Microbiological quality of water immersion-chilled and air-chilled broilers

Validation of Immersion Precooling and Drip Sanitation Standard Operating Procedures on Weight, Temperature, Microbiological Quality, and Safety of Chicken Carcasses

This study aims to validate sanitation standard operating procedures (SSOPs) of the precooling system in two immersion stages with different temperatures followed by dripping for 3 min. The variables evaluated were temperature, weight, microbiological quality, and safety of chicken carcasses. Groups of indicator microorganisms were quantified and the occurrence of Salmonella spp., Listeria monocytogenes, diarrheagenic Escherichia coli (non-157), and Staphylococcus aureus with enterotoxigenic potential was investigated, before and after cooling by immersion and dripping. Salmonella serovars were determined by real-time PCR. Immersion of the carcasses in water at 9.5 (±2.89) and 2.33 (±1.30) °C in the first and second stages was sufficient to considerably reduce the carcass temperature to 5.70 and 7.41 °C at the system outlet and after dripping, respectively. The weight gain was 5.5%, in accordance with Brazilian legislation (<8%). Immersion cooling significantly reduced (p < 0.05) the total counts of enterobacteria, total coliforms, and E. coli. Contamination was reduced in the carcasses, which increased the water counts in the system to 3.76 log CFU/mL for psychrotrophs. Salmonella spp. was identified in 100% of the carcasses evaluated and in the water from the first and second stages of cooling. The main serovars were S. Newport and S. Minnesota. Pathotypes of diarrheagenic E. coli, mainly atypical EPEC and STEC, and S. aureus with enterotoxigenic potential were highly prevalent in the carcasses even before entering the precooling systems by immersion, which was not sufficient to rule out the occurrence of any pathogen studied. Despite the notable SSOP effect on the quantification of microbiological indicators during immersion cooling, the high occurrence of different pathogens underlies the need to review procedures and techniques not only in slaughterhouses but also throughout the production chain, acting in an integrated manner to provide biosecurity and reduce risks to the consumption of chicken meat.

Spoilage Bacteria Counts on Broiler Meat at Different Stages of Commercial Poultry Processing Plants That Use Peracetic Acid

In poultry processing, spoilage microbes are persistent microorganisms, which affect the quality of broiler meat. Peracetic acid (PAA) is the most common antimicrobial used by commercial processing plants, which can reduce the prevalence of these microbes. The goal of this study was to determine the concentrations of aerobic bacteria, coliforms, lactic acid bacteria, and Pseudomonas on broiler meat in processing plants that use peracetic acid in various concentrations as the primary antimicrobial. Samples were collected from three processing plants at five processing steps: post-pick (defeathering), pre-chill, post-chill, mechanically deboned meat (MDM), and drumsticks. Samples were rinsed in buffered peptone water for bacteria isolation. Over six log CFU/sample of aerobic plate counts (APC), lactic acid bacteria, and coliforms were detected on post-pick samples. All spoilage bacteria were reduced to nondetectable levels on post-chill samples (p < 0.001). However, the presence of all bacteria on mechanically deboned meat (MDM) samples indicated varying degrees of cross contamination from post-chill and MDM samples. These results suggest PAA effectively reduces spoilage microbes in chilling applications irrespective of differences in PAA concentrations. However, due to the levels of spoilage microbes detected in MDM, it may be worth investigating the potential interventions for this stage of processing.

A systematic review and meta-analysis of the efficacy of processing stages and interventions for controlling Campylobacter contamination during broiler chicken processing

Systematic review and meta-analysis were conducted to quantify the effects of processing stages and interventions on the prevalence and concentration of Campylobacter on broiler carcasses. To comprehensively capture relevant evidence, six databases were searched using the keywords "Campylobacter" and "broiler chicken." The literature search yielded 10,450 unique citations, and after applying predetermined inclusion and exclusion criteria, 72 and 53 relevant citations were included in meta-analyses for processing stages and interventions, respectively. As the two primary outcomes, log reduction and prevalence changes were estimated for each stage or intervention using a random-effects meta-analysis approach whenever possible. The outcome-level quality assessment was conducted following the Grading of Recommendations Assessment, Development, and Evaluation (GRADE) approach. The analysis revealed that scalding and chilling majorly reduces the prevalence and concentration of Campylobacter. Immersion chilling reduces the concentration regardless of chemical additives, but its effect on prevalence is not conclusive. The effects of carcass washing applications remain uncertain due to the inconsistency and imprecision of both outcomes. Defeathering and evisceration were identified as stages that can increase both prevalence and concentration. Both chemical and physical processing interventions provide limited efficacy in concentration and prevalence reduction. Major limitations of the review were inconsistency and imprecision at the outcome level and reporting issues and data gaps at the study level. The results are expected to inform quantitative microbial risk assessment model development and support evidence-based decision-making.

