SGDEPARTMENT
OF HEALTH AND HUMAN SERVICES
FOOD AND DRUG ADMINISTRATION
CENTER FOR FOOD SAFETY AND
APPLIED NUTRITION
CONTAMINANTS AND NATURAL TOXICANTS SUBCOMMITTEE
OF THE FOOD ADVISORY COMMITTEE
VOLUME II
Wednesday, March 19, 2003
8:39 a.m.
4700 River Road
Riverdale, Maryland
PARTICIPANTS
Francis
Fredrick Busta, Ph.D., Chair
James E.
Heubi, M.D., Co-Chair
MEMBERS
Alex D.W. Acholonu, Ph.D.
Lawrence J. Fischer, Ph.D.
Marion H. Fuller, D.V.M.
Lawrence N. Kuzminski, Ph.D.
Ken Lee, Ph.D.
ACTING
INDUSTRY REPRESENTATIVE (NON-VOTING)
R. Bruce Tompkin, Ph.D.
TEMPORARY
VOTING MEMBERS
James Anderson, Ph.D.
Robert D. Baker, M.D., Ph.D.
Larry R. Beuchat, Ph.D.
Henry M. Blumberg, M.D., Ph.D.
Margaret E. Briley, Ph.D., R.D., L.D.
Laurie J. Moyer-Mileur, Ph.D., R.D., C.D.
Marguerite A. Neill, M.D.
Virginia A. Stallings, M.D.
Phillip Tarr, M.D.
Patti Thureen, M.D.
C O N T E N T S
Page
Opening
Remarks
4
Questions
from the Committee
7
Subcommittee
Discussion of Issues, 47
Recommendations,
and Response to Charges
P R
O C E E D I N G S
Opening Remarks
DR.
BUSTA: Good morning. It looks like we are all here on time and
ready to go, bushy-tailed and no snowstorm, here in College Park.
If we
could convene the committee meeting at this point. A few announcements.
First of all, microphone style.
It's the switch closest to the mouthpiece into which you speak, that is
the off-on switch, the one that is closest to the end of the microphone. The bottom one, you just don't bother
with. Just work with the top one, that
is the on-off, and it has to be turned off when we are not using it because we
get a lot of feedback if we don't.
The
second important announcement. On the
sheet that we got yesterday called Charge and Questions, the most recent draft,
if you would strike "Draft," because those are our final questions
that we are addressing today, so it is really not a draft. That is the set of questions that we are
addressing.
That is
the one that, if you recall, the third line in Charge 1, No. 1, is factors, not
facts. That is how you differentiate
that final draft, last draft, but it is no longer a draft, it is, in fact, the
Charge and Questions.
A number
of committee members have indicated that there are some questions they would
like to ask for clarification and explanation this morning before we continue
on with our discussion of the charges and our committee responses, so
arbitrarily, we are going to take 30 minutes.
We will limit it to 30 minutes of asking questions of the presenters
from yesterday.
We really
need to limit it to 30 minutes, so we will try to be succinct in our questions
because otherwise, we could spend I imagine the whole day grilling various
people for details, so I think just key questions, we will take 30 minutes and
try to get some of those clarifications made this morning.
If the
individual isn't here that needs to answer the questions, then, we will just
have to go on.
Are there
any other items that anyone on the committee would like to bring up?
The
approach to the questions that we are contemplating, not necessarily final
depending on your committee, for example, after the first 30 minutes, again
discuss Charge 1 as we were doing just before 6 o'clock yesterday, discuss that
as best we can, and the Chairs will do their best to summarize what that
discussion was and what we think is a consensus and see if everyone agrees with
that consensus.
If there
are dissenting comments, then, obviously, those can be put in the record, as
well. If that doesn't work well, we can
go around with each individual making a statement, but we will try that
approach first.
Is that
all right with everyone? We will give
that a try.
I see Dr.
Tompkin with a microphone in his hand, poised and pointed, so I assume that you
wish to start.
DR.
TOMPKIN: I would just like to make a
comment. As we progress with the discussion and as we try to reach a consensus,
there will be some issues where we don't have all the data we need, and are we
capturing the data gaps separately, because we can only take a discussion only
so far in the absence of more data.
