A CONTROL (fully retorted shelf-stable poultry products)

A CONTROL (fully retorted shelf-stable poultry products)

Summary

Significant hazards a r Cl. botulinum, enteric pathogens, Staph. aureus.

Control measures

Initial level (H 0 )

r Selection of raw materials.

Reduction (ΣR) r Control temperature and time during retorting to inactivate

spore-formers.

Increase (ΣI) r Use of appropriate containers and lids (e.g. resistant to corrosion). r Ensure integrity of the cans with satisfactory seals; avoid damage to

containers from poor handling. r Use potable water for cooling.

r Avoid manual handling of wet cans.

Testing

r No microbiological testing is recommended; routine checking of

seals.

Spoilage

r Selection of raw materials. r Control of temperature and time during retorting (spore destruction). r Control of can seams (to avoid recontamination). r Hygienic handling of wet cans while cooling and drying.

a In particular circumstances, other hazards may need to be considered. Hazards to be considered. The primary hazard of concern is Cl. botulinum that may occur in the raw

materials (e.g. ingredients, raw poultry meat). With good process control and canning practices, the risk of Cl. botulinum is controllable. There have been instances where other microbiological hazards have

155 occurred in low-acid canned foods, such as recontamination through the container seals during cooling

POULTRY PRODUCTS

due to contaminated cooling water (salmonellae) or manual handling of wet cans (Staph. aureus). Very rarely, recontamination with Cl. botulinum has occurred and resulted in illness and deaths because Cl. botulinum was present in the post-retorting environment.

Control measures. Process control is essential. Codes of practice for the production of low-acid canned foods have been established (e.g. FDA, 1973; FAO/WHO, 1979; CFPRA, 1977; AOAC/FDA, 1984; Thorpe and Barker, 1984), and the CCPs outlined (ICMSF, 1988). Control is needed at pre-processing, thermal processing, and post-processing.

Initial level (H 0 ). Raw materials are stored and prepared under hygienic conditions to prevent spoilage before retorting and possible increase in spore level. Certain ingredients (e.g. dehydrated onions and other root crops) naturally may contain botulinal spores.

Reduction (ΣR). Containers must be resistant to corrosion from the contents, of the required size, strength, and seam construction, undamaged, and free from defects. Containers are properly filled (e.g. weight, head-space, packing density, vacuum and temperature of filled product, time between filling and retorting) and container closure equipment is functioning correctly.

The retort is properly calibrated and operated (e.g. venting, loading pattern and operational parameters like steam pressure, temperature, time, water circulation, and chain speed).

Increase (ΣI). Cooling is carried out carefully to avoid damage to the integrity of the container and contamination of the contents. Handling equipment and runways are clean and prevent physical shock to the container. Avoid manual handling of containers until they are dry.

Testing. Microbiological testing of product is not recommended.

Cooling water should be checked for disinfectant concentration and, if uncertain, potable quality. Monitoring the microbiological quality of cooling water is useful. Integrity of can seals must be routinely checked.

Spoilage. Spoilage of low-acid canned foods, including canned poultry products is controllable and should rarely occur.

VII Dried poultry products

Several methods have been used to prepare dried poultry meat products (Mountney, 1976). Finely comminuted chicken meat has been sprayed-dried for use in soups. Thin layers of ground cooked meat on trays have been dried in ovens or vacuum chambers. Chunk-size poultry meat has been dried in conventional air dryers. Poultry meat products have also been dried on heated rollers and by heating in edible oil.

Freeze dehydration offers another means to produce dried poultry meat. During preparation for freeze-drying, carcasses are cooked, skinned, and then boned. The meat is then drained, cooled, diced, frozen, and put into a chamber under vacuum where the temperature is raised so that sublimation occurs.

MICROORGANISMS IN FOODS 6

The pressure is then equalized with nitrogen. The product is then packaged in an oxygen- and moisture- impermeable package or can. Freeze-dried meat can be blended with other dry ingredients to produce dry soup mixes and similar products.

A Effects of processing on microorganisms Most vegetative forms of microorganisms are killed during heating in ovens and oil, but the more

sophisticated drying methods are designed to preserve cellular structure and, thus, microbes may survive. Post-processing contamination during packaging should not be a serious problem.

B Spoilage Dried poultry meat containing <10% moisture and packaged in a water-impermeable container will not

support microbial growth and can be held for prolonged periods at ambient temperature. If the moisture content is slightly above 10%, molds and possibly yeasts may grow and spoil the product.

C Pathogens Sporeforming pathogens (e.g. B. cereus, Cl. perfringens) can survive cooking, freezing, drying, and

subsequently germinate and multiply if the products are reconstituted and held at temperatures permitting their multiplication. Cooked dried products can become contaminated with salmonellae, staphylococci, listeriae, and other microorganisms if they are processed in an environment where cross-contamination from raw poultry can occur or if the processing conditions are not controlled.