Effect of extending processing plant operating time on the microbiological quality and safety of broiler carcasses

• Water use efficiency is of current importance for poultry processors.
• The microbiological status of broiler carcasses was determined after 24 and 48 h continuous processing.
• Bacterial counts did not differ (P > 0.05) after extending plant operating time.
• Delayed spin-chiller emptying and cleaning does not impact on carcass quality and safety.

In Australia, increased consumer demand for chicken meat and socioeconomic pressures have forced poultry operations to extend plant operating time with delayed spin-chiller emptying and cleaning to maximise water use efficiency. There are concerns that these measures may compromise the microbiological quality and safety of the product. Therefore, the objective of this trial was to determine the microbiological status of broiler carcasses collected hourly during 24 h and 48 h continuous chiller operation within a three week period (total n = 196). Carcass rinses were analysed for total viable count, Escherichia coli and Campylobacter spp. counts, and Salmonella prevalence. Corresponding spin-chiller parameters (pH, oxidation-reduction potential [ORP], core temperature and HOCl concentration) were recorded. There was no statistically significant difference (P > 0.05) in bacterial populations and spin-chiller parameters when various sized chickens were processed. Therefore, the microbiological data and consequent quality were shown to be statistically equivalent between carcasses sampled from 24 h to 48 h continuous processing using a fully automated (water temperature, pH and chlorine control) spin-chiller. However, improvements to processing, including rehang and scald hygiene, and weight-specific hypochlorous acid concentrations, should be researched in order to further reduce bacterial contamination.