I. Kang

Moisture content, processing yield, and surface color of broiler carcasses chilled by water, air, or evaporative air

This study was conducted to investigate the effects of water chilling (WC), air chilling (AC), and evaporative air chilling (EAC) on the moisture content, processing yield, surface color, and visual appearance of broiler carcasses. For the WC treatment, 1 group of birds was hard scalded and submersed into ice slush, whereas for AC, 1 group of birds was soft scalded and exposed to blowing air (1.0 m/s at 0°C) and for EAC, or 1 group of birds was soft scalded and exposed to blowing air and a cold water spray (every 5 min). During chilling, carcass temperature was reduced most effectively by WC (55 min), followed by EAC (120 min) and AC (155 min). After chilling, both WC and EAC carcasses picked up moisture at 4.6 and 1.0% of their weights, respectively, whereas AC carcasses lost 1.5% of their weight. On cutting at 5 h postmortem, WC carcasses showed the highest (2.5%), EAC showed the second highest (0.4%), and AC showed the least (0.3%) moisture loss. After 24 h of storage, almost 83% of the absorbed water in the WC carcass parts was released as purge, whereas EAC and AC carcasses maintained weights close to the prechilled weights. In an instrumental color evaluation and a visual evaluation by panelists, AC carcasses showed a darker appearance, a more yellow color, and more surface discoloration compared with WC or EAC carcasses.

Microbiological quality of water immersion-chilled and air-chilled broilers.

Carcass chilling during broiler processing is a critical step in preventing growth of pathogenic and spoilage bacteria. The objective of this study was to compare the microbiological quality of air- and water-chilled broiler carcasses processed at the same commercial facility. For each of four replications, 15 broilers were collected from the same commercial processing line after evisceration, after spraying with cetylpyridinium chloride (a cationic disinfectant), and after air chilling or water immersion chilling (WIC). All carcasses were quantitatively examined for mesophilic aerobic bacteria, Escherichia coli, coliforms, and Campylobacter as well as for the presence of Salmonella and Campylobacter. No significant differences (P > 0.05) were seen between air and water chilling for E. coli or coliforms or for the incidence of Salmonella and Campylobacter. Lower numbers of Campylobacter were recovered from WIC than from air-chilled carcasses (P < 0.05), but the incidence of Campylobacter on WIC carcasses was similar, suggesting that some Campylobacter organisms were injured rather than killed during WIC. In-line spraying with the disinfectant effectively decreased the incidence of Salmonella and Campylobacter on prechilled carcasses; however, cells presumably injured by the sanitizer recovered during chilling. Therefore, on-farm intervention strategies remain critically important in minimizing the spread of microbial contaminants during processing.

The evaluation of combined chemical and physical treatments on the reduction of resident microorganisms and Salmonella Typhimurium attached to chicken skin

This study was conducted to evaluate the efficacy of sodium hypochlorite (NaOCl, 0-200 mg/kg), thiamine dilauryl sulfate (TDS, 1,000 mg/kg), and ultrasound (37 kHz, 380 W) on reducing Salmonella Typhimurim, mesophilic aerobic bacteria (MAB), and coliforms on chicken skin. Chemical and physical treatments were applied for 5 min either singly or jointly, and Salmonella previously inoculated on chicken skin were quantitatively assessed using brilliant green agar, and the populations of MAB and coliforms in the native flora were enumerated using plate count agar and violet red bile agar, respectively. In the evaluation of bacterial attachment/detachment, chicken skin was quantitatively assessed for loosely, intermediately, and tightly attached bacteria. The treatment effects on bacteria detachment were also visualized using field emission scanning electron microscopy. In addition, color and textural properties of the skin after treatments were evaluated using a color difference meter and texture analyzer. Antimicrobial activity of NaOCl increased as the NaOCl concentration was increased, especially for loosely attached cells. The combination of 200 mg/kg NaOCl and ultrasound (NaOCl/ultrasound) significant reduced loosely, intermediately, and tightly attached bacteria populations by 0.75 to 0.47, 0.43 to 0.41, and 0.83 to 0.54 log cfu/g for MAB, coliforms, and Salmonella Typhimurium, respectively. However, the combination of NaOCl and TDS (NaOCl/TDS) did not sufficiently reduce those cells on chicken skins, except for loosely attached MAB and coliforms. The NaOCl/ultrasound combination produced a higher reduction in numbers of inoculated and native bacteria flora than any single application, with no negative effect on skin color or texture. Generally, the loosely attached bacteria were less resistant to the chemical and physical treatments than the intermediately and tightly attached bacteria in chicken skin, presumably due to their location in deeper skin layer and crevices. Further research is needed to investigate how the intermediately and tightly attached microorganisms can be effectively eliminated from chicken skin.

