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Clostridium botulinum in Ready-to-eat Foods: Risks, Prevention, and Natural Solutions

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Food safety in ready-to-eat products is a constant challenge for the industry. Among the most dangerous pathogens is Clostridium botulinum, responsible for botulism, a severe and potentially fatal foodborne illness. In products such as Spanish omelettes, refrigerated ready meals, and vacuum-packed foods, this microorganism can find ideal conditions to develop if proper control measures are not applied.

In this article, we analyse why this pathogen is of particular concern in this type of food, what the latest AESAN (Spanish Agency for Food Safety and Nutrition) report says, and how Amerex’s natural solutions help prevent risks and ensure compliance with current legislation.

Discharger inform AESAN: BOTULISMO_ENVASADOS

What is Clostridium botulinum and why is it a concern in prepared or ready-to-eat foods?

Clostridium botulinum is a spore-forming anaerobic bacterium capable of producing one of the most potent toxins known, extremely dangerous to human health and responsible for botulism. Although it is a rare pathogen, its severity makes it a top priority for the food industry.

There are two major groups:

  • Proteolytic strains: grow at higher temperatures and break down proteins, generating compounds that may alter the taste and smell of food.
  • Non-proteolytic strains: can grow at refrigeration temperatures (≥3.3 °C), making them a real threat in ready-to-eat foods stored under refrigeration.

In refrigerated ready-to-eat foods (such as Spanish omelettes, chilled prepared dishes, or vacuum-packed cooked meats), non-proteolytic strains are the main concern, since they can multiply if the right conditions of pH, water activity (aw), and temperature are met, even when processing has otherwise been optimal.

Wat are the characteristics of ready-to-eat foods?

Ready-to-eat foods are characterized by:

  • Vacuum or modified-atmosphere packaging.
  • Mild heat treatment (pasteurization or partial cooking).
  • Refrigerated storage for days or weeks.

From a microbiological perspective, these conditions can favour the survival of C. botulinum spores, especially non-proteolytic strains, if the product presents:

  • pH higher than 4.6.
  • High water activity (aw).
  • Reduced salt content.

The AESAN report highlights several historical outbreaks linked to products that fall under the ready-to-eat category. Although uncommon, such episodes have triggered food safety alerts, product withdrawals, and significant reputational damage to the companies involved.

What risks has AESAN identified in ready-to-eat foods?

According to AESAN, in refrigerated, vacuum-packed, ready-to-eat foods, the risk of botulism largely depends on:

  • Maintaining good hygiene practices throughout all production stages.
  • Controlling parameters such as pH, water activity, and salt concentration, and adding antimicrobial agents.
  • Strictly complying with storage temperatures (ideally below 3.3 °C).
  • Ensuring that consumers follow conservation and consumption instructions.

These measures are part of a multiple-barrier approach, where each control reduces the likelihood of the bacteria developing and producing toxins.

AESAN stresses that even in pasteurized or cooked products, the risk may persist if no additional control measures are applied.

Critical factors to prevent botulism in ready-to-eat foods

To reduce the risk of C. botulinum in these types of products, the industry must apply the multiple-barrier principle, combining various strategies:

  • Food formulation: adjusting pH, aw, and salt content.
  • Use of natural or authorized antimicrobial agents, such as Amerex’s protective cultures (see below).
  • Thermal control during processing.
  • Strict refrigeration throughout the product’s shelf life.
  • Clear consumer instructions regarding storage and consumption.

How do Amerex protective cultures help prevent Clostridium botulinum?

At Amerex, we develop clean-label microbiology-based solutions that act as a natural barrier against pathogens, including C. botulinum.

Our protective cultures produce metabolites such as organic acids and bacteriocins, which inhibit bacterial growth and extend the product’s shelf life without altering its organoleptic characteristics.

Through challenge tests and predictive microbiology studies, we have validated their effectiveness in various ready-to-eat foods, ensuring compliance with legal limits and providing reassurance for both manufacturers and consumers.

With Amerex solutions, companies can incorporate an additional natural safety barrier into their food safety systems, reducing the risk of alerts and product recalls while meeting the strictest regulatory requirements.

If you would like to learn more about how we can help you improve the safety of your prepared foods, don’t hesitate to contact us!

