The poultry industry in the United States has traditionally implemented non-chemical and chemical interventions against Salmonella spp. and Campylobacter spp. on the basis of experience and word-of-mouth information shared among poultry processors. The effects of individual interventions have been assessed with microbiological testing methods for Salmonella spp. and Campylobacter spp. prevalence as well as quantification of indicator organisms, such as aerobic plate counts (APC), to demonstrate efficacy. The current study evaluated the loads of both indicators and pathogens in a commercial chicken processing facility, comparing the “normal chemical”, with all chemical interventions turned-on, at typical chemical concentrations set by the processing plant versus low-chemical process (“reduced chemical”), where all interventions were turned off or reduced to the minimum concentrations considered in the facility’s HACCP system. Enumeration and prevalence of Salmonella spp. and Campylobacter spp. as well as indicator organisms (APC and Enterobacteriaceae—EB) enumeration were evaluated to compare both treatments throughout a 25-month sampling period. Ten locations were selected in the current bio-mapping study, including live receiving, rehanger, post eviscerator, post cropper, post neck breaker, post IOBW #1, post IOBW #2, prechilling, post chilling, and parts (wings). Statistical process control parameters for each location and processing schemes were developed for each pathogen and indicator evaluated. Despite demonstrating significant statistical differences between the normal and naked processes in Salmonella spp. counts (“normal” significantly lower counts than the “reduced” at each location except for post-eviscerator and post-cropper locations), the prevalence of Salmonella spp. after chilling is comparable on both treatments (~10%), whereas for Campylobacter spp. counts, only at the parts’ location was there significant statistical difference between the “normal chemical” and the “reduced chemical”. Therefore, not all chemical intervention locations show an overall impact on Salmonella spp. or Campylobacter spp., and certain interventions can be turned off to achieve the same or better microbial performance if strategic intervention locations are enhanced.

The purpose of this study was to evaluate the antimicrobial efficacy of an aqueous ozone (Bio-Safe) treatment and lactic acid solutions on natural microbiota and E. coli O157:H7 and Salmonella surrogates on beef carcasses and trim in a commercial beef processing plant. For every repetition, 40 carcass and 40 trim swabs (500 cm²) were collected. Samples were taken using EZ-Reach^TM swabs, and plated into aerobic plate count (APC), coliform, and E. coli Petrifilm^TM for enumeration. In addition, a five-strain cocktail (MP-26) of E. coli surrogates was inoculated onto trim. For every trim surrogate repetition, 30 trim pieces were sampled after attachment and after ozone intervention. Samples were diluted and counts were determined using the TEMPO^® system for E. coli enumeration. Ozone and lactic acid interventions significantly reduced (p < 0.003) bacterial counts in carcasses and trim samples. Moreover, lactic acid further reduced APC and coliforms in trim samples compared to ozone intervention (p < 0.009). In the surrogate trials, ozone significantly reduced (p < 0.001) surrogate concentration. Historical data from the plant revealed a reduction (p < 0.001) of presumptive E. coli O157:H7 in trim after a full year of ozone intervention implementation. The novel technology for ozone generation and application as an antimicrobial can become an alternative option that may also act synergistically with existing interventions, minimizing the risk of pathogens such as Salmonella and E. coli O157:H7.

The purpose of this study was to develop a quantitative baseline of indicator organisms and Salmonella by bio-mapping throughout the processing chain from harvest to final product stages within a commercial conventional design pork processing establishment. Swab samples were taken on the harvest floor at different processing steps, gambrel table, after polisher, before final rinse, after the final rinse, post snap chill, and after peroxyacetic acid (PAA) application, while 2-pound product samples were collected for trim and ground samples. The samples were subjected to analysis for indicator microorganism enumeration, Aerobic Count (AC), Enterobacteriaceae (EB), and generic Escherichia coli (EC), with the BioMérieux TEMPO^®. Salmonella prevalence and enumeration was evaluated using the BAX^® System Real-Time Salmonella and the SalQuant™ methodology. Microbial counts were converted to Log Colony-forming units (CFU) on a per mL, per g or per sample basis, presented as LogCFU/mL, LogCFU/g and LogCFU/sample, prior to statistical analysis. All indicator microorganisms were significantly reduced at the harvest floor (p-value < 0.001), from gambrel table to after PAA cabinet location. The reduction at harvest was 2.27, 2.46 and 2.24 LogCFU/mL for AC, EB and EC, respectively. Trim sample values fluctuated based on cut, with the highest average AC count found at neck trim (2.83 LogCFU/g). Further process samples showed the highest AC count in sausage with a mean of 5.28 LogCFU/g. EB counts in sausage (3.19 LogCFU/g) showed an evident increase, compared to the reduction observed at the end of harvest and throughout trim processing. EC counts showed a similar trend to EB counts with the highest value found in sausage links (1.60 LogCFU/g). Statistical microbial process control (SPC) parameters were also developed for each of the indicator microorganisms, using the overall mean count ($\stackrel{=}{\mathrm{X}}$), the Lower control limit (LCL) and Upper control limit (UCL) at each sampling location. For Salmonella prevalence, a total of 125/650 samples were found positive (19%). From those positive samples, 47 samples (38%) were suitable for enumeration using the BAX^® System SalQuant™, the majority detected at the gambrel table location. From those enumerable samples, 60% were estimated to be between 0.97 and 1.97 LogCFU/sample, while the rest (40%) were higher within the 2.00–4.02 LogCFU/sample range. This study provides evidence for the application of indicator and pathogen quantification methodologies for food safety management in commercial pork processing operations.

