This research investigates the potential risk of Salmonella in muffins when contamination is introduced via flour, the main ingredient. Flour was inoculated with a 3-strain cocktail of Salmonella serovars (Newport, Typhimurium, and Senftenberg) and re-dried to achieve a target concentration of ~8logCFU/g. The inoculated flour was then used to prepare muffin batter following a standard commercial recipe. The survival of Salmonella during and after baking at 190.6°C for 21min was analyzed by plating samples on selective and injury-recovery media at regular intervals. The thermal inactivation parameters (D and z values) of the 3-strain Salmonella cocktail were determined. A ≥5logCFU/g reduction in Salmonella population was demonstrated by 17min of baking, and a 6.1logCFU/g reduction in Salmonella population by 21min of baking. The D-values of Salmonella serovar cocktail in muffin batter were 62.2±3.0, 40.1±0.9 and 16.5±1.7min at 55, 58 and 61°C, respectively; and the z-value was 10.4±0.6°C. The water activity (a) of the muffin crumb (0.928) after baking and 30min of cooling was similar to that of pre-baked muffin batter, whereas the a of the muffin crust decreased to (0.700). This study validates a typical commercial muffin baking process utilizing an oven temperature of 190.6°C for at least 17min as an effective kill-step in reducing a Salmonella serovar population by ≥5logCFU/g.

This study was conducted to validate a simulated commercial baking process for hamburger buns to destroy Salmonella serovars and to determine the appropriateness of using nonpathogenic surrogates (Enterococcus faecium ATCC 8459 or Saccharomyces cerevisiae) for in-plant process validation studies. Wheat flour was inoculated (∼6 log CFU/g) with three Salmonella serovars (Typhimurium, Newport, or Senftenberg 775W) or with E. faecium. Dough was formed, proofed, and baked to mimic commercial manufacturing conditions. Buns were baked for up to 13 min in a conventional oven (218.3°C), with internal crumb temperature increasing to ∼100°C during the first 8 min of baking and remaining at this temperature until removal from the oven. Salmonella and E. faecium populations were undetectable by enrichment (>6-log CFU/g reductions) after 9.0 and 11.5 min of baking, respectively, and ≥5-log-cycle reductions were achieved by 6.0 and 7.75 min, respectively. D-values of Salmonella (three-serovar cocktail) and E. faecium 8459 in dough were 28.64 and 133.33, 7.61 and 55.67, and 3.14 and 14.72 min at 55, 58, and 61°C, respectively, whereas D-values of S. cerevisiae were 18.73, 5.67, and 1.03 min at 52, 55, and 58°C, respectivly. The z-values of Salmonella, E. faecium, and S. cerevisiae were 6.58, 6.25, and 4.74°C, respectively. A high level of thermal lethality was observed for baking of typical hamburger bun dough, resulting in rapid elimination of high levels of the three-strain Salmonella cocktail; however, the lethality and microbial destruction kinetics should not be extrapolated to other bakery products without further research. E. faecium demonstrated greater thermal resistance compared with Salmonella during bun baking and could serve as a conservative surrogate to validate thermal process lethality in commercial bun baking operations. Low thermal tolerance of S. cerevisiae relative to Salmonella serovars limits its usefulness as a surrogate for process validations.

A total of 154 enterococcal isolates from 95 stored-product insects collected from a feed mill, a grain storage silo, and a retail store were isolated and identified to the species level using PCR. Enterococcus casseliflavus represented 51% of the total isolates, followed by Enterococcus gallinarum (24%), Enterococcus faecium (14%), Enterococcus faecalis (7%), and Enterococcus hirae (5%). Many isolates were resistant to tetracycline (48%), followed by streptomycin (21%), erythromycin (14%), kanamycin (13%), ciprofloxacin (12%), ampicillin (4%), and chloramphenicol (<1%). Enterococci carried genes coding for virulence factors, including the gelatinase gene gelE (26% of isolates), an enterococcal surface protein gene esp (1%), and the cytolysin gene cylA (2%). An aggregation substance (asa1) gene was detected in six out of 10 E. faecalis isolates and five of these were positive for the aggregation substance. Enterococci were positive for hemolytic (57% of isolates) and gelatinolytic (23%) activity. The filter-mating assay showed that the tetracycline resistance gene, tetM, was transferable among E. faecalis by conjugation. These data demonstrated that stored-product insects can serve as potential vectors in disseminating antibiotic-resistant and potentially virulent enterococci.

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Laboratory experiments were designed to determine the survival of Enterococcus faecalis OG1RF:pCF10 in poultry and cattle feed and its acquisition and transmission by adults of the red flour beetle, Tribolium castaneum (Herbst), to sterile feed. Adult T. castaneum beetles were introduced into poultry and cattle feed inoculated with E. faecalis OG1RF:pCF10 and incubated at 28 degrees C with 65% relative humidity for 7 days in a growth chamber. E. faecalis survived in both poultry and cattle feed during the 7-day test period. There was a logarithmic decrease in E. faecalis concentration in poultry and cattle feed and in and on the insects. E. faecalis persisted on the surface and within T. castaneum adults for 7 days when adults were released on E. faecalis-inoculated poultry feed and for only 5 days on E. faecalis-inoculated cattle feed. The concentration of E. faecalis decreased more slowly on poultry feed than on cattle feed, and this may explain why adult T. castaneum insects were more successful in acquiring and transferring E. faecalis from inoculated poultry feed to sterile poultry feed during the 7-day test period. However, T. castaneum adults reared on inoculated cattle feed were unable to contaminate sterile cattle feed on day 7. To our knowledge, this is the first report documenting T. castaneum to successfully acquire antibiotic-resistant enterococci from animal feed and transfer them to sterile feed. Management of T. castaneum through effective integrated pest management program is therefore important to prevent the spread of antibiotic-resistant and virulent enterococci in animal feed and feed manufacturing environments.