Effect of hot water spray on broiler carcasses for reduction of loosely attached, intermediately attached, and tightly attached pathogenic (Salmonella and Campylobacter) and mesophilic aerobic bacteria

Chickens are known to harbor many bacteria, including pathogenic microorganisms such as Salmonella and Campylobacter. The objective of this study was to evaluate the efficacy of hot water spray (HWS, 71°C for 1 min) in reducing bacterial contamination of prechilled broiler carcasses. For each of 4 replications, skin samples from 5 broilers were collected at 3 processing stages: after bleeding (feathers removed manually), after evisceration (with/without HWS), and after water chilling. Broiler skin was quantitatively assessed for loosely attached (by rinsing the skin), intermediately attached (by stomaching the rinsed skin), and tightly attached (by grinding the rinsed/stomached skin) mesophilic aerobic bacteria (MAB) and Campylobacter as well as for the prevalence of Salmonella and Campylobacter. Broiler skins possessed 6.4 to 6.6 log cfu/g, 3.8 to 4.1 log cfu/g, and 2.8 to 3.5 log cfu/g of MAB populations after bleeding, evisceration, and chilling, respectively. The HWS resulted in more than 1 log unit of reduction in MAB immediately after evisceration and immediately after chilling regardless of microbial sampling method. Compared with MAB, the contamination of Campylobacter was low (1.7 to 2.6 log cfu/g) after bleeding, but the level was not reduced throughout the processing steps regardless of HWS. The application of HWS reduced the prevalence of Salmonella after chilling, but not for Campylobacter except for loosely attached cells. After hot water exposure, a partially cooked appearance was seen on both broiler skin and skinless breast surface. More research is required to effectively eliminate pathogenic organisms during processing and suppress any recovery of bacteria regardless of attachment type after chilling.

Cold-batter mincing of hot-boned and crust-freezing air-chilled turkey breast improved meat turnover time and product quality

The purpose of this research was to evaluate the combined effects of turkey hot-boning and cold-batter mincing technology on acceleration of meat turnover and meat quality improvement. For each of 3 replications, 15 turkeys were slaughtered and eviscerated. Three of the eviscerated carcasses were randomly assigned to water-immersion chilling for chill-boning (CB) and the remaining were immediately hot-boned (HB), half of which were used without chilling whereas the remaining were subjected to crust-freezing air chilling (CFAC) in an air-freezing room (1.0 m/s, -12°C) with/without 1/4; sectioning (HB-1/4;CFAC, HB-CFAC). As a result, CB and HB breasts were minced using 1 of 5 treatments: (1) CB and traditional mincing (CB-T), (2) HB and mincing with no chilling (HB-NC), (3) HB and mincing with CO2 (HB-CO2), (4) HB and mincing after CFAC (HB-CFAC), and (5) HB and mincing after quarter sectioning and CFAC (HB-1/4;CFAC). Traditional water-immersion chilling took an average of 5.5 h to reduce the breast temperature to 4°C, whereas HB-CFAC and HB-1/4;CFAC took 1.5 and 1 h, respectively. The breast of HB-CFAC and HB-1/4;CFAC showed significantly higher pH (6.0-6.1), higher fragmentation index (196-198), and lower R-value (1.0-1.1; P < 0.05) than those of the CB controls. No significant differences (P > 0.05) in sarcomere length were seen between CB-T and HB-CFAC filets regardless of quarter sectioning. When muscle was minced, the batter pH (5.9) of CB-T was significantly lower (P < 0.05) than those (6.1-6.3) of HB-NC, HB-CO2, and HB-1/4;CFAC, with the intermediate pH (6.0) seen for the HB-CFAC. When meat batters were cooked, higher cooking yield (90 - 91%; P < 0.05) was found in HB-CFAC, HB-1/4;CFAC, and HB-CO2, followed by HB-NC (90%) and finally CB-T (86%). Stress values (47-51 kPa) of HB-CFAC gels were significantly higher (P < 0.05) than those of CB-T (30 kPa) and HB-NC (36 kPa). A similar trend was found in strain values.