So, can
we somehow create a parking lot for those kind of things as we move through,
and then come back and discuss them further?
DR.
BUSTA: I think that is an excellent
comment, as always. We will do our best
to capture those here, and I would think that Charge 2, No. 4, Critical
Knowledge Gaps, would be the place to accumulate those, and that is toward the
end.
The other
thing is that you all should have gotten four handouts from the public comment
group that are the slides that they used in the last presentations.
Questions
for clarification.
Questions from the Committee
DR.
FULLER: Two questions. One is if we can have anyone from the
industry that spoke yesterday, one of the questions we had asked early on had
to do with what were the steps taken in, I believe it was the Norwegian plant,
that resulted in their not having problems further.
Then, the
second question, totally unrelated, has to do with the temperature of mixing
the powdered formula, and we heard that boiling water created problems with
protein coagulation. I am curious,
because we also heard that 70 seconds at just a few seconds resulted in
significant kill, you know, what happens at 75 degrees C or 80 degrees C, do
you still have that problem.
DR.
BUSTA: Do we have an industry
representative to respond to that?
DR.
SMOOT: I will try to respond to the
first question regarding the Netherlands plant. After the situation that occurred and the data that was used
yesterday to demonstrate microbiologically improvements in the process and the
environment, the primary actions that took place were in the hygienic design of
the process equipment itself where there was an elimination of water used.
Part of
the spray dry process is a water scrubber, so we found in the environment,
there were pockets in areas that were designed into the process that brought
more water into this dry processing environment.
So, there
was considerable engineering redesign efforts to improve the process and
eliminate the water that was currently in that type of process stream and to
improve the management and use of water in and around that area, as well as the
knowledge to further investigate breakdown equipment, design equipment that is
easily accessible, you know, designing in the cleanability of the equipment.
These
were the types of things that were the primary, as well as then enhancing our
surveillance in terms of the efficacy of good hygienic practices that were
being taken in the factory at that time, you know, a continuous improvement.
These are
the types of things that, in that particular factory, as well as learning some
best practices there, have been continually being spread throughout that
particular organization. I am sure the
learnings there have found their way throughout the infant industry, as well.
DR.
FULLER: So, did you end up having to replace
equipment or were they able just to make changes to existing equipment and
water, and I understand you did say water use, as well?
DR.
SMOOT: Both, there was both. I mean there was redesign of unit
operations, as well as replacement of equipment.
DR.
FULLER: Thank you.
DR.
SMOOT: I don't believe I would be
qualified to approach the second question.
There is
a point of information from Bruce.
DR.
TOMPKIN: The data that you provided
were data on product.
DR.
SMOOT: Correct.
DR.
TOMPKIN: In addition to that, there was
a lot of samples collected, I would assume, from the environment, and those
data are not included, so whereas, in each year, you had 700 to 900 and some
samples analyzed of product, that was supplemented with some additional environmental
samples.
DR.
SMOOT: Correct. The data that you I believe now have a copy
of, in that one table, that was a focused study that ran concurrent to the
normal process monitoring for finished product, which you have seen again cited
in the Codex risk profile, and many of you have made reference to where there
is a more stringent norm for coliforms, less than 0.3 npn/gram. That was the normal operating monitoring for
finished product.
This
dataset that you have access to was a concurrent focus study to look deeper
into that, and then as Dr. Tompkin pointed out, as a supplement to that
enhanced environmental monitoring, was also taking place at the same time, yes,
and that data has not been shared.
DR.
HEUBI: Just a quick question also about
that data. Is that product that was
actually stored in like a bag and then checked, or was it tested during the
process of drying?
DR.
SMOOT: I would say that I don't have
intimate detail, but knowing the nature of the process monitoring, it would
have been minimally into the big bag tote stage of the process.
DR.
BUSTA: Dr. Kuzminski.
DR.
KUZMINSKI: This is for Dr. Smoot, a
question. On your slide yesterday, it's on page 4 of the handouts which were
provided this morning, and thank you for that, the slide yesterday on current
manufacturing intervention strategies, and you outlined there programs and
practices, such as HACCP, supplier QA, et cetera, all the way from the raw
materials to the finished product steps of the manufacturing process.
