Improvement of the hygienic performance of the hindquarters skinning operations at a beef packing plant

The hindquarters skinning operations in a commercial beef carcasses dressing process were modified, and for short trial periods reorganized for the purpose of reducing the numbers of bacteria deposited on the carcasses. During performance of modified or reorganized operations, samples were obtained from randomly selected carcasses, by swabbing specified sites related to opening cuts, rump skinning or flank skinning operations, randomly selected sites along the lines of the opening cuts, randomly selected sites on the skinned hindquarters of carcasses, or randomly selected sites on carcass sides leaving the dressing process. For each form of the hindquarters skinning operations, a set of 25 samples of each type was collected, with a single sample being obtained from each selected carcass or side. Aerobic counts, coliforms and Escherichia coli were enumerated in each sample, and a log mean value was estimated for each set of 25 counts on the assumption of a log normal distribution of the counts. The data indicated that the log numbers of total aerobes, coliforms and E. coli that were deposited on carcasses during the modified hindquarters skinning operations were generally about 0.5, 1.0 and 1.0 log unit less, respectively, than the log numbers that had been deposited on the carcasses during the unmodified operations. Reorganization of the modified operations gave further small but consistent reductions in the numbers of bacteria. It, therefore, appears that changes to dressing procedures which are guided by appropriate microbiological data can produce consistent reductions in the microbiological contamination of carcasses.     

Combined effects of lactic acid and nisin solution in reducing levels of microbiological contamination in red meat carcasses

Changes in bacterial counts on beef carcasses at specific points during slaughter and fabrication were determined, and the effectiveness of nisin, lactic acid, and a combination of the lactic acid and nisin in reducing levels of microbiological contamination was assessed. Swab samples were obtained from the surfaces of randomly selected beef carcasses. Carcasses were swabbed from the neck, brisket, and renal site after skinning, splitting, and washing. Treatments involving lactic acid (1.5%), nisin (500 IU/ml), or a mixture of nisin and lactic acid were applied after the neck area was washed. A control group was not sprayed. Results indicated that the highest prevalence of aerobic plate counts (APCs), total coliforms, and Escherichia coli was found in the neck site after splitting, and the lowest level of microbial contamination was found after skinning. Washing with water did not significantly reduce the bacterial load. The largest reduction in APCs, total coliforms, and E. coli occurred on carcasses treated with a mixture of nisin and lactic acid. A mixture of nisin and lactic acid can be applied to beef carcasses through spray washing and can reduce bacterial populations by 2 log units.     

Identification of critical control points for control of microbiological contamination in processes leading to the production of ground beef at a packing plant

Carcasses, carcass portions and pieces of manufacturing beef were sampled by swabbing a 100 cm² randomly selected site on each of 25 randomly selected product units at each of several stages of the meat production processes at a large beef packing plant. After skinning, aerobes were recovered from each sample, at log mean numbers of 1.86 log cfu cm⁻²; and coliforms and Escherichia coli were recovered from <15 of 25 samples at log total numbers of 3.27 and 3.16 log cfu 2500 cm⁻². The numbers of bacteria recovered after preevisceration washing and spraying with 2% lactic acid solution were similar to the numbers recovered after skinning, and the numbers recovered from carcasses that had been eviscerated, split, vacuum/hot-water cleaned and trimmed were little different. However, the numbers of coliforms and E. coli were reduced by the washing of carcass sides; and pasteurizing followed by spraying with lactic acid reduced the numbers of aerobes to log mean numbers of 0.71 log cfu cm⁻² and coliforms and E. coli to log total numbers of 1.28 and 0.30 log cfu 2500 cm⁻², respectively. After cooling for 24 h, numbers of aerobes on carcass sides had increased to log mean numbers of 2.57 log cfu cm⁻², and log total numbers of coliforms and E. coli had increased to 3.34 and 2.18 log cfu 2500 cm⁻², respectively. Numbers had not increased after sides had been held for a further 12 h before breaking. Numbers of bacteria on forequarters increased during breaking operations on hanging sides and increased further after forequarters were dropped to conveyor belts. Numbers on hindquarters were little affected by those operations. Large numbers of bacteria were recovered from cleaned equipment that contacted forequarters. The numbers of bacteria on trimmings did not increase during conveying from breaking lines to bulk containers. The numbers of bacteria on manufacturing beef were less than the numbers on forequarters trimmings, but more than the numbers on hindquarters trimmings. The log mean numbers of bacteria in ground beef produced at the plant were 3.11 log cfu g⁻¹, and the log total numbers of coliforms and E. coli were 1.84 and 1.30 log cfu 25 g⁻¹, respectively. Similar numbers of bacteria were recovered from ground samples of manufacturing beef. It therefore appears that most of the E. coli as well as other bacteria in ground beef are deposited on the product during the initial operations for breaking forequarters. Thus, improvement of equipment cleaning rather than of production processes would be required to improve the microbiological condition of ground beef prepared at the plant. However, skinning, washing of dressed sides, pasteurizing and cooling are evidently critical control points in carcass production processes.     

