Enumeration of Escherichia coli Cells on Chicken Carcasses as a Potential Measure of Microbial Process Control in a Random Selection of Slaughter Establishments in the United States

To evaluate whether the number of Escherichia coli bacteria in carcass rinses from chicken slaughter establishments could be monitored for the purpose of microbial process control, we drew a random sample from 20 of 127 large USDA-inspected operations. In 2005, every 3 months, two sets of 10 carcass rinses, 100 ml each, were collected from establishments, netting 80 sample sets from the rehang and postchill stages. E. coli and Campylobacter numbers and Salmonella prevalence were measured. Mixed-effect models were used to estimate variance of mean log₁₀ E. coli cell numbers of 10-carcass rinse sample sets. Relationships between E. coli and Campylobacter and Salmonella were examined. For 10-carcass rinse sets, at both the rehang and postchill stages the mean log₁₀ E. coli CFU/ml fit the logistic distribution better than the normal distribution. The rehang overall mean log₁₀ E. coli was 3.3 CFU/ml, with a within-sample set standard deviation of 0.6 CFU/ml. The overall postchill mean log₁₀ E. coli was 0.8 CFU/ml, with 13 establishments having mean log₁₀ E. coli CFU/ml values of less than 1.0 and 7 having mean values of 1.2 or more. At the midpoint separating these establishments, a mean log₁₀ E. coli CFU/ml of 1.1, the within-sample set standard deviation was 0.5 CFU/ml, with smaller standard deviations as means increased. Postchill sample sets with mean log₁₀ E. coli counts less than or equal to 1.1 CFU/ml had lower overall prevalence of Salmonella and mean log₁₀ Campylobacter CFU/ml than sample sets with higher means. These findings regarding reductions in E. coli numbers provide insight relevant to microbial process control.Regulatory food microbiology standards are defined and enforced with the intent of protecting public health and maintaining consumer confidence in the safety of the food supply. Resource demands (22) and legal constraints (21) have hindered the U.S. Department of Agriculture (USDA) from enforcing its current Salmonella performance standard (3). For this reason, in 2004 the USDA requested guidance from its national scientific advisory committee on the possible use of E. coli numbers to monitor sanitary conditions during poultry slaughter (12). The committee acknowledged that, if valid, such a performance standard could facilitate inspection of slaughter processing establishments. The committee recommended studies to define how E. coli numbers vary in poultry carcass rinses during poultry processing by processing stage, time of year, and geographic region and with respect to food-borne pathogens.The widespread presence and high numbers of generic E. coli bacteria on poultry entering the slaughter establishment (2, 5, 14) are suitable characteristics for an indicator organism used to monitor microbial control processes. The ease and lower cost (5, 13) of E. coli enumeration also allow more observations than can be made when comparable resources are allocated for Campylobacter or Salmonella testing (15).Regulatory agencies and food manufacturers have recognized the potential utility of E. coli numbers as a measure of slaughter process control. For example, USDA''s hazard analysis and critical control point rule (3) specifies two criteria for evaluating process control: establishments are to maintain less than 100 CFU of E. coli per ml in 80% of poultry carcass rinses and never exceed 1,000 CFU/ml. Surveys have been performed to define precise E. coli performance criteria for poultry (5), to monitor microbial reduction during slaughter processing (6), and to validate interventions to reduce microbial numbers on poultry (20).If generic E. coli numbers on poultry carcasses fit a parametric distribution, with a predictable mean and standard deviation, then carcasses could be monitored using a statistical process control plan. For example, if E. coli numbers decrease by an acceptable amount during processing to a reasonable level, then the process could be considered to be under control. Or a plan could be designed to monitor for acceptable occurrences of small, medium, and large deviations above a target E. coli number (7). If relationships were found between E. coli and Campylobacter numbers during chicken slaughter as well as Salmonella prevalence, they would further support the use of E. coli numbers as a measure of process control.This study of a random sample of 20 large chicken slaughter operations located throughout the United States measured microbial numbers at two processing line locations. Once a quarter, 10 carcass rinse samples were collected from both the post-feather-pick (rehang) and postchill locations. Rinses were examined to estimate mean Salmonella prevalence and E. coli and Campylobacter numbers by location within establishments. The primary objective was to assess whether the reduction in E. coli numbers between the rehang and postchill stages or numbers at the postchill location might have utility as a measure of process control during chicken slaughter. A related objective was to estimate values of parameters that could be used to design statistical process control plans (7).