Air versus Water Chilling of Chicken: a Pilot Study of Quality, Shelf-Life, Microbial Ecology, and Economics

The United States' large-scale poultry meat industry is energy and water intensive, and opportunities may exist to improve sustainability during the broiler chilling process. By USDA regulation, after harvest the internal temperature of the chicken must be reduced to 40°F or less within 16 h to inhibit bacterial growth that would otherwise compromise the safety of the product. This step is accomplished most commonly by water immersion chilling in the United States, while air chilling methods dominate other global markets. A comprehensive understanding of the differences between these chilling methods is lacking. Therefore, we assessed the meat quality, shelf-life, microbial ecology, and techno-economic impacts of chilling methods on chicken broilers in a university meat laboratory setting. We discovered that air chilling methods resulted in superior chicken odor and shelf-life, especially prior to 14 days of dark storage. Moreover, we demonstrated that air chilling resulted in a more diverse microbiome that we hypothesize may delay the dominance of the spoilage organism Pseudomonas Finally, a techno-economic analysis highlighted potential economic advantages to air chilling compared to water chilling in facility locations where water costs are a more significant factor than energy costs.IMPORTANCE As the poultry industry works to become more sustainable and to reduce the volume of food waste, it is critical to consider points in the processing system that can be altered to make the process more efficient. In this study, we demonstrate that the method used during chilling (air versus water chilling) influences the final product microbial community, quality, and physiochemistry. Notably, the use of air chilling appears to delay the bloom of Pseudomonas spp. that are the primary spoilers in packaged meat products. By using air chilling to reduce carcass temperatures instead of water chilling, producers may extend the time until spoilage of the products and, depending on the cost of water in the area, may have economic and sustainability advantages. As a next step, a similar experiment should be done in an industrial setting to confirm these results generated in a small-scale university lab facility.

Effect of chilling methods on the surface color and water retention of yellow-feathered chickens

This study was conducted to investigate the effects of air chilling (AC), water chilling (WC), combined chilling consisting of WC for 20 min and AC (CO₂₀), and combined chilling consisting of WC for 30 min and AC (CO₃₀) on the microbiological status, surface color, processing yield, and moisture content of yellow-feathered chicken carcasses. After chilling, the carcasses treated by AC exhibited the highest total viable counts (TVC) (4.7 cfu/cm²), followed by those treated by CO₂₀ and CO₃₀, whereas the carcasses treated by WC showed the lowest (P < 0.05) mean log TVC (4.2 cfu/cm²). Based on an instrumental color evaluation and photographs of carcass surfaces, the carcasses treated by AC showed a notable yellow color (P < 0.05), whereas no significant difference (P > 0.05) was found among the carcasses treated by CO₂₀, CO₃₀, and WC. The skin samples of carcass parts treated by WC (breast, thighs, drumsticks, back, neck, and wings) exhibited higher moisture contents than the skin samples of the carcasses treated by AC (P < 0.05), providing evidence that weight gain during WC is due to higher water absorption by the skin. The different parts of the broiler carcasses treated by AC had lower cooking losses than those of carcasses treated by combined chilling or WC (P < 0.05), except for the thighs and claws. In breast and drumstick muscles, the moisture contents of the superficial parts from carcasses treated by WC were higher than those of the carcasses treated by AC, whereas the internal parts were not significantly affected by the chilling methods (P > 0.05). The results of this work can be useful for understanding and improving the chilling process for yellow-feathered chickens.

