Source: CAL POLY CORPORATION submitted to NRP
COMBINATION OF HOT WATER SPRAY AND SUB-ZERO SALINE CHILLING TO IMPROVE PROCESSING EFFICIENCY, MEAT TENDERNESS, AND MICROBIAL SAFETY OF BROILER CARCASSES CASSES
Sponsoring Institution
National Institute of Food and Agriculture
Project Status
COMPLETE
Funding Source
Reporting Frequency
Annual
Accession No.
1022324
Grant No.
2020-67017-31272
Cumulative Award Amt.
$460,000.00
Proposal No.
2019-06750
Multistate No.
(N/A)
Project Start Date
Jun 1, 2020
Project End Date
May 31, 2024
Grant Year
2020
Program Code
[A1364]- Novel Foods and Innovative Manufacturing Technologies
Recipient Organization
CAL POLY CORPORATION
(N/A)
SAN LUIS OBISPO,CA 93407
Performing Department
Animal Science
Non Technical Summary
Broiler chicken is the highest demand meat consumed in the U.S. and many other countries, whereas poultry is one of the leading causes of foodborne illnesses, particularly salmonellosis and campylobacteriosis. During poultry processing, various bacteria can attach and penetrate poultry skin, which is not easy to eliminate once they tightly attached. As a result, freshly slaughtered poultry carcasses must be chilled immediately to prevent bacterial growth and meat toughening. Inadequate or delayed chilling may lead to the growth of spoilage/pathogenic microorganisms and quality loss including tough meat. Currently, most birds are chilled in cold icy water (water immersion chilling) in the United States or cold air (air chilling) in the European community.In our preliminary test, the combination of hot water spray (HWS) and sub-zero saline chilling (SSC) significantly reduced bacterial populations on broiler carcasses potentially due to the synergistic effects of hot water (heat-sensitive bacteria reduction), cold water (Gram-negative bacteria reduction like Salmonella and E. coli), and salt-water (salt-sensitive bacteria reduction). Regarding meat tenderization, it is postulated that the muscle is tenderized when animal tissues are rapidly chilled due to the reduction of muscle shrink during chilling.In this project, chilling efficiency will be evaluated by comparing the carcass chilling times, microbial contamination will be assessed by comparing spoilage/pathogenic populations on carcasses, and meat tenderness will be compared using machinery device (shear force measure) and human subject (sensory analysis). The scientific results of this research will be delivered to the target audiences as following:Poultry equipment manufacturing company to develop new poultry chilling equipment.Poultry processing plants to implement the new chilling methods for the improvement of carcasses chilling efficiency, meat quality and safety, and potable/wastewater usage.Meat and poultry consumers who look for safer and more quality meat.University students and meat scientists who want to learn about meat science information and met processing technology.Regulatory agent who needs to define the method and condition of meat/poultry processing.
Animal Health Component
0%
Research Effort Categories
Basic
0%
Applied
0%
Developmental
100%
Classification

Knowledge Area (KA)Subject of Investigation (SOI)Field of Science (FOS)Percent
50132601100100%
Knowledge Area
501 - New and Improved Food Processing Technologies;

Subject Of Investigation
3260 - Poultry meat;