Assessment and development of procedures and apparatus to reduce contamination of lamb carcasses during pelt removal in low-throughput abattoirs.

Two series of experiments were carried out to investigate methods of reducing contamination of lamb carcasses in low-throughput abattoirs, where cradle dressing is normally employed. In the first series, cradle design and pelt removal procedure were investigated, and a method was developed for assessing gross visible contamination. Significant improvements in microbiological and gross visible contamination (P < 0.01) were achieved by procedural changes only; modifications to the cradle design had no effect. In the second series of experiments, two improved methods of pelt removal and the effect of hand washing prior to carcass contact during the pelt removal procedure were investigated. The improved methods comprised a Frame system, in which the pelt was removed in a manner similar to that in a high-throughput inverted line, and a Hybrid system, in which the pelt was removed from the forequarters on a conventional cradle before the carcass was suspended in an "inverted" vertical position for removal of the pelt from the abdomen and hindquarters. The results of microbiological and gross visible contamination from these methods, with and without hand washing, were compared with the conventional Cradle method of pelt removal. Both the Hybrid and Frame systems had significantly less microbiological and gross visible contamination (P < 0.01). However, hand washing had no significant effect on the level of carcass contamination for all three methods of pelt removal. Greatest reductions in microbiological and gross visible contamination were achieved using techniques that minimized hand contact with the carcass during pelt removal by adoption of inverted dressing procedures. Equipment redesign did not reduce carcass contamination.     

Decontamination of carcasses by vacuum-hot water cleaning and steam pasteurizing during routine operations at a beef packing plant

The microbiological effects of three operations for cleaning areas on dressed beef carcasses with vacuuming equipment which also applies hot water to the carcass, and of an operation for pasteurizing beef carcass sides with steam, were assessed. All four operations were routine in a commercial carcass dressing process. For each operation, swab samples were obtained from randomly selected carcasses, with a single sample being collected from each carcass, from a site selected at random from those affected by the operation. For the cleaning operations, 25 samples were obtained before and 25 after each operation. For the pasteurizing operation, 50 samples were obtained before and 50 after the operation. In addition, 50 samples were obtained from beef sides after the carcass cooling process which followed the pasteurizing operation. Total aerobic counts, coliforms and Escherichia coli from each sample were enumerated. The cleaning operations generally reduced the log mean numbers of bacteria on treated areas by ≤ 0.5 and had no discernible effect on the overall microbiological condition of the carcasses emerging from the process. The pasteurizing operation reduced the log mean numbers of total aerobic bacteria on carcasses by about 1, and the log mean numbers of coliforms and E. coli by > 2. The cooling process had no affect on the total counts, but further reduced the log mean numbers of coliforms and E. coli, apparently by about 1, to give beef sides from which E. coli were not recovered.     

