Evisceration Line Research Articles

Validation of an automatic scoring system for the assessment of hock burn in broiler

This study aimed to develop and validate a camera vision score that could detect macroscopic alterations of the hock, to identify errors and to assess possible factors that could influence the assessment. Two hundred hocks in the first (calibration) phase and 500 hocks in the second (validation) phase were collected at slaughter, visually assessed, placed back into the evisceration line and assessed by a camera system with 2 software systems. The size of the alteration in percent (%) measured by the camera system was evaluated (“camera score”, CS). Additionally, temperature, humidity, and light intensities were measured. In the calibration phase, threshold values of camera scores for respective macro scores were defined and performance measures evaluated. In the validation phase, the generated threshold values were validated, occurring errors, as well as possible impacts of climatic factors analyzed. The results showed that the generated thresholds predict the camera score values at which the respective macro score has the highest probability of appearance. Small hock burn lesions ≤0.5 cm have the highest probability at a camera score of ≥0.2 (original CS) or ≥0.1 (updated CS), and lesions >0.5 cm have the highest probability at a camera score of ≥0.7 (original CS) or ≥1.1 (updated CS). Large lesions (>0.5 cm) are more reliably identified by the system than small lesions. The risks of errors in assessing reference areas and lesions showed a correct identification of lesions to be the most probable result even if the reference area is not correctly identified. The probability of a correct identification of lesions by the camera system was slightly higher (not significant) with the updated software (risk = 0.66 [0.62–0.70]) than with the original software (risk = 0.63 [0.58–0.67]). Automatic assessment systems at slaughter could be adjusted to the presented threshold values to classify hock burn lesions. Software adaptations can improve the performance measures of diagnosis and reduce the probability of errors.

Survey of Meat Collected from Commercial Broiler Processing Plants Suggests Low Levels of Semicarbazide Can Be Created during Immersion Chilling

Semicarbazide (SEM) is routinely employed as an indicator for the use of nitrofurazone, a banned antimicrobial. The validity of SEM as a nitrofurazone marker has been scrutinized because of other possible sources of the compound. Nonetheless, a U.S. trade partner rejected skin-on chicken thighs because of SEM detection and suspected nitrofurazone use. Because nitrofurazone has been banned in U.S. broiler production since 2003, we hypothesized that incidental de novo SEM formation occurs during broiler processing. To assess this possibility, raw leg quarters were collected from 23 commercial broiler processing plants across the United States and shipped frozen to our laboratory, where liquid chromatography-mass spectrometry was used to quantitatively assess for SEM. Leg quarter samples were collected at four points along the processing line: hot rehang (transfer from the kill line to the evisceration line), prechill (before the chilling process), postchill (immediately following chilling), and at the point of pack. Thigh meat with skin attached was removed from 535 leg quarters and analyzed in triplicate for SEM concentrations. The concentrations ranged from 0 to 2.67 ppb, with 462 (86.4%) of 535 samples below the regulatory decision level of 0.5 ppb of SEM. The 73 samples over the 0.5-ppb limit came from 21 plants; 53 (72.6%) of positive samples were in meat collected after chilling (postchill or point of pack). The difference in both prevalence and concentration of SEM detected before and after chilling was highly significant (P < 0.0001). These data support our hypothesis that SEM detection in raw broiler meat is related to de novo creation of the chemical during processing.

Automatic Scoring System for Monitoring Foot Pad Dermatitis in Broilers

The assessment of foot pad dermatitis at slaughter is a suitable method to assess and monitor the welfare of broilers. The goals of this study were to define and validate a camera-based score that could identify macroscopic lesions of the foot pads, to identify errors, and to assess possible external factors that could influence the assessment. In the first phase 200 feet of broilers and in the second phase 500 feet were collected at slaughter, assessed visually, hung back into the evisceration line, and assessed by an automatic system. The camera score cut-off values were defined in the first (=calibration) phase. In the second (=validation) phase, the performance of diagnosis for these cut-off values was evaluated, and possible errors in the assessment of reference surface area and foot pad lesions were analyzed. The results showed that, in particular, Macro Scores 0, 2, and 3 could be identified with sufficiently high sensitivity. For Macro Score 1, the sensitivity of diagnosis was not sufficiently high in the two evaluated software versions. The current automatic assessment systems at slaughter could be adjusted to the cut-off values in order to classify foot pad dermatitis lesions. Furthermore, software updates can enhance the performance measures and lower the probability of errors.

