Bio-Mapping Indicators and Pathogen Loads in a Commercial Broiler Processing Facility Operating with High and Low Antimicrobial Intervention Levels

Poultry Processing Interventions Reduce Salmonella Serovar Complexity on Postchill Young Chicken Carcasses as Determined by Deep Serotyping

Nearly 20% of salmonellosis cases are attributed to broilers, with renewed efforts to reduce Salmonella during broiler production and processing. A limitation to Salmonella culture is that often a single colony is picked for characterization, favoring isolation of the most abundant serovar found in a sample, while low abundance serovars can remain undetected. We used a deep serotyping approach, CRISPR-SeroSeq (serotyping by sequencing the clustered regularly interspaced palindromic repeats), to assess Salmonella serovar complexity during broiler processing and to determine the impact of antimicrobial interventions upon serovar population dynamics. Paired hot rehang and postchill young chicken carcasses were collected from establishments across the United States from August to November 2022. CRISPR-SeroSeq was performed on Salmonella culture-positive hot rehang (n = 153) and postchill (n = 38) samples, including 31 paired hot rehang and postchill samples. Multiple serovars were detected in 48.4% (74/153) and 7.9% (3/38) of hot rehang and postchill samples, respectively. On average, hot rehang carcasses contained 1.6 serovars, compared to 1.1 serovars at postchill (Mann Whitney U, p = 0.00018). Nineteen serovars were identified with serovar Kentucky the most common at hot rehang (72.5%; 111/153) and postchill (73.7%; 28/38). Serovar Infantis prevalence was higher at hot rehang (39.9%; 61/153) than in postchill (7.9%; 3/38). At hot rehang, serovar Enteritidis was outnumbered by other serovars 81.3% (13/16) of the time but was always the single or most abundant serovar detected when it was present at postchill (n = 5). We observed 98.4% (188/191) concordance between traditional isolation with serotyping and CRISPR-SeroSeq. Deep serotyping was able to explain serovar discrepancies between paired hot rehang and postchill samples when only traditional isolation and serotyping methods were used. These data demonstrate that processing interventions are effective in reducing Salmonella serovar complexity.

Influence of peroxyacetic acid concentration, temperature, pH, and treatment time on antimicrobial efficacy against Salmonella on chicken wings

Peroxyacetic acid (PAA) is commonly used during poultry processing to reduce the prevalence of Salmonella on carcasses and parts. Wash solutions containing PAA are used at varying concentrations during processing and processors use internally validated practices that best suit the needs of the individual establishment. This study was conducted to determine how temperature, pH, and contact time in combination with PAA concentration can affect the survival of Salmonella on poultry. The effectiveness of PAA in reducing the population of Salmonella on chicken wings was dependent on the concentration and temperature of the PAA solutions. The pH or contact time had no effects (P > 0.05) on total Salmonella or Salmonella Infantis reduction (log CFU/mL). Treatment with 0 ppm PAA at 27°C did not reduce (P > 0.05) total Salmonella or Salmonella Infantis compared to the inoculated, untreated control; in contrast, treatment at 4°C and 0 ppm PAA reduced (P < 0.05) total Salmonella and Salmonella Infantis. Treatments applied at 4°C significantly reduced (P < 0.05) total Salmonella at 50, 200, and 500 ppm PAA, compared to treatment at 27°C among the same PAA concentration. The population of Salmonella Infantis was significantly reduced (P < 0.05) at 4°C with 0, 50, 200, 500, and 1,000 ppm PAA among the same PAA concentration, compared to treatment at 27°C. Treatment conditions, such as temperature, can impact the effectiveness of PAA used as an antimicrobial treatment during poultry processing, and the results from this study can provide useful insights that could assist poultry processors to effectively incorporate PAA into antimicrobial intervention systems.