Field Of Science
1100 - Bacteriology;
Goals / Objectives
The major goal of this project is to improve broiler chilling efficiency, meat quality, product safety, and sensory attributes. These goals will be achieved by combining hot water spray (HWS) and subzero saline chilling (SSC) on carcasses, immediately after evisceration. With the success of this project, we expect that broiler chilling time will be reduced by 20 - 40% using a sub-zero saline chilling method at -2.4 oC over a conventional method (icy water chilling) at 1 to 2 oC. The reduction of carcass chilling time by ≥ 25% will be considered a milestone for success. We expect that the meat quality (especially tenderness) of carcass fillets will be improved by 20 - 30% through the mitigation of muscle shortening (heat/cold shortening) after rapid chilling. Improvement of meat tenderness by ≥ 25% will be considered a milestone. We expect that the bacterial populations on carcasses will be reduced by 1 - 2 logs due to the synergistic effects of HWS and SSC combination. The reduction of bacterial populations by 1.0 log on carcasses will be a milestone. We expect that the sensory attributes scores (especially overall liking) will be improved. The improvement of overall liking by 20% will be a milestone.
Project Methods
In this project, the combination of hot water spray (HWS) and sub-zero saline chilling (SSC) will be implemented to broiler carcasses immediately after evisceration. The new method (HWS and SSC combination) is very unique and significantly different from the conventional method of icy water chilling at 0 oC or above. The synergistic effects of HWS and SSC are expected to reduce heat-sensitive, cold-sensitive, and salt-sensitive bacteria, resulting in shelf-life improvement. The lower the bacterial populations on carcasses, the better the shelf-life of the product. The new chilling method is expected to improve broiler chilling efficiency due to the sub-zero chilling temperature at - 2.4 oC compared to the icy chilling at 1 - 2 oC. In addition, meat tenderness is expected to be improved due to the mitigation of heat-shortening and cold-shortening in the rapid sub-zero chilling over the slow chilling at elevated temperatures. The chilling efficiency will be evaluated by comparing the carcass chilling times between control and treatment carcasses. The shorter the chilling time, the better the chilling efficiency. The meat tenderness will be measured by comparing shear force values of broiler breast fillets. The lower the shear force (physical force required to shear a piece of meat), the tenderer the meat. The science-based knowledge will be used to educate university students, industry employees, and meat/poultry consumers, with the information on why the combination of HWS/SSC chilling method will improve chilling efficiency (reducing potable water/waste water usage), meat tenderness (reducing muscle shortening), and improving product shelf-life (reducing spoilage and pathogenic bacteria especially Salmonella and E. coli).

Progress 06/01/20 to 05/31/24

Outputs
Target Audience:The target audience is the meat and poultry scientists in academia, industrial employees in meat processing plants, and labelling specialists in industry and government sectors. In addition, general meat consumers and health conscious meat eaters are the target audience. Changes/Problems:The project has been completed as scheduled with one year extension due to the COVID related delay in the project performance. What opportunities for training and professional development has the project provided?Through this project, one graduate student completed his master's degree project (except a thesis submission). One post-doctoral researcher and 12 undergraduate students have extensively been trained. With this project, students have been trained in the follow areas: 1) practice the guideline of institutional animal care and use committee (IACUC) when live animal was transported from farm to meat processing center at California Polytechnic State University, 2) practice poultry processing steps in stunning, bleeding, scalding, defeathering, evisceration, chilling, and fabrication, 3) have hands-on experience in new chilling technology, 4) evaluate raw quality using muscle pH, shear force, sarcomere length, color value, cooking yield, 5) practice the guideline for the approval of institutional review board (IRB), 6) performed consumer sensory attributes and trained sensory analysis, 7) conduct statistical analysis with the data obtained, and 8) prepared abstract and manuscript, and 9) made poster and oral presentation in national and international conferences. How have the results been disseminated to communities of interest?Based on the scholarly results, two patents have been filed and are currently pending. Two papers have been published in peer-reviewed journals, and an additional manuscript has been submitted. Two conference abstracts have been published, and Two presentations (oral or poster) were delivered at the Poultry Science Association. The project director (PD) has been invited to give five oral presentations at the USDA-NIFA PD conference, the Poultry Science Association, and the US Soybean Export Council. What do you plan to do during the next reporting period to accomplish the goals? Nothing Reported

