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Module 22. Investigation of 

Canned Food Spoilage Incidents 

Thermal Processing for Meat and Poultry 

Products Training 

1 
Spoilage Definition 

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SPOILAGE: THE PROCESS OF DECAYING 

2 
 

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Spoilage Diagnosis 

The primary reasoning behind spoilage 

diagnosis is to distinguish between post 

process contamination and insufficient 

thermal processing. 

3 
------------------

 

Spoilage Diagnosis 

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Spoilage diagnosis can only be completed 

with both inspectional and analytical 

evidence. 

Both are equally important! 

4 
 

 

 

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Inspectional and Analytical 

Evidence 

 Complementary: 

• Laboratory evidence may assist the CSI in 

determining the cause of spoilage. 

• Investigative evidence can provide 

assistance to the laboratory in determining 

the type of tests to perform. 

5 
 

 

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Analytical Evidence 

Analytical evidence includes identification of: 

 Gross container defects 

 Container seam/seal defects 

 Product appearance 

 Product chemical characteristics 

• pH, Water activity 

 Product microbiological test results 

• Identification of organism(s) and their growth 

characteristics 

Normal and abnormal container appearances may help to 

diagnose type of spoilage. 

6 
... 

l l l l l 

Normal Looking Container 

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concave 

FLAT 

FLAT 

A can with both 

ends concave 

and remaining in 

this position 

when brought 

down sharply on 

a hard surface. 

Struck on hard surface 
liUIIBrr liUIIO·rr 

 

 

Flipper 

End flips out 

Ends appear normal 

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Struck on hard surface 

Can appears to be normal but when brought down sharply on a flat 

surface one end flips out (convex). End can be pushed back in. 8 
-- ------✓ 

 

 

 

 

Springer 

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on this end 

Will cause 

this end to 

spring out 

A can with one end 

permanently bulged. 

When pressure is 

applied to an end the 

opposite end will 

spring out. May 

become soft or hard 

swell with time. 

9 
 

 

 

 

 

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Classification of Cans: Overfill 

 OVERFILL - Can that appears similar to a 

flipper or slight springer but when pressure is 

applied to the distended end, the other end 

does not flip out. When shaken, the product 

does not slosh in the can due to the lack of 

headspace. 

10 
 

 

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Classification of Cans: Lack of Vacuum 

 LACK OF VACUUM - Can that appears 

similar to a slight flipper or end is not concave 

 May be caused by canning operations which 

are not controlled 

• Low Initial Temperature 

• Low Mechanical Vacuum 

11 
 

 

Soft Swell 

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End 

moves in 

Pressure on top 

or bottom of can 

causes metal end 

to move in. May 

become a hard 

swell with time. 

12 
Hard Swell 

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Hard Swell cans should be shipped to the 

laboratory as directed and should be handled 

with care. 

HARD 

SWELL 

 

Pressure on top and 

bottom of can will not 

cause top and or 

bottom to move. 

13 
Classification of Cans: Buckle 

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A can that has a raised ridge on one end extending in 

from a double seam. Buckles are caused by excessive 

distortion of cans usually in the retort. 

14 
 

 

Classification of Cans: Paneling 

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Caused by lack of 

control over the 

cooling pressure 

in the retort. 

15 
 

 

 

CONTAINER TYPES 

Leakers 

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 May be micro leaks 

detectable only by 

lab testing. 

 May be visible on 

container or label. 

16 
 

 

 

 

 

Container Examinations 

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 An abnormal container is a container with any 

signs of swelling or product leakage or any 

evidence that the contents of the unopened 

container may be spoiled 

 Defective containers are severe dents near 

seams, gross seam defects, severe rust, etc. 

 Need to separate to determine % in lot 

17 
 

 

 

 

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Container Examinations 

 FSIS Canning Reference Manual 

• FDA, Bacteriological Analytical Manual 

Chapter – Examination of Container 

Integrity (Glossary and References 

• Examination of Containers 

• Canned Foods 

• Glass 

• Flexible and Semi-rigid Containers 

• FSIS Microbiological Laboratory Guidebook 

18 
 

 

 

 

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Swollen Containers 

 Often indicates microbiological growth. Note 

some microbiological growth does not 

produce gas. 

 May also be caused by production of 

hydrogen gas through interaction of the food 

with the container. 