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NATURAL PRESERVATIVES AGAINST CLOSTRIDIUM BOTULINUM IN TORTILLA

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The use of ready meals such as Spanish tortilla, Russian salad, fresh pasta, etc, is becoming more common among consumers due to new routines and lifestyles.

It is therefore essential that these foods are safe, and Amerex’s natural preservatives help achieve this.

What is Clostridium, and what foods can contain it?

Clostridium is a genus of bacteria that includes several pathogenic species, with the most dangerous being Clostridium botulinum, responsible for producing a lethal toxin known as botulinum toxin, which causes botulism. Although many species of Clostridium are harmless, when conditions are right (lack of oxygen, moderate temperature, and an appropriate pH), C. botulinum can multiply and release toxins that cause severe health problems.

This bacterium is anaerobic, meaning it can grow in environments without oxygen. It is naturally found in soil, water, and also in canned goods, cured meats, hams, prepared dishes such as Spanish tortilla, Russian salads, etc.—in short, in poorly processed products.

Why are Clostridium and botulism a concern for food manufacturers?

Clostridium botulinum is of particular concern for manufacturers of sterilized prepared dishes and canned goods due to its ability to grow in hermetically sealed, anaerobic environments. This type of food is prone to creating the ideal conditions for the bacteria’s development if proper precautions are not taken. In products with a pH above 4.5, it is crucial to ensure that the sterilization process is powerful enough to destroy the bacteria’s spores.

Food manufacturers are concerned about botulism because:

  • Botulinum toxin is extremely potent: Even in very small amounts, it can cause severe muscle paralysis and even death.
  • Clostridium can survive in tough conditions: The spores of this bacterium are highly resistant to heat and chemical treatments, making their complete elimination difficult in conventional food preservation processes.

Some types of C. botulinum are highly resistant to heat and can survive thermal treatment for 5 to 10 hours. The toxin, however, is not heat-resistant and can be inactivated by boiling temperatures (100°C). The problem arises when the product is poorly processed, failing to destroy the bacteria, which then finds the perfect conditions to generate the toxin in the food, causing botulism in the consumer.

How can Clostridium development be avoided in ready meals like tortilla?

In addition to the additives and treatments used by manufacturers, processing errors can still occur. Therefore, consumers must also follow certain food safety guidelines to prevent Clostridium from developing in their prepared dishes, such as tortillas.

First, packaged refrigerated tortillas are not the same as canned goods. Unlike canned goods, which can be stored at room temperature, tortillas require constant refrigeration to maintain their safety and prevent the proliferation of harmful microorganisms like C. botulinum. Proper storage is necessary, following the storage instructions on the label. Refrigerated tortillas should be kept at the recommended temperature, usually between 0°C and 4°C. If left out of the refrigerator, food safety cannot be guaranteed. Before consuming a packaged tortilla, it is essential to follow the heating instructions provided by the manufacturer. Heating the product to the correct temperature is crucial not only to improve its flavor but also to ensure the elimination of potential toxins.

What additives do manufacturers currently use to prevent botulism development?

To prevent Clostridium botulinum from developing in processed foods, preservatives like nitrites and nitrates have traditionally been used to inhibit the growth of anaerobic bacteria. Lactic acid is also used as a preservative that helps reduce pH, making it difficult for pathogenic microorganisms to grow. Buffered vinegar, now labeled with the code E267, was also commonly used. Buffered vinegar is a common and natural ingredient used as a preservative due to its ability to acidify the environment and prevent bacterial growth.

However, there is now an increasing demand for more natural alternatives, known as “clean label” additives, aimed at reducing the use of artificial preservatives.

Natural “clean label” preservatives offered by Amerex to prevent Clostridium growth in tortillas

Amerex is a company committed to food safety and offers natural preservatives focused on the “clean label” concept to prevent the growth of pathogens such as Clostridium botulinum. It also provides effective preservatives against other anaerobes and spore-forming bacteria. Among the products offered to the food industry is Biamex 150, which has demonstrated activity against these types of pathogens in both Spanish tortillas and cured meats or canned goods.

By using natural preservatives, not only is food safety ensured, but the demands of consumers for healthier, additive-free products are also met.

If you want to know more or how we can help you improve your sausage production processes, feel free to contact us!

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