Dennis R. Buege

Trimming and Washing of Beef Carcasses as a Method of Improving the Microbiological Quality of Meat

A study to compare procedures and interventions for removing physical and bacterial contamination from beef carcasses was conducted in six carcass conversion operations that were representative of modern, high-volume plants and located in five different states. Treatment procedures included trimming, washing, and the current industry practice of trimming followed by washing. In addition, hot (74 to 87.8°C at the pipe) water washing and rinsing with ozone (0.3 to 2.3 ppm) or hydrogen peroxide (5%) were applied as intervention treatments. Beef carcasses were deliberately contaminated with bovine fecal material at >4.0 log colony-forming units (CFU)/cm2 in order to be better able to observe the decontaminating effects of the treatments. Carcasses were visually scored by 2 to 3 trained personnel for the level of gross contamination before and after treatment. Samples (10 by 15 cm, 0.3 to 0.5 cm thick) for microbiological testing were excised as controls or after application of each procedure or intervention and analyzed for aerobic mesophilic plate counts, Escherichia coli Biotype I counts, and presence or absence of Listeria spp., Salmonella spp., and Escherichia coli O157:H7. Average reductions in aerobic plate counts were 1.85 and 2.00 log CFU/cm2 for the treatments of trimming-washing and hot-water washing, respectively. Hydrogen peroxide and ozone reduced aerobic plate counts by 1.14 and 1.30 log CFU/cm2, respectively. In general, trimming and washing of beef carcasses consistently resulted in low bacterial populations and scores for visible contamination. However, the data also indicated that hot- (74 to 87.8°C at the pipe) water washing was an effective intervention that reduced bacterial and fecal contamination in a consistent manner.

Validation of pepperoni processes for control of Escherichia coli O157:H7

The outbreak of Escherichia coli O157:H7 linked with dry-cured salami in late 1994 prompted regulatory action that required manufacturers of fermented products to demonstrate a 5-log unit reduction in counts of this pathogen during processing. Therefore, pepperoni batter (75% pork:25% beef with a fat content of ca. 32%) was inoculated with a pediococcal starter culture and a five-strain mixture of E. coli O157:H7 (≥2 × 107 CFU/g) and stuffed into 55-mm diameter fibrous casings 47 cm in length. The viability of the pathogen was monitored before stuffing, after fermentation, after thermal processing, and/or after drying. Chubs were fermented at 96°F (36°C) and 85% relative humidity (RH) to pH ≤ 5.0 and then dried at 55°F (13°C) and 65% RH to a moisture/protein ratio of ≤1.6:1 (modified method 6 process). Counts of the pathogen decreased about 1.2 log units after fermentation and drying. In subsequent experiments, heating chubs after fermentation to internal temperatures of 145°F (63°C) instantaneous or 128°F (53°C) for 60 min resulted in a ≥5-log unit decrease in numbers of strain O157:H7 without visibly affecting the texture or appearance of the product. These data revealed that a traditional nonthermal, process for pepperoni was only sufficient to eliminate relatively low levels (ca. 2 log CFU/g) of E. coli O157:H7, whereas heating to internal temperatures of 145°F (63°C) instantaneous or 128°F (53°C) for 60 min delivered a 5 to 6 log unit reduction in counts of the pathogen in pepperoni.

Sources and Extent of Microbiological Contamination of Beef Carcasses in Seven United States Slaughtering Plants