19 
 

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Microorganisms of Significance in 

Canned Food Spoilage 

 Microorganisms of public health significance 

• Clostridium botulium 

• Staphylococcus aureus 

 Other Bacteria 

• Coliforms 

• Butyric anaerobes 

• Putrefactive anaerobes 

 Yeast 

 Mold 

20 
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Types of Spoilage 

 Incipient 

 Underprocessing 

 Thermophilic 

 Post-Process (e.g., leaker spoilage) 

 Chemical 

 Mishandling 

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SPOILAGE DIAGNOSIS 

Definitions 

LEAKER SPOILAGE: 

 Spoilage caused by lack of hermetic seal. 

 Product is spoiled, contains mixed microflora 

and/or has improperly formed seams. ‘Pure’ 

cultures may also be found. 

22 
 

 

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Incipient Spoilage 

Definition/Characteristics 

INCIPIENT SPOILAGE: 

 Spoilage of canned foods or ingredients used in 

canned foods before thermal processing. 

 Cans may be buckled or appear swollen 

 Microorganisms noted during microscopic exam 

appear lysed or granular (non-viable) 

 pH may be changed from normal (lower) 

 Headspace gas differs from normal 

 Low or no vacuum 

 Subculture reveals NO viable microorganisms 

23 

 Off odor 
 

 

 

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Incipient Spoilage 

 Incipient Spoilage can lead to other problems 

• Can buckling in the retort can cause 

leakage 

• Off flavors or odors can lead to consumer 

complaints 

• Heat penetration can be adversely affected 

• Product can be considered adulterated and 

will have to be destroyed 

24 
 

 

 

 

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Supporting Investigational Evidence 

 Spoilage of ingredients or raw materials 

before or after receipt by the cannery 

 Excessive hold times between seaming and 

retorting (FSIS regulations limit hold time to 2 

hours) 

 High hold temperatures 

 Holding hot blanched product 

 Operations downtime 

25 
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Enterotoxin Formation 

 Staphylococcus growth before processing 

may lead to enterotoxin formation 

 There is no ‘apparent spoilage’ but the 

enterotoxin survives the thermal process 

26 
 

 

 

 

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Under Processing 

 Spoilage caused by a failure to apply enough 

heat to a food to ensure destruction of 

microorganisms capable of growing at normal 

conditions of distribution and storage 

27 
 

 

 

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Commercial Sterility 

 Condition achieved by the application of heat 

to destroy microorganisms capable of 

reproducing in the food under normal nonrefrigerated conditions of storage and 

distribution, and viable microorganisms 

(including spores) of public health 

significance. 

28 
 

 

 

 

 

 

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Commercial Sterility 

 By the control of water activity and the 

application of heat which renders the food free 

of microorganisms capable of reproducing in 

the food under normal non-refrigerated 

conditions of storage and distribution. 

 FSIS has similar definition for Shelf Stable 

and Shelf Stability. 

29 
 

 

 

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SPOILAGE DIAGNOSIS 

Definitions 

UNDERPROCESSING: 

 A process less than intended 

• Product is still commercially sterile 

 A process less than commercially sterile 

• Spoilage organisms may grow but no health 

hazard 

 A process less than minimum public health 

• Concern is Clostridium botulinum 

30 
 

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Under Processing: Causes 

 Equipment failure 

 Inadequate or improper product formulation or 

filling procedures 

 Inadequate design and/or delivery of the 

thermal process 

 HUMAN ERROR 

31 
 

 

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Under Processing: Causes 

 Failure to adhere to established critical factors 

• Process time and temperature 

• Initial temperature 

• Fill weights 

• Viscosity/Consistency 

• Excessive fines - product style 

• Headspace 

• Formulation changes (starches) 

• Improper rehydration of dry ingredients 32 
Comparison of Filler Methods 

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VIBRATING FILLER HAND FILL METHOD 

33 
 

 

Under Processing: Characteristics 

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 Swollen cans (not always immediate) 

 Sporeforming rods with or without spores 

 Usually ‘pure’ cultures 

 Containers may be toxic 

 Putrid odor 

34 
 

Gross Under-processing 

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 Mixed flora 

 High number of swells 

35 
 

 

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Investigational Support for Under Processing 

 Deviations in processing records 

 Formulation changes 

 Employee issues 

 Line stoppage/down time 

 Problems with automatic controllers such as 

fill weight 

 Gross insanitation 

 Contaminated raw materials 

36 
 

 

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Post-Processing Contamination 

Causes: 

 Container failure due to poor handling 

 Defects, improperly formed seams/seals 

 Cooling water contamination 

 Loss of sterility in aseptic systems 

37 
 

 

 

 

 

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Post-Processing Contamination 

Causes of Leakage: 

 Container abuse (rough handling) 

 Improper chlorination of cooling water 

 Improper cooling or handling of hot cans 

 Improper can manufacture 

 Insanitary can conveyors 

 Product in can seam or sealing surface 

 Mishandling (wet rags around seams) 

38 
 

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Post-Processing Contamination 

Causes of Leakage: 

 Misadjusted die coders 

 Improper seamer adjustment 

 Incipient spoilage causing weak seams 

 Rough handling during shipment and at retail 

39 
 

 

 

Post-Processing Contamination 

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 ANY microorganism can be involved with 

leaker spoilage. 

