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Keywords: In this communication, examples of applications of predictive microbiology in industrial contexts (i.e. Nestlé
Industrial applications and Unilever) are presented which cover a range of applications in food safety from formulation and process
Product development design to consumer safety risk assessment. A tailor-made, private expert system, developed to support safe
Modelling tools
product/process design assessment is introduced as an example of how predictive models can be deployed
Risk assessment
for use by non-experts. Its use in conjunction with other tools and software available in the public domain is
discussed. Specific applications of predictive microbiology techniques are presented relating to investigations
of either growth or limits to growth with respect to product formulation or process conditions. An example
of a probabilistic exposure assessment model for chilled food application is provided and its potential added
value as a food safety management tool in an industrial context is weighed against its disadvantages. The role
of predictive microbiology in the suite of tools available to food industry and some of its advantages and
constraints are discussed.
© 2008 Elsevier B.V. All rights reserved.
0168-1605/$ – see front matter © 2008 Elsevier B.V. All rights reserved.
doi:10.1016/j.ijfoodmicro.2008.07.006
J.-M. Membré, R.J.W. Lambert / International Journal of Food Microbiology 128 (2008) 10–15 11
Fig. 1. Illustration of microbiological expert system accessible through Unilever intranet; the main users are non-modelling experts, e.g. product developers; it helps them to speed up
time-to-market in a responsible way; it is regularly updated using advances in science and also internal demand.
12 J.-M. Membré, R.J.W. Lambert / International Journal of Food Microbiology 128 (2008) 10–15
3. Rapid predictive microbiology using time to detection method hypothesis. The model can be used to quickly construct a challenge test,
by targeting areas specific to the developers needs, e.g. a given shelf-life.
It has been stated that a predictive model can give results at least Another example relates to Staphylococcus aureus, which remains a
1000 times faster than a traditional challenge test (Zwietering et al., major cause of food borne illness and is especially a concern in
1996). Indeed it was suggested that the challenge test be used to increase intermediate moisture foods with aw in the region 0.84–0.9. PM models
the confidence in the predictive model. In an industrial context, more for S. aureus are well established (Buchanan et al., 1993; McCann et al.,
often a predictive model arises from challenge test data, which is 2003). The Nestlé software model for S. aureus is based on the study of
particularly the case for growth/no-growth models. If a model is already ATCC standard 6538 (S. aureus subsp. aureus Rosenbach, also NCIB 9518,
in existence for a particular product design then it is a very valuable tool NCTC 10788). Application of the TTD modelling technique (Lambert and
for subsequent further refinements or alterations. Conversely, for new
product development, if a bespoke predictive model takes months to
obtain using traditional methods, this can be of little direct value if
product development has the same time scale. A model (e.g. a logistic
growth/no-growth model) produced for one product design may be of
no use for another design type where, for example, a different pre-
servation system has been applied. Often, what is required is knowledge
of the areas of growth/no-growth to design a more optimum challenge
study. Time to detection (TTD) can be used to quickly provide such
‘product-stability maps’ (Lambert and Bidlas, 2007a). These can then be
used to direct the expensive challenge tests, which ensure a focussing of
the limited resource available to do such studies.
TTD using optical density techniques is as valid as the traditional
plate techniques used for growth curves. The growth curve examines the
total change in microbial numbers with time whereas TTD focuses very
accurately on a smaller part of the growth curve, normally near the end
of exponential growth. Although parameters such as the specific growth
rate and lag can be obtained from TTD (Cuppers and Smelt, 1993;
Lindqvist, 2006) and attempts have been made to directly use optical
density data for the construction of growth curves (McClure et al., 1993)
it is the ability to produce vast amounts of accurate data on growth very
quickly that appeals to an industrial laboratory. One particular problem
with using TTD are the limited number of models available — much
published work involves fitting primary-type models to the optical
density curve and this can lead to erroneous conclusions, especially
where no calibration curve is used as pointed out e.g. by Dalgaard and
Koutsoumanis (2001).
By using TTD and through the assumption of the Gamma hypothesis
(Zwietering et al., 1992), predictive models can be produced within a few
days, which can be augmented or modified ensuring that PM becomes a
timely tool for product development. For example, following the TTD
approach, it took Nestlé a total of 10 days (Two people working a total of
60 hours and using six Bioscreen instruments (Labsystems, Helsinki,
Finland)) to develop a software model for Salmonella Poona that is able to
predict the independent effects of pH, salt, acetate and sorbate. Combined
studies of the various factors showed that the Gamma hypothesis was
valid, i.e. that each hurdle in combination can be treated independently
within the overall model (Lambert and Bidlas, 2007c). The calculated
minimum growth pH (3.81) and minimum growth aw (0.948) were
consistent with the range given in the literature for salmonellae. Fig. 2a
shows an example of the model output for combinations of pH and salt.