This study determined microbiological loads of beef carcasses at different stages during the slaughtering to chilling process in seven (four steer/heifer and three cow/bull) plants. Potential sources of contamination (feces, air, lymph nodes) were also tested. Each facility was visited twice, once in November through January (wet season) and again in May through June (dry season). Carcasses were sampled by aseptic excision of surface tissue (100 cm2) from the brisket, flank, and rump (30 samples each) after hide removal (pre-evisceration), after final carcass washing, and after 24-h carcass chilling. The samples were analyzed individually by standard procedures for aerobic plate counts (APC), total coliform counts (TCC), Escherichia coli biotype I counts (ECC), and presence of Salmonella. Incidence of Salmonella was higher on dry feces of older compared to younger animals, fresh feces of younger compared to older animals, and on cow/bull carcasses compared to steer/heifer carcasses. Most factors and their interactions had significant (P < or = 0.05) effects on the bacterial counts obtained. Depending on plant and season, APC, TCC, and ECC were < or =10(4), < or =10(2), and < or =10(1) CFU/cm2 in 46.7 to 93.3, 50.0 to 100.0, and 74.7 to 100.0% of the samples, respectively. TCC exceeded 10(3) CFU/cm2 in 2.5% (wet season) and 1.5% (dry season) of the samples. ECC exceeded 10(2) CFU/cm2 in 8.7%, 0.3%, and 1.5% of the pre-evisceration, final carcass-washing, and 24-h carcass-chilling samples, respectively, during the wet season; the corresponding numbers during the dry season were 3.5%, 2.2%, and 3.0%, respectively. These data should serve as a baseline for future comparisons in measuring the microbiological status of beef carcasses, as the new inspection requirements are implemented.

Viability of Escherichia coli O157:H7 in Fermented Semidry Low-Temperature-Cooked Beef Summer Sausage

The population of inoculated Escherichia coli O157:H7 was monitored during the manufacture and storage of a semidry beef summer sausage processed by fermentation and cooking at a low temperature by heating to an internal temperature of 130°F (54°C). The all-beef batter (11% fat and nonmeat ingredients) was inoculated with the commercial starter culture Pediococcus acidilactici HP (≥8.6 log CFU/g of batter) and a five-strain mixture of E. coli O157:H7 (≥7 log CFU/g) and then hand stuffed into 2.5-inch (64-mm) diameter fibrous casings. The sausages were fermented at an initial temperature of 85°F (29°C) to a final temperature of 105°F (41°C) over ca. 13 h at 80% relative humidity (RH) to pH 4.6 or pH 5.0. After fermentation to pH 4.6, the internal temperature of the chubs was raised to 130°F (54°C) instantaneous over 3.6 h at 60% RH. After fermentation to pH 5.0, the internal temperature of the chubs was raised to 130°F (54°C) over 3.6 h at 60% RH and the chubs were maintained under these conditions for 0, 30, or 60 min. he chubs were cold water showered for 15 min and then chilled at 39°F (4°C) for 6 h before being vacuum packaged and stored at 39°F (4°C) or 77°F (25°C) for 7 days. Regardless of the target pH, fermentation alone resulted in only a 1.39-log CFU/g decrease in pathogen numbers. However, fermentation to pH 4.6 and heating to an internal temperature of 130°F (54°C) instantaneous reduced counts of E. coli O157:H7 by ≥7.0 log units to below detection levels (<10 CFU/g). Pathogen numbers remained below levels detectable by direct plating, but viable E. coli O157:H7 cells were recovered by enrichment of samples during sausage storage at either refrigeration or abuse temperatures. In contrast, fermentation to pH 5.0 and heating to an internal temperature of 130°F (54°C) instantaneous resulted in a 3.2-log-unit decrease in counts of E. coli O157:H7. No appreciable reductions in pathogen numbers were observed thereafter following storage at either 39°F (4°C) or 77°F (25°C) for 7 days. Fermentation to pH 5.0 and heating to an internal temperature of 130°F (54°C) instantaneous followed by holding for 30 or 60 min resulted in about a 5- or 7-log reduction, respectively, in pathogen numbers. For chubs held for 30 min at 130°F (54°C), pathogen numbers decreased to 2.02 and <1.0 log CFU/g at 39°F (4°C) and 77°F (25°C), respectively, after 7 days; viable cells were only observed by enrichment after storage at 77°F (25°C). For chubs held for 60 min at 130°F (54°C), pathogen numbers remained below levels detectable by direct plating, but viable cells were recoverable by enrichment after 7 days at both storage temperatures. These data will be useful guidelines to manufacturers for developing processing conditions to further ensure the safety of this category of fermented sausages relative to food-borne pathogens such as serotype O157:H7 strains of E. coli .