 Need to know organism and growth 

characteristics to assist in investigation. 

40 
 

 

 

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Post-Processing Contamination 

Critical Points in Determining Cause(s): 

 Incoming container examination 

 Relate container damage to plant practices 

 Container handling practices 

 Line maintenance (no protrusions) 

 Plant sanitation practices (lines and conveyors) 

 Closure record reviews 

 Interviews with plant employees 

 Microorganism subculture results 

41 
 

 

 

 

 

 

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Thermophilic Spoilage 

 Growth in canned foods by spore forming 

microorganisms capable of germination and 

outgrowth at elevated temperatures (120 -

170oF). 

 Processes designed to provide commercial 

sterility do not destroy thermopiles. 

 Thermophilic sporeformers are not of public 

health significance. 

 Thermophiles do not grow at normal 

conditions of distribution and storage. 

42 
 

 

 

 

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Thermophilic Spoilage 

Causes: 

 Improper cooling of retorted product (104°F or 

below) 

 Stacking or casing improperly cooled product 

 Storage at elevated temperatures 

 High spore loads in sugar, starch, etc. 

 In-plant sanitation problems 

 Failure to properly maintain blanchers 

43 
 

 

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Thermophilic Spoilage 

Types: 

 Flat sour (B. stearothermophilus) 

 Thermophilic anaerobes (C. 

thermosaccharolyticum) 

 Sulfide stinker (Desulfotomaculum nigrificans) 

 Aciduric thermophiles (B. coagulans) 

44 
 

 

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Thermophilic Spoilage 

Prevention: 

 Set standards for raw materials (sugar, starches, 

tapioca, spices) 

 Cool retorted containers properly 

 Maintain warehouse storage at cool temperatures 

 Do not stack warm or hot containers 

 Do not store loaded trucks in direct sunlight 

 Maintain good plant sanitation 

 Clean and sanitize blanchers 

 Maintain blanchers and brines above 160oF 

45 
 

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Chemical Spoilage 

Chemical Spoilage - Spoilage of canned food 

due to non-microbial causes 

Types: 

 Hydrogen swells 

 Non-enzymatic browning 

 Enzymatic spoilage 

46 
 

 

 

Chemical Spoilage 

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 It is not a major problem with low-acid canned 

foods 

 Normally due to 

product and 

container 

interaction such 

as with low pH 

foods or products 

containing nitrite 

47 
 

 

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Mishandling 

Types of mishandling: 

 Overfills 

 Freezing of cans 

 Under filled 

 Mechanical production errors 

48 
 

 

 

 

 

 

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Abnormal Containers Found at 

Official Establishments 

 When abnormal containers are detected by 

the establishment during incubation or by 

other means prior to shipment for the 

establishment, the establishment must inform 

the CSI of the finding. 

49 
 

 

 

 

 

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HACCP Plan/Written Procedure For 

Handling Abnormal Containers 

If microbial contamination is addressed in 

HACCP plan or the establishment uses an 

alternative written procedure to handle abnormal 

containers, CSIs are to: 

 Verify establishment has adequate procedures 

in place to control and prevent shipment of 

affected product. 

• Retain the affected product if the establishment 

does not have adequate procedures to control the 

affected product 

50 
 

 

 

 

 

 

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HACCP Plan/Written Procedure For 

Handling Abnormal Containers 

CSIs are to: 

 Verify the establishment takes action to 

determine the cause of the abnormal 

containers. 

 Request incubation records, microbial testing 

results from sample submitted to its laboratory, 

and other data that demonstrates food safety. 

 Verify the establishment disposes of the 

affected containers in the suspect lot(s). 

51 
 

 

 

 

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HACCP Plan/Written Procedure For 

Handling Abnormal Containers 

CSIs are to: 

 Verify the method of disposing of abnormal 

containers in the plan or procedure is fully 

implemented. 

