Sanitation and Disinfection

in Poultry Processing
Plants
S.T.Moubarak

?What is Sanitation
World Health Organization (WHO)
All precautions and measures
which are necessary in
production, processing, storage
and distribution, in order to
assure an unobjectionable, sound
and palatable product which is
.suited for human consumption
Sanitation from Greek Sanitas
Health

Sanitation Basics

Kill
Organisms

Exclude
Contamination

Prevent
Multiplication

The Enemies
Pathogens Food Safety
Illness, Disease and Death

Spoilage Food Quality

Poor Quality, Short Shelf Life, Off
Flavors, Customer Dissatisfaction

?What Bacteria Need for Growth

F ood
A cid (pH)
T ime
T
emperature
O xygen
M oisture

FAT TOM

Foodborne Illness
when a person becomes ill after...
...ingesting a contaminated food
:Foodborne illness can be caused by
Biological hazards (bacteria, viruses,
fungi)
Chemical hazards (cleaning agents,
toxins)
Physical hazards (bone, glass, metal)

Foodborne Hazards
Hazard
Est. Cases
Deaths
Norwalk virus
23,000,000
na
Campylobacter
2,453,926 0.1%
Salmonella
1,412,498
0.8%
C. perfringens
248,520 .05%
S. aureus
185,060 .02%
E. coli O157:H7
73,480 .83%
L. monocytogenes
2,518
20%
C. botulinum
58 8.6%

Centers for Disease Control and Prevention, 2001)

Salmonella
Rod-shaped, motile
bacterium
Non-spore forming
Gram negative
Found on animals
and in the
environment
Grows well at body
temperature
Spring 2009 Auburn University

Controlling Salmonella in Poultry

Plants
.Dr. Patricia Curtis and Ms. Jessica Butler

Salmonella (cont)
Optimum temperature for
growth is between 35C
and 37C
Slow growth has been
observed at 5C, with a
maximum growth
between 45C and 47C
Growth may occur
between pH 4.0
(depending on the acid)
and pH 9.0; optimum pH
is between 6.5 and 7.5
D-value of 4 to 5 minutes
at 60C has been
reported for Salmonella
9

It is important to know
which serotypes of
!Salmonella you have

10

Top 30 Serotypes in
2005

http://www.cdc.gov/ncidod/dbmd/phlisdata/salmtab/2005/SalmonellaTable1
_2005.pdf
Screen clipping taken: 11/11/2008, 7:31 PM

11

Campylobacter
Slender, curved, and
motile rod
Gram negative
Relatively fragile and
sensitive to
environmental
stresses
Microaerophilic
organism requires
3% 5% oxygen and
2% 10% carbon
dioxide for optimal
growth conditions
12

Campylobacter
(cont)
Carried in the intestinal tract
of a wide variety of wild and
domestic animals
Can survive 24 weeks under
moist, reduced-oxygen
conditions at 4C
Can also survive 25 months
at 20C
Can only survive a few days
at room temperature
Exposure to air, drying, low
pH, heating, and freezing and
prolonged storage damage
cells and hinder recovery
Infective dose ranges from
500 to 10,000 cells
13

Risk Factors Associated with Sporadic

.Illness Due to Campylobacter spp
Eating undercooked poultry
Handling raw poultry
Frequent contact with dogs or cats, particularly
young pets, such as kittens and puppies
Drinking non-potable water
Drinking unpasteurized milk or dairy products
made from non-heat-treated milk
Eating barbequed poultry, pork, or sausages
Eating poultry liver
Taking trips abroad
Adapted from Opinion of the Scientific Committee on Veterinary Measures relating to
Public Health on Foodborne Zoonoses
14

Preharvest Control
Campylobacter is more difficult to control through
.on-farm practices than Salmonella

15

LISTERIA MONOCYTOGENS
Commonly found in GI tract of all
animals
Can survive for long periods in SOIL,
SEWAGE, DUST, VEGATATION AND
WATER
Resistant to cool temp - Cold storage
Can form biofilms on surfaces to
resist cleaning and sanitizing
Biggest threat:Pregnant women-
miscarriages and birth defects