The outer contour of the model output is the absolute growth/no-growth
contour irrespective of initial inoculum or temperature. This is where the Fig. 2. a: An ‘Intervention Diagram’ for the combined hurdles of salt and pH against Sal-
product of the gamma factors results in no growth. monella Poona. This figure plots the relative effects of the combined gamma factors for pH
The plot is split into 4 so-called ‘intervention areas’ based on the and salt. At a value of 1, no effect on growth is observed and uninhibited growth with respect
to pH and salt will be observed, at a combined gamma=0.1, there is a ten fold increase in the
value of the product of the gamma factors. These areas are reflective of time to detection relative to the control environment. Contours for the combined gamma
the size of the hurdle requirement if a product has salt/pH attributes factors of 0.1, 0.01 and 0.001 are used in the figure to suggest the magnitude of the (extra)
within that area. These range from a major hurdle(s) requirement to hurdle application that should be applied. Key: Red = major hurdles required; Yellow =
none (outer contour and beyond). An applied hurdle can be a reduced moderate level of hurdles required; Green = minimum hurdle intervention required; Blue =
no intervention required to prevent growth. b: An ‘Intervention Diagram’ for the combined
temperature, an increase in hygiene (to reduce initial loading), a
hurdles of salt, pH, Na acetate (1500 mg l− 1) and K sorbate (250 mg l− 1) against Salmonella
shorter shelf-life or the addition of weak acid preservatives. Fig. 2b Poona. The addition of a specific concentration of Na acetate and K sorbate has a differential
shows the same system (in terms of pH and aw) but with the addition effect over the pH values given due to the pH dependent equilibrium of the acid and anion
of 1500 mg l− 1 Na acetate and 250 mg l− 1 of K sorbate. The minimum forms. At the lower pH there is a greater concentration of the antimicrobial acetic and sorbic
pH for growth has increased (there is a ‘hidden’ gamma factor from acids and this increases the effectiveness of the combined antimicrobial factors. With
respect to a plot of only the gamma factors for pH and salt, the influence of the gamma factor
the concentration of acetic acid, which has the effect of giving an for acetic and sorbic acids is seen as an increase in the minimum pH for growth. (For
apparent increase in the minimum pH for growth), whereas the interpretation of the references to colour in this figure legend, the reader is referred to the
minimum aw has remained constant — a requirement of the Gamma web version of this article.)
J.-M. Membré, R.J.W. Lambert / International Journal of Food Microbiology 128 (2008) 10–15 13
Fig. 3. Effect of added salt on the loge time to detection of five strains of Staphylococcus aureus (left to right: ST121, ST55, ST68,ST84, ATCC 6538.; at NaCl = 12.2%, ST121 and ATCC 6538
failed to grow during the time of incubation of 5 days). Error bars are the standard deviation of the mean ln(TTD) value for 10 replicates per strain for each salt concentration.
Bidlas, 2007b) produced a multi-factor model including pH, aw (as salt), Assuming that there might be strong strain dependence, a selection
various weak acids including acetate, sorbate, benzoate and nitrate, and of factory isolates were examined in a similar way: pHmin ranged from
temperature. The model appeared to reproduce the experimental 4.2–4.5, and MICsalt 14.6–16%. Fig. 3 shows the logarithmically
observations well, especially in combinations. Product developers, transformed TTD results for all strains examined. The diagram appears
however, complained that the model appeared too conservative to show that although there are small differences between strains,
especially with respect to pH and aw. Originally (in 2004) experiments there is an overall similar response to increasing salt concentration.
were done using a serial dilution of salt — usually a half-fold dilution With increasing salt concentration the TTD increased as did the
sequence from 20%. Since concentrations below 2% of salt have very little variance in the data, this is a common observation as conditions
effect on the time to growth of S. aureus, and since most data was become more inimical (Ratkowsky et al., 1991; Ratkowsky et al., 1996;
collected below this, there were few data in the region which enabled an Schaffner, 1998). The use of the log transformation to stabilise the
accurate modelling of the inhibition (i.e. at concentrations N5%). variance in order to conduct unbiased regression modelling is
Repeating the salt study using linear dilutions between 0.5 and 20% of commonplace, the use of the reciprocal transformation as used in
salt, returned the approximate literature values for pHmin (4.2) and a the model described by Lambert and Bidlas (2007a) also homogenises
calculated MIC of salt of 15.94% (aw = 0.88) for the standard strain used. the variance. The calculated MICsalt of the standard strain was found to
Fig. 4. Schematic representation of the exposure assessment model structure used to estimate probability of having 105 cfu g− 1 or more of Bacillus cereus in chilled foods, at the time
of consumption, under realistic market conditions. 'HT' stands for Heat-Treated or Heat Treatment.
14 J.-M. Membré, R.J.W. Lambert / International Journal of Food Microbiology 128 (2008) 10–15
be higher than the factory isolates, so is in effect conservative, but in a temperature, aw and pH). Moreover, probabilistic models involving
positive/safe way. sophisticated techniques such as 2D Monte Carlo decomposition, and,
uncertainty and variability separation, are difficult to set up, interpret
4. Use of probabilistic exposure assessment in food and communicate. They require skilled and experienced staff to be
safety management deployed successfully. These constraints are out-balanced by the value
of running more realistic scenarios than deterministic assessments
Since mid-90s, microbiological risk assessments have been devel- would allow (e.g. considering variations of refrigerator temperatures),
oped in different parts of the world, early on mostly by academics, later being explicit and transparent in terms of the knowledge/data used in
more and more by government experts or under their auspices. In all the assessment as well as the uncertainty in the outputs, facilitation of
quantitative risk assessments, some form of modelling is involved and in identification of data gaps and prioritising key risk contributing or
many cases such models include PM models or combinations of PM mitigating factors.
models with process models. The aim of such risk assessments is to
characterise and estimate the risk to consumers related to a certain 5. Conclusions
pathogen possibly present in a particular food product or product group.
