Comparison of the Microbiological Status of Commercial Broiler Carcasses after 24 and 48 Hour Continuous Production

Introduction: In Australia, increased consumer demand for chicken meat has driven greater production and processing. At the same time, companies face pressures in processing, particularly with respect to environmental sustainability. The desire to extend processing operations while avoiding an increase in water use has led to concerns that the microbiological quality and safety of the product will be compromised

Purpose: To determine any difference in the microbiological status of whole chicken carcasses after 24 and 48 h of commercial production

Methods: Over three weeks, whole carcasses were collected hourly, through 24 h and 48 h of production runs, and rinsates prepared. The rinsates were analyzed quantitatively for total viable count (TVC), Escherichia coli and Campylobacter spp. using the Tempo, and qualitatively for Salmonella using the VIDAS UP Salmonellaassay, all with validated modifications. All microbiological data were analyzed statistically. Throughout the processing runs, the spin chiller water was monitored for temperature, pH, oxidative redox potential (ORP), and hypochlorous acid (HOCl) concentration.

Results: There was no statistically significant difference (P > 0.05) in bacterial populations from broiler carcass rinsates between 24 h (mean average; log CFU TVC, 2.2; E coli, 0.6; Campylobacter, 0.8; Salmonella prevalence 37%) and 48 h (mean average; log CFU TVC, 2.3; E. coli, 0.8; Campylobacter, 0.8; Salmonella prevalence 31%) of processing. Additionally, the spin-chiller parameters were not statistically different (P > 0.05) between the 24 h (mean average; pH 6.3, ORP 841 mV, HOCl 5.1 ppm; carcass core temperature, 2.4°C) and 48 h (mean average; pH, 6.4; ORP, 821 mV; HOCl, 5.3 ppm; carcass core temperature, 2.4°C) continuous processing.

Significance: Based on the analytical data obtained, commercial production of whole chicken carcasses, in the processing plant under study, can be continued for 48 rather than 24 h with no significant negative impact upon microbiological quality and safety.