 Verify completion of product disposition and 

release control of normal appearing 

containers, if product was retained. 

52 
 

 

 

 

 

 

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No HACCP Plan/Written Procedure 

For Handling Abnormal Containers 

When microbial contamination is not addressed 

in a HACCP plan and the establishment does 

not have an alternative written procedure for 

handling abnormal containers, CSIs are to: 

 Retain the abnormal containers and the 

product lot with abnormal containers pending 

FSIS laboratory analysis 

• A minimum of 2 hours of continuous production 

must be retained. There is no maximum. 

53 
 

 

 

 

 

 

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No HACCP Plan/Written Procedure 

For Handling Abnormal Containers 

CSIs are to: 

 Perform physical examination of the containers 

in the lot(s) using the criteria in FSIS Directive 

7520.2 , Procedures for Condition of Canned 

Product Container Examination, to determine 

number of abnormal containers/containers with 

defects. 

• Springers, flippers, soft and hard swells, leakers, no 

vacuum, and defects such as vees, droops, and 

deadheads 

54 
 

 

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No HACCP Plan/Written Procedure 

For Handling Abnormal Containers 

CSIs are to: 

 Contact the FSIS Western Laboratory by phone 

at 510-982-4957 

• Both abnormal and normal containers are submitted 

for analysis according to the lab’s instructions 

55 
 

 

 

 

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No HACCP Plan/Written Procedure 

For Handling Abnormal Containers 

CSIs are to: 

 Inform establishment management that it 

needs to place all abnormal containers under 

refrigeration to prevent rupture and to 

preserve their contents and not to freeze 

abnormal container 

56 
 

 

 

 

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No HACCP Plan/Written Procedure 

For Handling Abnormal Containers 

When no obvious defects (droops, vees, 

deadheads, channel leakers, or incomplete seals) 

appear on abnormal containers CSIs should: 

 Review all processing records for the lot to 

determine if a process deviation occurred 

• Thermal (retort) operator’s log 

• Time/temperature recording chart 

• Critical factor records 

• Formulation records 

57 
 

 

 

 

 

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No HACCP Plan/Written Procedure 

For Handling Abnormal Containers 

When no obvious defects (droops, vees, 

deadheads, channel leakers, or incomplete seals) 

appear on abnormal containers, CSIs should: 

 Review additional records 

• Thermal processing system maintenance 

• MIG accuracy records 

• Incubation records for the lot (if any) 

• Closure integrity records to determine if 

teardown/physical test results were within the 

specifications 

58 • Process deviation file 
 

 

 

 

 

 

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No HACCP Plan/Written Procedure 

For Handling Abnormal Containers 

When obvious defects (droops, vees, deadheads, 

channel leakers or incomplete seals) appear on 

abnormal containers, CSIs should: 

 Review closure integrity records to determine if 

the establishment identified the defect and the 

corrective action taken (when and how 

corrective actions were taken) 

 When obvious defects are found that may 

explain the spoilage, lab confirmation is still 

necessary. 

59 
 

 

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No HACCP Plan/Written Procedure 

For Handling Abnormal Containers 

CSIs should also: 

 Determine the storage temperature for the lot 

 Determine if the establishment has experienced 

any other incidents of spoilage, e.g., are there 

any consumer complaints? 

• How did the establishment handle them? 

• micro exams, seam teardowns, or record reviews 

60 
 

 

 

 

 

 

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No HACCP Plan/Written Procedure 

For Handling Abnormal Containers 

CSIs should also: 

 Examine other lots produced before and after to 

determine if similar defects are present 

• Conduct a warehouse inspection, e.g., look for 

shipping containers with stains/additional abnormal 

containers 

 “Bracket” dates in which the defects occurred 

• Bracketing the time periods in which defects were 

found may allow FSIS to take regulatory action against 

all product produced during that time period 

61 
 

 

 

 

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Sample Submission to the FSIS Lab 

 CSIs are to follow the specific instructions 

provided by the Western lab from the initial call 

• If the affected product is reprocessed or retained 

pending disposition by a PA, they still submit 

samples to the lab. 

• If the establishment decides to destroy the product, 

no further action is required by the CSI, except 

verifying the establishment properly documents and 

disposes of the product. 

