2006 Annual Report 1.What major problem or issue is being resolved and how are you resolving it (summarize project aims and objectives)? How serious is the problem? Why does it matter? Food-borne illness continues to be an important public health problem in the U.S. The Center for Disease Control and Prevention (CDC) has estimated that food-borne diseases account for 6 to 81 million illnesses and up to 9,000 deaths in the U.S. each year. Of these, approximately 5 million cases and more than 4,000 deaths may be associated with the consumption of contaminated poultry and meat products. The annual cost of human illnesses associated with the consumption of contaminated poultry and meat is estimated to be $4.5 to $7.5 billion. In spite of this, per capita consumption of poultry has more than doubled during the last 35 years. For this reason, a better understanding of the harmful microorganisms associated with poultry processing and successful methods for reducing the number of the microorganisms on processed poultry are urgently needed to decrease the number of food-borne illnesses, deaths and medical expenses and lost wages associated with these diseases. The research in this project plan is critical to consumers because it will focus on reducing contamination and cross-contamination of poultry products with human pathogens and spoilage microorganisms by using innovative processing procedures and novel antimicrobial treatments. Traditionally, the primary methods for reducing poultry microbial contamination during processing have involved diluting bacteria by increasing the amount of water and/or adding more sites along the processing line for antimicrobial treatments. Poultry processing water usage has become a major issue for the industry because of limited availability of fresh water, variable water quality, increasing water and sewer costs, strict discharge requirements and a higher water demand by residential areas. To solve this problem, a team composed of a food technologist, a microbiologist and two animal physiologists uses multi-faceted research approaches to examine food safety problems during poultry processing. Research encompasses the final stages of live broiler grow-out because the initial level of bacteria on the live birds affects the microbiological characteristics of poultry carcasses, through further processing of poultry. Project areas include development and evaluation of novel antimicrobial treatments and multiple bacteriological intervention strategies, new or modified poultry processing technologies to optimize processing water usage, and methodologies to evaluate and reduce opportunities for bacterial populations to cross-contaminate poultry during processing. Specifically, the project has three objectives: Developing and analyzing poultry processing methods that utilize electrolyzed water, antimicrobial fatty acids and other novel antimicrobial treatments as poultry microbicides during processing; Examining and developing innovative processing techniques to optimize water use in during poultry processing; Evaluating the movement of microorganisms from broiler carcasses to processing water and equipment, specifically scalders, eviscerators and chillers. These objectives were designed to contribute towards accomplishing the goals of the National Program 108, Food Safety: Animal and Plant Production Action Plan for 2006-2010, sections 1.2.3 (Production and Processing Ecology), 1.2.4 (Processing Intervention Strategies), and 1.2.9 (Food Security). The research also addresses Agency Performance Measure 3.1.2: Develop and transfer to Federal agencies and the private sector systems that rapidly and accurately detect, identify, and differentiate the most critical and economically important food-borne microbial pathogens. Moreover, the objectives address the U.S. Department of Health and Human Services’ Healthy People 2010 Initiative. The impact of the research project is relevant to consumers of poultry products, poultry processing and live production management, industry organizations (U. S. Poultry & Egg Association, National Chicken Council, Poultry