MAP for take and bake pizza
I have been finding bits and pieces of informations about this topic but because my limited experience I can't find a clear answer to my many questions. I would appreciate if anybody can share some expertise on this matter.
We are a facility in the US that produce pizza. We par-bake the crusts, then pizza is topped with tomato, cheese, and other ingredients such as pepperoni, fresh tomato, pesto etc.
As of today pizza was only shrink-wrapped, but we are thinking to implement a MAP/ROP process, either vacuum or with addition of other gases, which bring up the problem of C botulinum.
The pizza does not meet the required value of Aw or pH typical to control C botulinum, so how can my HACCP plan ensure the safety of the products?
Cooling and keep the product under 41°F/5°C, will that be enough?
Do I need to constantly run laboratory tests to ensure contamination is controlled through my SSOP and prerequisites program?
The pizza is a NRTE product, it need to be cooked at 500°F/260°C for 5/7 min, will this step help?
thank you in advance
I have been finding bits and pieces of informations about this topic but because my limited experience I can't find a clear answer to my many questions. I would appreciate if anybody can share some expertise on this matter.
We are a facility in the US that produce pizza. We par-bake the crusts, then pizza is topped with tomato, cheese, and other ingredients such as pepperoni, fresh tomato, pesto etc.
As of today pizza was only shrink-wrapped, but we are thinking to implement a MAP/ROP process, either vacuum or with addition of other gases, which bring up the problem of C botulinum.
The pizza does not meet the required value of Aw or pH typical to control C botulinum, so how can my HACCP plan ensure the safety of the products?
Cooling and keep the product under 41°F/5°C, will that be enough?
Do I need to constantly run laboratory tests to ensure contamination is controlled through my SSOP and prerequisites program?
The pizza is a NRTE product, it need to be cooked at 500°F/260°C for 5/7 min, will this step help?
thank you in advance
Hi Vaal,
Just for starters I anticipate the temperatures mentioned are oven values. Actually it is the product core temperature/time which determines process lethality. You probably need to perform a validation study.
L.mono is possibly also relevant.
Regarding C.botulinum, the detailed control requirements are well known for RTE of course. NRTE/FDA/USDA legalities (if any) will necessitate some searching. In Principle, HACCP analysis is based on (assumed) correct customer application of labelled/validated cooking instructions.
Hi Charles.C
Yes the temperature is the oven value, I could run some test and see the actual temperature of the pizza, even though spores need a very high temperature to be destroyed, also we need to consider the skills of consumers to cook the product properly.
I am still researching, and red many documents, I also found other post on ifsqn for pasta that have the same questions.
In conclusion, it seems to me that the only secure way to control the spore formation of MAP product are:
the product must be packed under specific Aw or pH conditions or apply kill step after packaging, otherwise they're always going to be a risk involved, I really wonder how all those package meals are made.
otherwise you can just limit/stopping the growth by controlling the temperature and the shelf lite duration. which bring up another question:
is labeling the product with detailed safety storage instruction enough? considering temperature can vary during distribution and in home refrigerators