In the US, dried beef products (beef jerky) are a popular snack product in which the manufacture often requires the use of a heat lethality step to provide adequate reduction of pathogens of concern (i.e., 5-log reduction of Salmonella as recommended by the United States Department of Agriculture Food Safety and Inspection Service (USDA-FSIS)). Biltong, a South African-style dried beef product, is manufactured with low heat and humidity. Our objectives were to examine processes for the manufacture of biltong that achieves a 5-log reduction of Salmonella without a heat lethality step and with, or without, the use of additional antimicrobials. Beef pieces (1.9 cm × 5.1 cm × 7.6 cm) were inoculated with a 5-serovar mixture of Salmonella (Salmonella Thompson 120, Salmonella Heidelberg F5038BG1, Salmonella Hadar MF60404, Salmonella Enteritidis H3527, and Salmonella Typhimurium H3380), dipped in antimicrobial solutions (lactic acid, acidified calcium sulfate, sodium acid sulfate) or water (no additional antimicrobial), and marinaded while vacuum tumbling and/or while held overnight at 5 °C. After marination, beef pieces were hung in an oven set at 22.2 °C (72 °F), 23.9 °C (75 °F), or 25 °C (77 °F) depending on the process, and maintained at 55% relative humidity. Beef samples were enumerated for Salmonella after inoculation, after dip treatment, after marination, and after 2, 4, 6, and 8 days of drying. Water activity was generally <0.85 by the end of 6–8 days of drying and weight loss was as high as 60%. Trials also examined salt concentration (1.7%, 2.2%, 2.7%) and marinade vinegar composition (2%, 3%, 4%) in the raw formulation. Nearly all approaches achieved 5-log10 reduction of Salmonella and was attributed to the manner of microbial enumeration eliminating the effects of microbial concentration on dried beef due to moisture loss. All trials were run as multiple replications and statistical analysis of treatments were determined by repeated measures analysis of variance (RM-ANOVA) to determine significant differences (p < 0.05). We believe this is the first published report of a biltong process achieving >5.0 log10 reduction of Salmonella which is a process validation requirement of USDA-FSIS for the sale of dried beef in the USA.

Process validation studies often require the inoculation of select foodborne pathogens into targeted foods to determine the lethality of the process or antimicrobial ingredients, and quantitative recovery of surviving inoculum bacteria helps to make those assessments. Such processes introduce various stressors on the inoculated challenge microorganisms whereby traditional selective media are too harsh to enumerate the remaining viable and injured population quantitatively. Innate antibiotic resistance of challenge organisms has often been used to establish simple selective media (i.e., Tryptic Soy Agar/TSA + antibiotics) for recovering inoculated strains, but sometimes antibiotic resistant background microorganisms are higher than desired. Salmonella Thompson 120, Salmonella Heidelberg F5038BG1, Salmonella Hadar MF60404, Salmonella Enteritidis H3527, and Salmonella Typhimurium H3380 were characterized for antibiotic resistance and acid adaptation in Tryptic Soy Broth containing 0%, 0.25%, or 1.0% glucose. Sodium pyruvate was evaluated for recovery after stress but no enhancing effect was observed, possibly because the strains were acid-adapted. Selenite Cystine Broth, traditionally used as a selective enrichment broth, was used as the basis for Selenite Cystine Agar (SCA) in combination with three antibiotics to which our Salmonella are resistant. Serovars of Salmonella, both individually and in mixtures, were enumerated on TSA, SCA, Xylose Lysine Desoxycholate (XLD), and Hektoen Enteric (HE) selective agars (all containing the same antibiotics) after conditions of nutrient starvation, desiccation, acid stress, and thermal stress. The data show that quantitative enumeration of our Salmonella serovars on SCA was not significantly different (p > 0.05) than those achieved on TSA for all tested stress categories. Levels of Salmonella enumerated on XLD and/or HE were significantly different (p < 0.05) than on TSA and SCA and often more than 1–2-log lower, consistent with the inhibition of injured cells. These data confirm that SCA (+ antibiotics) is a suitable selective medium for enumeration of these acid-adapted Salmonella serovars as challenge organisms recovered from various conditions of stress.

