1 SUMMARY
The over-all objective for this project is the protection of the consumer’s health by describing measures for decreasing the amount of ochratoxin A in cereals produced in Europe. This has been achieved by identifying the key elements in an effective HACCP programme for ochratoxin A for cereals, and by providing tools for preventive and corrective actions. A summary of the tools provided by this project is presented in Table 1. The project included the whole food chain from primary production to the final processed food product. The objectives and expected achievements were divided into four different tasks, all important steps in a HACCP managing programme for ochratoxin A in cereals: 1. Identification of the critical control points (CCP); 2. Establishment of critical limits for the critical control points; 3. Developing rapid monitoring methods, and 4. Establishment of corrective actions in the event of deviation of a critical limit. The outcome will serve as a pool of knowledge for HACCP-based management programmes, which will increase food safety and support the EU cereal industry.
TASK 1. Investigation of grain samples has revealed that Penicillium verrucosum is the main, if not the only, producer of ochratoxin A in European cereals. It was concluded that P. verrucosum infection was best detected on DYSG media after seven days at 20ºC. Numbers of P. verrucosum found on DYSG and ochratoxin A content in cereals were correlated. . More than 7 % kernels infected with P. verrucosum indicated ochratoxin A contamination. In the action to identify critical control points for infection, the AFLP fingerprinting, which was developed, did not generate additional important information to that gained by the detection of P. verrucosum at species level by “traditional” taxonomic methods. The sources of infection of the grain were the contaminated environments of combines, dryers, and silos. Prompt and effective drying of cereals at harvest is the major CCP for preventing the formation of ochratoxin A. In regions of Europe where the cereal harvest is at greatest risk, measures to avoid mould and toxin problems are often most effective, while areas normally at less risk may not be the best prepared to avoid storage problems when unusual conditions occur. A significant problem arises where conditions at harvest are unpredictable as it may not be economic to have expensive drying machinery idle some years while in others the supply of damp grain may exceed the drying capacity available. Delays in drying may then put the grain at risk. Another problem arises when the infrastructure is such that sufficient funds and expertise are unavailable to advise on and ensure best storage practice.
TASK 2. The studies of the effect of temporal environmental factors on fungal growth, patterns of colonisation and ochratoxin A production revealed interesting characteristics, which may explain why P. verrucosum is the main ochratoxin A producer in cereal grain in Europe. Generally, P. verrucosum was more dominant at lower aw and 15ºC, whereas Aspergillus ochraceus was more dominant at higher aw at 25ºC. Furthermore, results indicated that P. verrucosum was less sensitive to higher concentrations of CO2 than A. ochraceus, which may also be a competitive advantage during storage. A mathematical model for safe storage time before onset of significant growth of P. verrucosum and ochratoxin A production have been developed, which describes the effect of water activity and temperature on the rate of growth of P. verrucosum in cereal grain. The model is valid for aerobic conditions, for instance when drying grain in near-ambient dryers or cooling grain by aeration prior to high-temperature drying.
Table 1. Summary of tools to prevent ochratoxin A in the cereal production chain as provided by the OTA PREV project.
Site Control type Tools provided Comments
(possible % reduction of OTA)
Harvest GAP - Recommendation: Keep machinery and areas, which are in contact with the harvested grain, clean. Remove old grain and dust. (WP1)
(% prevention not possible to estimate, but significant)
Buffer storage before drying and during drying (in near-ambient dryers) CCP -Mathematical model which can predict safe storage time (critical limits). (WP4)
(up to 100 % prevention possible)
- Rapid monitoring methods for OTA and producing fungi. (WP8) Monitoring tolls: LFDs and ELISAs.