Impacts
What was accomplished under these goals? Poultry became the world's most consumed meat in 2019, and this trend is expected to continue among livestock sectors. This rise in consumption is primarily due to the recognition that poultry products are affordable, nutritious (high in protein), tasty, and healthy due to their low-fat content. To meet this growing demand, faster poultry processing methods are desirable, provided they maintain or improve product safety, quality, and sensory attributes compared to conventional methods. This research evaluated the effects of subzero saline chilling (SSC), with or without hot water spray (HWS), on broiler carcasses to improve chilling efficiency, carcass quality, and sensory attributes while potentially reducing water usage and wastewater release. This study was conducted to determine the most effective chilling method. Our first finding was that SSC chilled broiler carcasses faster than WIC. Both SSC and WIC-SSC produced more tender meat and longer sarcomere length than other methods. Secondly, SSC without HWS resulted in faster chilling times and more tender meat than SSC with HWS at either 68 or 71 oC, while WIC consistently produced tougher meat than SSC, regardless of HWS treatment. SSC and SSC-HWS68 did not cause a partially cooked appearance, whereas SSC71 did. Thirdly, SSC significantly reduced total plate count (TPC) and Salmonella prevalence, especially when combined with HWS. SSC alone was also effective in reducing Campylobacter and E. coli. Fillets from SSC and SSC-HWS treatments received higher consumer acceptance for flavor, juiciness, tenderness, saltness and overall acceptance than WIC and WIC-HWS, with fewer negative attributes such as bloody, cardboardy, and metallic. Lastly, SSC68 showed lower bacteria populations for TPC, E. coli, and coliforms than WIC in the recycled solution after 3 days. SSC68 had fewer residual components and blood spots than WIC68, followed by SSC and WIC. Both SSC68 and WIC68 showed lower residual weights than SSC and WIC In conclusion, this study demonstrated that SSC significantly improved chilling efficiency and meat tenderness than traditional WIC. The combination of SSC and HWS at 68 oC significantly reduced bacterial populations on broiler carcasses and in the chilling water, without causing visual defect on broiler breast fillets. This new chilling technology offers the potential to enhance chilling efficiency, bacterial safety, and meat quality, while reducing water consumption and wastewater production.

Publications

  • Type: Journal Articles Status: Published Year Published: 2022 Citation: Kang I., H.C. Lee, B. Adhikari, S. D. Ha, and Y.M. Kwon. 2022. Effects of Hot Water Spray and Sub-zero Saline Chilling on Bacterial Decontamination of Broiler Carcasses. Poultry Sci.101:101688. https://doi.org/10.1016/j.psj.2021.101688.
  • Type: Journal Articles Status: Published Year Published: 2023 Citation: Kawamura, K., D. M., A. Pereira, D. U. Ahn, D. M. Kim, and I. Kang. 2023. Subzero Saline Chilling with or without Prechilling in Icy Water Improved Chilling Efficiency and Meat Tenderness of Broiler Carcasses. Poultry Science 102. 103070. https://doi.org/10.1016/j.psj.2023.103070.
  • Type: Journal Articles Status: Submitted Year Published: 2024 Citation: Kang, I. Ma D, D. U. Ahn, K. Kawamura. S. Seo, V. Hogan, L. N. Stephen, J. W. Jin, and J. Moallem. 2024. Combination of Hot Water Spray and Subzero Saline Chilling Improved Chilling Efficiency, Meat Quality, and Sensory Attributes.
  • Type: Conference Papers and Presentations Status: Published Year Published: 2021 Citation: Kawamura, K., Ma, D., Pereira, A. and Kang, I. 2021. Combination of Water Immersion Chilling and Subzero Saline Chilling Improved Chilling Efficiency and Meat Tenderness of Broiler Carcasses. Poultry Science Association (Omaha, NE). July 2021.
  • Type: Conference Papers and Presentations Status: Published Year Published: 2023 Citation: The combination of hot water spray and sub-zero saline chilling of broiler carcasses improved the safety and sensory attributes of breast fillets. Poultry Science Association (Philadelphia, PA).
  • Type: Conference Papers and Presentations Status: Published Year Published: 2023 Citation: Subzero saline chilling of poultry carcasses improved microbiological safety, meat quality, and water saving. Poultry Science Association (Philadelphia, PA).
  • Type: Conference Papers and Presentations Status: Published Year Published: 2024 Citation: The Combination of Hot Water Spray and Subzero Saline Chilling Improved Chilling Efficiency, Meat Quality, and Sensory Attributes. USDA-NIFA PD conference (Amherst, MA).
  • Type: Conference Papers and Presentations Status: Published Year Published: 2022 Citation: Combination of Water Immersion Chilling and Subzero Saline Chilling Improved Chilling Efficiency and Meat Tenderness of Broiler Carcasses. USDA-NIFA PD Meeting (virtual).
  • Type: Conference Papers and Presentations Status: Published Year Published: 2021 Citation: Improvement of poultry meat quality via new chilling technology. U.S. Soybean Export Council (Houston, TX).
  • Type: Conference Papers and Presentations Status: Published Year Published: 2021 Citation: Improvement of poultry meat safety and quality using a new chilling technology. U.S. Soybean Export Council (Houston, TX).