Quantification of Salmonella Infantis transfer from transport drawer flooring to broiler chickens during holding

Transportation is a potential point of cross-contamination before broiler chickens arrive at the processing plant for slaughter. Previous studies have associated the use of uncleaned transport containers with the introduction of pathogenic bacteria onto uncontaminated broilers. The objective of this study was to quantify the transfer of Salmonella from transport drawer perforated flooring to broiler chickens during different holding times. For traceability, the flooring of each drawer was inoculated with fecal content slurry containing a marker strain of Salmonella Infantis. Three drawers per treatment were used, and each drawer was subjected to one of the following treatments: pressure wash, disinfectant, and pressure wash (A), pressurized steam followed by forced hot air (B), or no cleaning (C). Drawers were classified as top, middle, or bottom based on their relative position with each other. After treatment, broilers were introduced to each drawer and held for 2, 4, or 6 h. At each timepoint, broilers were removed from drawers, euthanized, and carcasses rinsed to obtain Salmonella counts. Samples under the limit of direct plating detection were enriched, plated, and later confirmed positive or negative. Differences were observed per treatment, holding time, and drawer relative position (P < 0.0001). Broilers placed in transport containers that underwent a cleaning procedure (A or B) had lower levels of Salmonella when compared to broilers placed in noncleaned containers (C). However, most of the samples below the limit of detection were positive after enrichment, indicating that both procedures evaluated need improvement for efficient pathogen inactivation. A decrease in Salmonella transfer was observed after 6 h in rinsates obtained from broilers placed in noncleaned containers (C). Rinsates obtained from top drawers had less Salmonella than the middle or bottom drawers when broilers were placed in transport containers that underwent a cleaning procedure (A and B). The application of pressurized steam and forced hot air was comparable to the use of water washes and disinfectant indicating a potential role in cleaning poultry transport containers.

Developing a risk management framework to improve public health outcomes by enumerating and serotyping Salmonella in ground turkey

Salmonella enterica continues to be a leading cause of foodborne morbidity worldwide. A quantitative risk assessment model was developed to evaluate the impact of pathogen enumeration and serotyping strategies on public health after consumption of undercooked contaminated ground turkey in the USA. The risk assessment model predicted more than 20,000 human illnesses annually that would result in ~700 annual reported cases. Removing ground turkey lots contaminated with Salmonella exceeding 10 MPN/g, 1 MPN/g, and 1 MPN/25 g would decrease the mean number of illnesses by 38.2, 73.1, and 95.0%, respectively. A three-class mixed sampling plan was tested to allow the detection of positive lots above threshold levels with 2-6 (c = 1) and 3-8 samples per lot (c = 2) using 25-g and 325-g sample sizes for a 95% probability of rejecting a contaminated lot. Removal of positive lots with the presence of highly virulent serotypes would decrease the number of illnesses by 44.2-87.0%. Based on these model prediction results, risk management strategies should incorporate pathogen enumeration and/or serotyping. This would have a direct impact on illness incidence linking public health outcomes with measurable food safety objectives, at the cost of diverting production lots.

Bio-Mapping Salmonella and Campylobacter Loads in Three Commercial Broiler Processing Facilities in the United States to Identify Strategic Intervention Points

The poultry industry in the United States is one of the largest in the world. Poultry consumption has significantly increase since the COVID-19 pandemic and is predicted to increase over 16% between 2021 and 2030. Two of the most significant causes of hospitalizations and death in the United States are highly related to poultry consumption. The FSIS regulates poultry processing, enforcing microbial performance standards based on Salmonella and Campylobacter prevalence in poultry processing establishments. This prevalence approach by itself is not a good indicator of food safety. More studies have shown that it is important to evaluate quantification along with prevalence, but there is not much information about poultry mapping using quantification and prevalence. In this study, enumeration and prevalence of Salmonella and Campylobacter were evaluated throughout the process at three different plants in the United States. Important locations were selected in this study to evaluate the effect of differences interventions. Even though there were high differences between the prevalences in the processes, some of the counts were not significantly different, and they were effective in maintaining pathogens at safe levels. Some of the results showed that the intervention and/or process were not well controlled, and they were not effective in controlling pathogens. This study shows that every plant environment is different, and every plant should be encouraged to implement a bio-mapping study. Quantification of pathogens leads to appropriate risk assessment, where physical and chemical interventions can be aimed at specific processing points with higher pathogen concentrations using different concentrations of overall process improvement.

