2016 was a busy year with four new baking process kill step calculators released to the industry. Per FSMA, each registered food manufacturing facility in the U.S. is required to implement this mandatory rule demonstrating scientific documented evidence of preventive controls ensuring control of possible harmful pathogens, such as Salmonella spp., E. coli O21, Listeria monocytogenes, etc., that may have come with the raw ingredients, or be attributed to pests and other environmental factors.
Therefore the main objective of each baking process kill step calculator is to provide bakers around the world a scientific tool to evaluate the lethality of their baking process for the destruction of Salmonella spp. in a variety of bakery products. These kill step calculators can be downloaded from AIB International’s website and come with detailed instructions and procedures. In short, the baking process kill step calculator utilizes the product’s internal temperature and baking time data to determine the total process lethality for Salmonella in log values. The D, Z and T-ref (i.e., reference temperature) is already built into the calculators. Bakers just need to enter at least 20 time X temperature data points to the calculator, which automatically calculates the total log reductions for Salmonella. Upon entering 20 data points to the calculator, it automatically calculates the total process lethality for Salmonella in log values and generates three graphs:
- Product internal temperature
- F value/minimum
- Cumulative log reduction
If the desired log reduction is achieved, then the process lethality report generated can be used as guidance and as a supporting document for FSMA validation and verification purposes. Generally, a kill step validation research study using a pathogen or surrogate microorganism could cost an estimate of $40,000 to $50,000 per product with a minimum of four to six months of time. Using AIB International’s Baking Process Kill Step Calculators, bakers can validate a baking process in about four hours. The following calculators were released this last year:
Released February 2016
Released June 2016
Released September 2016
Released October 2016
AIB International strongly believes that our Baking Process Kill Step Calculators will enable bakeries of all sizes to meet the requirements of FSMA without investing in costly and time-consuming microbial challenge studies. To date 2,800 downloads of various calculators have helped those in the industry. The next calculator released will be flour tortillas.