Progress 06/01/22 to 05/31/23

Outputs
Target Audience:Meat scientists in academia, government, and the meat industry, college students, and consumers who consume poultry products regularly. Changes/Problems:One major challenge was made due to the impact of COVID-19, which caused less student availability. As a result, the analyses of structural change in skin/muscle and relative/quantitative microbiome profiles were not conducted. The two assignments will be conducted in the following report period. What opportunities for training and professional development has the project provided?Several undergraduate students, one graduate student, and one postdoc at Cal Poly, and one graduate student at Iowa State University, and one undergraduate student at University of Arkansas were trained in this project. Some students actively participated in transporting live birds from a local farm to the meat processing laboratory at Cal Poly. In handling live birds, students followed the guidelines of the institutional animal care and use committee (IACUC). Upon arrival, all birds were processed humanely and chilled following the experimental design in this project. After processing, students and a postdoc took samples, conducted analysis, and recorded raw data. While performing the project, undergraduate students had the opportunity to work with graduate students and had hands-on experience in poultry processing, sample preparation, and scientific analyses. Graduate students collaboratively trained undergraduate students in a collaborative manner in conducting the project. The postdoc took the lead, oversaw undergraduate/graduate students, and performed the project in a timely manner under the supervision of the project PD and Co-PDs. After sample analyses, students and a postdoc were trained to analyze the data and prepare abstracts for national/international scientific conferences. They were trained to prepare a manuscript for publishing in peer-reviewed journals based on the scholarly results. How have the results been disseminated to communities of interest?The unique chilling technology was presented with the title of "Combination of Hot Water Spray and Subzero Saline Chilling Improved Chilling Efficiency, Meat Tenderness, and Sensory Attributes of Broiler Carcasses" in the 2023 PD meeting of A1364 from June 10 - 14, 2022 (Davis, CA). A poster was presented with the title of "The Combination of Hot Water Spray and Subzero Saline Chilling of Broiler Carcasses Improved the Safety and Sensory Attributes of Breast Fillets" in the 2023 Poultry Science Association (Philadelphia, PA).An oral presentation was invited to the Symposium: Primary Poultry Meat Processing and addressed with the title of "Subzero chilling (SSC) Improved Processing Efficiency, Microbial Safety, and Meat Tenderness of Poultry Carcasses" in the 2023 Poultry Science Association (Philadelphia, PA). What do you plan to do during the next reporting period to accomplish the goals?The next report will evaluate the structural change of skin/muscle and relative/quantitative microbiome profiles. The scholarly results will be published in peer-reviewed journals.