My
question is related to this. If we
consider the Tennessee incident in 01 as an event, were all of these practices
in place at that point in time? I am
not saying that your organization is linked to the Tennessee event, I just
don't know--
DR.
SMOOT: I would have to defer specific
comment to that particular event to people more knowledgeable of the quality
and safety procedures in place. I could
not speak for that particular event.
DR.
KUZMINSKI: Is there someone here,
others from the industry, that could answer that question?
DR.
SMOOT: Yes, I believe so.
DR.
MARCH: My name is Dan March. I am with Mead Johnson. Yes, I can say that the HACCP programs were
in place at the time. We looked at the
quality of that product at release. It
was probably one of our best batches microbiologically that we had produced
under the standards that currently existed at that time.
DR.
KUZMINSKI: Thank you. If these processes or programs were in place
at that time, what different has industry done since the event in 01?
DR.
MARCH: HACCP is an evolving process,
and it is always open to improvement, so we have instituted improvement in our
HACCP programs in the plants to take account for some things that we had not
noticed in the past, such as use of water and minimization of water in certain
processing.
We have
gone to a higher level of HACCP, looking at different control points or
controlling what we thought were critical control points to a higher level, so
it is an evolving process.
DR.
KUZMINSKI: And the sampling plant that
was described on finished product yesterday, the 5 grams in 5 for the
Enterobacteriaceae. That would be
something new in terms of the evolving HACCP, to verify HACCP.
DR.
MARCH: Yes, it would, exactly.
DR.
KUZMINSKI: Thank you very much.
DR.
BUSTA: We had a second half of a
question on the lower temperature, 70 to 80 degrees C causing coagulation or
clumping in the product. I know the
statement was that very hot water caused clumping yesterday. Does that occur at
70 or 80?
DR.
MARCH: I can speak to that. We had done studies with the boiling water
and had shown that there is an immediate, as Dr. Buchanan's graph showed, there
was an immediate loss of temperature when you add boiling water to product that
is tempered at room temperature.
So, you
have to take into account there is immediate loss of temperature, so therefore,
in order to get the temperatures of what we would say pasteurization around 70
degrees where the kill is most effective, you do need to heat it up somewhat,
85, or something like that.
We do
know that somewhere in that range between that temperature and boiling, there
is going to be some effect on the protein, potential coagulation. Again,
vitamin C losses will still be substantial in the presence of oxygen and
heat.
Also, we
do need to consider the potential burn hazard even at 75, 80 degrees to the
preparer and also to the infant. Does
that help?
DR.
BUSTA: Dr. Stallings.
DR.
STALLINGS: To clarify that, then, if we
were talking about preparation in the home, we could ask people to boil water
and add it to room temperature formula or in a nursery setting.
What
would be the temperature that we would achieve in that sort of setting, are we
going to be at the 70 degree killing temperature, or are you suggesting that if
you did that--part of what we are trying to figure out is, is that effective in
killing bacteria that would be in the product at the point of preparation.
DR.
MARCH: Was that to boil the water, cool
it, and then prepare products with it?
I am sorry.
DR.
STALLINGS: I thought the question may
be a misunderstanding, it was about preparation of a dry powder, so if I were
doing that at home, I would be boiling water, adding it, and you reminded us
that you have an immediate temperature drop, and what is the temperature of a
mixed formula, and it cools.
The
question is are we going to get any killing if we use that.
DR.
MARCH: Yes, there would be an immediate
kill. If you used boiling water, there would be an immediate, once mixed,
immediately, but the graph that Dr. Buchanan showed, showed that there was an
immediate loss of temperature down to somewhere around 80, 85 degrees.
That is
still too hot, and it showed by leaving that out over a period of time, the
cooling curve did flatten out, so it took much longer then to drop down once it
reached equilibrium with the product, it remained at a temperature that is
still capable of causing burns.
DR.
STALLINGS: What is an acceptable
serving temperature just so we have an idea of what that number would be?
DR.
MARCH: An acceptable serving
temperature is probably going to be around body temperature, you know, 98
degrees or something like that--37 C.
DR.
STALLINGS: Let's stay in one unit or
the other. So, we are starting out with
boiling water at 100. We mix it, we are
at 80 something. We have got to let it,
in an equilibration, come down to 30.