- Data on environmental conditions conducive to growth and OTA production. (WP3) (% prevention not possible to estimate, but useful tools in DSS)
Storage GSP/CCP - Recommendations on silo design and maintenance. (WP5) (% prevention not possible to estimate, but significant)
- Critical limits for remoistening. (WP5) (up to 100 % prevention possible)
- Food grade antioxidants and natural control measures to prevent OTA formation in wet grain. (WP 6) (>80 % prevention but not yet economically feasible)
Intake at cereal processing industry
CCP - Rapid monitoring methods for OTA* and OTA producing fungi in grain. (WP8) LFD (with reader for ochratoxin A) and ELISA
- Critical limit: less than 1000 cfu/g P. verrucosum in wheat. (WP4 and WP11) Indicating risk of OTA levels above 5 μg/kg
- Monitoring method for P. verrucosum. (WP1, WP8, and WP9) Monitoring tools: DYSG, LFD, ELISA, and PCR
Milling industry GMP - Reductive measures during milling . (WP10) (cleaning 2-3%, scouring 3-44%, milling up to 60%)
Cereal processing industry GMP - Reductive measures during extrusion and baking. (WP10) (baking up to 5-10%, extrusion up to 40%)
Intake at malting industry CCP - Critical limits: <3% internal infection or <400 cfu/g with P. verrucosum in barley. (WP11) (up to 100 % prevention possible)
Malting industry GMP - Recommendation: effect of temperature on OTA formation during malting. (WP11) (a decrease of temperature from 16-18 to 12-14ºC reduces OTA formation 4 times)
Intake at brewing industry CCP - Rapid monitoring methods for OTA* in malt. (WP8) LFD (with reader) and ELISA
Brewing industry GMP - Fate of OTA during brewing. (WP 11) (up to 80 % reduction)
Official control CCPs - Rapid monitoring methods for OTA*. (WP8) LFD (with reader) and ELISA
* the critical limits at these points are the same as the legislative limits (today 5 and 3 µg/kg for the unprocessed cereals and products, respectively)
Abbreviations used: GAP, Good Agricultural Practice; GSP, Good Storage Practice; GMP, Good Manufacturing Practice; CCP, Critical Control Point; DSS, decision support systems; cfu, colony forming units; OTA, ochratoxin A; LFD, lateral flow device; WP, project workpackage.
The probability, of ochratoxin A levels above the EC maximum limit of 5 µg/kg at different concentration of P. verrucosum in the grain, clearly increased when the levels of P. verrucosum were above 1000 colony forming units/gram. A mathematical model was developed, which describes the risk for condensation in the headspace of a silo during storage of cereal grain. The model has been used to identify the conditions, which cause moistening of the grain, and to develop control strategies to reduce this and the risk for mould growth and ochratoxin A production. Essential oils, resveratrol and lactic acid bacteria (LAB) can control growth and ochratoxin A production by P. verrucosum and A. ochraceus on grain. However, in small-scale storage experiments and experimental maltings, the inhibitory effect of the selected LAB strain could not be clearly shown. Out of twenty-four essential oils tested the most effective were found to be thyme, cinnamon leaf and clove bud.
TASK 3. New diagnostic tools have become available that will provide the means for rapid determination of ochratoxin A in cereals. This will enable the effective implementation of the European legislation and facilitate future internal control and scientific studies. Immunoassays in ELISA format, sensitive enough to meet the EU legislation for ochratoxin A, have been developed where large numbers (100’s) can be analysed in a few hours. In addition a lateral flow device (LFD) taking less than five minutes to perform, which can be used on-site, has also been developed. A number of genes have been cloned, among them a polyketide synthase gene, which is involved in ochratoxin A biosynthesis. PCR primer pairs have been developed which appear to be highly specific for A. ochraceus and P. verrucosum. The primers may find use a in the development of rapid identification protocols for ochratoxigenic fungi. Several advances have been made towards a molecularly imprinted polymer (MIP) specific for ochratoxin A and its integration into a solid phase extraction (SPE) and sensor systems. Several polymers have been designed using a computational method and tested using SPE. The materials demonstrate a high affinity and specificity for the target molecule in aqueous model samples, however integration in real samples with complex biological matrices (grain samples) has proved difficult as interfering compounds affect binding and measurements of ochratoxin A. Attempts to isolate and remove these interfering materials were unsuccessful and consequently the detection limits were not at the level required to meet the legislative requirements
TASK 4. This project has contributed with tools and recommendations for the cereal processing industry. These will will facilitate decisions to be made to enable the dual maximum levels for ochratoxin A described in the Commission Regulation (EC) No 472/2002 of 12 March 2002 setting maximum levels for ochratoxin A in foodstuffs to be followed. Examining the fate of ochratoxin A during milling revealed white flour having the most significant reduction of ochratoxin A of about 50%. An initial cleaning stage and scouring (1-2%) prior to milling, removed small amounts of ochratoxin A. Baking resulted in only a small fall in concentration. However, an overall reduction of about 80% is achievable for white bread with scouring included and up to 35% similarly for wholemeal bread. The increase of ochratoxin A concentration during malting was 2-4-fold in 75 % of the samples studied and process temperature had a pronounced effect. At the higher temperatures of 16-18°C ochratoxin A formation was 20-fold compared to 5-fold at the temperatures of 12-14°C. During the brewing process approximately 20% of the original ochratoxin A from the malt remained in the beer.