Impact of broiler processing scalding and chilling profiles on carcass and breast meat yield

Avian campylobacteriosis, prevalence, sources, hazards, antibiotic resistance, poultry meat contamination, and control measures: a comprehensive review

Avian campylobacteriosis is a vandal infection that poses human health hazards. Campylobacter is usually colonized in the avian gut revealing mild signs in the infected birds, but retail chicken carcasses have high contamination levels of Campylobacter spp. Consequently, the contaminated avian products constitute the main source of human infection with campylobacteriosis and result in severe clinical symptoms such as diarrhea, abdominal pain, spasm, and deaths in sensitive cases. Thus, the current review aims to shed light on the prevalence of Campylobacter in broiler chickens, Campylobacter colonization, bird immunity against Campylobacter, sources of poultry infection, antibiotic resistance, poultry meat contamination, human health hazard, and the use of standard antimicrobial technology during the chicken processing of possible control strategies to overcome such problems.

The Defeathering Effect by Scalding in Chickens Follows Their Intrinsic Dermal Histologies

This study aimed to delineate the fundamental skin histology and its association with feathers in broilers and native Red-Feather (RF) chickens and further elucidate their thermal alterations in respect to the defeathering effect by scalding. Comparisons of skin thickness between fresh samples and those after dehydration and fixation, as well as their collagen contents and histological differences, suggested that RF chickens had a thicker dermal layer with more collagen deposition and compact architecture, particularly in the neck and abdominal skin, but a thinner hypodermal layer in the back, chest, and abdomen skin. Despite an adolescent age, RF chickens showed a shorter calamus depth of tail feathers but a larger calamus diameter of wing feathers. Within the feather follicle punch, a very intense follicle sheath layer with compact collagenous matrixes to fulfill the space next to the inner feather root sheath was observed in RF chickens. Under both soft and hard scalding, RF chickens showed a lower degree of denaturation on hip skins and were more resistant to structural disintegration, primarily within the epidermal and dermal layer. Accordingly, a much narrower gap space between the feather sheath and surrounding follicle sheath was observed, and the gap expansion was also resistant to thermal changes. These results suggest that the defeathering effect by scalding follows the intrinsic skin histologies in chickens of various breeds and ages, primarily depending on the interaction of the feather calamus with the surrounding follicle sheath and neighboring cutaneous tissues, reflecting their resistance to thermal denaturation, but is irrelevant to the feathers per se.

The application of adaptively evolved thermostable bacteriophage ΦYMFM0293 to control spp. in poultry skin

Bacteriophages, bacterial viruses, are now being re-highlighted as one of the promising alternative antimicrobial agents to control bacterial pathogens in various fields, including the food industry. However, wild-type (WT) phages isolated from nature are vulnerable to external stresses such as heat, limiting the usability of phages in thermal processing. Here, we applied an adaptive laboratory evolution approach to improving the heat stability of newly isolated Salmonella-infecting lytic phage ΦYMFM0293 and examined its application in the poultry scalding process. After 15 cycles of exposure to sub-lethal temperature, the obtained adaptively evolved (AE) phages maintained approximately 3-log more infectious particles at 73 or 74 °C than the WT and non-heat-treated control phages. Missense mutations mainly concentrated in the genes related to the phage tail module were identified from the independently obtained heat-challenged phages, regardless of host Salmonella's heat-shock protein chaperone induction. These results demonstrated the necessity and sufficiency of the phage exposures to heat for thermal adaptation and suggested the involvement of the phage tail in heat stability. No significant physiological or morphological changes except the mutually offsetting phage replication parameters were observed in the AE phages. Accordingly, hot water supplemented with the AE phages significantly reduced the number of artificially contaminated Salmonella cells on chicken and duck skin in the mimicked scalding process. The AE strategy used here could be applied to other WT phages to improve their usability as more feasible antimicrobials for food safety.