Impacts
What was accomplished under these goals? Major goals of this project In this period of the report, the major goal of the project is to evaluate chilling efficiency, raw meat quality (meat tenderness, pH, and glycogen), bacterial populations (mesophilic aerobic bacteria, Salmonella, Campylobacter Escherichia coli, and coliforms), and cooked meat quality (cooking yield, consumer acceptance, and trained sensory analyses). Using 108 broilers (6 birds/treatment, 6 treatments with 3 replications), the effects of carcass treatments were evaluated on raw meat quality, bacterial populations, and cooked meat quality. The treatments used are showen below: 1. 0% NaCl chilling at 0.5 oC (water immersion chilling, WIC) 2. WIC after hot water spray (HWS) at 68oC/1 min (WIC-HWCS68) 3. WIC after HWS at 71 oC/1 min (WIC-HWS71) 4. 4% NaCl chilling at -2.4 oC (subzero saline chilling, SSC) 5. SSC after HWS at 68oC/1 min (SSC-HWS68) 6. SSC after HWS at 71oC/1 min (SSC-HWS71) The quality and safety of poultry were largely influenced by chilling type, chilling temperature, and chilling time. Currently, two chilling methods, WIC and air chilling (AC), are predominantly practiced for poultry carcasses in the United States and European Communities. This research evaluated the effects of six different chilling methods on broiler carcasses using WIC and SSC with/without HWS at 68 oC or 71 oC for 1 min . After chilling, four major parameters of broiler carcasses were evaluated for chilling time, meat quality, microbial safety, and sensory attributes. Chilling efficiency and meat tenderness: The carcass temperature after evisceration was ~ 99 oC, which increased to 102 - 104 oC shortly after HWS at 68 oC or 71 oC for 1 min. During chilling, the carcass temperatures gradually decreased to the end-chill temperature of 4.4 oC or below, and the SSC showed the best chilling efficiency, followed by the WIC, and WIC-HWS combinations, regardless of the HWS temperature. The improved chilling efficiency of the SSC showed a high potential for water savings as more carcasses could be chilled in each volume of water. There was no difference in carcass chilling yield and fillet cooking yield, regardless of chilling methods. Similarly, there was no significant difference in muscle pH and glycogen content. The fillets from the SSC resulted in higher tenderness values than the SSC-HWS, regardless of the HWS temperature.All fillets from the SSC were significantly more tender than the WIC or WIC-HWS. Currently, the poultry industry debones carcasses immediately after chilling with no interruption between the chilling and the deboning line speeds to improve processing efficiency. As a result, the meat becomes tough as the fillets are deboned earlier than the recommended time of aging (< 4 h postmortem), and consumers complain about the toughness of the meat. One of the milestones of this research is to allow carcasses to be deboned in the processing line, without speed reduction or meat tenderness. Microbial contamination Various bacteria can attach to poultry skin during poultry processing, especially in hair follicles, ridges, and crevices. In water immersion chilling, the skin of broiler carcasses swells and provides larger areas for bacterial attachment. This research evaluated microbial populations, including total plate counts (TPC), Salmonella, Campylobacter, Escherichia coli (E. coli) and coliforms. The HWS significantly reduced TPC, especially when combined with the SSC, regardless of water temperature. However, only the combination of WIC-HWS68 showed a similar reduction as the SSC alone, which was significantly lower than the WIC-HWS71 and WIC. Similarly, the prevalence of Salmonella was lowered when the HWS was combined with WIC and SSC over the WIC and SSC alone. Campylobacter was reduced in the SSC more than WIC, with intermediate values observed for HWS combinations. The population of E. coli was reduced stepwise from the WIC to the WIC-HWS combinations, and to the SSC treatments, where the SSC-HWS68 showed the greast reduction. A similar pattern was observed for coliforms, with the best reduction observed for the SSC-HWS68 again. Sensory attributes Using cooked breast fillets, both consumer acceptance and trained sensory attributes were analyzed. The carcasses fillets from the SSC and SSC-HWS showed higher consumer acceptance than the WIC and WIC-HWS for flavor, juiciness, tenderness, saltness and overall acceptance. In the trained sensory analysis, the fillets from SSC and SSC-HWS received less descriptive values for bloody, cardboardy, and metallic attributes than WIC and WIC-HWS, whereas more descriptive values were obtained for saltiness and hardness. These results strongly indicated that consumer and trained panels preferred the fillets from the SSC and SSC-HWS to the WIC and WIC-HWS.