Impact of animal husbandry and slaughter technologies on microbial contamination of meat: Monitoring and control

The microbial flora transferred to carcasses during slaughter is a reflection of the care taken on the slaughter floor and of the types and numbers of microorganisms acquired by the animal on the farm or during the period of transportation to the slaughter house. These microogranisms may include those able to cause illness in the consumer, or microorganisms responsible for spoilage of the product. Considerable progress has been made in reducing contamination at slaughter and thereby extending the shelf-life of meat. In contrast, international statistics still clearly show that meat and meat products are responsible for a major proportion of all foodborne infections. This latter aspect is not determined by the overall number of microorganisms present but by the bacterial composition of the animal's gut flora at slaughter. Preventive quality assurance along the whole productions and processing line is therefore the only effective means of controlling the microbiological safety and quality of meat. This includes hazard analysis techniques to identify critical control points and procedures for monitoring the microbiological status of both animals and carcasses since most of the critical points cannot be totally controlled. At early stages in the production line, colonisation of meat animals with pathogens should be prevented. Subsequently, good slaughter practices will ensure carcasses of good overall microbiological quality. This paper deals with microbiological monitoring systems that can be used at different stages of production and processing to control the microbiological quality of poultry and pig meat.     

Proximate sources of bacteria on boneless loins prepared from routinely processed and detained carcasses at a pork packing plant

Microbiological samples were obtained by swabbing detained and routinely processed pig carcasses before and after cooling, and sides, loin portions and loin cuts at various stages of the carcass breaking process. Aerobes, coliforms and Escherichia coli were enumerated in each sample. All three groups of bacteria were more numerous on detained than on routinely processed carcasses. Both trimming and cooling reduced the numbers of E. coli but not the numbers of aerobes on detained carcasses. After cooling, the log mean number of aerobes and E. coli on detained carcasses were each about 0.5 log unit more than the log mean numbers on routinely processed carcasses, but numbers of coliforms on the two types of carcass were similar. There were small increases in the numbers of coliforms and E. coli on carcasses during their movement from the cooler to the breaking facility. The numbers of bacteria on the meat apparently did not increase during the carcass-breaking process, although bacteria were redistributed on the product. Despite that, substantial numbers of bacteria were recovered from parts that do not contact food in cleaned conveying equipment used for carcass breaking. However, those bacteria included few coliforms and no E. coli. These findings suggest that the contamination of meat with E. coli from persistent detritus in carcass breaking equipment, such as has been found to occur at beef packing plants, may be prevented when carcass-breaking equipment and facilities are dried after cleaning, and wetting of equipment during processing is avoided.     

Microbiological conditions of detained beef carcasses before and after removal of visible contamination

The microbiological conditions of carcasses detained for the removal of visible contamination at four beef packing plants were examined. The numbers of aerobes and Escherichia coli recovered from most visibly contaminated sites did not exceed numbers generally regarded as acceptable for beef carcasses. The numbers of bacteria at visibly contaminated sites were reduced when those sites were trimmed, but additional and/or routine decontaminating treatments after trimming gave greater reductions in numbers at three of the plants. At each plant, at the end of the dressing process, the microbiological condition of the carcasses that had been detained was similar or superior to the condition previously determined for carcasses routinely produced from the process.     

Microbial assessment of an upward and downward dehiding technique in a commercial beef processing plant

Preventing microbial contamination during dehiding is challenging, and skinning methods are of critical importance for the hygienic status of beef carcasses. Two skinning methods are usually employed: upward hide pulling (UHP) and downward hide pulling (DHP). This study has compared the microbiological contamination of carcasses using both systems in a beef processing plant in the process of changing its dehiding method from UHP to DHP. 100 cm² areas from eight carcass sites (ham, chuck, rump, bung, flank, brisket, shin and neck) were sampled on 36 skinned carcasses dehided by each technique. Total viable counts (TVCs) and Enterobacteriaceae counts for each site were determined. No significant differences were observed in total (pooled-samples) carcass contamination regardless of the method used. However, significant differences (p < 0.05) in TVCs were observed at the flank, shin, brisket and neck. These differences can be attributed to possible deficiencies in the implementation of the HACCP pre-requisite programmes, and are not necessarily associated with the skinning method per se.     

