Almond Pasteurization Action Plan Moving Forward Sensory

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Almond Pasteurization Action Plan Moving
Forward / Sensory Quality Evaluations
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Action Plan History

• How far have we come?

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2001-Where Things Began

• 2001 Canada issues alert on raw almonds
• Bulk food retail outlet linked to Salmonella
• Limited distribution, limited media

• Industry develops Food Quality and Safety (FQS)
  Program
• Good Agricultural Practices (GAPs)
• Good Manufacturing Practices (GMPs)
• Lethality research initiated

Almonds are on the radar screen with health
authorities
Raw refers to whole, natural almonds. Excludes
sliced and slivered forms of almonds that have
been processed.
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2001-2004 Increased Focus on Almonds-Food
Safety

• May 13, 2004 5 cases of Salmonellosis in Oregon
  potentially associated with almonds

• Data gathering begins
• Expert epidemiologist hired to interpret science
• Relationship and role with regulators established
• Additional states report cases
• Notification of 8 countries which received
  shipments

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Almond An Agriculture Crop with Associated Risks
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Even Low Levels of Salmonella Can Cause Illness
Examples of salmonellosis outbreaks with known
low infectious doses
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Industry Recognizes Need to Act

• Two Salmonella outbreaks linked to consumption of
  raw almonds from last 4 years
• Almonds are listed in the routine questionnaire
  for food-borne illness incidents
• Increased detection sensitivity
• Almond industry cant afford to have another
  Salmonella incident
• Almond industry proactive efforts will reduce
  need for regulatory action

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Industry Consensus

• Pathogens, such as Salmonella, may be present at
  low levels in raw agricultural products
  including almonds.

June 23, 2004 ABC Board of Directors approves an
Action Plan calling for voluntary pasteurization
of outgoing raw, natural almonds
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2004 Pasteurization Action Plan

• Plan Criteria
• 1. Destruction of the most resistant pathogen of
  public health significance
• Salmonella SEPT30 (Minimum 4-log reduction)
• 2. Maintaining overall sensory and quality
  attributes
• 3. Avoiding negative health and/or safety
  concerns for consumers.
• 4. Maintain acceptable shelf life and quality
  throughout

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ABC Technical Expert Review Panel (TERP)

• Established October 2004
• Consists of experts in microbiology,
  pasteurization processes, food industry
  applications, and regulatory requirements
• The Panel conducts technical reviews of almond
  pasteurization technologies against specific
  scientific parameters and performance standards
• Specific scientific criteria drawn from
  parameters established by the National Advisory
  Committee on Microbiological Criteria for Foods
  (NACMCF)
• Provides reports to the ABC outlining the Panels
  determination that a technology has/has not met
  established criteria

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2004-Now Almond Industry Searches for
Pasteurization Technologies

• 5 log is the performance standard for
  Pasteurization
• Conduct basic research to evaluate lethality of
  current manufacturing processes
• Investigate potential pasteurization technologies
  for raw almonds
• Cooperate with private companies to pursue
  pasteurization equipment development
• Technical Expert Review Panel (TERP) to
  facilitate evaluation of pasteurization process
  proposed by private companies
• Establish a quality/sensory task force to
  evaluate post pasteurization almond
  characteristics

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Potential Pasteurization Treatments
Non-thermal Cold plasma high hydrostatic
pressure UV E-beams
Chemical PPO fumigation organic acid spraying
(ethanol) gaseous chlorine dioxide, vaporized
hydrogen peroxide
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Steam Pasteurization

• Under ambient steam of 88oC, a greater than 4-log
  reduction can be achieved within 60-75 seconds or
  less

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Typical Steam Pasteurization Process
Average Almond Surface Temperatures
The core temperature increased from 70 F to 80F
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Steam Pasteurization
An ambient steam process that delivers 5-log
reduction doesnt cause noticeable difference on
almond appearance
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One Technology accepted by TERP
Pasteurized almonds still show liveliness
(germination)
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PPO (Propylene Oxide) Pasteurization