Incidence of Mycoplasma gallisepticum and Mycoplasma synoviae in broiler flocks at the Federal District of Brazil and its surrounding areas

Mycoplasma is an important avian pathogen that can cause both respiratory disease and synovitis in birds, resulting in considerable economic losses to the poultry industry worldwide. This study aimed to determine the incidence of Mycoplasma gallisepticum and M. synoviae in broiler flocks at the Federal District and its surrounding regions using polymerase chain reaction (PCR). All slaughtered lots (57 flocks) were analyzed from July to November in one of the two slaughterhouses at the Federal District with Federal inspection services. Approximately 10 samples of broiler tracheae per slaughtered batch were collected from the evisceration line. The results obtained from the accumulated incidence over the study period were 7.02% and 35.09% for M. gallisepticum and M. synoviae, respectively. A greater concentration of flocks affected by M. synoviae was observed during October. The sample design as well as the PCR technique assisted in detecting both agents in the broiler batches in the first epidemiological study of these two agents in the region.

Variation in Campylobacter Multilocus Sequence Typing Subtypes from Chickens as Detected on Three Plating Media

The objective of this study was to compare subtypes of Campylobacter jejuni and Campylobacter coli detected on three selective Campylobacter plating media to determine whether each medium selected for different subtypes. Fifty ceca and 50 carcasses (representing 50 flocks) were collected from the evisceration line in a commercial broiler processing plant. Campylobacter was cultured and isolated from cecal contents and carcass rinses on Campy-Cefex, Campy Line, and RF Campylobacter jejuni/coli agars. When a positive result was obtained with all three media, one colony of the most prevalent morphology on each medium was selected for further analysis by full genome sequencing and multilocus sequence typing. Sequence types were assigned according to PubMLST. A total of 49 samples were positive for Campylobacter on all three media. Forty samples contained only C. jejuni , three had only C. coli , and both species were detected in six samples. From 71% of samples, Campylobacter isolates of the same sequence type were recovered on all three media. From 81.6% of samples, isolates were all from the same clonal complex. From significantly fewer samples (26%, P < 0.01), one medium recovered an isolate with a sequence type different from the type recovered on the other two media. When multiple sequence types were detected, six times the medium with the odd sequence type was Campy-Cefex, four times it was Campy-Line, and six times it was RF Campylobacter jejuni/coli . From one sample, three sequence types were detected. In most cases, all three plating media allowed detection of the same type of Campylobacter from complex naturally contaminated chicken samples.

Genetic Diversity of Campylobacter on Broiler Carcasses Collected Preevisceration and Postchill in 17 U.S. Poultry Processing Plants

Campylobacter jejuni and Campylobacter coli are the most important human enteropathogens among the campylobacters. The objective of this study was to determine how diversity in Campylobacter populations found on chicken carcasses collected from 17 broiler processing plants in the United States is impacted by processing. Genetic diversity was determined for up to four isolates per carcass by sequencing the short variable region (SVR) of the flaA locus. On 70% of Campylobacter-positive carcasses, all isolates were indistinguishable by flaA SVR typing. The genetic diversity of Campylobacter decreased as carcasses proceeded through processing; Campylobacter populations obtained early in processing where carcasses are moved from the kill line to the evisceration line (rehang) were significantly more genetically diverse (P < 0.05) than those from carcasses sampled postchill (diversity indices of 0.9472 and 0.9235, respectively). Certain Campylobacter subtypes were found only at rehang and not at postchill. Other subtypes were found at postchill and not at rehang. These data suggest that some subtypes may not be able to survive processing, whereas others may persist on the carcass or within the equipment despite stressors encountered in the processing environment.

Hyperspectral-Multispectral Line-Scan Imaging System for Automated Poultry Carcass Inspection Applications for Food Safety

A hyperspectral-multispectral line-scan imaging system was developed for differentiation of wholesome and systemically diseased chickens. In-plant testing was conducted for chickens on a commercial evisceration line moving at a speed of 70 birds per minute. Hyperspectral image data was acquired for a calibration data set of 543 wholesome and 64 systemically diseased birds and for a testing data set of 381 wholesome and 100 systemically diseased birds. The calibration data set was used to develop the parameters of the imaging system for conducting multispectral inspection based on fuzzy logic detection algorithms using selected key wavelengths. Using a threshold of 0.4 for fuzzy output decision values, multispectral classification was able to achieve 90.6% accuracy for wholesome birds and 93.8% accuracy for systemically diseased birds in the calibration data set and 97.6% accuracy for wholesome birds and 96.0% accuracy for systemically diseased birds in the testing data set. By adjusting the classification threshold, 100% accuracy was achieved for systemically diseased birds with a decrease in accuracy for wholesome birds to 88.7%. This adjustment shows that the system can be feasibly adapted as needed for implementation for specific purposes, such as paw harvesting operations or prescreening for food safety inspection. This line-scan imaging system is ideal for directly implementing multispectral classification methods developed from hyperspectral image analysis.