Assessment of F-RNA Coliphage as a Potential Indicator of Enteric Virus Contamination of Hog Carcasses

Hepatitis E virus (HEV) is common in pigs, and some swine HEV strains are closely related to human strains. The zoonotic transmission of HEV is now well established. HEV can be detected by molecular techniques, but the significance of the presence of viral nucleic acid is questionable when foods are subjected to virus inactivation treatments. F-RNA coliphages are attractive candidates as indicators for enteric viruses because they are similar in size and survival characteristics and can be rapidly cultured. Information on the contamination of hog carcasses with enteric or hepatic viruses during slaughter is lacking. The objective of this study was to compare the incidence and levels of contamination of hog carcasses with F-RNA coliphages, HEV, total aerobic bacteria, coliforms, and Escherichia coli at different stages of the dressing process. Hog carcasses entering the commercial slaughter facility are heavily contaminated with F-RNA coliphages and HEV. Subsequent processes such as scalding, singing, and pasteurization can reduce the incidence and levels of F-RNA coliphages and HEV substantially to almost undetectable levels. Large discrepancies between the amount of viral nucleic acid and infectious F-RNA coliphage particles, both at high levels and low levels of contamination, were observed. The prevalence and levels of viable F-RNA coliphages were lower than those of total aerobic bacteria, coliforms, and E. coli in the anal area and on random sites before pasteurization. At a research abattoir, there was no overall mean reduction of viable F-RNA coliphages recovered from random sites before pasteurization and after washing, whereas overall mean reductions of 1.2, 2.6, and 2.9 log CFU for total aerobic bacteria, coliforms, and E. coli, respectively, were obtained. These findings suggest that bacteria such as coliforms and E. coli may not be suitable as indicators for enteric viruses in a meat processing environment.     

Determination of the principal points of product contamination during beef carcass dressing processes in Northern Ireland

To determine the principal points of microbial contamination of carcasses during beef carcass dressing in Northern Ireland, 190 carcasses were sampled by swabbing 1,000 cm2 of the brisket. A detailed survey of one abattoir was initially conducted, with sampling of a total of 100 carcasses immediately after hide removal (H), after carcass splitting (S), and immediately after washing (W) before dispatch to the chiller. The total bacterial counts after incubation at both 22 and 37 degrees C indicated that there was no significant increase in the numbers of bacteria after the first sampling point, H (P > 0.05). To determine whether this was the case in the majority of Northern Ireland abattoirs, 15 carcasses were then sampled at each of an additional six abattoirs, at points H and W only. Total bacterial counts were significantly higher (P < 0.05) at H than at W, indicating that hide pulling was the major point of bacterial contamination of beef carcasses and hence a critical control point for the final microbiological quality of the carcasses. Mean counts of Enterobacteriaceae at both incubation temperatures were very low (< 10 CFU/cm2) but were higher at W than at H, probably indicating that washing was redistributing bacteria from the posterior to the anterior region.     

Microbial contamination on beef in relation to hygiene assessment based on criteria used in EU Decision 2001/471/EC

Thirty-six carcasses were sampled over a 12-month period at an Irish beef abattoir. Between one and five carcass sites (including the hock, brisket, cranial back, bung, inside round and outside round) were sampled after hind leg skinning, hide removal, bung tying, evisceration, splitting, washing, chilling for 24 h and boning, using a wet and dry, cotton wool swab technique. For each sample, total viable counts (TVC), Escherichia coli, total coliforms and Enterobacteriaceae were enumerated. The results are considered in relation to European Union Decision 2001/471/EC which sets performance criteria for TVCs and Enterobacteriaceae in samples taken by excision. Though not explicitly stated in the Decision, it has been proposed that microbiological performance criteria for samples taken by swabbing be set at 20% of the values set for excision samples. Therefore, log mean TVCs in carcass swab samples taken before chilling are acceptable, marginal and unacceptable when they are <2.8, 2.8-4.30 and >4.30 cm(-2), respectively. By these criteria, TVCs on carcasses in the present study were in the marginal range. The marginal result for TVCs was due in the most part to hide removal operations, particularly at the hock and brisket sites. Bacterial contamination on post-chill carcasses was similar or lower to that on pre-chill carcasses, while boning resulted in general increases in TVCs and in E. coli, total coliform and Enterobacteriaceae numbers. In Decision 2001/471/EC, the effects of chilling and boning are not included in the assessment of process control. Data from this study indicate that performance criteria based on log mean Enterobacteriaceae values are unsuitable because of the infrequent occurrence of these organisms on the carcass.     