Viability of Escherichia coli O157:H7 in ground and formed beef jerky prepared at levels of 5 and 20% fat and dried at 52, 57, 63, or 68°C in a home-style dehydrator

Beef jerky batter was prepared to fat contents of about 5 and 20% and inoculated with about 10(8) cfu g(-1) of a five-strain inoculum of Escherichia coli O157:H7. Pathogen numbers were determined in the raw batter and in the strips formed from it after drying at 52, 57, 63, and 68 degrees C for times that ranged from 2 to 20 h. For both the high and low fat products, pathogen numbers were reduced by about 5 log10 cfu g(-1) within 4 h drying at 68 degrees C and within 8 h drying at 63 degrees C. At 57 degrees C, a 5-log10-unit reduction was achieved within 10h drying for the 5% fat product and within 16 h drying for the 20% fat product. At 52 degrees C, a 5-log10-unit reduction was achieved within 10 h drying for the 5% fat product and within 20 h drying for the 20% fat product. In at least one of the three trials for all four drying temperatures tested, the pathogen was present following enrichment of the samples in synthetic media. The calculated D values decreased from 2.59, 2.48, 1.23, and 1.17 as the temperature increased from 52, 57, 63, and 68 degrees C and as the fat content decreased from 20 to 5%. However, there was no direct correlation between the moisture-to-protein ratio and either the doneness of the strips or the viability of the pathogen. These data indicate that the fat content and the time and temperature at which strips are dried directly impact the viability of E. coli O157:H7 in ground and formed beef jerky.

Survival of Listeria monocytogenes during Storage of Ready-to-Eat Meat Products Processed by Drying, Fermentation, and/or Smoking

The survival of Listeria monocytogenes was evaluated on 15 ready-to-eat meat products made using drying, fermentation, and/or smoking. The products were obtained from six processors and included summer sausage, smoked cured beef, beef jerky, snack stick, and pork rind and crackling products. The water activity of the products ranged from 0.27 (pork rinds and cracklings) to 0.98 (smoked cured beef slices). Products were inoculated with a five-strain cocktail of L. monocytogenes, repackaged under either vacuum or air, and then stored either at room temperature (21degrees C) or under refrigeration (5 degrees C) for 4 to 11 weeks. Numbers of L. monocytogenes fell for all products during storage, ranging from a decrease of 0.8 log CFU on smoked cured beef slices during 11 weeks under vacuum at 5 degrees C to a decrease of 3.3 log CFU on a pork rind product stored 5 weeks under air at 21degrees C. All of the products tested could be produced under alternative 2 of the U.S. Department of Agriculture regulations mandating control of L. monocytogenes on ready-to-eat meat and poultry products. For many of the products, 1 week of postprocessing storage prior to shipment would act as an effective postlethality treatment and would allow processors to operate under alternative I of these regulations.

Effectiveness of spraying with tween 20 and lactic acid in decontaminating inoculated Escherichia coli O157:H7 and indigenous Escherichia coli biotype I on beef.

