Continuous online processing of fecal- and ingesta-contaminated poultry carcasses using an acidified sodium chlorite antimicrobial intervention.

The objective of this study was to determine the effectiveness of the combined use of an inside-outside-bird-washer for the removal of visible contamination and an online acidified sodium chlorite (ASC) spray system in reducing microbial levels on contaminated poultry carcasses. Specifically, we attempted to determine if this technique (referred to as continuous online processing [COP]) would (i) eliminate the need for offline reprocessing of contaminated carcasses, (ii) meet Zero Fecal Tolerance standards, and (iii) attain significant reductions in titers of some of the commonly found bacterial species. Carcasses were sampled for Ercherichia coli, Salmonella, and Campylobacter at five stations along the processing lines in a series of five commercial plant studies to compare the efficacy of the COP system to that of offline processing. The microbiological quality of fecally contaminated carcasses was found to be significantly better following COP treatment (E. coli, 0.59 log10 CFU/ml; Salmonella, 10.0% incidence) than after standard offline reprocessing (E. coli, 2.37 log10 CFU/ml; Salmonella, 31.6% incidence). Zero Fecal Tolerance requirements were met by all but 2 (0.2%) of the 1.127 carcasses following COP. COP also significantly reduced the titers of Campylobacter; residual titers were 1.14 log10 CFU/ml (49.1% incidence) following COP, compared to 2.89 log10 CFU/ml (73.2% incidence) in carcasses that underwent offline reprocessing. These results support the combined use of an inside-outside-bird-washer for the removal of visible contamination and an online ASC spray system to reduce microbial levels in commercially processed poultry.

Acidified sodium chlorite antimicrobial treatment of broiler carcasses.

An acidified sodium chlorite (ASC) solution was investigated for its antimicrobial effects on broiler carcasses processed under conditions similar to those used in U.S. commercial poultry facilities. Of particular interest was the ability of the ASC solution to reduce natural bioburden in a prechill procedure. A number of parameters such as pretreatment washing of carcasses with water (no wash versus water wash), ASC concentration (500, 850, and 1,200 ppm), method of application (spray versus dip), and method of acid activation (phosphoric acid versus citric acid) were explored to evaluate disinfection conditions. ASC dip solutions (18.9 liters) were freshly prepared for groups of five prechill eviscerated carcasses per treatment (n = 10 carcasses). ASC treatment was shown to be an effective method for significantly reducing naturally occurring microbial contamination on carcasses. Reductions following immersion dipping were demonstrated at all disinfectant concentrations for total aerobes (82.9 to 90.7%), Escherichia coli (99.4 to 99.6%), and total coliforms (86.1 to 98.5%). Additionally, testing showed that ASC solutions maintained stable pH and minimal chlorite ion concentration deviations throughout each treatment. The results of the parameter evaluations indicated that maximal antimicrobial activity was achieved in carcasses that were prewashed and then exposed to a 5-s dip in a solution containing phosphoric acid- or citric acid-activated ASC. At 1,200 ppm ASC, a mild but transitory whitening of the skin was noted on dipped carcasses. The results support the methods currently approved by the U.S. Department of Agriculture for the use of ASC solutions as a prechill antimicrobial intervention in U.S. poultry processing plants.