Airborne Microorganisms During the Commercial Production and Processing of Japanese Quail

Total aerobic bacteria, molds/yeasts, E. coli and Enterobacteriaceae in the air during the commercial production and processing of Japanese quail were enumerated at twelve different sites. Production-related sampling sites included the breeder and grow-out houses along with the hatchery setter, hatcher, egg room and chick room. Processing-related sampling sites included the hanging/stunning area, scalding/defeathering room, evisceration line, chiller exit, further processing area and shipping room. Sampling site had a significant effect on the log counts for total aerobic bacteria, molds/yeasts, E. coli and 10 Enterobacteriaceae and (P < 0.0001). Moreover, significant correlation was found between airborne bacteria counts and both environmental temperature and humidity (P < 0.05). During production, highest counts for total aerobic bacteria (8.1 log cfu/ml air), molds/yeasts (3.6 log cfu/ml air), E. coli (1.9 log cfu/ml air) and 10 10 10 Enterobacteriaceae (2.3 log cfu/ml air) occurred in the grow-out house. Lowest production-related counts 10 for total aerobic bacteria (3.5 log cfu/ml air), molds/yeasts (2.5 log cfu/ml air) and Enterobacteriaceae (2.0 10 10 log cfu/ml air) occurred in the chick room at the hatchery. At the processing facility, highest counts for total 10 aerobic bacteria (6.8 log cfu/ml air), E. coli (1.4 log cfu/ml air) and Enterobacteriaceae (1.5 log cfu/ml air) 10 10 10 occurred in the areas where quail are hung/stunned and scalded/defeathered. E. coli was not found at any of the sampling sites in the hatchery (setter, hatcher, egg room, chick room) or at the chiller exit, further processing area or shipping room at the processing facility. Data gathered during this study may be useful in identifying the sources and levels of airborne contaminates in commercial production and processing of quail so that effective intervention practices may be established or strengthened.

Variability and Determinants of Carcass Bacterial Load at a Poultry Abattoir

Roaster chicken carcasses (2,928) were collected from the evisceration line of a poultry abattoir over a 5-month period and identified as to the lot (truck load) and supplier. Bacterial load was determined by mechanically rinsing each eviscerated carcass in sterile water and then using an automated hydrophobic grid membrane interpreter system to obtain the log10 most probable number of aerobic bacteria per gram of carcass. Analysis of variance demonstrated that the between-carcass, between-lots-within-supplier, and between-supplier components of variability in bacterial load represented 73.2, 14.2, and 12.6% of the total variability, respectively. There was a significant (p < 0.001) supplier and lots-within-supplier effect on bacterial load of carcasses. A regression model demonstrated that bacterial load of lots significantly (p ≤ 0.05) decreased with increasing hours of operation of the evisceration line. Factors in the model which were significantly (p ≤ 0.05) associated with increased bacterial load included longer crating and holding times, higher visible contamination scores, slaughter during winter months, higher outdoor temperatures, and slaughter of lots composed of only pullets. The model explained about 23% of the variability in bacterial load.

Application of an Automated Hydrophobic Grid Membrane Filter Interpreter System at a Poultry Abattoir

The performance of a system to measure broiler carcass hygiene was investigated in the abattoir environment. The system involved: whole carcass rinses aided by a mechanical carcass shaker; filtration of rinse solutions though hydrophobic grid membrane filters (HGMF) (ISO-GRIDR, QA Laboratories Ltd.); and use of an automated HGMF interpreter. The interpreter recorded culture results in units of most probable number (MPN) of aerobic bacteria, in electronic data files (MI-100 HGMF Interpreter System, Richard Brancker Research Ltd.). Set-up and operation of the system by government inspection staff at an abattoir ran relatively smoothly with minimal interference to normal plant operation. The system demonstrated good repeatability in measuring log10 most probable number per gram of carcass (LgMPN/g), between repeat readings of the same filters (r=0.993 p<0.001), and good repeatability between repeat filters within the same carcass rinses (r=0.970 p<0.001). Overall, the LgMPN/g ranged from 0.258 to 3.955 with a mean of 2.276 and a variance of 0.324. These corresponded to MPN/g counts in the range of 2 to 9000 and a geometric mean of 188.8 MPN/g. A regression model was developed to investigate poultry supplier and abattoir effects on the variability of counts. A significant supplier effect was observed. The addition of two more carcass showers located just after the venting machine along the evisceration line was not associated with a change in carcass hygiene.