Beef carcass quarters and fat-covered subprimal cuts were suspended vertically and inoculated with a bovine manure slurry containing a five-strain mixture of Escherichia coli O157:H7 to deliver about 4 to 5 log10 CFU/cm2. To identify treatments that would improve the effectiveness of spraying with lactic acid (LA), the inoculated quarters and cuts were treated as follows: experiment A, (i) not treated (control), (ii) sprayed with 2% (vol/vol) LA, (iii) tempered at 21 degrees C for 4 h, and (iv) tempered and then sprayed with LA; experiment B, (v) sprayed with water, (vi) sprayed with LA, (vii) sprayed with LA containing 0.5% (vol/vol) sodium benzoate (SB), and (viii) sprayed with LA containing SB and 5% (vol/vol) Tween 20 (TW20); and experiment C, (ix) sprayed with water (no prespray), (x) presprayed with TW20 and then sprayed with LA, and (xi) presprayed with TW20 and then sprayed with LA containing SB. In experiment A, spraying carcasses with LA significantly (P < 0.05) reduced the numbers of E. coli Biotype I and serotype O157:H7 after 1 and 3 days of storage, respectively. The tempering process employed did not affect the effectiveness of the LA spray on either type of E. coli. In experiment B, there was no significant difference in the reduction of E. coli O157:H7 on subprimal cuts sprayed with water and that on cuts sprayed with LA alone or with LA in combination with SB and TW20 after 1 or 3 days of storage (total reductions ranged from about 1.6 to 2.8 log10 CFU/cm2). In experiment C, prespraying subprimal cuts with TW20 significantly (P < 0.05) increased the effectiveness of LA (reductions of 2.8 and 3.2 log10 CFU/cm2, respectively) and that of LA with SB (reductions of 2.6 and 3.3 log10 CFU/cm2, respectively) compared with spraying with water alone (reductions of ca. 1.0 and 2.0 log10 CFU/cm2, respectively) after I and 3 days of storage, respectively. In a separate experiment, the incorporation of TW20 (0.1 or 0.25%) into buffered peptone water prior to the maceration of excised carcass surface samples resulted in the recovery of significantly larger numbers (ca. 5.1 to 5.2 log10 CFU/cm2) of E. coli O157:H7 cells than did the control treatment without added TW20 (ca. 3.8 to 4.6 log10 CFU/cm2). These results demonstrate that the treatment of beef carcasses with LA reduces the number of viable E. coli O157:H7 cells and that this inactivation or removal by LA is enhanced by prespraying of the carcass with a 5% solution of TW20.

Validation of a manufacturing process for fermented, semidry Turkish soudjouk to control Escherichia coli O157:H7.

Two soudjouk batters were prepared from ground beef (20% fat) and nonmeat ingredients and inoculated with a five-strain mixture of Escherichia coli O157:H7 to yield an initial inoculum of 7.65 log10 CFU/g. One batter contained a commercial-starter culture mixture (approximately 8.0 log10 CFU/g) and dextrose (1.5%), while the other batter relied upon a natural fermentation with no added carbohydrate. Following mixing, sausage batters were held at 4 degrees C for 24 h prior to stuffing into natural beef round casings. Stuffed soudjouk sticks were fermented and dried at 24 degrees C with 90 to 95% relative humidity (RH) for 3 days and then at 22 degrees C with 80 to 85% RH until achieving a product moisture level of approximately 40%. After fermentation and drying with an airflow of 1 to 1.5 m/s, the sticks were either not cooked or cooked to an instantaneous internal temperature of 54.4 degrees C (130 degrees F) and held for 0, 30, or 60 min. The sticks were then vacuum packaged and stored at either 4 or 21 degrees C. For each of three trials, three sticks for each treatment/batter were analyzed for numbers of E. coli O157:H7 after inoculation, after fermentation, after cooking, and after storage for 7, 14, 21, and 28 days. Reductions in numbers of E. coli O157:H7 after fermentation and drying for sticks fermented by the starter culture (pH 4.6) and for sticks naturally fermented (pH 5.5) were 1.96 and 0.28 log10 CFU/g, respectively. However, cooking soudjouk sticks produced with a starter culture and holding at 54.4 degrees C for 0, 30, or 60 min reduced pathogen numbers from an initial level after fermentation and drying of 5.69 log10 CFU/g to below a detectable level by either direct plating (<1.0 log10 CFU/g) or by enrichment. In contrast, cooking soudjouk sticks produced without an added starter culture decreased pathogen numbers from an initial level after fermentation and drying of 7.37 to 5.65 log10 CFU/g (54.4 degrees C, no hold), 5.04 log10 CFU/g (54.4 degrees C, 30 min hold), and 4.67 log10 CFU/g (54.4 degrees C, 60 min hold). In general, numbers of E. coli O157:H7 within both groups of soudjouk sticks decreased faster during storage at 21 degrees C compared to 4 degrees C. After 28 days of storage, total reductions in pathogen numbers in soudjouk sticks produced using a starter culture but that were not subsequently cooked were 7.65 and 3.93 log10 CFU/g at 21 and 4 degrees C, respectively. For naturally fermented soudjouk, total reductions varied from 4.47 to 0.45 log10 CFU/g, depending on the cooking time and storage temperature. These data provide guidelines for manufacturers of dry sausage of ethnic origin, including soudjouk, to assess the safety of their processes for control of E. coli O157:H7.

