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Two years ago, we lauded High Pressure Processing (“HPP”) as “one of the most promising food safety technologies.” As it turns out, we were right.

In 2005, the American Pasteurization Company (“APC”) became the first company in the country to offer HPP on a commercial tolling basis. Just five years after the company opened its doors, we are excited to report that APC has been embraced by industry and the company is expanding.

As we wrote previously, HPP is a post-packaging pasteurization technique. The technology can be applied to food products with high water content, such as ready-to-eat meat and poultry products, seafood, fruits, vegetables and soft cheeses. HPP works by uniformly applying up to 87,000 psi of hydrostatic pressure to foods, often in their final packaging, for up to three minutes. The hydrostatic pressure does not compress the food product, but it does destroy food-borne pathogens and spoilage microorganisms.

APC’s first processing facility in Milwaukee started with just two employees processing about 5,000 pounds of food each week. Today, the company’s staff numbers over 50 and is processing more than 700,000 pounds per week. In order to meet the growing demand, APC just opened a second processing facility in Evansville, Indiana. The company hopes to open even more locations across the United States in the future.

The benefits of HPP are especially significant given its proven ability to eliminate food-borne pathogens in certain products. The emotional and financial toll of a food-borne illness outbreak and product recall can devastate a manufacturer. The average cost of a recall to companies is $10 million, in addition to brand damage and lost sales. Thus, by removing pathogens from treated products, and by extension all associated risk, the long term benefits can be substantial.

HPP can also double a product’s shelf life while simultaneously removing the manufacturer’s need to add chemical preservatives. Longer shelf life means longer production runs and fewer markdowns. The business of one APC customer went from static to growing when, with an extended shelf life, it was able to switch its product from frozen to fresh.

These feats are accomplished without the use of chemicals or irradiation, and amazingly, without affecting product quality, thus satisfying some the most significant consumer issues right now: (1) safe; and (2) natural. While irradiation has remained controversial for many years, HPP is quickly gaining a much wider acceptance.

With regard to regulatory compliance, HPP is USDA and FDA approved and helps processors comply with current Listeria regulations. APC “works with food processors in many ways to make the utilization of HPP as seamless and cost effective as possible.”

So is there any downside to HPP? Well, yes. While HPP makes our ready-to-eat meats, raw shellfish, and salsa safer, the process cannot yet be applied to all foods. The good news is that APC is diligently working to expand HPP’s portfolio of products, which will hopefully someday include ground beef.

We are grateful and happy for our friends at APC who now anticipate processing more than 50 million pounds of safe food each year!

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Everyone feels sick about the vast amounts of oil continuing to leak into the Gulf of Mexico. And, for the last 2 months, it has been impossible to visit your favorite news site without cringing at the depressing headlines and photos.

Thankfully, however, in addition to the ongoing containment and clean-up efforts, our government and the seafood industry are working diligently to protect us from becoming ill (literally) from seafood tainted by the massive spill.

The Food and Drug Administration (“FDA”) is working with the National Oceanic and Atmospheric Administration (“NOAA”) and other federal and state agencies to monitor the safety of seafood from the Gulf. The agencies have issued several assurances to the public that their efforts should prevent any contaminated seafood from reaching our shores.

The NOAA’s first action was to swiftly close waters polluted by the oil spill to fishing and shellfish harvesting. NOAA has the authority to close Federal waters, and also works closely with the coastal states (who have authority to close waters within 3 miles of their shoreline). These closed areas continue to expand as the agency monitors the movement of the oil. A map of the closed Federal waters illustrates the enormity of the situation and its impact on our seafood industry.

The FDA affirms that “closing harvest waters which could be exposed to the oil is the best way to protect the public from potentially contaminated seafood, because it keeps the product from entering the food supply.” It has been over 60 days since the oil began pouring into the Gulf, and the well is still releasing as much as 2.5 millions of gallons of oil each day.

So, when will seafood from the region be safe again?