Federations, etc.), regulatory agencies (FSIS, APHIS), other university and ARS scientists, as well as allied industries (chemical companies). The research project is also significant because it has a direct impact on poultry microbiological safety and the USDA’s Pathogen Reduction/HACCP Final Rule. In 2005, FSIS inspection personnel issued 129,978 non-compliance reports (NRs) to poultry and meat establishments for notification of food safety-related processing deficiencies. Nearly all of these NRs were related to HACCP and sanitation (source of cross-contamination). Possible technology transfer opportunities that will emerge from this research are: . 1)new antimicrobial treatments and their optimal application for reducing pathogenic bacteria and spoilage microorganisms on processed poultry;. 2)original information on immersion, evaporative, dry and combination chilling of processed poultry; and. 3)new knowledge of cross-contamination of poultry during processing and the role of antimicrobial treatments in reducing poultry cross contamination. This research may be used by FSIS to approve new antimicrobial treatments or to identify new methods of antimicrobial application. Air chilling or a combination of immersion and air chilling of poultry will not only assist companies in meeting the FSIS requirement for retained water during chilling, and it will also reduce the environmental impact on community water treatment facilities. 2.List by year the currently approved milestones (indicators of research progress) Year 1 (FY 2006): Objective 1, Milestone 1: Determine in-vitro antimicrobial properties of alkali salts of fatty acids. Objective 1, Milestone 5: Evaluate efficacy of other antimicrobials applied to broiler carcasses. Objective 2, Milestone 1: Evaluate the microbiological impact of using different volumes of water (gallons per pound) during immersion chilling of broiler carcasses. Objective 3, Milestone 1: Determine the contribution of internal and external broiler carcass microbiological contamination through partitioning studies. Year 2 (FY2007): Objective 1, Milestone 1: Complete studies on determining in-vitro antimicrobial properties of alkali salts of fatty acids. Objective 1, Milestone 5: Continue evaluation of efficacy of other antimicrobials applied to broiler carcasses. Objective 2, Milestone 3: Evaluate antimicrobial treatments for reducing pathogenic bacteria on broiler carcasses during chilling. Objective 3, Milestone 2: Evaluate the carriage of pathogens on scalded poultry carcasses and cross-contamination during scalding. Year 3 (FY2008): Objective 1, Milestone 2: Evaluate the effects of heat on the antibacterial activity of alkali salts of fatty acids. Objective 1, Milestone 5: Continue testing efficacy of antimicrobial treatments applied to broiler carcasses. Objective 2, Milestone 2: Evaluate recovery of bacteria from broiler carcasses after immersion or air chilling. Objective 2, Milestone 3: Continue to evaluate antimicrobial treatments for reducing pathogenic bacteria on broiler carcasses during chilling. Objective 3, Milestone 3: Conduct studies on Salmonella cross-contamination during scalding. Objective 3, Milestone 4: Evaluate effect of antimicrobial treatments on microbial cross-contamination. Objective 3, Milestone 6: Determine if scalder contamination can be reduced with addition of antimicrobial treatments or adjustment of water volume. Year 4 (FY2009): Objective 1, Milestone 3: Conduct studies to examine synergistic, antimicrobial activity of 2 or 3 alkaline fatty acid mixtures. Objective 1, Milestone 5: Continue testing efficacy of antimicrobial treatments applied to broiler carcasses. Objective 2, Milestone 2: Continue to evaluate recovery of bacteria from broiler carcasses after immersion or air chilling. Objective 2, Milestone 3: Complete studies on evaluating antimicrobial treatments for reducing pathogenic bacteria on broiler carcasses during chilling. Objective 3, Milestone 4: Complete studies on evaluating antimicrobial treatments as a means to reduce carcass cross-contamination during scalding and defeathering. Objective 3, Milestone 5: Test the effects of antimicrobial treatments as a means of reducing the transfer of bacteria from carcasses to stainless steel surfaces. Objective 3, Milestone 6: Continue studying the relationship between scalder contamination, antimicrobial treatments and scalder water volume. Year 5 (FY2010): Objective 1, Milestone 4: Evaluate the efficacy of alkali-fatty acids on broiler carcasses during processing. Objective 1, Milestone 5: Complete studies on testing efficacy of antimicrobial treatments applied to broiler carcasses. Objective 2, Milestone 2: Complete studies on evaluating recovery of bacteria from broiler carcasses after immersion or air chilling. Objective 2, Milestone 4: Evaluate microbiological impact on a combination chilling procedure using both immersion and air processes. Objective 3, Milestone 5: Complete testing the effects of antimicrobial treatments as a means of reducing the transfer of bacteria from carcasses to stainless steel surfaces. Objective 3, Milestone 6: Complete studying the relationship between scalder contamination, antimicrobial treatments and scalder water volume. 4a.List the single most significant research accomplishment during FY 2006. Effect of Antimicrobial Treatments on Poultry Pathogens Antimicrobial treatments were tested for efficacy against poultry pathogens because product safety continues to be a priority (NP 108, sections 1.2.3.; 1.2.4; 1.2.9; PP Obj. 1-3). Spraying poultry carcasses with the following treatments did not enhance removal of pathogens:. 1)lactic acid bacteria and nutrient solutions;. 2)a blend of citric, hydrochloric, phosphoric acids; and. 3)chlorinated water at different temperatures. Microbicidal activity was observed in-vitro and on poultry skin for potassium hydroxide and lauric acid mixtures. 4b.List other significant research accomplishment(s), if any. Microbiology of Immersion Chilling With Reduced Volumes of Water Research was conducted to determine the microbiological impact of immersion chilling poultry with lower volumes of water. Lower numbers of pathogens were recovered from inoculated carcasses after chilling in a high volume of water (16.8 L/kg) as compared to carcasses chilled in a low volume of water (2.1 L/kg). However, when the chiller water was evaluated for bacteria, levels in each mL were the same and did not vary with changes in volume. (NP 108, sections 1.2.3.;1.2.4; 1.2.9; PP Obj. 2) Microbiology of Water Collected from Poultry Scalders Evaluated microbiology of water from a multiple-tank scalder operating under different conditions from previous reports. Numbers of coliforms, E. coli, and Campylobacter on carcasses are sharply reduced in the third tank compared to the first tank (as much as a 3 log reduction in numbers) with a reduction in incidence of Campylobacter and Salmon-ella in water from successive tanks. Bacteria in scald water do not predict incidence of bacteria in rinses of defeathered carcasses. (NP 108, sections 1.2.3.;1.2.4; 1.2.9; PP Obj. 3) Efficacy of High Levels of Chlorine on Poultry Pathogens Recovery of pathogens from pre-chilled poultry carcasses was evaluated before washing or after a 1 minute wash in either sterile water or a solution containing a high level of chlorine (500 ppm). When compared to sterile water, chlorine reduced levels of aerobic bacteria, E. coli and coliforms by 1.3, 0.6 and 0.6 log10 cfu/mL rinse, respectively; however, carcasses washed with sterile water and chlorine had the same incidence (number of samples positive) of Salmonella. (NP 108, sections 1.2.3.;1.2.4; 1.2.9; PP Obj. 1, 2) Efficacy of Electrolyzed Water on Poultry Pathogens Determined that acidic electrolyzed water can be effectively be used in inside-outside bird washers to decrease the population of spoilage bacteria and yeasts on processed broiler carcasses. (NP 108, sections 1.2.3.; 1.2.4; 1.2.9; PP Obj. 1, 2) Reduction in Poultry Bacterial Contamination During Defeathering Determined that volatile fatty acids can reduce Campylobacter contamination of broiler skin during defeathering operations when solutions of the acids are placed into the cloaca of the processed carcasses. (NP 