Publications

  • Type: Conference Papers and Presentations Status: Published Year Published: 2023 Citation: Poster (410P) in 2023 Poultry Science Association (Philadelphia, PA)
  • Type: Conference Papers and Presentations Status: Published Year Published: 2023 Citation: Symposia in 2023 Poultry Science Association (Philadelphia, PA)
  • Type: Other Status: Published Year Published: 2023 Citation: 2023 PD meeting of A1364 (Davis, CA)


Progress 06/01/21 to 05/31/22

Outputs
Target Audience:The target audience could be: Meat scientists in academia, government, and the meat industry especially poultry sector. Students in university and community colleges. Consumers who consume poultry products regularly. Changes/Problems:One major challenge was the impact of COVID-19 causing less student availability. As a result, the analyses of microbial contamination and lipid oxidation have not been performed in this report period. The two assignments will be conducted in the following report period. What opportunities for training and professional development has the project provided?Several undergraduate students, one graduate student/one post doc at Cal Poly, and one graduate student at Iowa State University were trained in this project. Students actively participated at the transportation of live birds from a local farm to the meat processing laboratory at Cal Poly. While handling live birds, students followed the guideline of institutional animal care and use committee (IACUC). Upon arriving, all birds were processed humanely and chilled following the experimental design. All students and post doc took samples, conducted physico-chemical analysis, and recorded raw data. While performing the project, undergraduate students had the opportunity to work with graduate students and get hands-on experience on poultry processing, sample preparation, and scientific analysis. Graduate students trained undergraduate students in a collaborative manner while conducting in-depth research. A post doc took the lead, oversaw undergraduate/graduate students, and performed the project in a timely matter under the supervision of the project PD and Co-PDs. In addition, graduate students and post doc were trained to analyze the data and prepare abstracts for international scientific conferences. Based on the scholarly results, a manuscript was published in a peer-reviewed journal. How have the results been disseminated to communities of interest?Scholastic results were added to a provisional patent prior to being filed for a patent application. The unique chilling technology was presented in the 2022 Poultry Science Association from July 11 - 14, 2022 (San Antonio, TX). One manuscript was published in Poultry Science, with the title of "Effects of Hot Water Spray and Sub-zero Saline Chilling on Bacterial Decontamination of Broiler Carcasses". What do you plan to do during the next reporting period to accomplish the goals?In the next period of report, we will evaluate the structural change of skin/muscle (transmission/scanning electron microscopy, light microscope), microbial analysis, relative/quantitative microbiome profiles, lipid oxidation, cooked meat quality (cooking yield, meat tenderness), and sensory attributes.