Effects of Hard and Soft Scalding on Defeathering and Carcass Quality of Different Breeds of Chickens

Current soft scalding in broilers is not applicable to various strains of chickens with different market weights and ages. This study aimed to examine the effectiveness of soft (57 °C for 120 s) and hard (60 °C for 60 s) scalding on defeathering and carcass quality of the local strain of Red Feather (RF) country chickens and determine age, breed, and body weight factor in accounting for the defeathering effectiveness using adult layers and juvenile broilers as a reference. Results showed no differences between soft and hard scalding in broilers with 60% and 80% of acceptable defeathering scores, respectively, while a significantly better effect by hard scalding was observed in adult layers, young and old RF chickens with more than 70% of birds exhibiting desirable scores and less than 20% by soft scalding. In contrast to soft scalding, hard scalding had no significant effects on breast meat color but impaired skin color in broilers as assessed by L*, a*, and b* value analysis. Interestingly, hard scalding increased breast skin yellowness and lightness in young RF chickens and lightness in old RF chickens, while there were no significant changes in layers. However, hard scalding decreased skin elasticity in layers and old RF chickens. The effectiveness of defeathering by scalding method was governed by the age to reach a certain threshold in the development of dermal architecture and feather richness, irrelevant to body weight. The alteration of carcass color primarily depends on age, body weight/breed, and their interaction. In conclusion, current soft scalding is suitable for broiler chickens for desirable defeathering effect and carcass color, whereas layers and RF chickens scaled at 60 °C for 60 s showed a better defeathering effect without unfavorable changes of breast meat and skin color.

Evaluation of Steam-Ultrasound Decontamination on Naturally Contaminated Broilers through the Analysis of Campylobacter, Total Viable Count, and Enterobacteriaceae

ABSTRACT

This study aimed to evaluate the decontamination effects of steam-ultrasound application, through specially designed nozzles installed inside a constructed machine, with a capacity of 10,500 birds per h on naturally contaminated broilers. Using three different skin-sampling areas-back, breast, and neck skin-microbial analysis of Campylobacter, Enterobacteriaceae, and total viable count (TVC) was performed before and after steam-ultrasound treatment. In total, 648 skin samples were analyzed for Campylobacter, and 216 samples were analyzed for Enterobacteriaceae and TVC. Results showed Campylobacter reductions (P < 0.001) of 0.8, 1.1, and 0.7 log, analyzed from back, breast, and the neck skin samples, respectively. Furthermore, reductions of Enterobacteriaceae (P < 0.001) by 1.6, 1.9, and 1.1 log and reductions of TVC (P < 0.001) by 2.0, 2.4, and 1.3 log were found on back, breasts, and neck, respectively. Campylobacter levels were evaluated after 8 days of refrigeration at 4°C in control and steam-ultrasound-treated broilers to determine contamination stability in a small 12-sample trial. The results showed no changes in reductions during refrigeration, indicating that reduced Campylobacter numbers remained stable in treated broilers. This study showed significant bacterial reduction was achieved in three different broiler surface areas at a slaughter speed of 10,500 birds per h at temperatures more than 80°C. The rapid treatment of less than 1.5-s exposure time inside the chamber makes this technology potentially suitable for modern and fast poultry processing lines.

HIGHLIGHTS

Using Risk–Benefit Analysis to Control Salmonella in Chicken Meat

We have created a risk–benefit analysis (RBA) model to assist in food safety decision-making by analyzing Salmonella control in Brazilian chicken meat. First, we described the issues in a risk profile and used a 5×5 matrix to rank the risks associated with Salmonella. We then classified the magnitude of benefits and costs of control measures using another matrix. Finally, we verified the beneficial effects of recommended control measures using Quantitative Microbiological Risk Assessment (QMRA). The RBA classified Salmonella contamination as risk 6, indicating that control measures should be taken in the short and medium terms. It also recommended the adoption of biosecurity measures on farms to reduce the prevalence of Salmonella in birds, better control of carcass washings and chiller tank management, and information placement on packages and campaigns to raise the awareness of the population about the need to control Salmonella contamination before consumption. On the other hand, it did not recommend better controls at scalding and defeathering. QMRA confirmed the beneficial effects of the recommended control measures. For example, as Salmonella prevalence in poultry increased from 4.04 per cent to 50 per cent, the risk of infection per serving also increased from 0.0080 to 0.071. Although better controls in washings and chiller tank management did not affect the risk of infection, it reduced Salmonella counts on carcasses. We assume that the presence of Salmonella on carcasses was due to improper thermal processing or cross-contamination, which increased the risk from 0.0080 to 0.015962. The RBA demonstrated the logic involved in the adoption of control measures, and this can be helpful in the risk management of food safety issues.