The poultry industry in the United States is one of the largest in the world. Poultry consumption has significantly increase since the COVID-19 pandemic and is predicted to increase over 16% between 2021 and 2030. Two of the most significant causes of hospitalizations and death in the United States are highly related to poultry consumption. The FSIS regulates poultry processing, enforcing microbial performance standards based on Salmonella and Campylobacter prevalence in poultry processing establishments. This prevalence approach by itself is not a good indicator of food safety. More studies have shown that it is important to evaluate quantification along with prevalence, but there is not much information about poultry mapping using quantification and prevalence. In this study, enumeration and prevalence of Salmonella and Campylobacter were evaluated throughout the process at three different plants in the United States. Important locations were selected in this study to evaluate the effect of differences interventions. Even though there were high differences between the prevalences in the processes, some of the counts were not significantly different, and they were effective in maintaining pathogens at safe levels. Some of the results showed that the intervention and/or process were not well controlled, and they were not effective in controlling pathogens. This study shows that every plant environment is different, and every plant should be encouraged to implement a bio-mapping study. Quantification of pathogens leads to appropriate risk assessment, where physical and chemical interventions can be aimed at specific processing points with higher pathogen concentrations using different concentrations of overall process improvement.

The use of antimicrobials in the pork industry is critical in order to ensure food safety and, at the same time, extend shelf life. The objective of the study was to determine the impact of antimicrobials on indicator bacteria on pork loins under long, dark, refrigerated storage conditions. Fresh boneless pork loins (n = 36) were split in five sections and treated with antimicrobials: Water (WAT), Bovibrom 225 ppm (BB225), Bovibrom 500 ppm (BB500), Fit Fresh 3 ppm (FF3), or Washing Solution 750 ppm (WS750). Sections were stored for 1, 14, 28, and 42 days at 2–4 °C. Mesophilic and psychrotrophic aerobic bacteria (APC-M, APC-P), lactic acid bacteria (LAB-M), coliforms, and Escherichia coli were enumerated before intervention, after intervention, and at each storage time. All bacterial enumeration data were converted into log10 for statistical analysis, and the Kruskal–Wallis test was used to find statistical differences (p < 0.05). Initial counts did not differ between treatments, while, after treatment interventions, treatment WS750 did not effectively reduce counts for APC-M, APC-P, and coliforms (p < 0.01). BB500, FF3, and WS750 performed better at inhibiting the growth of indicator bacteria when compared with water until 14 days of dark storage.

The objective was to conduct a bio-mapping of microbial indicators to determine statistical process control (SPC) parameters at a beef processing plant to establish microbiological baselines and process control parameters to support food safety management decisions. EZ-Reach^TM swabs were used to collect 100 cm² area samples at seven different locations throughout the beef processing line at four different regions on the carcass. Each of the eight sampling days evaluated included three samples collected per sampling location/carcass region for a total of 84 samples per day. Enumeration of total aerobic bacteria, Enterobacteriaceae, and Escherichia coli was performed on each sample. Microbial SPC parameters were estimated for each sampling point. Statistical differences between sampling points for all carcass locations (p < 0.001) followed an overall trend with higher values at pre- and post-evisceration with a continuous decrease until final interventions with a slight increase in counts during the chilling process and a final increase after fabrication. Variability at sampling points is the result of the nature of the process and highlights open opportunities for improvement of the food safety system. Microbial baselines and SPC parameters will help support decision making for continuous process improvement, validation of intervention schemes, and corrective action implementation for food safety management.