Food Safety Issues/BBQ sauce developed mold


I manufacture BBQ and hot sauces in Spain. I recently had two batches develop mold and can´t figure out why. I use canned tomato sauce that has a little garlic and onion in it, and has preservatives. I also use dried garlic, onion, paprica, honey, and chipotle in adobo. I use wheat flour as a thickener. The PH is 4.2. Its the first timem in three years this has happened, and have the same bbq sauce still in jars that is three years old with no problems.
Could it be that I had a bad ingredient, or somehow it wasn´t filled at temperature? I hot pack at 85 degrees celcius, cap, and flip the jars. I appreciate any ideas or input.
Thank you very much.

It seems likely you had a bad ingredient and the mold spores survived your cooking process. You could try putting your dry ingredients through a heat process that reaches about 80C before putting them into your recipe. This can be done simply in an oven and shouldn't affect the ingredient quality. Let me know what happens and if this helps

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Carl LaFrate


I can answer food safety questions relative to food processing, retail food and food salvage after a catastrophic event such as a hurricane, flood, ammonia leak or fire. Questions related to HACCP, Regulatory, GFSI, SQF, BRC, liability issues, contamination events, pest infestation, pest control methodology,food safety defense, pathogen prevention such as L. Monocytogenes control in food processing and retail, any subject related to food safety including at home issues.


30 years experience as a food safety consultant working for the top food processors, food retailers and insurance companies that write liability policies related to food processing, storage and distribution. My firm employees 6 full time food safety auditors. I work for top law firms throughout the USA and am a staff consultant for Douglas Peterson and Associates, one of the top forensic engineering firms in the world. I also work with Risk Solutions International, a global leader in risk management.

New York State Association for Food Protection, past president, executive board Central Atlantic States Association of Food and Drug Officials

Progressive Grocer Magazine Smart Money Magazine Private Label Buyer Magazine Supermarket News Natural Foods Merchandiser Magazine Food Service Director Magazine NYS Association for Food Protection Annual Report NYS Association for Food Protection Newsletter

Syracuse University, Microbiology/Biology NYS College of Environmental Sciences, Plant and Environmental Biology Cornell University, Food and Dairy Processing

Awards and Honors
Wm. Hickey Award (2006), NYS Association for Food Protection, for contributions in the field of food safety and sanitation New York State Integrated Pest Management Award (2007), NYS Assoc. for Food Protection, for contributions in the filed of integrated pest management.

Past/Present Clients
Pillsbury, Agri-Mark, Associated Grocers, Beatrice Foods, Cargill, Southern Cold Storage, Quaker, Ben & Jerry’s, Delverde Pasta (Italy), New York Bakery, Cabot Cheese, Hazelwood Farms, General Mills, Price Chopper Supermarkets, P&C Supermarkets, Great American Supermarkets, Tops Markets, Big M Supermarkets, Big Bear Supermarkets, Frito-Lay Distribution Centers, IBP, Excell, Eckerd Drugs, Rite Aid Drug Stores, Fay’s Drugs, Carl’s Drugs, AWI Wholesale Food Distribution, McLane Food Distributors, Golub Food Distribution, many supermarket chains (many include large scale specialty food service operations), Burger King, Pizza Hut, Taco Bell, McDonald’s, Darden Foods (Red Lobster, Olive Garden), LSG Skychefs (Germany, US), Glen Mills Schools, Cornell University, Crider Poultry, Caesar’s Palace, The Oneida Indian Nation, Taylor Meat Packing, UCB Packaging Films

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