Implementation of ATP and Microbial Indicator Testing for Hygiene Monitoring in a Tofu Production Facility Improves Product Quality and Hygienic Conditions of Food Contact Surfaces: a Case Study

Abstract

Rapid ATP testing and microbiological enumeration are two common methods to monitor the effectiveness of cleaning and sanitation in the food industry. In this study, ATP testing and microbiological enumeration were implemented at a tofu production facility with the goal of improving cleaning practices and overall plant hygiene. Results from ATP monitoring were used to target areas of the production environment needing additional cleaning; ATP results were verified by microbiological enumeration of aerobic microorganisms, lactic acid bacteria, and yeasts and molds. Products from the production line were enumerated for the same microorganisms to determine if there was an impact on product quality. After the implementation of ATP monitoring and targeted cleaning, there was a statistically lower proportion of swabs that failed to meet established sanitary requirements for ATP, aerobic microorganisms, and lactic acid bacteria (p < 0.05), but not for yeasts and molds. ATP swabs and microbiological enumeration agreed on site hygiene 75.1% (72.3-77.7%, 95% CI) of the time. Product data indicated that unpasteurized finished products contained a statistically lower microbial load of the three groups of organisms following implementation of the practices (p < 0.05). Importance Cleaning and sanitation are critical to maintaining safe and high-quality food production. Monitoring these activities is important to ensure proper execution of procedure and to assure compliance with regulatory guidelines. The results from monitoring activities can direct targeted cleaning of areas with higher risk of contamination from foodstuffs and microorganisms. The results of this study show that ATP monitoring and microbiological enumeration are useful tools to verify and improve the efficacy of cleaning and sanitation practices, which can have a positive impact on both plant hygiene and product quality. However, testing regimes and critical parameters will vary based on the product and facility.

Biological analysis using a luminometer of surfaces intended for preparing meals

“…This is caused by environmental conditions (temperature, air humidity) and the working surface, which remains dirty and wet for a long time (Scott and Bloomfield, 1990). The importance of caring for the hygiene of surfaces where food is prepared was also emphasised by Sogin et al (2021).…”

Luminescent Analysis of ATP: Modern Objects and Processes for Sensing

“…Sanitary control of the cleaning efficiency of various surfaces in the food industry [18] Swabs at predetermined sites of tofu production facility ATP-assay revealed the areas of the production environment needing additional sanitary treatments.…”

“…The express analysis in real time and sensitivity of the bioluminescent determination of ATP, as well as the amount of total information obtained, make it possible to assess the degree of contamination by microbial cells from different points of examination, identify the main sites of cell pollutions and monitor the effectiveness of methods and reagents used for sanitary treatment. Comparing the method of bioluminescent ATP determination with microbiological methods of cell counting, the authors often note the effectiveness of the first approach [13,18,32]. It should be noted here that in some cases, the comparison of the results of ATP-metry and classical methods of microbiology do not always coincide [6,16] due to the fact that detergents and disinfectants used for sanitary treatment can partially inhibit the catalytic activity of luciferase, which forms the basis of the reagent used in bioluminescent ATP-assay.…”

Microbial Control of Raw and Cold-Smoked Atlantic Salmon (Salmo salar) through a Microwave Plasma Treatment

“…Hygiene is a significant element in the food production chain, i.e., the outgoing produce has to be within microbial specifications given by a national or international legislator [ 1 , 2 , 3 ]. Given this background, poor-hygiene production environments and inadequate sanitation will result in healthcare-associated infections and foodborne diseases as well as high production losses of food [ 4 , 5 ].…”