Inhibitory effect of ethanol and thiamine dilaurylsulfate against loosely, intermediately, and tightly attached mesophilic aerobic bacteria, coliforms, and Salmonella Typhimurium in chicken skin

The effects of 3 ethanol levels (30, 50, and 70%) with and without thiamine dilaurylsulfate (TDS; 1,000 ppm) were evaluated for the reduction of natural mesophilic aerobic bacteria (MAB), coliforms, and inoculated Salmonella Typhimurium (S. Typhimurium) in chicken skin. The chicken skin was inoculated with a 7 log cfu/mL suspension of S. Typhimurium. Loosely, intermediately, and tightly attached cells were recovered from chicken skin through shaking at 200 rpm for 5 min, stomaching for 1 min, and blending for 1 min, respectively. Increasing the ethanol concentration reduced the number of MAB, coliforms, and S. Typhimurium on the chicken skin, whereas TDS treatment without ethanol was not effective. Intermediately and tightly attached microorganisms (total MAB, coliforms, and S. Typhimurium) were more resistant to chemical disinfectants than loosely attached microorganisms. The combination of 70% ethanol with TDS was most effective than the combination of TDS with lower concentrations of ethanol in reducing populations of loosely, intermediately, and tightly attached MAB (by 1.88 log cfu/g, 1.21 log cfu/g, and 0.84 log cfu/g, respectively), coliforms (by 1.14 log cfu/g, 1.04 log cfu/g, and 0.67 log cfu/g, respectively), and S. Typhimurium (by 1.62 log cfu/g, 1.72 log cfu/g, and 1.27 log cfu/g, respectively). However, the chicken skin treated with higher concentrations of ethanol was tougher (P < 0.05) and more yellow and less red (P < 0.05) than that treated with lower concentrations of ethanol or with water (control). On the other hand, a combination of 30% ethanol and TDS yielded the best results, showing the reduction greater than 0.5 log cfu/g in S. Typhimurium, with no negative effect on chicken skin color or texture. Thus, a combination of 30% ethanol and TDS appears to be the optimal treatment for reducing microbial contamination of skin-on chicken products to enhance poultry safety without decreasing food quality, and this treatment could be applied in the poultry industry.

Impact of ethanol and ultrasound treatment on mesophilic aerobic bacteria, coliforms, and Salmonella Typhimurium on chicken skin

The present study evaluated the efficacy of ethanol treatment (0, 30, 50, or 70%) alone or in combination with ultrasound (37 kHz, 380 W) for the reduction of natural indigenous mesophilic aerobic bacteria (MAB), coliforms, and inoculated Salmonella Typhimurium on chicken skin. Bacterial cells with loose, intermediate, or tight attachment to chicken skin were recovered by shaking in an incubator (200 rpm) for 5 min, stomaching for 1 min, or blending for 1 min, respectively. Chicken skins were inoculated with a suspension (7 log CFU/mL) of S. Typhimurium. Ethanol reduced the number of MAB, coliforms, and S. Typhimurium on the chicken skin in a concentration-dependent manner, whereas ultrasound treatment without ethanol was ineffective. A combination of 70% ethanol with ultrasound treatment was the most effective in reducing S. Typhimurium populations with loose, intermediate, and tight attachment (reduction by 2.86 log CFU/g, 2.49 log CFU/g, and 1.63 log CFU/g, respectively). However, chicken skin treated with 50% ethanol alone or with a combination of >50% ethanol and ultrasound showed significant changes in Hunter color values (a* and b*) and texture (shear force) (P > 0.05). On the other hand, a combination of 30% ethanol and ultrasound yielded the best results, leading to a reduction of S. Typhimurium by a >1.0 log CFU/g, but did not alter the color or texture of chicken skin. Thus, a combination of 30% ethanol and ultrasound appears to be the optimum treatment for reduction of microbial contamination in production and distribution of skin-on chicken products, and enhance poultry safety without decreasing food quality.

The Effect of Sanitizers on Microbial Levels of Chicken Meat Collected from Commercial Processing Plants

Chicken meat can potentially become contaminated with bacteria at the processing plant. In Australia, there is currently a lack of knowledge on the parameters and indications of use of non-chlorine based treatments in the chicken meat processing plants. Chlorine is widely used as a sanitizer in Australian chicken meat processing plants but due to occupational health and safety concerns and consumer perception, there is a need to identify alternative sanitizers. This study aimed to assess the efficacy of four different sanitizers in reducing the microbial load from naturally contaminated chicken meat carcasses collected from the processing plants in South Australia. There was a significant variation in a load of Campylobacter and total viable count (TVC) between samples collected from two different processing plants and within carcass batches collected from the same plant that was tested during the study. All sanitizers generally reduced the load of Campylobacter on chicken meat carcasses. Treatment with acidified sodium chlorite significantly reduced the level of Salmonella enterica serovars at all temperatures tested during this study. These findings are helpful to the industry for selection of the appropriate sanitizers. Findings are also useful for the regulatory authorities in Australia for providing approval for the use of sanitizers.