Broken bones in domestic fowl: handling and processing damage in end-of-lay battery hens.

1. 3115 end-of-lay battery hens and carcases were sampled at set points in the sequence of events that occurred between depopulation of the battery cages at the layer farms and the end of the evisceration line in two processing plants. Live birds were killed in a convulsion-free manner and carcases were dissected to determine the incidence of broken bones. 2. Of the live battery birds 29% had broken bones by the time they reached the waterbath stunner, with on average 0.5 broken bones per bird. Removing birds from the battery cages and hanging them on the slaughter line were identified as causes of broken bones. 3. By the time birds left the end of the eviscerating line, 98% of carcases had broken bones, with on average 6 broken bones each. The stunning, plucking and eviscerating processes caused most of this damage. In particular, stunning broke the furculum, coracoid and scapula, plucking broke the ischium, pubis and ribs, and evisceration damaged the ischium and pubis.

The Microbiology of Raw, Eviscerated Chickens: A Ten Year Comparison

In 1979 a survey of selected chicken eviscerating plants was conducted to determine the levels of coliforms, Escherichia coli, and Salmonellae sp. on eviscerated chickens under current manufacturing practices. A comparison was made of the data from this survey and one conducted in 1969.The 1979 survey found that the chickens did not have a statistically significant reduced incidence of salmonella compared to chickens analyzed in 1969. Also, much of the bacterial contamination on a carcass at the end of the evisceration line was transient and was readily removed by the final spray washer. The addition of chlorine to chiller water did not appear to have an unusually beneficial effect on the microbiological quality of the chickens.In 1969, in the nine plants studied, the incidence of salmonella on chickens at the exit of the chillers was 20.5%. In 1979, in the nine plants studied, the incidence of salmonella on chickens at the exit of the chillers was 11.6%. In 1979 there was about a 45% reduction in the incidence of salmonella in eviscerated chickens in the nine plants studied compared to the incidence of salmonella in eviscerated chickens in 1969.

Identifying Broiler Processing Plant High Electrical Use Areas

ABSTRACT A representative broiler processing plant on DELMARVA was surveyed to determine high elec-trical use areas. Electrical consumption for 22 plant areas was estimated by converting all electrical uses to horsepower and by using plant operational records for time-and-motion data. Five areas accounted for approx-imately 74 percent of the electricity consumed. A 28-day time-and-motion and electrical consumption study was conducted on an evisceration line to evaluate the estima-tion procedure used. The electrical consumption measured was 9.3 percent less than estimated.

The distribution of Mycoplasma meleagridis in normal turkey carcases and those affected with air sac disease.

Mycoplasma meleagridis was isolated from both normal and diseased air sacs of turkeys examined and graded for air sacculitis on the evisceration line in a processing plant. It was also cultivated from wing bone cavities of turkeys with severe air sac lesions but not from leg bones or from samples of deep muscle. A further investigation, using material taken randomly from the condemned meat container, confirmed that M meleagridis was recoverable from wing bones.

Plant Processing of Sub-atmospheric Steam Scalded Poultry

Sub-atmospheric steam at ordinary scalding temperatures was shown in laboratory tests to readily loosen feathers on dry birds. The possibility that this type of pure steam treatment can be used to avoid the conventional scald tank was investigated in a broiler and a turkey processing plant using a batch scale vacuum tank. Steam scalded birds were interspersed with birds on the same picking line used for tank scalded birds. Pure steam at sub-atmospheric pressure readily provided a uniform scald of either dry or damp birds. A steam temperature of 124°F. (51°C.) for 2 min loosened the feathers sufficiently to give clean broilers comparable to birds tank scalded at 128°F. (53°C.) for 2 min. Little or no abrasion of the outside occurred. Under subscald conditions (134–138°F.) typical subscald broilers, fowl, and turkeys were obtained by a 1 min. treatment.As anticipated, the air sacs of steam scalded birds had very few bacteria compared with the air sacs of tank scalded birds (more than 1,000-fold difference). However, after passing through the evisceration line and chiller the total bacterial load on the birds scalded by the two methods was similar.Steam scalded and tank scalded broilers had about the same shelf life at 37°F. (3°C.) and about the same degree of tenderness.