Impacts
What was accomplished under these goals? Major goals of this project In this period of report, the major goal of the project is to evaluate biochemical parameters of muscle (pH, R-value, glycogen, nucleotides, glucose, lactate), raw meat quality (sarcomere length, lipid oxidation, water/salt absorption, and skin color, water holding capacity), and bacterial populations (MAB, E. coli, Salmonella, Campylobacter) on broiler carcasses. Using 108 broilers (6 birds/treatment) with 3 replications, treatment effects were evaluated on carcass chilling time, chilling yield, cooking yield, meat tenderness, and skin color using 6 treatments as below: 1. 0% NaCl chilling at 0.5 oC (water immersion chilling, WIC) 2. WIC after hot water spray (HWS) at 68 oC/1 min. 3. WIC after HWS at 71 oC/1 min. 4. 4% NaCl chilling at -2.4 oC (subzero saline chilling, SSC) 5. SSC after HWS at 68 oC/1 min. 6. SSC after HWS at 71 oC/1 min. The quality and safety of poultry chilling are largely influenced by chilling type, chilling temperature, and chilling time. Currently, two chilling methods of WIC and AC are predominantly practiced for poultry in the United States and European Communities, respectively. In this research, the control of WIC and the proprietary method of SSC were evaluated with and without HWS at 68 oC or 71 oC for 1 min. After chilling in 6 different methods, broiler carcasses were evaluated for chilling efficiency, chilling yield, and visual appearance whilebreast fillets were assessed for cooking yield, meat tenderness, and basic mechanism fortenderness. Chilling yield, cooking yield, meat tenderness and sarcomere length: There was no significant difference for chilling yield of broiler carcasses and cooking yield of breast fillets, regardless of chilling method. In comparison of SSC with and without HWS, the breast fillets of carcasses in SSC without HWS showed faster chilling and more tender meat than those in SSC with HWS at 68 or 71 oC for 1 min. Among the chilling of WIC and SSC with and without HWS, the fillets of carcasses in WIC showed significantly tougher meat than those in SSC, regardless of HWS. These results are consistent with the previous results, indicating that the fillets of carcasses in SSC produced better chilling efficiency and more tender meat than those of WIC. During carcass chilling, poultry muscles are subjected to hot shortening in the temperature range from 40 oC to15 oC, whereas cold shortening occurs at 15oC or lower. The major reason for the meat tenderness in SSC over WIC is potentially due to less muscle shortening during chilling. The reduced muscle shortening is expected from the reduced time for hot shorting at the early stage of chilling and the reduced time for cold shortening in the later stage of chilling. The hypothesis of less muscle shortening was supported by the results of sarcomere length. The breast fillets of carcasses in SSC showed the longest sarcomere length followed by SSC with HWS and WIC regardless of HWS. Muscle pH, R-value, and glycogen After an animal dies, muscle cells struggle to survive by switching from aerobic metabolism to anaerobic metabolism, resulting in lactate accumulation. As a result, the muscle pH decline from 7.0 to 5.3 - 5.8 in 24 h postmortem while R-vale (status of APT breakdown) increases. There was no significant difference for pH and glycogen content, whereas higher R-value was observed in the fillets of SSC than those of WIC, regardless of HWC. The range of pH at 3 h postmortem was near 5.9, and the glycogen ranged from 26 to 30 µmol/g. In case of lactate, the lactate concentration increased when HWS was implemented regardless of chilling method. Visual appearance (L*, a*, and b*) of breast fillets. The chilling method and HWS temperature affect the visual appearance of carcasses on skin and skinless fillets. The brightness (L*) of breast fillet increased as HWS was applied, regardless of chilling method. The hot water spray at 68 oC or higher resulted in partially cooked appearance on breast fillets. The values of redness (a*) and yellowness (b*) generally decreased with the HWS potentially due to denaturation of skin protein and reduction of color intensity at high temperatures.

Publications

  • Type: Journal Articles Status: Published Year Published: 2022 Citation: Kang I., H.C. Lee, B. Adhikari, S. D. Ha, and Y.M. Kwon. 2022. Effects of Hot Water Spray and Sub-zero Saline Chilling on Bacterial Decontamination of Broiler Carcasses. Poultry Sci.101:101688. https://doi.org/10.1016/j.psj.2021.101688


Progress 06/01/20 to 05/31/21

Outputs
Target Audience:The target audience could be the meat scientists in academia and poultry processors in the poulltry industry who are working on meat processing efficiency, quality improvement, healthy product development, and potable water/wastewater savings. People working in poultry slaughter plants and further processing areas are the main audience for the results of this project that can be implemented to their plants and products. In addition, poultry consumers who look for good quality meat are the target audience. Changes/Problems: Nothing Reported What opportunities for training and professional development has the project provided?Several undergraduate and graduate students at Cal Poly and Iowa State University were involved in transporting live birds from a local farm to the meat processing laboratory at Cal Poly, following the guideline of institutional animal care and use committee (IACUC). They also had hands-on experience during processing as well as collaborative work with master students and post doc in the sample taking and subsequent analysis. Mr. Kota Kawamura and Ms. Anise Pereira are extensively trained as a MS student under the supervision of Drs. Kang and Ahn. They have been practiced for the poultry processing such as bird stunning, bleeding, scalding, picking, evisceration, and chilling. In addition, they have been taught with physicochemical analysis for pH, R-value, chilling/cooking yield, sarcomere length, tenderness, and visual color evaluation. Dr. Danyi Ma is a post doc under the supervision of Dr. Kang. She has learned poultry processing and connecting meat quality and biochemical parameters to interpret the scientific data. In addition, she practiced how to supervise undergraduate and MS students while conducting the research project. How have the results been disseminated to communities of interest?The results of unique processing method have been submitted for a patent application that is pending. The scholarly results have been disseminated by making an oral presentation by a MS student in the 2021 Poultry Science Association from July 19 - 22, 2021 (Omaha, NE). The U.S. Soybean Export Council has invited Drs. Kang and Ahn to make oral presentations and panel discussions to the poultry industry personnel from Columbia (country) from August 1 - 4, 2021 (Houston, TX). What do you plan to do during the next reporting period to accomplish the goals?To accomplish our 1st- and 2nd-year goals, the chilling method with sub-zero saline solutions will be evaluated further. Based on the results of the 1st year research, the best two chilling treatments will be selected. The 2nd-year research will further improve bacterial safety and raw meat quality with/without hot-water spray. The scholarly results will be published through a peer-reviewed journal(s) and a thesis at Cal Poly.

