill up an average drain with Sterilex PerQuatTM foam in less than one minute and eliminates the need for scrubbing or rinsing drains. The plant is to foam all drains nightly with Sterilex PerQuatTM chemistry after all other foaming and rinsing has been completed in the plant (typically right before pre-op). The foam will break down into liquid sanitizer on its own after 15 minutes. Sterilex also recommended that the plant sprinkle Sterilex’s powder version of its PerQuatTM chemistry, CW502, into the drain cavity following pre-op to ensure that the drains are protected from contamination during production as rinsate runs into the drain cavity. There is no need for quat rings or drain scrubbing during this program.

2. Eliminate resistant Listeria from environmental and food contact surfaces by foaming Sterilex Ultra Disinfectant Cleaner and Activator Solution on a daily basis. Following the use of an alkaline detergent and a rinse, the plant is to foam the Sterilex chemistry onto all surfaces using wall or tank foamers as a first rinse disinfectant/cleaner. A final no-rinse sanitizer may be used if required. The use of Sterilex chemistry as part of a comprehensive sanitation program has proven to prevent spikes in counts, eliminate resistant pathogens such as Listeria, and enhance the sanitation program as a whole.

Results

The plant adopted daily use of the Sterilex PerQuatTM chemistry as part of a drain program as well as for equipment foam disinfection. One week following the adoption of the program outlined above, all Listeria counts were completely eliminated from drains, floors, environmental surfaces, and food contact surfaces. In addition, the sanitation crew reported that they were able to save one hour of cleaning time by replacing the existing drain scrubbing program with the Sterilex drain foam sanitation program outlined above. By using the only chemistry EPA registered to remove biofilm and kill Listeria in drains, the plant was able to rapidly eradicate the microbiological contaminant without the need to scrub – eliminating a primary vector of cross-contamination.

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To learn more about Sterilex’s PerQuatTM chemistry and how it may be able to benefit your facility, call 800-511-1659 or visit http://www.sterilex.com.