On-Line Reprocessing with Spectrum™

FMC recently received a letter of “No Objection” from the USDA for use of its Spectrum™ antimicrobial agent in On-Line Reprocessing (OLR) systems for poultry processing. This means that Spectrum™ antimicrobial agent can now be used in OLR applications to effectively reduce the percentage of birds sent to “rehang” for off-line reprocessing or manual hand washing. Spectrum™ has been successfully commercialized in a number of intervention points including chillers, dip tanks, and cutting devices to help plants achieve Category 1 status. The performance of Spectrum™ antimicrobial agent provides opportunities for processors to reduce water usage rates.

Spectrum™ antimicrobial agent can be used in conjunction with normal spray cabinet applications to wash and agitate poultry carcasses to not only physically remove loose particulate matter but also provide an effective microbial control treatment against bacteria such as E. coli and Salmonella.

Results

FMC measured and tested against E. coli, total mean (average) aerobic plate counts, total coliforms, and Salmonella throughout the OLR validation test trials.

Salmonella reduction was a key parameter for all of the sites tested and followed the typical sample population designations except that individual carcasses were either positive or negative. In Fig. 1, it is apparent that Salmonella control is improved with the use of Spectrum™ antimicrobial agent in the OLR by the notable reduction in counts between untreated and treated populations from ~22% positive to ~5% positive respectively.

Fig. 1
Cumulative Salmonella Results

“Clean Untreated” birds are those that would normally pass inspection and go directly to the chiller. “Clean Treated” birds passed inspection and were tested for residual microbial activity after passing through the OLR cabinet with Spectrum™. “Dirty Untreated” birds were those that would not have passed inspection and were removed from the line, tested, and put back into the rehang line for off-line reprocessing. “Dirty Treated” carcasses were those that failed inspection, tagged, treated with Spectrum™ antimicrobial agent through the OLR, and removed immediately prior to entry into the chiller system for sampling. These carcasses were then sent to off-line reprocessing during the validation trials. They now would pass through to the chiller.

The graph (Fig. 1) represents the cumulative sampling across 4 separate trials at one plant location where each trial comprises a statistically significant sampling within each population type, i.e. “Dirty Treated”.

The results in presented in Figure 2 show the impact of the OLR at one of the plants in the validation trials specific to E. coli.

Fig. 2 E. coli Plate Counts

In this case, the dirty treated sample group was clearly better than either of the untreated sample populations and is essentially equivalent to the clean treated sample group.

Another parameter monitored was the Aerobic Plate Count and is shown in Fig. 3

Fig. 3 Average APC Counts

This data is taken from the one of the sample trials at the second of the three plants. Here the dirty treated and clean treated values on a Log₁₀ scale are very similar, but more importantly, the dirty treated sample values are less than the values of both the clean untreated and dirty untreated populations.

The total coliform counts had similar performance characteristics and the data in Fig. 4 taken from one of the trials in the third plant using Spectrum™ in an OLR system.

Fig. 4 Coliform Counts

In this case, the “Dirty Treated” carcasses are improved over the “Clean Untreated” sample and thereby demonstrate improved microbial control. The graph also shows that the loading from the “Dirty Untreated” sample population was brought to levels less than the “Clean Untreated” sample population by using Spectrum™ antimicrobial agent in the OLR system.

The contact time of the Spectrum™ antimicrobial agent treatment and its concentration in the wash stream are determined by the wetted travel time from the wash cabinet to the chiller system. FMC personnel will work with your cabinet to optimize the performance of such a system. We expect that the concentration will range between 100-180 ppm of Spectrum™ antimicrobial agent in order to optimize microbial control and organoleptic quality.

The Spectrum™ OLR system is easy to use, has a small footprint, and is low maintenance. Some ongoing testing is required by the end user to show that the OLR system is properly functioning and must be submitted to the USDA on a periodic basis and on a regular frequency.

As part of our service package, FMC will also review with your personnel and USDA staff the safety characteristics of the Spectrum™ antimicrobial agent and orient the whole team to using the product. An assessment of other chemistries at your site will be conducted to ensure that no adverse reactions will occur to your personnel, USDA personnel, or the product. Additionally, we will provide start-up support with tech service personnel on-hand to transfer the technical knowledge to operate the equipment safely. As an added benefit, FMC will also examine the opportunity to reduce processing water usage with the plant and operating personnel at your request.