Controlling Salmonella: strategies for feed, the farm, and the processing plant

Controlling Salmonella in poultry is an ongoing food safety measure and while significant progress has been made, there is a need to continue to evaluate different strategies that include understanding Salmonella-poultry interaction, Salmonella-microbiota interactions, Salmonella genetics and response to adverse conditions, and preharvest and postharvest parameters that enable persistence. The purpose of this symposium is to discuss different strategies to consider from feed milling to the farm to the processing environment. This Poultry Science Association symposium paper is divided into 5 different sections that covers 1) immunological aspects of Salmonella control, 2) application of Salmonella genetics for targeted control strategies in poultry production, 3) improving poultry feed hygienics: utilizing feed manufacture techniques and equipment to improve feed hygienics, 4) practical on farm interventions for controlling Salmonella-what works and what may not work, and 5) monitoring and mitigating Salmonella in poultry. These topics elucidate the critical need to establish control strategies that will improve poultry gut health and limit conditions that exposes Salmonella to stress causing alterations to virulence and pathogenicity both at preharvest and postharvest poultry production. This information is relevant to the poultry industry's continued efforts to ensure food safety poultry production.

In vitro Effect of Photoactive Compounds Curcumin and Chlorophyllin Against Single Strains of Salmonella and Campylobacter

Salmonella and Campylobacter are two of the most common foodborne pathogens associated with poultry meat. Regulatory restrictions and consumer concerns have increased the interest for plant-derived antimicrobials and emerging novel technologies. The objective of this study was to determine the antimicrobial activity of photoactive compounds curcumin (CUR) and chlorophyllin (CH) followed by activating light exposure for the reduction of Salmonella and Campylobacter. Peroxyacetic acid (PAA) was also evaluated as a poultry industry standard antimicrobial processing aid. CUR and CH were evaluated in 96-well plates at concentrations of 100, 500, and 1,000 ppm, along with PAA at 100, 200, and 300 ppm, or distilled water (DW). Each well was inoculated with 105 CFU/mL of Salmonella Typhimurium or Campylobacter jejuni, and plates were exposed to activating light (430 nm) for 0 or 5 min. No detectable reductions were observed for Salmonella or Campylobacter when treated with CUR, CH, or 100 ppm PAA. However, when Salmonella was treated with 200 ppm PAA, counts were reduced from 4.57 to 2.52 log10 CFU/mL. When Salmonella was treated with 300 ppm PAA, counts were reduced to below detectable levels (5 CFU/mL). Campylobacter was reduced from 4.67 to 2.82 log10 CFU/mL when treated with 200 ppm PAA. However, no further reductions were observed when Campylobacter was treated with 300 ppm PAA (2.50 log10 CFU/mL). These results indicate that CUR and CH were not effective as antimicrobials under the evaluated conditions, particularly in comparison to the commonly used antimicrobial, PAA.

Mitigation of Salmonella in Ground Pork Products through Gland Removal in Pork Trimmings

Bio-mapping studies conducted in pork harvest and fabrication facilities have indicated that Salmonella is prevalent and mitigations are needed to reduce the pathogen in trim and ground products. Salmonella can be isolated from the lymph nodes and can cause contamination in comminuted pork products. The objective of this study was to determine if physically removing topical and internal lymph nodes in pork products prior to grinding would result in the mitigation of Salmonella and a reduction in indicators in the final ground/comminuted products. In total, three treatment groups were assigned in a commercial pork processing facility as follows: (1) untreated control, (2) topical (surface) glands removed before grinding, and (3) topical, jowl, and internal lymph nodes and glands removed before grinding. Indicator microorganisms were determined using the BioMérieux TEMPO® system and the quantification of Salmonella was performed using the BAX® System Real-Time Salmonella SalQuant® methodology. The removal of lymph nodes located on the topical and internal surfaces and in the jowl significantly (p < 0.05) reduced the presence of Salmonella and also reduced the presence of indicator organisms according to this study. Briefly, 2.5-Log CFU/sample of Salmonella was initially observed in the trim samples, and the ground samples contained 3.8-Log CFU/sample of Salmonella. The total numbers were reduced to less than 1-Log CFU/sample in both trim and ground products. This study indicates a need for lymph node mitigation strategies beginning prior to harvest, in order to prevent contamination in further-processed pork products.

