Decreasing Microbial Instances

Immersion chilling systems serve as the most effective line of defense against microbial pollutants when they are properly managed, scientists say. While additional methods of intervention are undoubtedly necessary in the process of eliminating microbial contamination from poultry, the most significant drop in carcasses positive for salmonella or campylobacter occurred subsequent to submersion in a chiller. These results, of a study conducted in 2003, were published in a report entitled "Post-Evisceration Microbial Interventions" in the December 2004 issue of Watt Poultry USA.

In a prior study first published in the December 2003 issue of Watt Poultry USA, ("Managing Immersion Chilling Systems"), Assistant Professor A.P. McElroy and her associates recommended immersion chiller best management practices:

	Free available Chlorine levels must be maintained in order to guarantee essential bacterial reduction during immersion chilling. Three aspects of the chiller environment contribute to maintaining free available Cl levels:
		1. total Cl level
			Total Cl within the chilling system should remain within 15 to 25 ppm
			*	Failure to stay within this range increases occurrence of post-chill salmonella
			*	Plant personnel should measure Cl levels in chiller water throughout the course of each day and make adjustments in the rate of Cl application to stay within above stated range
		2. pH
			Use of CO2 to acidify recirculated chiller water
		3. presence or absence of organic matter or solids
			Using an IOBW immediately prior to chill is effective in reducing the presence or organic matter and solids within the chilling system throughout the day of processing.
	Proper management of each factor will result in consistently high measurements of free available Cl throughout the processing day.

In the study, four different forms of chlorine were applied to chiller water as chief microbial intervention agents:

• Chlorine gas (Cl₂)
• Sodium Hypochlorite (NaOCl)
• Calcium Hypochlorite (Ca(OCl)₂)
• Chlorine Dioxide (ClO₂)

Each form, when managed effectively, was found to be effective in reducing incidence levels of either salmonella or campylobacter, or both, on post-chill poultry carcasses. However, the use of Ca(OCl)₂ was associated with the most noteworthy decreases in post-chill campylobacter incidence.

For a copy of the full article, "Managing Immersion Chilling Systems," contact our Marketing Department at 919-779-1250.

House of Raeford Helps Pioneer JetBird™

When House of Raeford acquired Columbia Farms in South Carolina, they not only gained market share and production capability, but also a seasoned management team that could work independently and increase sales and production. As an added bonus, the relationships that now Assistant Complex Manager, David Rush, brought with him would eventually lead the House of Raeford to the installation of the most ground-breaking development in poultry chilling since the continuous poultry chiller.

David was recruited by the current Complex Manager, Jim Mabe, who grew up in the poultry business. Both Jim’s father and brother have, with great success, devoted their careers to the poultry industry, so it was only natural for Jim to follow in their large footprints. Jim hired David as a shipping dock supervisor in 1984. David brought a sense of hard-work and determination with him, and his hard work paid off as he was eventually promoted to plant manager of the Columbia Farms Greenville, SC plant. When David went to work with Jim in the Columbia plant as Plant Manager, he brought with him the full-bird deboning experience learned in Greenville.

While in Greenville, David’s zeal to push the envelope of production performance lead him to a relationship with Morris & Associates. Through joint R&D efforts in bird chilling, David was exposed to the diligent and caring team of engineers and experienced chiller operators at Morris. This sparked a partnership with Morris & Associates that has remained strong for over 15 years, when David installed his very first Morris Auger Chiller. According to David, the extraordinary service and quick response provided by Morris at his Greenville plant has directly lead to all of their equipment decisions. House of Raeford and the former Columbia Farms, have Morris equipment in all of their facilities.

“One thing that I have learned about Morris,” says David, “is that if they say a system is going to do something, it does it! Whether that is for a poultry chilling system to match a certain load (bird size and line speed) or for an ice maker to make a certain tonnage of ice, it will do what it is designed for and more.”

Due to David’s confidence in Morris, it should come as now surprise that he jumped at the opportunity when Morris asked to test their latest innovation in his plant. These tests soon lead to the new JetBird™ water flow system, which has allowed him to decrease bird temperatures and bacteria levels in his auger chillers. “We were able to increase bird size and line speed while decreasing overall temperatures and bacteria counts in the chilling system and only increasing the residence time by 2 minutes,” said David. It is cooperative relationships like these by which discoveries are made that revolutionize poultry chilling.

Ask the Expert

Q & A Session
with one of the foremost experts
in the poultry industry,
Blake Lovette

Submit your question to the editor!

Blake D. Lovette has had an impressive career in poultry that spans 40 years. His father, well-known in the poultry industry in his own right, inspired Blake to begin a career in poultry.

Blake began his career in 1965 at Holly Farms. He held many positions in the company until he was eventually named Executive Vice President in 1976. In 1978 he joined Valmac Industries and served as EVP and general manager before being named CEO a year later. Lovette became president of Perdue Farms’ Shenandoah in 1985. He later served as President and CEO of ConAgra Poultry Companies.

Today, Blake serves on the Board of Directors of Pilgrim's Pride and Morris & Associates, Inc.

Q: The poultry industry, on the whole, has seen steady growth in recent years. What are your thoughts on the current state of the industry and how long will this cycle last?

A: Two years ago I gave a speech at the NCC marketing meeting entitled "How to Manage in a Mature Industry." In the talk I emphasized that low margins on a steady basis would replace the “boom” and “bust” cycles of the past and this would happen only if production increases were held to population growth. At that time, leg meat was very cheap because of sluggish export demand around the world due to trade barriers which were put in place because of AI outbreaks in some key states. What I failed recognize was just how high leg quarter prices could go if the trade barriers were reduced and economies around the world improved. The industry has enjoyed excellent profits for more than 2 years, buoyed by strong export demand and controlled expansion in RTC pounds. Year-to-date export volume and value are up 30% and 20%, respectively, and this is above the 13% increase in value for 2004 over 2003. This is an increase in value of more than 35% in the last 18 months.

Domestic demand and prices have continued to be good but not stellar. Foodservice continues to lead the way with new products and new offerings and some of the established brands are reporting year-over-year increases for the first time in a long time.

But make no mistake, current profits are largely a result of strong world demand for US leg meat and that impacts every company’s bottom line regardless of whether they participate in export markets. Profit based on exports has always been a very tenuous position for the industry because there are too many factors beyond its control that can slow or even stop product flow. When that happens we simply cannot consume all of the leg meat that is produced for the insatiable appetite for breasts and wings in this country.

The industry has shown a fair amount of restraint from over-production for the last few years but there is a lot of planned production on the books now. I believe the industry is entering another expansion phase that will put pressure on domestic markets in the next 12 months. It is impossible to predict what may happen around the world and how that may impact the poultry industry but anything that interrupts the flow of exports even temporarily will have huge and immediate effect on the bottom line.

Editor's Chicken Joke Pick

Q: Why does a chicken coop have two doors?

A: Because if it had four doors it would be a chicken sedan!

Submit your chicken joke for publication!