Impacts
What was accomplished under these goals? Carcass chilling is a necessary step in post-harvest processing to prevent microbial growth, meat toughness, and quality loss. Previously, little research has been carried out to evaluate the effects of subzero saline chilling on broiler carcasses especially with the various factors such as salt concentrations, solution temperatures, and chilling steps (pre-/post-chilling). This project fully focused on the effects of chilling temperature and salt content with/without pre-chilling step. We hypothesized that the right combination of sub-zero saline conditions and chilling step can result in the best outcome in processing efficiency, meat tenderness, and bacterial reduction on broiler carcasses. Chilling efficiency and meat tenderness: In comparison of chilling efficiency, all sub-zero saline chilling methods showed more rapid chilling than WIC and WWC-WIC, regardless of pre- or post-chilling step with WIC. Both SSC and WIC-SSC showed significant lower shear values (or more tenderness) than the remining chilling methods. The results of lower shear force in WIC-SSC than SSC-WIC were interested, considering that the end-chilling times remains similar, and the two methods differ only in their order. We assume that the higher shear force in SSC-WIC than those of the WIC-SSC is related the carcass temperatures: The SSC-WIC has more hot-shortening in the first-half and cold-shortening in the second-half chilling than the WIC-SSC. The higher carcass temperature with the SSC-WIC in the first half is attributed to the surface freezing and heat trap in the carcasses in the sub-zero saline solution, while the lower temperature in the second half released heat rapidly because of the surface thawing from the carcasses in the ice slurry solution. Sarcomere length of breast fillets. The broilers chilled in SSC and WIC-SSC solutions showed significantly longer sarcomere lengths (1.9 - 2.0 µm) than those (~ 1.4 µm) of carcasses in other solutions. They also showed lower shear force or more meat tenderness. It has been known that meat tenderness likely increases as the muscle sarcomere length is extended. After animal death, pre-rigor muscles go through various biochemical changes, called rigor mortis, during the carcass chilling for several hours. The degree of rigor shortening is largely affected by the external and internal factors including muscle temperature, chilling media, and chilling condition. The internal temperatures of broiler carcasses in SSC and WIC-SSC solutions decreased rapidly from 40 oC to 15 oC, which was faster than those in other solutions, and lowered the potential of the hot-shortening in the carcass. Similarly, the internal temperature of carcasses in SSC and WIC-SSC solutions showed more rapid reduction from 15 oC to 4 oC than those in other solutions, potentially reducing the cold-shortening. As a result, the meat from SSC chilling was more tender meat than those in other chilling methods. Chilling yield, pH, R-value, cooking yield, and color Broiler carcasses showed no significant difference in physicochemical factors such as chilling yield, pH, and cooking yield, except the chilling yield of WIC-SSC, regardless of chilling methods. The chilling yield of broiler carcasses in WIC-SSC was 103% while those of broilers in other solutions showed ~ 101%, all of which are in the similar values that are observed in the carcasses chilled traditionally. In skin color, WIC-SSC showed less L* (lightness) value than WIC and WWC-WIC, with an intermediate value seen for SSC and SSC-WIC. Both SSC and SSC-WIC had less a* (redness) and b* (yellowness) values than other chilling solutions.

Publications

  • Type: Conference Papers and Presentations Status: Published Year Published: 2021 Citation: Combination of Water Immersion Chilling and Subzero Saline Chilling Improved Chilling Efficiency and Meat Tenderness of Broiler Carcasses