A systematic review and meta-analysis of the sources of Campylobacter in poultry production (preharvest) and their relative contributions to the microbial risk of poultry meat

A systematic review and meta-analysis were conducted to idetnify the relative contributions of the sources of Campylobacter in poultry live production to Campylobacter prevalence of broiler meat. The keywords of Campylobacter, prevalence, live production, and broiler were used in Google Scholar to address the research interest. A total of 16,800 citations were identified, and 63 relevant citations were included in the meta-analysis after applying predetermined inclusion and exclusion criteria. A generalized linear mixed model approach combined with logit transformation was used in the current meta-analysis to stabilize the variance. The analysis revealed that Campylobacter is ubiquitous in the poultry house exterior environment including surroundings, wildlife, domestic animals, and farm vehicle, with a predicted prevalence of 14%. The recovery of Campylobacter in the interior environment of the poultry house is far less abundant than in the exterior, with a prevalence of 2%, including litter, water, insects, mice, feed, and air. A lack of evidence was observed for vertical transmission due to the day-old chicks being free of Campylobacter from 4 studies identified. Live birds are the predominant carrier of Campylobacter, with a predicted prevalence of 41%. Transportation equipment used for live haul had an overall prevalence of 39%, with vehicles showing a predicted prevalence of 44% and crates with a predicted prevalence of 22%. The results of this meta-analysis highlight the need to implement effective biosecurity measures to minimize the risk of Campylobacter in poultry meat, as human activity appears to be the primary factor for Campylobacter introduction.

Bio-Mapping of Microbial Indicators and Pathogen Quantitative Loads in Commercial Broiler Processing Facilities in South America

A bio-mapping study was conducted with the aim of creating a microbiological baseline on indicator organisms and pathogens in commercial broiler processing facilities located in a country in South America. Whole chicken carcass and wing rinses were collected from five stages of the poultry processing line: live receiving (LR), rehanger (R), post-evisceration (PE), post-chilling (PC), and wings (W). Rinses (n = 150) were enumerated using the MicroSnap™ system for total viable counts (TVC) and Enterobacteriaceae (EB), while the BAX®-System-SalQuant® and BAX®-System-CampyQuant™ were used for Salmonella and Campylobacter, respectively. TVC and EB were significantly different between stages at the processing line (p < 0.01). There was a significant reduction from LR to PC for both microbial indicators. TVC and EB counts increased significantly from PC to W. Salmonella counts at PC were significantly different from the other stages at the processing line (p = 0.03). Campylobacter counts were significantly higher than the other stages at PC (p < 0.01). The development of bio-mapping baselines with microbial indicators showed consistent reduction up to the post-chilling stage, followed by an increase at the wings sampling location. The quantification of pathogens demonstrates that prevalence analysis as a sole measurement of food safety is not sufficient to evaluate the performance of processing operations and sanitary dressing procedures in commercial processing facilities.

Data-Mining Poultry Processing Bio-Mapping Counts of Pathogens and Indicator Organisms for Food Safety Management Decision Making

Bio-mapping studies play an important role, as the data collected can be managed and analyzed in multiple ways to look at process trends, find explanations about the effect of process changes, activate a root cause analysis for events, and even compile performance data to demonstrate to inspection authorities or auditors the effect of certain decisions made on a daily basis and their effects over time in commercial settings not only from the food safety perspective but also from the production side. This study presents an alternative analysis of bio-mapping data collected throughout several months in a commercial poultry processing operation as described in the article "Bio-Mapping Indicators and Pathogen Loads in a Commercial Broiler Processing Facility Operating with High and Low Antimicrobial Interventions". The conducted analysis identifies the processing shift effect on microbial loads, attempts to find correlation between microbial indicators data and pathogens loads, and identifies novel visualization approaches and conducts distribution analysis for microbial indicators and pathogens in a commercial poultry processing facility. From the data analyzed, a greater number of locations were statistically different between shifts under reduced levels of chemical interventions with higher means at the second shift for both indicators and pathogens levels. Minimal to negligible correlation was found when comparing aerobic counts and Enterobacteriaceae counts with Salmonella levels, with significant variability between sampling locations. Distribution analysis and visualization as a bio-map of the process resulted in a clear bimodality in reduced chemical conditions for multiple locations mostly explained by shift effect. The development and use of bio-mapping data, including proper data visualization, improves the tools needed for ongoing decision making in food safety systems.