DR.
MARCH: That is correct.
DR.
LEE: On the same subject, you know, I
bottle fed three of my own at home. One
of the first things I do is I pour some of the formula on my hand to make sure
it is not too hot.
Are we
saying that these healthcare professionals are not capable of observing the
temperature of what is being fed to the neonate? I am kind of missing--there seems to be some significance given
to the potential burn hazard to the healthcare worker and to the baby, but I
think most parents do this at home all the time, so I am just wondering what is
different, because to me, it's a tradeoff to kill these bacteria.
DR.
MOYER-MILEUR: I think in a NICU
situation what you would have is this formula is being prepared in a formula
room. They would have to be held I
guess at a certain temperature and then cooled, and then taken to the unit and
then rewarmed to room temperature in a Level 3 NICU.
Now, whether
or not you are going to have people who are trying to mix it just prior to a
feeding or not in a smaller nursery, I don't know.
DR.
BUSTA: Dr. Fuller.
DR.
FULLER: Thanks. I guess what I am trying to get at is--and I
don't have the experience here--but I was thinking more along the lines of if
we have identified a population that is very highly at risk, and yet we have
also heard there is a very real need for some of these products, my question is
can you not heat the water to, say, 85 degrees, yes, you will have a rapid
dropoff, do you then have enough to mix with formula, you know, mix for one
minute, let cool a minute, mix with formula a minute and then rapidly cool to
the temperature either for storage or to serving temperature.
That is
where I was going with that, and does that take care of the protein coagulation
problem.
DR.
BUSTA: I see no volunteers.
DR.
THUREEN: I would like to just add this,
because it is the same question.
How
significant is the clumping issue, would it be enough to clog up a tube or clog
up a bottle, or is it just an inconvenience, it might not be digested as well,
and is the remaining protein of the same nutritive value, which is really the
important question, because boiling, I mean it seems like a good way to get rid
of the bacteria, but are we really going to be destroying the product, so that
it is not effective for nutrition.
DR.
MARCH: I don't believe that I can
respond to the clumping and the degree of clumping, however, when we get
into--going back to the previous comment--there was a thought of doing an
incremental heating and cooling.
I guess
what we are looking at there is some very complicated hospital protocols that
could possibly become very confusing. I
don't mean very complicated, but at least more complicated than it is now. I guess that is the danger of that. If not properly heated and cooled, you could
be getting yourself into an incubation situation if you are not warm enough
then.
That
would be my fear of a microbiologist warming the product up 10 degrees doubles
or I guess shortens the growth of bacteria.
I guess I would discourage that in that it does complicate the matter.
DR.
BUSTA: Dr. Heubi.
DR.
HEUBI: I have a manufacturing
question. Yesterday, Dr. Zink told us
that there was not any major advantage to one of the other drying methods for
formula, and now both Dr. Smoot and Dr. March have told us that in response to
some of the issues that were raised, they reduced the amount of water used in
this process.
Is it
your opinion as industry that, generally speaking, the less water that is
utilized, the safer the procedure is, and are you moving in the direction to
minimize water in this process?
DR.
SMOOT: Very succinct, yes. The issue of use of water, parts of the
process, whether you are using steam heat or water cooling of some type, there
is water somewhere throughout the system, so engineering designed to minimize
that exposure to the process stream is one aspect.
The
other, as we talk about spray dried runs, I believe Dr. Zink had mentioned
yesterday his preference to run longer and dryer, I think even Dr. Tompkin had
pointed out is very true. However, due
to formula changes and allergen issues and cleaning, you have to address allergen
issues with wet cleaning, so depending upon production schedules and
changeover, you have to do some type of wet clean sanitation.
But
again, working with our partners in sanitation practices, we are trying to even
improve how we do wet cleaning in a controlled wet clean scenario. So, yes, by all means, it is something that
we are working very hard with in industry.
DR.
BUSTA: Dr. Thureen.
DR.
THUREEN: Thank you. So, if we assume that you can't eradicate
all E. sak contamination at the plant level, and that you could potentially
eliminate it at the nursery level, I think most nurseries would be willing,
with boiling, to go ahead and take that step particularly since most Level 3
nurseries have milk labs with fairly well trained people.