Preharvest
Salmonella Control

17

Preharvest Salmonella Control

Restricting access
Vehicles
People
Animals

Biosecurity
Dedicated clothing
and boots
Disinfectant boot
dip

18

Preharvest Salmonella Control (cont)

Feed
Heat treated
Pelletized

Litter
Maintain low
water activity

ARS Photo by Stephen Ausmus

19

Recommended Preharvest Best Practices

Implement biosecurity
measures

Use good sanitation

practices
Control litter moisture

Use well-timed feed

withdrawal
Use acids in drinking water
during feed withdrawal
ARS Photo by Stephen Ausmus

20

Target for Salmonella Reduction

Compliance Guideline for Controlling Salmonella and Campylobacter in Poultry, Second Edition, May 2008

21

Basic Steps in Poultry Processing

ne
i
L
l
l
Ki

Pre-slaughter

Immobili
ze

Air Flow

Feather Removal

Ev

n
o
i
t
a
r
e
c
is

ne
i
L

Separation Wall
Evisceration
Chillin
g

Further Processing or
Packaging

Salmonella and HACCP Plans

A poultry HACCP plan
MUST have a critical
control point (CCP) to
address Salmonella
Support documentation
is required
Verification of the HACCP
plans ability to control
Salmonella is required
24

Sanitation

What role does

sanitation play
in controlling
?Salmonella

25

Sanitation and
Hygiene
Clean before
sanitizing
Enforce employee
hygiene

26

Sanitation and Hygiene (cont)

Alkaline Detergents
Sodium hydroxide
Sodium silicate
Trisodium phosphate
Note: Frequently used
and vary in strength

Acid Detergents
Hydrochloric acid
Sulfuric acid
Phosphoric acid
Acetic acid
Note: Vary in strength

27

Sanitation and Hygiene (cont)

Sanitizers
Quaternary
ammonium
.*compounds
Industrial strength
bleach
Iodine compounds
Peracetic acid
Steam
Ozone

Some sanitizers work

better in certain parts
of the plant
Iodophors

Aluminum equipment,
rubber belts, tile walls

Active chlorine

Walls (other than tile),

wooden crates,
concrete floors

Quaternary ammonium compounds are synthetic*

.detergents

28

Live Receiving and Live Hanging

Recommended best
practices
Sanitize and dry cages
thoroughly
Maintain positive air flow
from inside to outside the
plant
Provide SOP and
employee training
Schedule flocks for
slaughter based on
pathogen loads
29

Stunning and
Bleeding
Recommended
best practices
Use well-timed
feed withdrawal
to reduce feces
release

30

Scalding
Recommended best
practices
Use high flow rates with
agitation to help dilute dry
matter and bacteria
Maintain pH above 7.5 or
below 6.5
Use pre-scald brushes to help
clean birds before entering
scalder
Use post-scald rinse to help
remove debris
Maintain scalder temperature
31
(51 54 C)

Picking
Recommended best
practices
Prevent feather
buildup on
equipment
Rinse equipment
and carcasses
Use 1830 ppm
chlorine rinse postpicking
32

Evisceration
Recommended best
practices
Use 20 ppm chlorine
for whole-carcass
rinses
Enforce employee
hygiene standards
Note: Feed withdrawal practices affect
.process control at this step
33

Evisceration (cont)
Carcass rinses
ppm free available 23
chlorine
TSP (trisodium 10%
phosphate)
lactic acid 2%
sodium bisulfate 5%
cetylpyridinium 5%
chloride

Be aware how
chemical residues
can impact pH of

34

Immersion Chilling
If using chlorine, maintain
chill water at pH between
6.0 and 6.5 and at a
temperature of less than
4C
Use high water flow rate
and counter-current flow
Use 2050 ppm free
available chlorine in the
potable water measured at
intake
Use oxidation reduction
potential pH with pH 35