• PPO sterilization process can deliver greater
  than 5-log reduction to Salmonella
• Approved by U.S. Environmental Protection Agency
  (EPA) as a fumigant
• Residues dissipate within one month or sooner
• PPO has been used for microbiological and insect
  control for decades
• U.S. Food Drug Administration (FDA) issued
  determination letter allowing PPO as a
  pasteurization process for almonds

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Mandatory Treatment

• August 2006
• ABC Board of Directors recommended that a
  mandatory treatment program be implemented.

• Handler Treatment Plans Required
• Must address specific parameters for the handler
  to ship almonds
• Handlers Required to subject their almonds to a
  treatment or processes that achieve in total a
  minimum 4-log reduction of Salmonella bacteria
• Exemption provided for handlers who
• 1. Ship untreated almonds under a direct
  verifiable (DV) program
• 2. Ship almonds outside of U.S., Canada or Mexico

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AP-DV User Program

• Allows shipment of non-pasteurized almonds by
  handlers directly to manufacturers in North
  America, Mexico and Canada that are qualified DV
  Users
• DV Users must have equipment in place that
  delivers a minimum 4-log reduction and has been
  validated by a board approved PA.
• DV user applications and PA reports are TERP
  reviewed

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Rule Effective September 1, 2007

• All Handler Treatment Plans (HTP) were received
• ABC Board requested to delay implementation
• Reflected concern that sufficient validated
  capacity would not be available prior to
  September 1
• USDA determined that the rule would allow
  consideration of in-process facilities
  therefore providing sufficient capacity
• Soft Start to allow ramping up completion of
  treatment validations
• Intent was to allow companies actively engaged in
  validation efforts on equipment that would
  eventually obtain a minimum 4-Log reduction to
  operate

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Action Plan Progress

• Status (As of 1/15/08)

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Process Approvals
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Sensory/Quality

• The Final Piece of the Puzzle

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Comprehensive Review

• 1. Evaluation of the effects of pasteurization on
  almond varieties
• Dr. Tim Sanders-USDA ARS Market Quality
  Handling Research Unit
• Raleigh, NC
• 2. Sensory Overview
• Gail Civille-President-Sensory Spectrum
• New Providence, NJ

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June-2006 Comprehensive Study

• Comprehensive study initiated to understand the
  impact of three pasteurization processes ( One
  PPO and Two Thermal)
• Study design involved industry stakeholders and
  sensory/quality experts in protocol development
• State-wide samples chosen
• NP, Carmel, Butte varieties (4 lots for each
  variety chosen from 12 lots each)
• Natural variability
• Test lots treated in duplication under parameters
  determined to yield 5-log reduction for PPO and
  4-log for the thermal processes
• Sensory and quality evaluation at specific
  intervals
• Natural shelf-life under ambient conditions
• Consumer validation

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Analyzed Separately by variety

• Treated samples-divided into 3 groups
• Raw, Roast and Delay Roast (roasting after 3
  months in cold storage)

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Off-Flavors

• Where do off-flavors come from?
• In foods with high oil content, lipid oxidation
  often is the source of major off-flavors. This
  is why we monitor the chemistry of the oil
  changes in chemistry often translate into changes
  in flavor
• Free Fatty Acids (FFA)-Chemical precursors of
  some of the compounds responsible for off-flavors
• Working specification for FFA in almonds is
  1.5-By 15 months FFA values in all samples were
  below 0.5
• Peroxide Value (PV)-Indicator of rancidity
• High PV values may indicate rancidity
• Industry specification lt5 meq/kg- By 15 months
  PVs in all samples were lt1.5 meq/kg

