Controlling Listeria monocytogenes is one of the most persistent challenges for food manufacturers, particularly in ready-to-eat (RTE) and refrigerated products. This hardy pathogen thrives in environments unsuitable for other bacteria and is a major contributor to foodborne illness outbreaks leading to product recalls.
Kalsec’s DuraShield™, a patented synergistic blend of antioxidants and antimicrobials provides a natural, scientifically validated solution to inhibit Listeria growth, extend shelf life, and protect product quality across diverse food categories. This article explores the unique risks posed by Listeria and how DuraShield addresses these challenges for traditional meat, emerging plant-based meat and refrigerated food products.
The Challenge of Listeria monocytogenes
L. monocytogenes is a resilient and adaptable pathogen that poses a significant threat in food production environments. It can infiltrate the food supply through environmental sources like soil, water, and vegetation and persist in facilities despite routine cleaning and sanitation.
A major survival mechanism of L. monocytogenes is its ability to form biofilms—dense bacterial communities that adhere to food contact surfaces. Biofilms protect the bacteria from cleaning agents and sanitization protocols, enabling them to survive on equipment, conveyors, and other surfaces, creating persistent contamination risks.
Combined with its ability to grow at refrigeration temperatures, L. monocytogenes requires enhanced safety measures beyond standard sanitation practices. Targeted use of antimicrobials like DuraShield play a critical role in ensuring product sterility and addressing this formidable pathogen.
High-risk categories include:
Meat Products: L. monocytogenes presents a critical challenge, particularly concerning post-processing contamination. Even small amounts of L. monocytogenes present after processing and packaging can multiply rapidly under refrigerated conditions, posing a significant risk of severe foodborne illness, especially in products consumed without adequate cooking.
The neutral pH and high-water activity of meat products create ideal conditions for the bacterium to survive and proliferate. To address these risks, processing facilities adopt varying control measures. For example, Alternate Type 3 plants rely primarily on sanitation protocols, while Type 1 and 2 facilities often incorporate additional strategies such as antimicrobials and optimized storage conditions. These diverse approaches highlight the need for a multifaceted strategy to combat such a resilient pathogen effectively.
Plant-Based Meats: The wide range of ingredients and complex processing methods used in plant-based foods introduce numerous opportunities for L. monocytogenes contamination. Post-processing contamination, especially in deli-style plant-based meats, presents a critical dilemma as even small amounts of L. monocytogenes can multiply rapidly under refrigerated conditions, posing a significant food safety risk.
Plant-based meats share characteristics with traditional meat products, such as near-neutral pH and high-water activity, which create an environment conducive to bacterial growth. These factors, combined with unique processing techniques and ingredient variability, require rigorous safety measures. To effectively combat L. monocytogenes in plant-based products, manufacturers must implement comprehensive strategies, including the targeted use of antimicrobials and adoption of optimized handling protocols, to ensure product safety and shelf life.
L. monocytogenes requires enhanced safety measures beyond standard sanitation practices. Targeted use of antimicrobials like DuraShield play a critical role in ensuring product sterility and addressing this formidable pathogen.
Refrigerated Ready-to-eat (RTE) Foods: Foods such as dips, deli salads, hummus, and other prepared foods present significant food safety threats because these products often feature pH levels and moisture content that create ideal conditions for the growth of harmful pathogens like L. monocytogenes. Contamination risks are particularly high in manufacturing processes that lack an effective kill step.
Historically, several recalls of refrigerated RTE foods have been linked to L. monocytogenes contamination, often stemming from issues during manufacturing, processing, or post-packaging handling. Additionally, contaminated individual ingredients can serve as persistent sources of L. monocytogenes if no steps are taken to neutralize the bacteria. These risks underscore the importance of implementing rigorous safety measures including the use of antimicrobials to properly address the challenges.
DuraShield: A Natural Antimicrobial + Antioxidant Solution
To combat these challenges, Kalsec developed DuraShield Food Protection Blends —a line of natural antimicrobial and antioxidant products scientifically designed to inhibit L. monocytogenes and other microorganisms of concern. Backed by rigorous scientific testing, DuraShield offers manufacturers a reliable, clean-label alternative to synthetic antimicrobials.
Proven Performance Across Food Categories
DuraShield’s effectiveness has been demonstrated across various food matrices, including traditional meat, plant-based products, and RTE foods. Key results include:
- Traditional Meat Products: DuraShield effectively inhibited L. monocytogenes growth while preserving sensory attributes such as flavor and aroma during refrigerated storage.
- Plant-Based Foods: In plant-based meat applications, DuraShield demonstrated exceptional control of L. monocytogenes, maintaining bacterial counts at safe levels over extended storage periods.
- Refrigerated RTE Foods: DuraShield reduced L. monocytogenes contamination in deli salads and similar products, providing a powerful solution for foods at high risk of post-processing contamination.
These results highlight DuraShield’s ability to address food safety, extend shelf life, and maintain product quality across diverse categories while meeting consumer demand for natural, clean-label solutions.
Why Partner with Kalsec?
Kalsec’s Food Protection unit is equipped with state-of-the-art Biosafety Level 1 and Level 2 laboratories to address microbiological challenges. Our team of experienced scientists collaborates with manufacturers to develop tailored solutions, providing comprehensive support that includes:
- Identification of spoilage and pathogenic microorganisms
- Testing and validation of antimicrobial solutions
- End to end support throughout the entire project
Take the Next Step
Discover how DuraShield can safeguard your products from Listeria monocytogenes while meeting clean-label demands. Get in touch with our experts today to learn more about our proven natural food protection solutions.