Lethality of Commercial Whole-Muscle Beef Jerky Manufacturing Processes against Salmonella Serovars and Escherichia coli O157:H7

Thermal processes used in making whole-muscle beef jerky include a drying step, which may result in enhanced pathogen thermotolerance and evaporative cooling that reduce process lethality. Several salmonellosis outbreaks have been associated with beef jerky. In this study, a standardized process was used to inoculate beef strips with five-strain cocktails of either Salmonella serovars or Escherichia coli O157:H7, to marinate the strips at pH 5.3 for 22 to 24 h at 5 degrees C, and to convert the strips to jerky using various heating and drying regimes. Numbers of surviving organisms were determined during and after heating and drying. Salmonella reductions of > or = 6.4 log CFU and similar reductions in E. coli O157:H7 were best achieved by ensuring that high wet-bulb temperatures were reached and maintained early in the process (51.7 or 54.4 degrees C for 60 min, 57.2 degrees C for 30 min, or 60 degrees C for 10 min) followed by drying at 76.7 degrees C (dry-bulb temperature). Processes with less lethality that reduced counts of both pathogens by > or = 5.0 log CFU were (i) heating and drying at 76.7 degrees C (dry bulb) within 90 min of beginning the process, (ii) heating for successive hourly intervals at 48.9, 54.4, 60, and 76.7 degrees C (dry bulb), and (iii) heating at 51.7 degrees C (dry bulb) and then drying at 76.7 degrees C (dry bulb), starting before the product water activity dropped below 0.86. In several trials, separate beef strips were inoculated with a commercial Pediococcus acidilactici starter culture as a potential surrogate for evaluating pathogen thermotolerance. The results of these trials suggested that this experimental approach may be useful for in-plant validation of process lethality.

Viability of Escherichia coli O157:H7 during Manufacturing and Storage of a Fermented, Semidry Soudjouk-Style Sausage

Soudjouk-style batter was inoculated with a five-strain mixture of Escherichia coli O157:H7 at about 7.6 log10 CFU/g in each of two trials. The sticks were fermented and dried at 22 degrees C and 50% relative humidity (RH) for 3 days and then at 9 degrees C and 40% RH for 18 h. After being flattened to about 1.25 cm, the sticks were conditioned at 38 degrees C and 70% RH or at 22 degrees C and 50% RH for about 3 days. After the latter conditioning treatment, sticks either were cooked to an internal temperature of 63 degrees C or received no heat treatment. Final mean pH values after conditioning at 22 degrees C and 50% RH for soudjouk manufactured with a starter culture and dextrose (1.0%) and for soudjouk manufactured without a starter culture were about 4.9 and 6.0, respectively. For soudjouk produced with a starter culture, pathogen numbers were reduced by 4.53 and 0.88 log10 CFU/g after conditioning at 38 degrees C and 70% RH and at 22 degrees C and 50% RH, respectively. For soudjouk produced via natural fermentation, pathogen numbers were reduced by 1.39 and 0.09 log10 CFU/g after conditioning at 38 degrees C and 70% RH and at 22 degrees C and 50% RH, respectively. Cooking reduced pathogen numbers to below the levels detectable by direct plating (<1.0 log10 CFU/g) and by enrichment for soudjouk produced with a starter culture and also reduced pathogen numbers by 6.28 log10 CFU/g for soudjouk produced via natural fermentation. However, cooking also resulted in an unacceptable product. In general, the reduction in pathogen numbers achieved by storage at ambient temperature (25 degrees C) was greater than that achieved by storage at cooler temperatures (4 and 15 degrees C), particularly for soudjouk prepared with a starter culture (for which a final pH value of 4.8 and a 6.4-log10 reduction were obtained after 21 days at 25 degrees C) rather than for that prepared without a starter culture (for which a final pH value of 6.1 and a 2.6-log10 reduction were obtained after 21 days at 25 degrees C). These results indicate that naturally fermented old-country-type sausage may allow the survival of E. coli O157:H7 in the absence of controlled fermentation, postfermentation cooking, and/or an ambient-storage processing step.