Assessment of prerequisite programs implementation and hygiene status at food packaging companies in Mount Lebanon: cross-sectional study

Abstract

Food packaging has a critical role in all food types and along the food chain from product preservation to transportation, distribution, storage, retailing, and end-use. However, it can become a source of contamination and transfer of microorganisms to the packed food when its hygienic status is not well maintained. The aim of this study was to evaluate the Prerequisite programs (PRPs) implementation in 5 food packaging companies across Mount Lebanon through on-site inspections and to assess the compliance of contact surfaces, employee hands and packaging materials to microbiological specifications. Following on-site inspection, none of the companies achieved a full total score of 100% and scores ranged from 25 to 62%. Regarding the assessment of hygienic status of contact surfaces, non-conforming results (acceptable limit ≤ 0.6 log CFU/cm2) were observed in 50% (5/10) of the surfaces for total viable count (TVC). For the employee hands, none of the hand swab samples (10/10) was conforming for TVC that was present in all samples above the acceptable limit. Highest and lowest reported values were 4.4 and 1.7 log CFU/hands respectively. For packaging samples collected during on-site inspections, TVC and yeasts and molds were detected in 20% (2/10) of the samples but the counts were within the acceptable limit. As for the samples collected from the retail market, TVC was detected 95% (19/20) of samples but the counts didn’t exceed the set acceptable limit. Yeasts and molds were detected within acceptable limit in 65% (13/20) of the samples with the highest value in a dairy/ice cream sample at 1.1 log CFU/Container. As for Enterobacteriaceae, it not detected in all tested contact surfaces, employees' hands and packaging samples. PRPs assessment and related verification activities showed the need for companies to strengthen their hygienic programs and highlighted the importance of food safety management systems implementation not only in food companies but also in food packaging companies. Additionally, the effectiveness of PRPs implementation should be assessed on planned routine basis.