OCCURRENCE OF Clostridium perfringens IN BROILER PROCESSING AND FURTHER PROCESSING OPERATIONS

SUMMARY —Three broiler processing plants were surveyed to determine the occurrence of Clostridium perfringens in processing areas, and in further processed products. Direct plating on SPS agar and enrichment techniques were used. Samples were taken from nine points in the processing areas of two plants. The following products were examined from the further processing operations of three plants: uncooked broiler parts, cooked products, batter, flour with and without spice mixture and spice. A limited number of rolls (4) and diced meat (5) were also sampled. Results from all plants were similar. C. perfringens was isolated from the following sources in the processing area: feet, feathers, caecum, vent area, scald tank water, chill tank water, breast surface after the chill tank and neck skin from the end of the evisceration line. Though C. perfringens was found frequently on live birds coming into the plant, it was isolated in relatively small numbers from all but the feet, feathers, and caecum. With few exceptions, C. perfringens was isolated from the further processing area by enrichment techniques only. This organism was most frequently isolated from samples of flour and batter. Only 2.6% of 118 samples of cooked product were positive.

ISOLATION OF SALMONELLAE AND OTHER AIR-BORNE MICROORGANISMS IN TURKEY PROCESSING PLANTS

The air in seven Minnesota turkey processing plants was analyzed microbiologically for total numbers of bacteria per cubic foot, number of coliform organisms per cubic foot, and the presence of salmonellae. Plant environmental samples, that is walls, floors, and equipment adjacent to air sampling areas, also were tested for the presence of salmonellae. Areas sampled included: live bird area (hanging, stunning, killing), scald and picking areas, evisceration line, packaging line, and further Processing.Total numbers of bacteria in the air of one plant (T-5) ranged from more than 200,000/ft3 in the live bird area to 1/ft3 near the. evisceration line. Coliform numbers in the air of .a second plant (T-l) ranged from 400/ft3 in the live bird area to none in 100 ft3 in the other areas of the plant. Similar results were obtained in the other plants.Salmonellae were found in the air of the live bird area in 6 of the 7 plants and in the picking room of the other one. In each of the 7 plants salmonellae were not recovered from the air in other processing areas. The data indicate that salmonellae are frequently found in the air of areas where live birds are handled but difficult to isolate or find in other areas of the plant.

IMPROVING THE BACTERIOLOGICAL QUALITY OF CHICKEN FRYERS

Two commercial fryer processing operations were investigated to determine the bacteriological quality of the fryers during and after evisceration. Alterations of washing, rinsing, and chilling methods were made to reduce bacterial numbers on skin surfaces of fryers. Swab samples were collected from fryer skin surfaces at various points in the processes and from table surfaces. Total plate counts, psychrophile counts, and coliform counts were determined.Total plate counts provided the greatest amount of useful information. Coliform counts were not suitable indicators of bacteriological conditions in the evisceration process.The major sources of bacteria on the skin surface of chilled fryers were the skin of freshly picked fryers and contamination added during the transfer of carcasses from the picker to the evisceration line. Evisceration of the fryers did not add significant numbers of bacteria to the skin surface. Bacteria on the skin of freshly picked fryers were firmly affixed to the surface. They could be removed in increased numbers by combining increased volumes of wash water with the scrubbing action of flexible rubber fingers in the washer.

Effect of Processing on Bacteria Associated with Turkey Giblets

THE effect of flowing water in reducing bacterial populations on the surfaces of poultry has been demonstrated by several workers. Gunderson et al. (1946) found that washing birds after they were eviscerated reduced the total bacterial count, but did not eliminate coliforms. According to May (1961), the transfer station for moving chicken carcasses from the picking to the evisceration line was the most consistent source of increases in bacterial counts, probably because there were no hand washing facilities at this station. He also found that final washing by a spray washer after evisceration reduced total counts significantly. Kotula et al. (1962) noted that a significant decrease occurred in bacterial populations on the skin of chickens chilled in a continuous counterflow-tumbler chiller. This was believed to be due to the fact that fresh coolant was added to the chill unit and water overflowed continuously from the chiller, resulting in dilution and…