Effects of shearing and fleece cleanliness on microbiological contamination of lamb carcasses

The meat industry in Norway has developed national guidelines for Good Hygiene Practices for slaughtering and skinning, based on categorisation of animals. These include shearing sheep and lambs in the abattoirs immediately before slaughter. The aim of this study was to investigate microbiological carcass contamination associated with: (i) different shearing regimes; (ii) fleece cleanliness; and (iii) the slaughter process. In addition, the efficacy of the national guidelines in reducing microbial contamination was evaluated. A total of 280 swab samples were collected from the brisket areas (100 cm(2)) of 140 naturally contaminated lamb carcasses in a commercial abattoir. Half the samples were collected at skinning of brisket areas at the start of the slaughter-line and half of them were collected at the end of slaughter-line, just before chilling. The lambs were divided into four groups (n=35) according to the duration of the period between shearing and slaughter: (i) 0 days (shorn at the abattoir immediately before slaughter); (ii) three days; (iii) seven days; and (iv) not shorn. Mean log colony forming units (CFU) per 100 cm(2) at skinning were 5.78 and 6.95 for aerobic plate count (APC) (P<0.05), 1.65 and 2.78 for Escherichia coli (P<0.05) for shorn and unshorn lambs, respectively. For shorn lambs, divided according to the period between shearing and slaughter, the mean log CFU per 100 cm(2) were 5.45, 5.75, 6.12 (APC) and 1.77, 1.46, 1.71 (E. coli) for the 0-days, 3-days and 7-days groups, respectively (P<0.05 for the difference between 0- and 7-days groups in APC results). A four-category scale (0-3) was used for assessing fleece cleanliness before skinning. Visually clean lambs (score '0') had lower levels of APC on the carcass surfaces than those categorised as dirty (score '2-3') (P<0.05). The carcasses at the end of the slaughter-line had lower levels of APC than they had at skinning. However, the statistical significant reduction of E. coli on carcass surfaces at skinning point for shorn lambs, were impaired and no longer significantly different from the unshorn group at the end of the slaughter-line. The increased E. coli level at the end of the slaughter-line might be explained by weaknesses related to slaughter hygiene in particular suboptimal evisceration in the abattoir which was used as a basis for our trial, and thus the national guidelines concerning shearing had not the fully intended effect on reducing microbial carcass contamination.     

Microbiological conditions of meats from large game animals and birds

Large game animals and birds used for the commercial production of meat include deer of various species, wild boar and feral pigs, ostriches, emus and rheas, crocodiles and alligators, bison, and kangaroos. Meat from feral pigs and kangaroos is obtained from wild animals only, but much or most meat from the other game animals or birds is obtained from farmed animals. The microbiological conditions of meats from hunted animals can be compromised by poor placement of shots, the usual evisceration and sometimes further dressing of carcass in the field, and ageing of carcasses at ambient temperatures. However, the general microbiological conditions of carcasses from farmed game animals or birds slaughtered and dressed at suitable abattoirs can be comparable with or better than the microbiological conditions of carcasses from domestic animals or birds. The incidences of enteric pathogens on meat from wild or farmed game animals or birds can be less than those for meat from intensively reared domestic animals, but infection of some game meats with Trichinella or other foodborne parasites may occur.     

Microbiological effects of carcass decontaminating treatments at four beef packing plants

The effects on the microbiological conditions of carcasses of decontaminating treatments at four beef packing plants were examined. Spraying with 2% lactic acid, vacuum-hot water cleaning and trimming were generally ineffective. Washing reduced numbers of bacteria on carcasses when numbers were relatively high but not when they were relatively low. Pasteurizing with steam or hot water was consistently effective. The results suggest that the maximum reduction of bacteria on carcasses may be obtained by washing and pasteurizing without the other decontaminating treatments that are currently applied to carcasses.     