So, it
seems like if you don't know, that there could clearly be steps outlined that
would show effective means of heating and cooling, might require special
equipment, but you could develop that, that nurseries, with all their costs,
would clearly be willing to invest in something like that, so that there should
be able to be research done that would identify the proper process for that,
and if you get a good kill, then rewarming shouldn't be a huge issue for
bacterial contamination, at least to E. sak, or not. I mean that may not be true.
There are
clearly other bacteria in the process and you are going to introduce them
during the process, but if you could have a good heating and cooling procedure,
and then rewarming procedure, and then do studies to see if the protein is
denatured or not, then, you could at least say this is an intact product, maybe
we need to add some extra vitamin C after we finish the product or give the
baby vitamin C supplementation, but it seems like if we can't clear up the
problem at the manufacturing level, we could at least go a long way at the
preparation level.
Clearly,
there is going to be a lot of education involved in that, but it seems to me
that that would be a part of the solution.
DR.
BUSTA: That was not a question.
DR.
THUREEN: It is a question in that there
was a lot of no head shaking from that little group over there that this is not
a realistic solution.
DR.
BUSTA: Let the record note that she was
pointing to the previous respondent.
DR.
THUREEN: Several of them. There are some yes's and no's over
there. Do you not think that is a
realistic solution?
DR.
GEHRIG: Good morning. This is Tom Gehrig with Wyeth
Nutrition. My background is mostly in
food technology, in that area. I have
done some work in denaturing of milk proteins, soy proteins, and I guess if you
look at the milk proteins, your wheys particularly, they start to denature
about 60 degrees C, and as you go up the time-temperature relationship, they
continue to denature.
The soy
proteins are even a little bit more susceptible and my quandary would be that
you are going to have to make it so precise on the mixing that, you know, we
design these, we do a lot of protein efficiency studies to ensure that the
protein is intact, that I think you would start to see, especially through the
nasogastric feeding tubes, especially when the diemers go down, that you would
have some problems with plugging of those tubes.
We know
we have plugging in the nipples of the baby bottles, and I think it would be a
big issue if we start taking these things up to 80 degrees and holding them for
any amount of time.
I think
it works, but, you know, from the industry standpoint, we spend a lot of time
on our processes, especially on the evaporation, on the drying, to try and
minimize the changes to the proteins, and I fear that if we take and
reconstitute with 80 or 90 degree water, and hold it for any amount of time, we
are going to be in some trouble.
DR.
THUREEN: Thank you. That really lays the issue to rest for me,
and I didn't think I had had a good answer before, so thank you for that.
DR.
BUSTA: Dr. Lee.
DR.
LEE: I appreciate that
observation. If one were to anticipate
reformulating with hot water, say, even as high as 100 degrees centigrade, one
could design the proteins appropriately, so they are soluble, perhaps hydrolyze
them somewhat, maintain your protein availability.
It is
really a process design question, is it not?
I mean the protein is not adversely--correct me if I am wrong--the
protein is not destroyed nutritionally by this boiling water syndrome. I mean you can solubilize protein in hot
water.
DR.
WALLINGFORD: John Wallingford, Wyeth.
I think
this is an area that we need to work together on. We don't have all the information we need, so if I could
recommend this be one of the parking lot items where we actually go out and get
the data at what happens to the physical properties with formula after
different temperatures of mixing and actually after subsequent mixing different
temperatures of holding prior to feeding, I think this is an area where there
is a potential for some improvement in the ultimate bacterial safety of the
product.
DR.
BUSTA: Dr. Tarr.
DR.
TARR: I have two questions.
First,
yesterday, you talked about microbial sampling. I forget what the exact numbers were, but I know the numerator
was expressed in grams and the denominator was expressed in tons.
How
validated are these sampling techniques, can we be confident there, in this
part of the HACCP protocol, you are
getting reliable data from your production line? That is my first
question. I can wait for the answer.
DR.
BUSTA: Dr. Smoot, it looks like he is
being nominated.
DR.
SMOOT: Referring to the validation of
this type of sampling plan, currently, the sampling plans for coliforms in our
finished product monitoring now is at the level of N equal 5, and the sample
size equal 1 gram.