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Off-Flavors
Oil Chemistry
free fatty acid (FFA)
triacylglycerol
- heat (roasting) or - enzymic attack
diacylglycerol
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Off-Flavors
Lipid Oxidation
Free fatty acids (FFA) with double bonds are
very susceptible to oxidation.
O2
free fatty acid (FFA)
Saturated without double bonds
O
O
Unsaturated with double bonds
Lipid hydroperoxide
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Off-Flavors
Lipid Oxidation
O
O
hydrolysis
Lipid hydroperoxide
These fragments undergo further reactions to
produce volatile compounds, many of which are
objectionable ( off-flavors).
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Variation in Fresh Almonds
Free Fatty Acids
Peroxide Value
Non-pareil
Carmel
Butte
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Lot and Treatment Variation- Roast Variation
among lots within a variety low
Means
Treatment 1
Treatment 2
Treatment 3
Treatment 4
Peroxide Value Butte
Peroxide Value Butte
Peroxide Value Butte
Peroxide Value Butte
Peroxide Value Butte Means
Peroxide Value Carmel
Peroxide Value Carmel
Peroxide Value Carmel
Peroxide Value Carmel
Peroxide Value Carmel Means
Peroxide Value Non-pareil
Peroxide Value Non-pareil
Peroxide Value Non-pareil
Peroxide Value Non-pareil
Peroxide Value Non-pareil Means
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Moisture Content

• Moisture graphics show the normal situation when
  storing raw and roasted samples in a shelf-life
  study
• Industry moisture specification is 3.5-5.5 for
  raw almonds and 1.5-2.5 for roasted almonds
• Raw samples MC trend downward and roast samples
  trend upward
• An equilibrium exists somewhere in-between
• Data indicates that storage was uniform and did
  not affect other results.

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Butte
Carmel
Non-pareil
6.0
5.0
4.0
Raw
Moisture Content ( w/w)
3.0
Moisture Content Raw Butte
Moisture Content Raw Carmel
Moisture Content Raw Non-pareil
2.0
1.0
0.0
Roast
Moisture Content ( w/w)
Moisture Content Roast Butte
Moisture Content Roast Carmel
Moisture Content Roast Non-pareil
Delay Roast
Moisture Content ( w/w)
Moisture Content Delay-Roast Butte
Moisture Content Delay-Roast Carmel
Moisture Content Delay-Roast Non-pareil
Time (months)
Time (months)
Time (months)
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Free Fatty Acids (FFA)

• Variation in FFA related to type (raw) and
  treatment. Variation among lots within variety
  was significant but small in comparison to type
  and treatment variation
• Treatments sorted high to low typically as
  4-2-3-1 or 4-3-2-1 indicating that pasteurization
  typically lowered FFA accumulation. Treatment 4
  (control) often contrasted significantly from
  treatments1, 2, and 3
• Differences due to type typically sorted raw gt
  delay roast gt roast FFA behaved similarly with
  all varieties. This indicated that the
  pasteurization treatments will result in similar
  shelf-life behavior no matter what variety is
  used

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Butte
Carmel
Non-pareil
Raw
Free Fatty Acids (w/w)
Roast
Free Fatty Acids (w/w)
Delay Roast
Free Fatty Acids (w/w)
Time (months)
Time (months)
Time (months)
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Peroxide Value (PV)

• Variation among lots was significant but small
  indicating good lot selection
• Largest contributors to variation in PV were
  pasteurization treatment and type (raw, roast or
  delay roast)
• Treatments sorted typically as 4-1-3-2 or
  4-3-1-2 with treatment 4 (control) contrasting
  significantly from treatments 1, 2, and 3
• Type always sorted delay roast gt roast gt raw
• PV was similar across varieties
• Pasteurization did not cause peroxide values to
  rise faster than in the unpasteurized control

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Summary - Sensory Protocol

• Full Descriptive Profile at Time 0 Degree of
  Difference score (DOD)
• Raw
• Roasted
• Delay Roasted
• Only Overall Degree of Difference (DOD) after
  Time 0
• At designated time points - 3, 6, 9, 12 months
  (all samples), 18, 21, 24 months (raw only)
• Any DOD score 4.0 triggers full descriptive
  profiling if determined to be necessary by
  Sensory Spectrum
• Note Full Descriptive Profile at 15 Months (raw
  samples only)
• Determined by Almond Board to be end of shelf
  life based on study data