FDA and NOAA have a plan to answer this vital question. Under the plan, harvest waters will not re-open until oil from the spill is no longer present and the seafood samples from the area pass both sensory analysis by trained experts and a chemical analysis to ensure there are no harmful residues.
Some coastal food processing plants are still able to harvest product from Gulf areas not yet affected by the spill. These processors are complying with a surveillance sampling program just implemented by the FDA by providing samples of oysters, crabs and shrimp for pollutant testing. This current testing, and the analyses to be performed once waters are re-opened, will verify that the seafood on our tables is safe to eat.

On June 14, 2010, the FDA distributed a letter to seafood processors emphasizing the processors’ obligations under the FDA’s Fish and Fishery Products Regulation. Click on the following link to view a copy of the FDA Letter. FDA urges processors to verify that their HACCP plans account for the hazard created by the oil spill, and to reassess the plans as needed. FDA also advises processors on their duty to only process fish and shellfish harvested from waters that have not been closed. FDA and NOAA said they would increase inspections to ensure that processors maintain proper documentation on the origin of their products.

While we can feel confident in the federal food safety strategy to deal with this disaster, the full impact of this spill on the Gulf Coast seafood industry will not be known for years. Thirty percent of the Gulf of Mexico federal waters are currently closed, with no re-open date in sight.

AmeriPure, one of America’s largest suppliers of Gulf oysters, just temporarily closed its doors because it could not harvest enough to keep operating. AmeriPure is remarkable for the pasteurization-like process it applies to its oysters. The process does not affect quality, but leaves the oysters safe to eat. We applaud AmeriPure’s commitment to food safety, and extend our sincere hope to both the company and seafood industry that the well can be quickly capped and seafood, rather than oil, will once again begin flowing from the Gulf.

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In recent years, we have witnessed a large increase in the number of reported food-borne illnesses and outbreaks. As a result of improved governmental surveillance, aided by PulseNet and OutbreakNet, more food-borne illnesses and outbreaks are being identified. In turn, as food companies attempt to overcome these trends, new antimicrobial interventions are receiving even greater attention.

One of the most promising food safety technologies is a post-packaging pasteurization technique known as High Pressure Processing (“HPP”). HPP can be used for a wide variety of perishable foods, and works by uniformly applying up to 87,000 psi of hydrostatic pressure to prepackaged foods for up to three minutes. The application of high pressure to the product inactivates both spoilage microorganisms and harmful pathogens by causing the microbial cell membrane to become more porous, and by inactivating enzymes vital for microbial survival. This process, which the American Pasteurization Company (“APC”) has been performing on behalf of customers for years, reduces microorganisms and increases shelf-life significantly.

Notably, the USDA-FSIS currently regards high pressure processing as a valid intervention method for Listeria monocytogenes in prepackaged, ready-to-eat meat products. Because the pressure is hydrostatic (think of a grape in a bottle), there is no impact on the texture or flavor of products that are treated. Other applications include ready-to-eat meat and poultry products, guacamole, fresh salsa, humis, raw and marinated meats, seafood, oysters, dips, wet salads, and various cheese products. The list of appropriate uses and products, of course, continues to expand daily.

Additional benefits of HPP include:

• Dramatically increasing the safety of food products;

• Affording greatly enhanced brand equity protection;

• Extending the optimal freshness of food products using a non-thermal technology;

• Dramatic extension of shelf life;

• Allows reformulation to reduce or eliminate dependency on added microbial inhibitors;

• Facilitates the migration of many products from frozen to fresh; and

• For USDA plants, HPP is considered an effective intervention and helps processors comply with current Listeria regulations.

APC is the first company in the United States to offer HPP on a commercial tolling basis. This arrangement is extremely beneficial to customers because, once pre-packaged foods are received from customers and treated, the products can be custom labeled, packed and shipped directly from APC’s USDA-inspected facility to end-users. Moreover, recent advances in pressure equipment have significantly lowered the cost of use.

To date, APC has successfully processed more that 50 million pounds of food products for more than 30 separate food processors. APC is located in Milwaukee, and because it does not manufacture food (it only makes food safer), the company does not compete with its customers.

Thus, for food companies looking to utilize this new technology on a commercial tolling basis, without incurring the necessary infrastructure costs, don’t hesitate to contact Greg Zaja (of APC’s Research and Development Group) for more information.

Special thanks to APC (www.pressurefresh.com) for helping make our food safer.

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