Performance of a novel casing made of chitosan under traditional sausage manufacturing conditions

The goal of this study was to validate the commercial feasibility of a novel casing formed from chitosan containing cinnamaldehyde (2.2%, w/v), glycerol (50%, w/w) and Tween 80 (0.2% w/w) under traditional sausage manufacturing conditions. Meat batter was stuffed into both chitosan and collagen (control) casings and cooked in a water bath. Before and after cooking, both casings were compared for mechanical, barrier, and other properties. Compared to collagen, the chitosan casing was a better (P≤0.05) barrier to water, oxygen, liquid smoke, and UV light. In mechanical and other properties, the chitosan casing had higher (P≤0.05) tensile strength, lower (P≤0.05) elongation at break and tensile energy to break, and better (P≤0.05) transparency whereas a similar (P>0.05) water solubility to the collagen casing. Overall, the chitosan casing was less affected by sausage manufacturing conditions than the collagen casing, indicating that chitosan casing has potential as an alternative to the current collagen casing in the manufacture of sausages.

Quantification of loosely associated and tightly associated bacteria on broiler carcass skin using swabbing, stomaching, and grinding methods

This research was conducted to quantify bacterial populations after swabbing or stomaching, followed by grinding the swabbed or stomached broiler skins. For each of 3 replications, 3 eviscerated broilers were randomly taken from a processing line in a local broiler processing plant. Ten swabs and 10 stomachs per bird were conducted on the left- and the right-side skins (10×7 cm), respectively, which were then finally ground. Results indicated that mesophilic aerobic bacteria (MAB) in the first swabbed sample were significantly lower than those in the first stomached sample (P<0.05), with no difference seen for the remaining sampling times (P>0.05). During 10 swabbings followed by final grinding, 8, 9, and 83% of MAB were detected after the first swabbing, after the second through 10th swabbings, and after final grinding of the skin, respectively. During 10 stomachings followed by the final grinding, 17, 18, and 65% of MAB were detected after the first stomaching, after the second through 10th stomachings, and after final grinding of the skin, respectively. Escherichia coli (E. coli) and coliforms were significantly higher in the first stomaching than those in the first swabbing (P<0.05), with no difference seen between the 2 sampling methods for the rest sampling times (P>0.05). Populations of E. coli and coliforms decreased step-wisely from the highest after grinding to the intermediate after first and second sampling, and to the least after 10th sampling (P<0.05), regardless of swabbing or grinding. In this study, less than 35% of MAB seemed loosely associated in the skin of eviscerated broiler, whereas more than 65% of MAB looked tightly associated, which were not recovered by stomaching or swabbing even 10 times but were recovered by grinding the skin.

Fear responses and postmortem muscle characteristics of turkeys of two genetic lines

Commercial turkey production has increased greatly in recent decades. Along with increased production, problems with turkey meat quality have also increased. Research with other species has demonstrated that differences in meat quality exist among pigs and cattle differing in characteristics such as fearfulness. However, associations between fear responses and postmortem (PM) muscle characteristics related to the meat quality of turkeys have not been examined. This study evaluated the test-retest repeatability of responses of male commercial (COMM) and randombred (RB) turkeys in an open field (OF) test, which is used to assess fear and activity levels of poultry. Another objective of this study was to evaluate the relationship between behavioral OF responses and PM breast muscle characteristics (pH and R-value) that are related to meat quality. Thirdly, this study evaluated differences in pH and R-value between the turkey lines. Male COMM and RB turkeys were each housed in groups in 4 pens. Turkeys were individually tested in an OF (2.74×2.74 m, divided into 81 squares) at 1, 4, and 11 wk (COMM N=27; RB N=33). Turkeys were then grouped into clusters based on a cluster analysis of OF behavior. Turkeys were processed and meat quality characteristics were evaluated at 15-17 wk for COMM and 20-21 wk for RB turkeys. Results were analyzed using a mixed model (SAS 9.4). Breast muscle pH and R-value did not differ between genetic lines, and there were no differences in pH and R-value among clusters within genetic lines. These findings suggest that OF responses measured during rearing are not related to PM breast muscle pH and R-value, which ultimately affect meat quality. Further research is needed to assess whether other types of fear responses are associated with meat quality and whether differences in R-value between genetic lines are associated with differences in other meat quality characteristics.