Reviewing Interventions against Enterobacteriaceae in Broiler Processing: Using Old Techniques for Meeting the New Challenges of ESBL E. coli?

Extended-spectrum beta-lactamase- (ESBL-) producing Enterobacteriaceae are frequently detected in poultry and fresh chicken meat. Due to the high prevalence, an impact on human colonization and the spread of antibiotic resistance into the environment is assumed. ESBL-producing Enterobacteriaceae can be transmitted along the broiler production chain but also their persistence is reported because of insufficient cleaning and disinfection. Processing of broiler chickens leads to a reduction of microbiological counts on the carcasses. However, processing steps like scalding, defeathering, and evisceration are critical concerning fecal contamination and, therefore, cross-contamination with bacterial strains. Respective intervention measures along the slaughter processing line aim at reducing the microbiological load on broiler carcasses as well as preventing cross-contamination. Published data on the impact of possible intervention measures against ESBL-producing Enterobacteriaceae are missing and, therefore, we focused on processing measures concerning Enterobacteriaceae, in particular E. coli or coliform counts, during processing of broiler chickens to identify possible hints for effective strategies to reduce these resistant bacteria. In total, 73 publications were analyzed and data on the quantitative reductions were extracted. Most investigations concentrated on scalding, postdefeathering washes, and improvements in the chilling process and were already published in and before 2008 (n=42, 58%). Therefore, certain measures may be already installed in slaughterhouse facilities today. The effect on eliminating ESBL-producing Enterobacteriaceae is questionable as there are still positive chicken meat samples found. A huge number of studies dealt with different applications of chlorine substances which are not approved in the European Union and the reduction level did not exceed 3 log10 values. None of the measures was able to totally eradicate Enterobacteriaceae from the broiler carcasses indicating the need to develop intervention measures to prevent contamination with ESBL-producing Enterobacteriaceae and, therefore, the exposure of humans and the further release of antibiotic resistances into the environment.

Microbiome Profiles of Commercial Broilers Through Evisceration and Immersion Chilling During Poultry Slaughter and the Identification of Potential Indicator Microorganisms

Commercial poultry abattoirs were evaluated to determine the efficacy of the multi-hurdle antimicrobial strategy employed to reduce the microbial load present on incoming broilers from the farm. As next generation sequencing (NGS) has been recently employed to characterize the poultry production system, this study utilized 16S High throughput sequencing (HTS) and quantitative plating data to profile the microbiota of chicken carcasses and determine the efficacy of the multi-hurdle antimicrobial system. Aerobic plate count (APC) and Enterobacteriaceae (EB) microbial counts were quantified from whole bird carcass rinsates (WBCR). The remaining rinsates underwent microbiome analysis using 16S rRNA gene fragments on an Illumina MiSeq and were analyzed by Quantitative Insights into Microbial Ecology (QIIME). The key stages of processing were determined to be at rehang, pre-chill, and post-chill as per the Salmonella Reduction Regulation (75 Fed. Reg. 27288-27294). The APC microbial data from rehang, pre-chill, and post-chill were mean log 4.63 CFU/mL, 3.21 CFU/mL, and 0.89 CFU/mL and EB counts were mean log 2.99 CFU/mL, 1.95 CFU/mL, and 0.35 CFU/mL. NGS of WBCR identified 222 Operational Taxonomic Units' (OTU's) of which only 23 OTU's or 10% of the population was recovered post-chill. Microbiome data suggested a high relative abundance of Pseudomonas at post-chill. Additionally, Pseudomonas, Enterobacteriaceae, and Weeksellaceae Chryseobacterium have been identified as potential indicator organisms having been isolated from all processing abattoirs and sampling locations. This study provides insight into the microbiota of commercial broilers during poultry processing.

Enhancement of bactericidal effects of sodium hypochlorite in chiller water with food additive grade calcium hydroxide

An alkaline agent, namely food additive grade calcium hydroxide (FdCa(OH)₂) in solution at 0.17%, was evaluated for its bactericidal efficacies in chiller water with sodium hypochlorite (NaOCl) at a concentration of 200 ppm total residual chlorine. Without organic material presence, NaOCl could inactivate Salmonella Infantis and Escherichia coli within 5 sec, but in the presence of fetal bovine serum (FBS) at 0.5%, the bactericidal effects of NaOCl were diminished completely. FdCa(OH)₂ solution required 3 min to inactivate bacteria with or without 5% FBS. When NaOCl and FdCa(OH)₂ were mixed at the final concentration of 200 ppm and 0.17%, respectively, the mixed solution could inactivate bacteria at acceptable level (10³ reduction of bacterial titer) within 30 sec in the presence of 0.5% FBS. The mixed solution also inhibited cross-contamination with S. Infantis or E. coli on chicken meats. It was confirmed and elucidated that FdCa(OH)₂ has a synergistic effect together with NaOCl for inactivating microorganisms.