In the US, sodium nitrate is used as a preservative and curing agent in processed meats and is therefore a regulated ingredient. Nitrate reducing bacteria (NRB) can convert vegetable nitrate into nitrite allowing green/clean label status in the US as per the USDA-FSIS definition of ‘natural nitrite’. The current ‘in-liquid’ test tube assay for detecting nitrite is not suitable for screening mixtures of bacteria nor is commercial nitrate broth suitable for growth of many Gram (+) bacteria. M17 broth was therefore used to develop M17-nitrate broth to be inclusive of Gram (+) bacteria. An ‘on-agar’ colony-screening assay was developed to detect the conversion of nitrate to nitrite on agar plates and could detect one NRB+ colony among ~300–500 colonies on a single plate. Samples that might have NRB were spread-plated on M17 agar plates, sandwiched with nitrate agar, and after incubation followed with sequential agar overlays containing the reagents used in the nitrate reduction assay; the appearance of red color zones above colonies indicated the presence of nitrite. NRB derived from various samples were confirmed for nitrate conversion and both nitrate and nitrite were quantified by C8 reversed-phase (RP) ion-pairing high performance liquid chromatography (HPLC) analysis (1 ppm limit of detection). Staphylococcus carnosus, a strain commonly used for nitrate reduction, was able to convert 1100 ppm M17-nitrate broth to 917 ppm nitrite. Staphylococcus caprae and Panteoa agglomerans, NRB isolated using the M17-nitrate agar assay, were also able to ferment the same broth to 916 ppm and 867 ppm nitrite, respectively. This is the first report of an on-agar colony screening assay for the detection and isolation of nitrite reducing bacteria allowing NRB to be readily isolated. This may allow for the identification of new bacteria that may have a more efficient process to generate nitrite, and possibly concomitant with production of additional natural antimicrobials, as vegetable nitrite becomes more widely used to prevent spore germination.

In the US, sodium and potassium nitrite are regulated food preservatives that prevent the germination of Clostridium spores in cured and processed meats. In recent years, the use of vegetable-derived nitrite (i.e., vegetable nitrate fermented to nitrite) has been designated as ‘natural nitrite’ to accommodate natural meats that cannot use artificial ingredients, and such meat products can be labelled as having ‘no added preservatives’. This new status and labelling allowance for microbially-modified nitrite provides for a ‘clean label’ application of nitrite against the stigma of chemical ingredients and has found increased use within the processed meat industry. The objectives of this study were to examine Clostridium sporogenes as a pathogen-surrogate challenge organism and the use of vegetable (celery) nitrite to prevent spore germination in cooked meat products. A three-strain spore crop of C. sporogenes ATCC 3584, ATCC 19404 and ATCC BAA-2695 was applied during ingredient formulation of low and high-fat hotdogs that were divided into three sub-batches (control without nitrite, hotdogs with sodium nitrite, hotdogs with celery nitrite). In both low and high-fat processes, sodium nitrite was compared to hotdogs made with comparable levels of celery nitrite (156 ppm). All treatments were performed with duplicate trial replication and triplicate sample testing within each trial. Comparisons were analyzed by repeated measures analysis of variance to determine significant difference (p < 0.05) of time course treatments. In shelf-life assays, growth was inhibited at both 5 °C and 15 °C, even if nitrite was absent; however, spore germination and growth readily occurred at 35 °C. Comparison of nitrite effects was best evaluated at 35 °C as a permissive condition to examine the effects of nitrite treatments. Celery nitrite showed no significant difference from sodium nitrite when used in both low and high-fat hotdogs, and spore outgrowth was only observed after 2–3 days at 35 °C compared to hotdogs without nitrite. Application of bacteriocin preparations in the formulation that were effective against Listeria monocytogenes, and moderately inhibitory towards the 3-strain spore mixture of C. sporogenes, were not effective in spore control in manufactured hotdogs. The nitrite validation hotdog trials described herein demonstrates that (celery or sodium) nitrite may prevent Clostridium spore germination for 24–48 h even under permissive conditions to help keep processed meat safe.