Inhibitory effect of chlorine and ultraviolet radiation on growth of Listeria monocytogenes in chicken breast and development of predictive growth models

The inhibitory effect of chlorine (50, 100, and 200 mg/kg) was investigated with and without UV radiation (300 mW·s/cm(2)) for the growth of Listeria monocytogenes in chicken breast meat. Using a polynomial model, predictive growth models were also developed as a function of chlorine concentration, UV exposure, and storage temperature (4, 10, and 15°C). A maximum L. monocytogenes reduction (0.8 log cfu, cfu/g) was obtained when combining chlorine at 200 mg/kg and UV at 300 mW·s/cm(2), and a maximum synergistic effect (0.4 log cfu/g) was observed when using chlorine at 100 mg/kg and UV at 300 mW·s/cm(2). Primary models developed for specific growth rate and lag time showed a good fitness (R(2) > 0.91), as determined by the reparameterized Gompertz equation. Secondary polynomial models were obtained using nonlinear regression analysis. The developed models were validated with mean square error, bias factor, and accuracy factor, which were 0.0003, 0.96, and 1.11, respectively, for specific growth rate and 7.69, 0.99, and 1.04, respectively, for lag time. The treatment of chlorine and UV did not change the color and texture of chicken breast after 7 d of storage at 4°C. As a result, the combination of chlorine at 100 mg/kg and UV at 300 mW·s/cm(2) appears to an effective method into inhibit L. monocytogenes growth in broiler carcasses with no negative effects on color and textural quality. Based on the validation results, the predictive models can be used to accurately predict L. monocytogenes growth in chicken breast.

Cold-batter mincing of hot-boned and crust-frozen air-chilled turkey breast allows for reduced sodium content in protein gels

The purpose of this research was to evaluate sodium reduction in the protein gels that were prepared with turkey breasts after hot boning (HB), quarter (¼) sectioning, crust-frozen air-chilling (CFAC), and cold temperature mincing. For each of 4 replications, 36 turkeys were slaughtered and eviscerated. One-half of the carcasses were randomly assigned to water immersion chilling for chill boning (CB), whereas the remaining carcasses were immediately HB and quarter-sectioned/crust-frozen air-chilled (HB-¼CFAC) in a freezing room (-12°C, 1.0 m/s). After deboning, CB fillets were conventionally minced, whereas HB-¼CFAC fillets were cold minced up to 27 min with 1 or 2% salt. From the beginning of mincing, the batter temperatures of HB-¼CFAC were lower (P < 0.05) than those of CB batters up to 12 and 21 min for 2 and 1% salts, respectively. Upon mincing, the batter pH of the HB-¼CFAC (P < 0.05) rapidly decreased and was not different (P > 0.05) from the pH of CB batters, except for the 1% salt HB-¼CFAC batter after 15 min of mincing. The pattern of pH was not changed when the batters were stored overnight. The protein of 2% salt HB-¼CFAC fillets was more extractable (P < 0.05) than that of CB fillets at 9, 12, 18, and 24 min. Similarly, the protein of 1% salt HB-¼CFAC fillets was more extractable (P < 0.05) than that of CB fillets from 12 min. Stress values of 2% salt HB-¼CFAC gels were higher (P < 0.05) than those of 1 and 2% salt CB gels, with intermediate values for 1% salt HB-¼CFAC gels. In the scanning electron microscope image, prerigor batter appears to have more open space, less protein aggregation, and more protein-coated fat particles than those of postrigor batters. Based on these results, the combination of HB-¼CFAC and cold-batter-mincing technologies appear to improve protein functionality and sodium reduction capacity.