The
proposal, continuing with a N equal 5, in other words, number of samples, is
consistent with an ICMSF Class VI sampling plan for fecal coliforms. That would give you a certain level, and has
through time been validated as an acceptable sampling plan for a bacterium of
moderate risk.
So, what
we have proposed from industry is to cast a broader net on our process control
monitoring going from coliforms to the family of Enterobacteriaceae first, and
then secondly, increasing the sample size from 5 grams to 25 grams.
So far we
have found at least working with the N equal 5 one gram for coliform has been
reasonably successful in monitoring and assuring the process control, and what
we were proposing yesterday was a step moving into the more stringent with both
the target of the sampling, as well as the sampling size.
DR.
TARR: A follow-up to that then, and
this might have been answered yesterday, the incriminated product in Tennessee,
did that meet, exceed, or was under the cut points for what you would consider
acceptable for your process?
DR.
MARCH: Yes, it did meet the
specifications at that time for coliform organisms according to the plan that
Dr. Smoot just laid out.
DR. TARR: To meet the future protocols or the
proposed?
DR.
MARCH: Retrospectively, that would be a
difficult question to answer because it would be hard to make the
equation--there would be some challenges, but I have a feeling, and it is only
speculation, that it would meet that.
DR.
TARR: And then my second question
unrelated, it looks like the breast milk substitute is an important priority
for both medicine and industry, and we would like to keep that available, and
it might have to remain in powder form for the near future.
How
close, though, is industry towards coming up with a liquified higher caloric
concentrated form that could be sterilized and administered safely? We heard yesterday that it was technically
difficult, but how active is the scenario developing?
DR.
BUSTA: It doesn't appear that we have
anybody on that. For clarification, Dr.
Zink said that the breast milk supplement was tested.
DR.
ZINK: Going back into our little
database of samples, two human milk fortifier products were tested and
classified as transitional formula, so in the survey we did two human milk
fortifier products were tested.
DR.
TARR: What were the results?
DR.
ZINK: They were negative.
DR.
BUSTA: In regard to the plant that you
showed the data on that were reducing the count, and the last data for 2002,
the fourth one, there were 6 positives and all 6 were E. sak positive, and that
appeared to me that as the plant was improving all of their cleaning processes
and design, et cetera, it ended up selecting for E. sak.
Am I
reading that wrong?
DR.
SMOOT: Clarification. The data that was presented was on a
percentage basis, so it was 0.6, not 6 positives, individual positives.
But, yes,
as our experience with that particular factory, and across the 70, 80 that we
have around the world, as we improve our hygienic practices and reducing water
and driving down and monitoring the environment, the comment made yesterday,
and I think it was borne out as well by Dr. Buchanan's data, is that this
particular organism adapts well to warm, dry environments.
So, as we
continually monitor the environment for the Enterobacteriaceae family, which is
basically a biologic indicator for the presence of water, hence, we use it to
assure we are keeping the environment as dry as possible, because they need
water to grow.
High
levels of EB indicate that you had water somewhere in the system at an
unacceptable level. But with refining
with this particular organism, E. sakazakii, is that out of this group of the
Enterobacteriaceae family, it does appear to possess the adaptation to warm,
dry environments, so as we are driving that number low, yes, we are starting to
see exactly what you observed.
DR.
BUSTA: So, in fact, another placeholder
for research would be trying to determine why ecologically we are selecting for
that type of organism and how we can modify the ecology to eliminate that kind
of organism.
DR.
SMOOT: I would say yes, that is a
correct assumption.
DR.
BUSTA: Peggy.
DR.
NEILL: I think my question is somewhat
headed in your direction, Les, but it combines some of the information that Don
Zink gave us yesterday with his illustration of the process, as well as the
implications of the most recent data that you were just explaining.
Don
painted a fairly powerful portrait that by the time the product is coming
through the dry sifter spray dryer, it has undergone several kill steps, and
the subsequent suspicion, obviously not proven, is that this is a contamination
of product post that step.
My
question relates to the following. What
are the technical obstacles for creating a sterile product post the spray dryer
including conceptualizing that it would not have to be the entire product lot,
production run, et cetera?