Rapid Quantitative Method Development for Beef and Pork Lymph Nodes Using BAX® System Real Time Salmonella Assay

The goal of this study was to develop a rapid RT-PCR enumeration method for Salmonella in pork and beef lymph nodes (LNs) utilizing BAX^®-System-SalQuant^® as well as to assess the performance of the methodology in comparison with existing ones. For study one: PCR curve development, pork, and beef LNs (n = 64) were trimmed, sterilized, pulverized, spiked with 0.00 to 5.00 Log CFU/LN using Salmonella Typhimurium, and then homogenized with BAX-MP media. Samples were incubated at 42 °C and tested at several time points using the BAX^®-System-RT-PCR Assay for Salmonella. Cycle-Threshold values from the BAX^®-System, for each Salmonella concentration were recorded and utilized for statistical analysis. For study two: Method comparison; additional pork and beef LNs (n = 52) were spiked and enumerated by (1) 3M™EB-Petrifilm™ + XLD-replica plate, (2) BAX^®-System-SalQuant^®, and (3) MPN. Linear-fit equations for LNs were estimated with recovery times of 6 h and a limit of quantification (LOQ) of 10 CFU/LN. Slopes and intercepts for LNs using BAX^®-System-SalQuant^® when compared with MPN were not significantly different (p < 0.05), while the same parameters for 3M™EB-Petrifilm™ + XLD-replica plate were significantly different (p > 0.05). The results support the capability of BAX^®-System-SalQuant^® to enumerate Salmonella in pork and beef LNs. This development adds support to the use of PCR-based quantification methodologies for pathogen loads in meat products.

Development and Verification of a Poultry Management Tool to Quantify Salmonella from Live to Final Product Utilizing RT-PCR

The United States Department of Agriculture Food Safety and Inspection Service (USDA FSIS) does not maintain a zero-tolerance policy for Salmonella in poultry and poultry products, despite being a known food safety hazard throughout the poultry industry. In 2016, USDA FSIS established performance standards for a 52-week moving window with the maximum acceptable percent positive for comminuted turkey (325 g sample) at 13.5% (7 of 52 samples). Based upon FSIS verification sampling results from one 52-week moving window, the Salmonella prevalence for each poultry establishment in category 1 (below limit), 2 (meeting limit), or 3 (exceeding limit) are published for public viewing. Moreover, many poultry producers continue to have post-intervention samples test positive. Therefore, the use of quantification would be more valuable to determine the efficacy of process control interventions, corrective actions, and final product Log CFU/g of Salmonella to make rapid, within shift, food safety decisions. Therefore, the objectives of these studies are to develop, verify, and validate a rapid and reliable quantification method utilizing RT-PCR to enumerate Salmonella in the poultry industry from flock to final product and to utilize the method in an application study. BAX® System SalQuant® is an application of the BAX® System Real-Time PCR Assay for Salmonella to enumerate low levels of Salmonella with shortened enrichment times. Curve development encompassed inoculating poultry matrix samples at four levels with an ATCC strain of Salmonella, with three biological replicates per inoculation level, and five technical replicates being run on the BAX® System for various timepoints, gathering the data, and creating a linear-fit equation. A linear-fit equation was provided for each timepoint. The ideal timepoint, based on the statistical parameters surrounding the equation (R2 > 0.80, Log RMSE < 0.60, and enumerable range 0.00 to 4.00 Log CFU/mL (g)) that most accurately estimate Salmonella compared to most probable number (MPN), was chosen to be utilized for further studies.