While it is of interest to the industry to learn from those risk The predictive modelling history in Unilever and Nestlé shows
assessments, there are also interesting industrial applications of some parallels with the rise in utility and applicability of PM within food
of the techniques used in risk assessment (Lammerding, 2007). Unilever microbiology in general. The difference shows a strong lead by Unilever
staff have been engaged with some of those applications, e.g. linking microbiologists and managers to bring PM into their industry, whereas
industrial food safety management to risk assessment or establishing Nestlé has preferred to continue with challenge test methods
more sophisticated exposure assessments than traditionally were augmented by published models or particular external studies where
possible (Brown et al., 1998; Van Gerwen and Gorris, 2004; Membré appropriate. As product development continues to accelerate in nearly
et al., 2006). As an example of the latter application, Unilever developed every area of food manufacture, the use of PM as an accelerating tool is
a probabilistic exposure assessment to assess the safety of REPFEDs recognised by all of industry. The degree to which it is applied in specific
(refrigerated processed foods of extended durability) in relation to Ba- areas is dependent on the understanding within the management
cillus cereus. Fig. 4 illustrates the many factors considered in this structures of the particular industries and the knowledge base that
assessment, which included raw material contamination, heat treat- underpins those decisions. However, its diligent application comes with
ment, bacterial spore heat resistance, injured spore lag time and growth a number of pre-requisites amongst which are adequately increasing the
potential, chilled supply-chain market (split into warehouse, retail, skill and training of non-expert users.
consumers steps) and consumers' habits (e.g. time for shopping, time Many manufacturers have used PM to reduce the risk to consumer
before consuming). A sensitivity analysis, including uncertainty and associated with pathogen growth. The same is almost certainly true for
variability separation, was run to identify the impact of each factor on spoilage organisms, but tailor-made models for these are not or very
the output (Membré et al., 2007b). rarely published by industry for competitor advantage reasons. Product
The exposure assessment model was structured to provide the developers often require models of spoilage organisms, for example in
probability of having 105 cfu/g or more of B. cereus at the point of low pH beverages yeast and mould spoilage is extremely important.
consumption. Different scenarios of process, formulation and chilled Only a few published mould and yeast models exist, however, and even
market were generated and outputs compared. In Fig. 5, the model fewer for this particular food product. A recent review by (Dantigny et al.,
output is presented for two heat-treatment temperatures and three 2005) emphasised the gap between the bacterial (especially pathogen)
heat-treatment times. The 95% confidence interval bars in this graph models and those dealing with fungi: “In order to improve food quality
capture the uncertainty in the model output. From these outputs, iso- and safety, there is a need for a tool allowing prediction of fungal
probability contour plots (Havelaar et al., 2004) can be generated to help development.”
food developers to choose between various processes and formulations Challenge studies require considerable labour, time, and materials,
that perform equivalently, this in analogy to the “window-of-opportu- and the number of parameters that can be tested is often limited. If a
nity” approach followed with individual PM models or the Unilever predictive model is available (especially a validated model), then rapid
expert system. information about the microbial stability (with respect to spoilage) of
Developing a probabilistic exposure assessment model, is of course a product can be obtained and can itself be used in conjunction with
more time demanding, more resource and computer intensive than challenge studies to improve product stability and reduce costs. This
building deterministic PM models involving two or three factors (e.g. makes such work, when done appropriately and diligently, quite
valuable.
Within a safety frame, PM is recognised as a versatile and helpful (if
not essential) tool for risk assessment and the maturation of this area
of PM application is far from completed. Predictive modelling is a
continuously developing tool in industry, being driven by academics,
academic-industry joint ventures, governments, software and statis-
tical developments, legal and regulatory issues and to some extent the
industry's need to innovate and deliver food products that satisfy
consumer demands. Often, however, it is the need for ease of
communication to the internal end user, typically the product/process
developer that is the crux within industry. Application of predictive
microbiology within Unilever and Nestlé and probably in other
industries too, will continue along with further scientific develop-
ments in modelling techniques, microbiology and food technology.
Acknowledgements
Fig. 5. Illustration of simulation results showing the probability of having 105 cfu g−1 or
more of Bacillus cereus when the product is consumed after various heat-treatment
conditions. Simulations were carried out for product with high raw material The authors would like to thank Leon Gorris for critically reading
contamination, pH of 6, aw of 0.996 and a shelf-life of 40 days. and improving the draft version of this manuscript.
J.-M. Membré, R.J.W. Lambert / International Journal of Food Microbiology 128 (2008) 10–15 15
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