Remember these panelists are highly trained
and find small details
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Initial Raw Results
Initial-0 Month

• Treatment 2 was different from the Control
• Higher in Crunch, Woody/ Hulls/ Skins,
  Vegetable/ Squash/ Pumpkin
• Lower in Cohesiveness, Almond Nut Meat, Fruity/
  Red Fruity (aroma flavor)
• Treatment 2 was different from the Control
• Higher in Fruity/ Fermented (aroma flavor),
  Vegetable/ Squash/ Pumpkin, Cohesiveness
• Lower in Hardness, Crunch, Almond Nut Meat

Initial Roasted Results
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3 Months DOD Results

• Raw Roasted
• Overall, there were far fewer DODs 4.0 in the
  three month samples than seen initially (2 vs.
  20)
• Samples seem to level out by 3 months
• Delay Roasted
• Initially, the 3 Month Delay Dry Roasted samples
  had a larger number of DOD scores 4.0 than seen
  in the Time 0 Roasted samples (34 vs.15)
• However, by 3 months, there were no scores 4.0
  in this sample set
• Samples seemed to level out similarly - Raw
  Roasted samples

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6 9 Months DOD Results

• 6 Months- DOD Results
• Raw, Roasted Delay Roasted
• There were no DOD scores 4.0 in any of the
  samples at 6 months
• 9-Months-DOD Results
• Raw Roasted
• There were no DOD scores 4.0 in any of the
  samples at 9 months
• Delay Roasted
• There were three (3) samples with DODs ? 4.0 in
  the 9 month
• Full descriptive profiling was conducted to
  better understand the differences. Higher DODs
  driven primarily by flavor
• Control has stale flavor cardboard or painty
• Three test have fermented, stale or dark roast

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12 Months DOD Results

• Raw
• 5 samples with DODs ? 4.0
• Full descriptive profiling to understand the
  differences
• Stale/Painty Treat samples
• Similar increase in chewy- both Control Treat
  Roasted
• Roasted
• There were no samples with DODs ? 4.0 in the
  twelve month roasted samples
• Delay Roasted
• There were 24 samples with DODs ? 4.0 in the
  twelve month Delay Roasted samples
• Full descriptive was forgone as both Control
  Treat samples showed signs of rancidity

Note 12 Months is the end of study for Roasted
samples. No further evaluations are scheduled.
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Sensory Conclusions

• Initially some differences were seen between
  Control Treated samples just different, not
  negative
• By 3 months, sample differences have leveled
  out (Raw, Roasted, Delay Roasted)
• At 9 months, Delay Roasted samples have a few (3)
  DODs ? 4.0 a few stale and a bit chewy
• At 12 months
• Five (5) of 72 Raw samples have DOD scores ? the
  cutoff of 4.0 again stale all samples chewy
• All Roasted samples (P2) have DOD scores less
  than the 4.0 cutoff
• 24 Delay Roasted samples have DOD scores ? the
  cutoff of 4.0 (Both control and treat samples
  showed rancid)

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Summary

• Almonds are variable
• Pasteurized samples in some cases had similar or
  better results in terms of sensory and quality
  attributes
• The three pasteurization processes improved shelf
  stability of raw almonds in terms of peroxide
  value and free fatty acid levels
• Differences between treated and control in roast
  samples didnt reach a level at which consumers
  may be able to tell the difference
• In delay roast samples at 9 months, the control
  showed more degradation in terms of flavor than
  treated samples
• While some differences exist these did not prove
  to be good or bad, just different!

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Thank You!Tim BirminghamAssociate Director
Industry Relations/Food Quality SafetyAlmond
Board of California