Shelf-Life Evaluation of Pork Loins as Influenced by the Application of Different Antimicrobial Interventions

The objective of the study was to determine the impact of antimicrobial interventions and refrigerated dark storage on the shelf-life of pork chops. Boneless pork loins (n = 36) were split and stored for 1, 14, 28, and 42 days at 2–4 °C after being treated with the following antimicrobials: water (WAT), Bovibrom 225 ppm (BB225), Bovibrom 500 ppm (BB500), Fit Fresh 3 ppm (FF3), or washing solution 750 ppm (WS750). After the end of dark storage, pork loins were further processed and sliced into chops, overwrapped in trays, and displayed for up to an additional 96 h in a retail case. Instrumental and visual color measurements as well as mesophilic and psychrotrophic aerobic bacteria, and lactic acid bacteria were measured. BB500 and FF3 performed better in inhibiting the growth of indicator bacteria under 6 logs; however, FF3 presented the best stability for color during storage. Principal component analysis clustered initial dark storage days with a* and chroma while % discoloration, hue, b* and microorganisms where clustered with longer dark storage times. In general, treatment FF3 presented the best performance, both in inhibiting microbial growth and maintaining the stability of color, thus increasing the shelf-life of pork loins.

Quantitative Bio-Mapping of Salmonella and Indicator Organisms at Different Stages in a Commercial Pork Processing Facility

The purpose of this study was to develop a quantitative baseline of indicator organisms and Salmonella by bio-mapping throughout the processing chain from harvest to final product stages within a commercial conventional design pork processing establishment. Swab samples were taken on the harvest floor at different processing steps, gambrel table, after polisher, before final rinse, after the final rinse, post snap chill, and after peroxyacetic acid (PAA) application, while 2-pound product samples were collected for trim and ground samples. The samples were subjected to analysis for indicator microorganism enumeration, Aerobic Count (AC), Enterobacteriaceae (EB), and generic Escherichia coli (EC), with the BioMérieux TEMPO®. Salmonella prevalence and enumeration was evaluated using the BAX® System Real-Time Salmonella and the SalQuant™ methodology. Microbial counts were converted to Log Colony-forming units (CFU) on a per mL, per g or per sample basis, presented as LogCFU/mL, LogCFU/g and LogCFU/sample, prior to statistical analysis. All indicator microorganisms were significantly reduced at the harvest floor (p-value < 0.001), from gambrel table to after PAA cabinet location. The reduction at harvest was 2.27, 2.46 and 2.24 LogCFU/mL for AC, EB and EC, respectively. Trim sample values fluctuated based on cut, with the highest average AC count found at neck trim (2.83 LogCFU/g). Further process samples showed the highest AC count in sausage with a mean of 5.28 LogCFU/g. EB counts in sausage (3.19 LogCFU/g) showed an evident increase, compared to the reduction observed at the end of harvest and throughout trim processing. EC counts showed a similar trend to EB counts with the highest value found in sausage links (1.60 LogCFU/g). Statistical microbial process control (SPC) parameters were also developed for each of the indicator microorganisms, using the overall mean count (X=), the Lower control limit (LCL) and Upper control limit (UCL) at each sampling location. For Salmonella prevalence, a total of 125/650 samples were found positive (19%). From those positive samples, 47 samples (38%) were suitable for enumeration using the BAX® System SalQuant™, the majority detected at the gambrel table location. From those enumerable samples, 60% were estimated to be between 0.97 and 1.97 LogCFU/sample, while the rest (40%) were higher within the 2.00−4.02 LogCFU/sample range. This study provides evidence for the application of indicator and pathogen quantification methodologies for food safety management in commercial pork processing operations.

Bio-Mapping of Microbial Indicators to Establish Statistical Process Control Parameters in a Commercial Beef Processing Facility

The objective was to conduct a bio-mapping of microbial indicators to determine statistical process control (SPC) parameters at a beef processing plant to establish microbiological baselines and process control parameters to support food safety management decisions. EZ-ReachTM swabs were used to collect 100 cm2 area samples at seven different locations throughout the beef processing line at four different regions on the carcass. Each of the eight sampling days evaluated included three samples collected per sampling location/carcass region for a total of 84 samples per day. Enumeration of total aerobic bacteria, Enterobacteriaceae, and Escherichia coli was performed on each sample. Microbial SPC parameters were estimated for each sampling point. Statistical differences between sampling points for all carcass locations (p < 0.001) followed an overall trend with higher values at pre- and post-evisceration with a continuous decrease until final interventions with a slight increase in counts during the chilling process and a final increase after fabrication. Variability at sampling points is the result of the nature of the process and highlights open opportunities for improvement of the food safety system. Microbial baselines and SPC parameters will help support decision making for continuous process improvement, validation of intervention schemes, and corrective action implementation for food safety management.