Enhancing microbial control in poultry processing: A comprehensive study on carcass washing systems

Abstract

In the poultry industry, the evisceration stage often sees the highest microbial load on chicken carcasses. While manual trimming has traditionally been employed to remove gastrointestinal contamination, Brazilian legislation allows the use of a carcass washing system as an alternative. This study aimed to establish and validate a protocol for the use of a chicken carcass washing system as a replacement for manual trimming in a major poultry processing facility in southern Brazil. The methodology followed international standards for microbial analysis such as total mesophilic counts and Enterobacteriaceae. Comparing contamination levels before and after treatments, significant reductions are seen. Manual trimming reduced contamination by 39.43% (gastric), 53% (fecal), and 50% (biliary). Washing achieved greater reductions, with a 96.37% drop in gastric contamination and complete elimination (100%) of fecal contamination. These results met statistical significance. Both procedures reduced contamination levels. Manual trimming maintained 50% of samples below the mean value without exceeding upper control limits (UCL). Washing increased the percentage of samples below the mean value from 46% to 54%, demonstrating its superior efficiency. For Enterobacteriaceae, trimming maintained 44% of samples below the mean value, and washing increased it from 46% to 48%. In conclusion, the carcass washing system effectively removes visible gastrointestinal contents, meeting regulatory standards and receiving authorization from the Federal Inspection Service for use in the facility.