108, sections 1.2.3.; 1.2.4; 1.2.9; PP Obj. 1) Efficacy of Alternative Antimicrobials Treatments Determined that optimal concentrations of selected organic acids can be used to support the growth of campylobacter in vitro. (NP 108, sections 1.2.3.; 1.2.4; 1.2.9; PP Obj. 1) Exterior Contamination of Poultry With Pathogenic Bacteria Recent FSIS reports have emphasized on-farm microbiological intervention strategies to reduce in-plant product contamination. Reducing opportunities for contamination depends on knowledge of reservoirs of bacteria. For this reason, various litter sampling techniques were tested for detecting Salmonella in market-age broiler chickens. In addition, a survey of Salmonella incidence in samples from on-farm broilers (external rinse versus cecal contents) was completed. (NP 108, sections 1.2.3.; 1.2.4; 1.2.9; PP Obj. 3) Immersion and Air Chilling of Poultry On-going project with U.S. Poultry & Egg Association to compare microbiology and quality of poultry after immersion or air chilling. Levels of pathogens recovered from non-chlorinated immersion chilled carcasses were not significantly different from the levels recovered from dry air chilled carcasses. Air chilled carcasses had darker skin color and lost approximately 2% in yield during chilling, while immersion chilled carcasses absorbed 8 to 9% water. (NP 108, sections 1.2.3.; 1.2.4; 1.2.9; PP Obj. 2) External versus Internal Carcass Contamination Initiated experiments designed to partition Salmonella incidence and numbers in external samples (feathers, skin, feet, head) versus internal samples (crop, ceca, colon and cloaca) of broilers after transportation to the processing plant. (NP 108, sections 1.2.3.; 1.2.4; 1.2.9; PP Obj. 3) 4c.List significant activities that support special target populations. None. 4d.Progress report. None. 5.Describe the major accomplishments to date and their predicted or actual impact. A new 5-year project plan was prepared and initiated for FY2006. The project's research goals are to reduce the risk of human food-borne illnesses associated with consumption of poultry by developing and evaluating novel antimicrobial treatments and poultry processing techniques to reduce carcass microbial contamination and cross-contamination during processing. To accomplish these goals, novel antimicrobial treatments are being developed and evaluated for efficacy against pathogenic and spoilage microorganisms on processed poultry. In addition, new and modified technologies, such as air chilling, are being investigated as a means of reduce the amount of processing water without compromising carcass microbiology. The extent to which poultry becomes cross-contaminated with pathogenic bacteria during processing is being determined, and opportunities for reducing cross-contamination are being investigated. Major accomplishments over the life of the project (1 year) are listed below. A series of experiments were conducted to determine the antimicrobial properties of various treatments applied during spray washing. The treatments included:. 1)chlorinated solutions applied at different temperatures;. 2)a blend of organic acids (citric, hydrochloric and phosphoric acids);. 3)potassium hydroxide (KOH) and lauric acid mixtures; and. 4)lactic acid bacteria and nutrient solutions. Levels of bacteria recovered from carcasses washed with chlorine were identical to the levels recovered from carcasses washed with tap water, regardless the temperature. Similar findings were observed with carcasses treated with lactic acid bacteria and nutrient solutions. Washing carcasses with the organic acids did not reduce incidence of Salmonella, but produced a slight reduction in level of E. coli (reduced by 0.6 log10 cfu/mL). The most significant reduction in microbial populations occurred in-vitro and on poultry skin after treatment with KOH and lauric acid. Research demonstrates that mixtures of KOH and lauric acid can be used to reduce levels of microorganisms on poultry during processing. (NP 108, section 1.2.4; PP obj 1, 2, 3) Limited availability of water and strict wastewater discharge restrictions have caused