62 
 

 

 

 

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Sample Submission to the FSIS Lab 

 Lab will request both normal and abnormal 

containers 

 Lab will send an email to the CSI requesting 

information about the affected product 

 CSIs are to provide all information requested, 

from both the initial phone call and in the e-mail 

received from the lab 

63 
 

 

 

 

 

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Sample Submission to the FSIS Lab 

 CSIs are to complete and submit the following 

original forms with the product samples 

• FSIS Form 10,000-2, Laboratory Report; 

• FSIS Form 10,000-3, Canned Foods--Abnormal 

Containers; and 

• FSIS Form 7500-1 Canned Food Sample Reporting 

Form (Note: Not applicable for domestic sample 

submissions). 

• For import abnormal containers, IPP are to complete 

the laboratory sample form 8000-21 and the 

questionnaire in the abnormal container TOI. 

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Sample Submission to the FSIS Lab 

 CSIs send one copy of each form, and any 

additional information requested to: 

• The DO 

• The PDS canning team 

 CSIs retain one copy of each form in the 

government office file 

65 
 

 

 

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Sample Reporting 

 Sample forms include: 

• Number of containers in the lot 

• Total number of containers examined 

• Product information, e.g., product name 

container type and code(s) lot breakdown 

• Processing information, e.g., type of retort, 

process schedule, deviation noted, etc. 

• Storage temperature 

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Sample Reporting 

 Sample forms include: 

• Location where abnormals were found, 

e.g., incubator, warehouse, in distribution 

• The type and number of each type of 

container abnormality found 

• Correlate with samples (lab must confirm 

inspectors observations). Swollen cans can 

change over time. 

• Possible explanation for abnormal 

containers 

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Sample Reporting 

 Sample forms include: 

• Location of each type of defect noted 

• Use side seam as a marker or mark 12 o’clock 

position on container 

• Location in lot where sampled container 

was taken 

68 
..... 

t 

 

 

 

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Sample Reporting 

SIDE SEAM 12 

O’CLOCK 

DROOP AT 3 O’CLOCK 

ON CODED END SEAM 

Container defect location - use side seam as 

starting mark and locate defects by clock time. 

69 
 

 

 

Sample Reporting 

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TRAINING Pallet # 1 

2* 4 6

1 3* 5

1 3* 5

7 9 11

13 15 17

19 21 23

25 27 29

Lot consists of 8640 16 oz cans 

of beef stew in 360 cases 

stacked on 12 pallets. Each 

pallet holds 30 cases (3 across 

x 2 deep x 5 high). Each case 

contains 24 cans (4 across x 3 

deep x 2 high). Swollen 

containers were found in the 

cases indicated with an * in the 

diagram. These cases would 

have been packed at the 

beginning and at the end of 

production on 8/12/2015. 

T

O

P 

F

R

O

N

T 

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Sample Reporting 

 Sample location: 

• Sample 1 - soft swell collected from lot #, 

pallet 1, case 2, container 3 

• Sample 2 - hard swell collected from lot #, 

pallet 1, case 3, container 19 

• Sample 3 - normal container collected from 

lot #, pallet 1, case 11, container 22 

71 
 

 

 

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Sample Reporting 

 Sample location (continued) 

• Sample 4 – sharp dent on the seam at 3:00 

pm on coded end of can from lot #, pallet 1, 

case 15, container 8 

• Description would continue for all samples 

• Describe pallet/case/container numbering 

system on sample form 

72 
 

 

 

 

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Disposition of Affected Lot(s) 

 Lab completes its analysis of abnormal 

containers submitted 

 Forwards the findings to PDS 

 PDS reviews lab findings and makes 

disposition recommendation to DO 

 DO makes final disposition ruling on affected 

product and notifies IPP 

73 
 

 

 

 

 

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Assist in the Spoilage Diagnosis - Using The Facts 

 Analytical results 

 Number of spoiled containers 

 Age of the product 

 Location of the spoilage 

 History of processing - records 

 Determine cause of spoilage and hazard to 

public health 

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Importance of Determining Causes of Spoilage 

 Regulatory – 

• Protect public health 

• Basis for regulatory action 

 Industry – 

• Protect public health 

• Ensure product wholesomeness 

• Reputation 

• Identify source of problems 

• Economic good sense 

75 
 

 

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Affected Lot Disposition 

 Under-processing: below public health cook 

• Reprocess or destroy 

 Process less than commercially sterile -

above minimum health 

• Incubate and sort, determine pH 

76 
 

 

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Affected Lot Disposition 

 Post-processing contamination; non-health 

hazard 

• Sort out swells/defects 

• Dud detection (sort out cans with little or no 

vacuum) 

77 
Questions 

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Questions?

78