Modeling the Reduction of Salmonella spp. on Chicken Breasts and Wingettes during Scalding for QMRA of the Poultry Supply Chain in China

The objective of this study was to develop predictive models for describing the inoculated Salmonella reductions on chicken during the scalding process in China. Salmonella reductions on chicken breasts at a 100 s treatment were 1.12 ± 0.07, 1.38 ± 0.01, and 2.17 ± 0.11 log CFU/g at scalding temperatures of 50, 60 and 70 °C, respectively. For chicken wingettes, 0.87 ± 0.02, 0.99 ± 0.14 and 1.11 ± 0.17 log CFU/g reductions were obtained at 50, 60 and 70 °C after the 100 s treatment, respectively. Greater bacterial reductions were observed on chicken breasts than on chicken wingettes (p < 0.05). A logistic (−1.12, 0.06) distribution could describe the bacterial reductions on chicken breasts at 50–60 °C. Weibull, exponential and log-linear models were compared for describing the bacterial reduction on chicken breasts at 70 °C and the Weibull model showed the best fit as indicated by the pseudo-R², root mean square error (RMSE) and standard error of prediction (SEP) values. For chicken wingettes, a logistic (−0.95, 0.07) distribution could be used to describe the bacterial reduction at 50–70 °C. The developed predictive models could provide parts of the input data for microbial risk assessment of the poultry supply chain in China.

Quality parameters of chicken breast meat affected by carcass scalding conditions

Objective

The influence of broiler carcass scalding conditions on chicken breast meat quality parameters was investigated.

Methods

Two hundred and seventy Cobb broiler chickens from 42 to 48 days old were slaughtered according to the standard industry practice and scalded in five temperature/time combinations—T₁, 54°C/210 s; T₂, 55°C/180 s; T₃, 56°C/150 s; T₄, 57°C/120 s; T₅, 58°C/90 s.

Results

Scalding temperature increase resulted in higher values of external and ventral lightness and in protein functionality reduction—determined by emulsification capacity and protein denaturation—in chicken breast fillets 24 h post-mortem. Protein secondary structures had conformational changes, with a decrease of the α-helix and an increase of the β-sheet and β-turn proportions, mainly in T₁ and T₅ samples, determined by Fourier-transform infrared spectroscopy in an attenuated reflectance mode analysis. The chemical composition, pH, water holding capacity and Warner-Bratzler shear force did not differ among the treatments. In the fatty acid profile, the 18:1n-9 was lower in T₅, which suggested that the high scalding-temperature could have caused the lipid oxidation. The values of the polyunsaturated fatty acids (PUFA), such as 22:2, 20:4n-6, and 22:6n-3, were highest in the T₅, thus being related to the phospholipid cellular membrane collapse in this experimental condition and subsequent release of these PUFA.

Conclusion

Intermediate scalding-parameters avoided the negative changes in the chicken meat quality.

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.

Carcass orientation and drip time affect potential surface water carryover for broiler carcasses subjected to a post-chill water dip or spray1

To estimate the potential for residual antimicrobial solution carryover, surface water accumulation and loss was measured on post-chill carcasses that were either dipped or sprayed with water. For all experiments, broilers were slaughtered, soft or hard scalded, defeathered, and eviscerated. Carcasses were immersion chilled, allowed to drip, and post-chill carcass weight (CW) recorded. For water dip treatment, carcasses were dipped for 0.5 min in water and hung by a wing (n = 33) or a leg (n = 30) and CW recorded at 0, 0.5, 1, 2, and 5 min post-dip. For water spray treatment, individual carcasses were hung by either the wings (n = 35) or legs (n = 34) from a shackle suspended from a scale. Water was sprayed at 80 psi and post-spray CW recorded. Initial water accumulation (0 min) for dipped carcasses was not significantly different (P > 0.05) for carcasses hung by the leg (101.0 g) or wing (108.8 g). Following the 5 min drip time, 31 g of water remained on the carcasses hung by the leg and only 10 g on carcasses hung by the wing (P < 0.05). When carcasses were sprayed with water, initial water accumulation (0 min) was 62 g for carcasses hung by the legs and 60 g for carcasses hung by the wings (P > 0.05). Following the 5 min drip time, 1 g or no water remained on the sprayed carcasses (P > 0.05). Carcasses that were dipped and hung by a leg for 5 min retained significantly more water (31 g) than carcasses that were dipped and hung by a wing (10 g) or sprayed carcasses hung either way (0.3 g) (P < 0.05). Post-chill water dip resulted in significantly higher initial carcass water accumulation than spraying (105 g vs. 61 g, P < 0.05). Carcass orientation during dripping only affected the amount of retained water for dipped carcasses. Dipped carcasses hung by a leg have the highest potential for residual carcass antimicrobial solution carryover and sprayed carcasses hung by either orientation have the lowest potential for residual antimicrobial solution carryover.