the poultry industry to implement water conservation and water reuse programs. With this in mind, two projects were conducted to evaluate the microbiological impact of reducing the volume of water used during immersion chilling. The first study compared a high level (16.8 L/kg) of water to a low levels (2.1 L/kg) of water for chilling inoculated carcasses. The second study evaluated a water reuse and superchlorination processing in a commercial facility. In both cases, immersion chilling significantly reduced levels of E. coli, Enterobacteriaceae and Campylobacter by 1.0 to 3.0 log units. Additional water during immersion chilling of broilers removed more bacteria from the carcass surfaces, but levels in the chiller water remained constant. 6.What science and/or technologies have been transferred and to whom? When is the science and/or technology likely to become available to the end-user (industry, farmer, other scientists)? What are the constraints, if known, to the adoption and durability of the technology products? Collaborations with manufacturer of a novel antimicrobial treatment (blend of acids) and a major poultry company to test for efficacy against pathogenic bacteria on poultry carcasses. Data suggest treatment may reduce the level of bacteria on carcasses, and the poultry company has permanently implemented the technology. Collaborations with a chemical company to test a novel antimicrobial treatment (acidified electrolyzed water) for efficacy against pathogenic bacteria on poultry carcasses. Electrolyzed water significantly reduced the level of Salmonella on carcasses, but had little effect on other pathogens. Collaborated with the U.S. Poultry & Egg Association and the University of Georgia to evaluate water reduction during immersion chilling of poultry. This is an on-going collaboration, with the goal of optimizing water use. Collaborated with a poultry equipment manufacturer to evaluated a new device designed to produce forced evacuation of carcasses prior to scalding. 7.List your most important publications in the popular press and presentations to organizations and articles written about your work. (NOTE: List your peer reviewed publications below). Cason, J. A. Limits on the Effectiveness of Antimicrobial Treatments. USDA-FSIS Invited Presentation during the public meeting entitled "Advances in Post-Harvest Interventions to Reduce Salmonella in Poultry" in Atlanta, GA, February 23-24, 2006. http://www.fsis.usda.gov/News_&_Events/Agenda_PostHarvest_022306/index.asp Northcutt, J. K. Impact of Chilling on Poultry Carcass Microbiology. USDA-FSIS Invited Presentation during the public meeting entitled "Advances in Post-Harvest Interventions to Reduce Salmonella in Poultry" in Atlanta, GA, February 23-24, 2006. http://www.fsis.usda.gov/News_&_Events/Agenda_PostHarvest_022306/index.asp Northcutt, J. K. Profile of Women in Management. U.S. Poultry & Egg Association Invited Presentation during "Women in Management Symposium" in Myrtle Beach, SC, October 26-29, 2005. Review Publications Berrang, M.E., Northcutt, J.K. 2005. Use of water spray and extended drying time to lower bacterial numbers on soiled flooring from broiler transport coops. Poultry Science. 84:1797-1801. Buhr, R.J., Northcutt, J.K., Richardson, L.J., Cox Jr, N.A., Fairchild, B.D. 2006. Incidence of unabsorbed yolk sacs in broilers, broiler breeder roosters, white leghorn hens, and athens-canadian randombred control broilers. Poultry Science. 85:1294-1297. Cason Jr, J.A., Buhr, R.J., Hinton Jr, A., Berrang, M.E., Cox Jr, N.A. 2005. External treatment of broiler chickens with lactic acid bacteria before slaughter. International Journal of Poultry Science. 4:944-946. Cason Jr, J.A., Berrang, M.E., Smith, D.P. 2006. Recovery of bacteria from broiler carcasses rinsed zero and twenty-four hours after immersion chilling. Poultry Science. 85(2):333-336. Cox Jr, N.A., Richardson, L.J., Bailey, J.S., Cosby, D.E., Cason Jr, J.A., Musgrove, M.T., Mead, G.C. 2005. Bacterial contamination of poultry as a risk to human health. Book Chapter. In: Food Safety Control in the Poultry Industry. Ed. G. C. Mead. Ch 2. p. 21-43. Hinton Jr, A. 2006. Comparison of growth of campylobacteriaceae on media supplemented with organic acids and on commerically available media. International Journal of Poultry Science. 