In other
words, if we are steering our way towards identifying that there is only a
subpopulation of recipients of formula that are at risk for this infection,
then, one could conceptualize that you only need some of this formula to be
sterile and directed towards that particular patient population.
DR. SMOOT: First of all, you know, we have been
successful in industry in terms of environmental control at assuring the
eradication for the most part from the process environment, other pathogens of
concern, such as Salmonella and Listeria.
As we
look at the Enterobacter sakazakii and its place as a member of the
Enterobacteriaceae family, though maybe not totally convinced, but we are
finding data on a weekly basis that it is a little bit more ubiquitous than
what we maybe thought to begin with.
So, this
organism has been able to eliminate it from the environment post-heating steps
of these either wet mix, dry mix technology streams. The proposal as I understand it then, can we divert or can we
provide some type of unit operation for a small production portion to go into
almost a Class I00 sterile room type environment.
I would
say on the scale of the industrial process, the total process, yes, that would
be very difficult, is that something that we could again maybe work in partner,
is this technologically feasible, is something like this possible, I wouldn't
say no, it is not possible, but this is something the industry would have to
study in terms of a risk-benefit there.
But you
are basically talking about going to a Class 100 room type environment for post-drying
process stream, and you saw the magnitude and size of the equipment to do that
even after the cooler, after dryer, which is the first unit operation post-star
valve on the bottom of the cone. To
even put that in the frame of a sterile environment would be very difficult
because what we are finding, that is a part of the areas that we need to
improve anyway in terms of hygienic design.
There
would have to be a considerable learning to go to that level of process control
to this sterile environment.
DR.
NEILL: I think my comment is that in
the hospitals, we do this all the time in terms of having a triage of medical
products and foods that are adjusted to the perceived risk of the recipient
population.
I mean
it's pasteurized egg product now in most hospitals, so that is where I am
coming from in terms of a conceptual approach.
I think what I am trying to ask is really much more at the level of the
technologies.
I am
intuiting that an ultra-high temperature step is likely to cause difficulties
with the protein denaturation, so that you may end up with an insoluble
product, and I don't think we heard a clear answer yesterday to irradiation,
and all irradiation is not created equal because there is certainly different
types.
What are
the perceived obstacles in the physical-chemical nature of the formula that
would prevent creation of a commercially sterile product? I think maybe that is a better way for me to
articulate the question.
DR.
SMOOT: I might have to defer to people
more intimately involved, maybe Tom, to someone more involved in the actual
process or in technology. Would you
want to speak to this? I defer to Tom
Gehrig, Wyeth.
DR.
GEHRIG: I was responsible for design of
our new factory largely, in part, in Singapore, which we started about a year
and a half ago. We took a good look at
this, and, you know, speaking to what Les said, the volume of the air that
moves through one of these dryers or in the conveying systems is tremendous,
you know, in the volume of like 270,000 cubic feet per minute.
What we
do is try and install Hepa filters on the inlets to these dryers, but where it
gets difficult is, you know, we can control on basically the transfer of the
powder into the packaging operations, and we take a lot of care to ensure that
that air is filtered especially going into the packaging hauls.
We set up
basically a hospital room environment where employees that move into that area
have to do full gowning. They have got
masks, they have got gloves, full head gear, so in the particular zones where
the powder can be exposed to the environment or to the employees, we actually
zone kind of on a concept of 1 through 5, 5 being the most stringent zone.
The only
people allowed in that area are the people working in that area. Where you get into some difficulties is when
you have a breakdown in the line and you have to have an intervention, and the
employees have to be very well educated when they go into this equipment,
especially a mechanic or something, that those tools basically have to be
sterilized or sanitized before they go into the system.
I think,
on the industry's part, it is requiring us to really go back and look at our
processes, kind of what Les was saying, that whenever there is an intervention,
we write it down, we mark down what has been done, who goes in, that the
equipment has been sanitized and cleaned.
But to
create a clean room environment basically from the spray dryer south, so to
speak, into the packaging line, I am sure it could be done, but it is going to be
extremely difficult to do.
It has been our experience that these powders for the E. sak, we can get down to counts that are actually less than 100 CFU per gram, and we still have E. sak in there, so as far as the drying