Presence of Salmonella in the red meat abattoir lairage after routine cleansing and disinfection and on carcasses

Foodborne pathogens, such as Salmonella, may remain in abattoir lairages after cleansing and pose a risk of transfer and contamination from one processing day to the next. These organisms may be transferred to the outer surface of animals held in lairage facilities, and the skin or hide may be a significant source of microbial contamination on the red meat carcasses subsequently produced. Sponge samples were taken from various sites in the lairage (n = 556), and single-pass sponge samples were taken from one side of red meat carcasses (n = 1,050) at five commercial abattoirs in Southwest England and tested for the presence of Salmonella. Of these, 6.5% of lairage samples were positive, containing estimated numbers of up to 10(4) Salmonella organisms per sampled area (50 by 50 cm). Salmonella was found on 9.6% of 240 lamb carcasses, 12.7% of 330 beef carcasses, 31% of 70 pig carcasses, 20% of 80 calf carcasses younger than 14 days of age, and none of 330 cull cow and bull carcasses. Subtyping divided the 137 isolates into seven serogroups and three pulsed-field gel electrophoresis clusters, and sensitivity testing against a bank of 16 antimicrobials indicated that 47 isolates had resistance to one or more antimicrobial agents. These results indicate that Salmonella contamination can persist in the lairage environment from one processing day to the next and that Salmonella is present on red meat carcasses, although the implications of residual lairage contamination on carcass meat microbiology are not clear from this study. Abattoir owners should take steps to reduce the level of contamination in their premises to prevent contamination from being carried over from one processing day to the next.     

Current and future technologies for the decontamination of carcasses and fresh meat

The objective of this review is to describe current methods and technologies used to decontaminate food animal carcasses in the United States and describe new technologies and methods that are under development. Bacterial reduction during the conversion of muscle to meat has always been an important challenge for the meat processing industry due to the impact on product safety and quality. More intense microbiological testing and improved microbiological methods have led to a greater awareness by industry and government about the levels of pathogenic bacteria on meat carcasses and in meat products. This increased awareness has spurred research and development on new technologies implemented sequentially in the process, aimed at reducing and eliminating bacteria on carcasses and meat products.     

A microbiological survey of fresh meat in the supermarket trade. Part 1: Carcasses and contact surfaces

Sanitary conditions were monitored at eleven supermarkets (from two major chains, Sup groups A & B) in the South African butcher industry. The variables measured were the temperature of carcasses and environments, the muscle pH of carcasses and the microbiological status of carcasses and human or personal and equipment contact surfaces (chillers-three surfaces, delivery trucks-five surfaces, cutting rooms-16 surfaces). All supermarkets, except one, received beef carcasses, distributed by one of two wholesale organizations from the same abattoir. No consistency was found in the contamination level of different parts of carcasses at different supermarkets, although there was a tendency for fore quarters to be more contaminated than hind quarters. Chiller surfaces, delivery truck surfaces and equipment had significantly different microbial counts at the different supermarkets. Sup group B received carcasses with higher mean surface temperatures and microbial counts than those of the carcasses received by Sup group A, but the mean microbial count of equipment was lower than that encountered at Sup group A. The result was less contaminated meat at the supermarkets in Sup group B, illustrating how a combination of the microbial quality of carcasses received by such supermarkets, and the sanitary programme in operation at such supermarkets affects the contamination level of retail premises. It could furthermore be shown that personnel surfaces (hands and clothes) and equipment like saws and mincers are consistent contributors to contamination at the retail level of the meat industry.     

Assessment of the adequacy of cleaning of equipment used for breaking beef carcasses

Enumeration of bacteria on product entering or leaving a beef carcass breaking process showed that the meat was being contaminated with Escherichia coli during the process. The equipment used in the process appeared to be well cleaned, and few bacteria were recovered from meat-contacting surfaces of cleaned equipment. However, careful inspection of the cleaned equipment revealed obscured locations in the equipment which harboured detritus that carried large numbers of aerobic bacteria including E. coli. The findings indicated that when the equipment was operated with wetting of the meat-contacting surfaces, bacteria from the persisting detritus were transferred to the meat-contacting surfaces and the meat. Similar increases in the numbers of E. coli on product as a result of the carcass breaking processes were observed at two of three other plants where the processes were examined. It therefore appears that compliance with current regulatory agency recommendations for conducting and monitoring the cleaning of carcass breaking equipment will not assure the control of hazardous microbiological contamination from carcass breaking equipment. Consequently, it is suggested that the adequacy or otherwise of each cleaning process should be assessed by reference to the mean numbers of suitable indicator organisms on product entering and leaving the production process that employs the cleaned equipment.