5(2):99-103. Jones, D.R., Musgrove, M.T., Caudill, A.B., Curtis, P.A., Northcutt, J.K. 2005. Microbial quality of cool water washed shell eggs. International Journal of Poultry Science. 4(12):938-943. Musgrove, M.T., Jones, D.R., Northcutt, J.K., Harrison, M., Cox Jr, N.A. 2005. Shell rinse and shell crush methods for the recovery of aerobic microorganisms and enterobacteriaceae from table eggs. Journal of Food Protection. 68(10):2144-2148. Musgrove, M.T., Jones, D.R., Northcutt, J.K., Harrison, M.A., Cox Jr, N.A., Ingram, K.D., Hinton Jr, A. 2005. Recovery of salmonella from commercial shell eggs by shell rinse and shell crush methodologies. Poultry Science. 84(12):1955-1958. Musgrove, M.T., Jones, D.R., Northcutt, J.K., Harrison, M.A., Cox Jr, N.A. 2005. Impact of commercial processing on the microbiological safety and quality of shell eggs. Journal of Food Protection. 68(9):2367-2375 Northcutt, J.K., Smith, D.P., Musgrove, M.T., Ingram, K.D., Hinton Jr, A. 2005. Microbiological impact of spary washing broiler carcasses using different chlorine concentrating and water temperatures. Poultry Science. 84:1648-1652. Musgrove, M.T., Jones, D.R., Cox Jr, N.A., Harrison, M., Northcutt, J.K. 2005. Determination of post-processing shell egg sanitizer efficacy. UJNR Food & Agricultural Panel Proceedings. p. 338-342. Musgrove, M.T., Jones, D.R., Hinton Jr, A., Ingram, K.D., Northcutt, J.K. 2006. Identification of yeasts isolated from commercial shell eggs stored at refrigerated temperatures [abstract]. International Association for Food Protection Proceedings. p. 126. Buhr, R.J., Richardson, L.J., Cason Jr, J.A., Cox Jr, N.A. 2006. Comparison of four sampling methods for the detection of salmonella in broiler litter [abstract]. Southern Poultry Science Society Meeting Abstracts. 85(1):209. Hinton Jr, A., Northcutt, J.K., Smith, D.P., Musgrove, M.T., Ingram, K.D. 2006. Psychrotrophic bacteria and yeasts on broiler carcasses washed with electrolyzed oxidizing water or chlorinated water using an inside-outside washer [abstract]. Poultry Science Meeting. 85(1):171-172. Ingram, K.D., Northcutt, J.K., Cason Jr, J.A., Hinton Jr, A. 2005. Microbiological efficacy of spray washing broiler carcasses using fresh fx on e. coli, total coliforms and salmonella populations [abstract]. Southern Poultry Science Society Meeting Abstracts. 85(1):198. Musgrove, M.T., Cox Jr, N.A., Richardson, L.J., Jones, D.R., Northcutt, J.K. 2006. Comparison of shell egg sanitizers and application methods [abstract]. Poultry Science. 85(1):162. Northcutt, J.K., Smith, D.P., Cason Jr, J.A., Buhr, R.J., Fletcher, D.L. 2006. Effects of immersion chilling using different volumes of water on bacteria recovery from broiler carcasses and chiller water [abstract]. U.S. Poultry and Egg Association. 1:1. Hinton Jr, A., Ingram, K.D. 2006. Antimicrobial activity of potassium hydroxide and lauric acid towards microorganisms associated with poutlry processing. Journal of Food Protection. 69:1611-1615. Hinton Jr, A. 2006. Growth of campylobacter in media supplemented with organic acids. Journal of Food Protection. 69:34-38. Musgrove, M.T., Jones, D.R., Northcutt, J.K., Cox Jr, N.A., Harrison, M.A. Reducing microbial contamination during shell egg processing. Midwest Poultry Federation Proceedings, March 21-23, 2006, St. Paul, Minnesota. CDROM Brinson, D.L., Buhr, R.J., Northcutt, J.K. 2006. Bleed-out and mechanical carcass washing impact on chiller water cooler, ph, chlorine level and carcass bacteria [abstract]. Poultry Science Association Meeting Abstract. 85(1):70. Northcutt, J.K., Cason Jr, J.A., Smith, D.P., Buhr, R.J., Fletcher, D.L. 2006. Broiler carcass bacterial counts after immersion chilling using either a low or high volume of water. Poultry Science. 85:1802-1806. Jones, D.R., Northcutt, J.K. 2005. A survey of common practices in shell egg processing facilities and water use. International Journal of Poultry Science 4(10):734-736.