The evaluation of combined chemical and physical treatments on the reduction of resident microorganisms and Salmonella Typhimurium attached to chicken skin

This study was conducted to evaluate the efficacy of sodium hypochlorite (NaOCl, 0-200 mg/kg), thiamine dilauryl sulfate (TDS, 1,000 mg/kg), and ultrasound (37 kHz, 380 W) on reducing Salmonella Typhimurim, mesophilic aerobic bacteria (MAB), and coliforms on chicken skin. Chemical and physical treatments were applied for 5 min either singly or jointly, and Salmonella previously inoculated on chicken skin were quantitatively assessed using brilliant green agar, and the populations of MAB and coliforms in the native flora were enumerated using plate count agar and violet red bile agar, respectively. In the evaluation of bacterial attachment/detachment, chicken skin was quantitatively assessed for loosely, intermediately, and tightly attached bacteria. The treatment effects on bacteria detachment were also visualized using field emission scanning electron microscopy. In addition, color and textural properties of the skin after treatments were evaluated using a color difference meter and texture analyzer. Antimicrobial activity of NaOCl increased as the NaOCl concentration was increased, especially for loosely attached cells. The combination of 200 mg/kg NaOCl and ultrasound (NaOCl/ultrasound) significant reduced loosely, intermediately, and tightly attached bacteria populations by 0.75 to 0.47, 0.43 to 0.41, and 0.83 to 0.54 log cfu/g for MAB, coliforms, and Salmonella Typhimurium, respectively. However, the combination of NaOCl and TDS (NaOCl/TDS) did not sufficiently reduce those cells on chicken skins, except for loosely attached MAB and coliforms. The NaOCl/ultrasound combination produced a higher reduction in numbers of inoculated and native bacteria flora than any single application, with no negative effect on skin color or texture. Generally, the loosely attached bacteria were less resistant to the chemical and physical treatments than the intermediately and tightly attached bacteria in chicken skin, presumably due to their location in deeper skin layer and crevices. Further research is needed to investigate how the intermediately and tightly attached microorganisms can be effectively eliminated from chicken skin.

Effect of hot water spray on broiler carcasses for reduction of loosely attached, intermediately attached, and tightly attached pathogenic (Salmonella and Campylobacter) and mesophilic aerobic bacteria

Chickens are known to harbor many bacteria, including pathogenic microorganisms such as Salmonella and Campylobacter. The objective of this study was to evaluate the efficacy of hot water spray (HWS, 71°C for 1 min) in reducing bacterial contamination of prechilled broiler carcasses. For each of 4 replications, skin samples from 5 broilers were collected at 3 processing stages: after bleeding (feathers removed manually), after evisceration (with/without HWS), and after water chilling. Broiler skin was quantitatively assessed for loosely attached (by rinsing the skin), intermediately attached (by stomaching the rinsed skin), and tightly attached (by grinding the rinsed/stomached skin) mesophilic aerobic bacteria (MAB) and Campylobacter as well as for the prevalence of Salmonella and Campylobacter. Broiler skins possessed 6.4 to 6.6 log cfu/g, 3.8 to 4.1 log cfu/g, and 2.8 to 3.5 log cfu/g of MAB populations after bleeding, evisceration, and chilling, respectively. The HWS resulted in more than 1 log unit of reduction in MAB immediately after evisceration and immediately after chilling regardless of microbial sampling method. Compared with MAB, the contamination of Campylobacter was low (1.7 to 2.6 log cfu/g) after bleeding, but the level was not reduced throughout the processing steps regardless of HWS. The application of HWS reduced the prevalence of Salmonella after chilling, but not for Campylobacter except for loosely attached cells. After hot water exposure, a partially cooked appearance was seen on both broiler skin and skinless breast surface. More research is required to effectively eliminate pathogenic organisms during processing and suppress any recovery of bacteria regardless of attachment type after chilling.