Immersion Chilling
(cont)
ppm free available 10
chlorine can eliminate
Salmonella in 120
minutes
ppm free available 30
chlorine can eliminate
Salmonella in 6
minutes
ppm free available 50
chlorine can eliminate
Salmonella from the
water in 3 minutes
Note: Organic matter in
the chiller binds the
free chlorine and thus
.makes it unavailable

36

Factors Affecting Chiller Water Quality

High flow rate (1 gallon
per bird)
Counter-current water
flow
ppm free available 5020
chlorine measured at
intake
Red water (recycled
water) may contain up
to 5 ppm free available
chlorine measured at
intake
Water pH 6.06.5
Water temperature less
than 4C
37

Air Chilling
Meet regulatory
requirements for chilling
Clean and oil chains
regularly
Inspect and replace
shackles as needed
Maintain tension on chain
to prevent carcass-tocarcass contact
Sanitation is important
no chemical interventions

38

Reprocessing
Use post-chill
antimicrobial dips to
reduce Salmonella
loads

39

Reprocessing: Approved Substances

Chlorine, chlorine dioxide, and acidified
sodium chlorite
Water soluble
Spray or dip
Agitation and application under pressure
enhance effectiveness

40

Reprocessing: Approved Substances

(cont)
Chlorine
Primarily used to treat processing and
chiller water
Heat and pH above 6.5 decrease its
effectiveness

Chlorine dioxide
Can be used in water
Leaves no residue
Should NOT exceed 3 ppm residual
chlorine dioxide
41

Reprocessing: Approved Substances (cont)

Acidified sodium chlorite

Combination of citric acid and sodium

chlorite
Can be used as spray or dip at 500 to 1,200
ppm singly or in combination with other
generally recognized as safe (GRAS) acids to
achieve a pH between 2.3 and 2.9 as an
automated reprocessing method
In chiller water, it is limited to 50 to 150
ppm singly or in combination with other
acids to achieve a pH between 2.8 and 3.2
42

Reprocessing: Approved Substances (cont)

Trisodium phosphate (TSP)

Approved for on-line reprocessing
Acts as a surfactant (high pH)
More effective with air chilling than
with immersion chilling

43

Reprocessing: Approved Substances (cont)

Cetylpyridinium chloride
Quaternary ammonium compound
Approved for processing in ready-to-
cook poultry products
Produces no adverse organoleptic
effects
pH is near neutral
Stable, non-volatile, and soluble in water

44

Reprocessing: Approved Substances (cont)

Peroxyacetic acid
Approved as a carcass spray
Must not exceed 220 ppm
Spectrum
Can be used in process, scalder, and
chiller water and as a carcass spray,
wash, or dip

45

Reprocessing: Approved Substances (cont)

Other organic acids

Lactic acid
Most commonly used organic acid
Applied as rinse
Has an organoleptic effect on raw product

Acetic acid
Decreases pH and enhances the washing
effect of scalder tank water
Has an organoleptic effect on raw product

46

?HACCP -What is it
HACCP -(HAS-SIP)
H azard
A nalysis and
C ritical
C ontrol
P oints
.HACCP often misused term
A systematic method of
documenting that food safety
.hazards have been addressed

? HACCP - What is it
HACCP involves only food safety
.issues
Out of control = unsafe food
.produced
Plans unique for each unit and
.product

?HACCP What is it
Step

Meaning

1. Hazard Analysis

What are the controllable food

safety hazards?

2. Establish Critical Control

Points

Where do things go wrong and

how can we reliably control it?

3. Establish Critical Limits

What value indicates the process

is in control?

4. Establish Monitoring
Procedures

Who, what, when , where and

how will CCPs be monitored?

5. Establish Corrective
Actions

What happens if we exceed a

Critical limit?

6. Establish a Record
Keeping System

If you dont write it down it

doesnt exit.

7. Establish Verification
Procedures

How do you know the system

works?