Faccenda Foods to implement SonoSteam technology after successful trial

• SonoSteam technology to move to continuous running

• Over 80% reduction in Campylobacter proven during in-line trials

• £1m investment in SonoSteam is one element of a comprehensive Campylobacter plan

Brackley, UK – Faccenda Foods, one of the UK’s leading food companies, has confirmed that its extensive in-line trials with SonoSteam technology have been successful and the next phase of its implementation, continuous running, will start in June 2015. Results from the SonoSteam trials have shown more than an 80% reduction in Campylobacter on the neck and breast skin of fresh, whole chickens; measured at the point in time when the consumer would typically purchase and cook the chicken.

Faccenda Foods is the first UK poultry producer to invest in SonoSteam technology and conduct comprehensive, full scale in-line trials. The £1m commitment to the technology is just one element of a comprehensive plan that touches every link in the Faccenda supply chain. The SonoSteam equipment was installed and commissioned in December 2014, and trials have been completed every week from January to May 2015 enabling performance to be refined. The excellent results from this intensive trialling process means Faccenda are now ready to move to the next phase of fully integrated continuous running, before the end of June.

SonoSteam kills Campylobacter and other micro-organisms on the skin of chickens through the simultaneous application of both steam and ultrasound, a process that takes just 1.5 seconds. Sonosteam is so effective because the process is consistently applied to every single bird. As well as being extremely effective, using only steam and ultrasound limits the environmental impact of the advanced technology.

Faccenda Foods Managing Director Andy Dawkins said: “While the industry is agreed that there is no silver bullet to solve the Campylobacter problem, we are very excited by results from our in-line trials which proves that SonoSteam will work in the real world. There is still a great deal of work for us all to do but, as part of our wider Campylobacter Action plan, I’m in no doubt that SonoSteam will help us significantly reduce levels of Campylobacter and improve food safety for consumers.”

SonoSteam Vice President Niels Krebs said: “It’s important not to underestimate just how challenging it was to successfully conduct a technology trial in-line. The investment so far has been very significant but the results show it has been worth it. Faccenda Foods now has a proven, intervention which is ready to operate on a continuous basis and which can be applied to every chicken on the line. Importantly, the in-line trials have proven that SonoSteam can be a key technology in helping the poultry industry significantly reduce the risk from Campylobacter.”

SonoSteam is another first for Faccenda Foods, having previously led the industry with its award-winning Roast in the Bag products, developed in partnership with Asda. The innovative packaging means consumers can put the product straight in the oven without having to handle any raw chicken, taking food safety in the kitchen to another level.

The Food Standards Agency has been a keen supporter of both of these innovative approaches to tackle Campylobacter which demonstrate Faccenda’s multimillion pound commitment to tackling the problem at all points of the supply chain to achieve the 2015 Campylobacter Reduction Target.

They are science-based and the result of the many projects undertaken since 2009.

Our key intervention points are:

• On farm biosecurity
• Catching practices
• Thinning practices
• Crates and modules
• Scalding practices
• Washing practices
• Heat treatments
• Cold treatments
• Novel packaging

This list represents those areas where research is suggesting the largest impact in the shortest time. Other intervention points, such as evisceration practices and kitchen hygiene awareness are still be examined.

On farm biosecurity

Biosecurity is the term used to describe the actions taken to prevent campylobacter entering flocks from the natural environment.

Good husbandry requires farmers to enter the houses a number of times every day to assess the health and welfare of birds, so consistent application of disinfectant foot dips, changing boots and clothing, and physical barriers to stop dirt entering from outside are important elements.

Red Tractor standards now have enhanced biosecurity requirement focused on campylobacter. This includes the human interaction with the flocks and also standards of cleanliness for all areas of the farm. Raising awareness of biosecurity, delivering appropriate training, and supporting consistent application are key areas of work for all chicken producing companies.

Research on model farms suggests that near perfect conditions and consistent application of working practices may give us a 10% reduction in the number of flocks infected by campylobacter. This has to be put in the context of farms being exposed to the environment and changing weather conditions, and the variability of working with livestock.

Catching practices

It is essential that catching teams operate to the same standards of biosecurity as farm workers, and Red Tractor standards have been updated to reflect this.

Clothing and equipment entering has to be clean and used in the correct manner. Focus has been on improving awareness and training of catchers, and this work is continuing.

Thinning practices

Thinning is where a proportion of a flock is removed prior (3 to 4 days) to depopulation. This is used to provide birds of different sizes to the retail market.

Work is focusing on limiting the effects of thinning on the remaining birds. For example, reducing the potential for contamination in the catching process, and minimising stress in the rest of the flock that can exacerbate campylobacter colonisation.

Crates and modules

As the equipment used to transport birds from farm to slaughterhouse the crates and modules have a high potential for exposure to campylobacter, and also to move it from site to site.

Traditional techniques that achieve visual cleanliness may leave campylobacter behind in a microbiological film, so work is on-going to enhance cleaning techniques, such as increased use of heat or improved application of disinfectant. Crates impregnated with silver (which has disinfectant properties) are also being trialled.

Practical methodologies for the handling and use of crates and modules are also being explored.

Scalding practices

In the slaughterhouse scalding tanks are vats of hot water through which the bird carcase is passed before de-feathering.

This equipment often sees a build-up of foam on the surface of the water that can increase the risk of cross-contamination between birds. Work is being conducted to look at improving the efficiency of scalding, such as through the use of secondary or multi-stage equipment.

Washing practices

Research has shown that carcase washing equipment operating at a consistently high efficiency can reduce the amount of campylobacter on a carcase by up to 10%. Producers are working on systems designed to maintain high efficiency.

Heat treatments

Campylobacter is sensitive to heat and cold and so interventions in these areas are being researched. Both heat and cold interventions must be balanced with the need to maintain the appearance of the bird that is acceptable to the consumer.

SonoSteam is an intervention that use a combination of ultrasound and steam to reduce the number of micro-organisms on the surface of the bird. More information can be found on their website.

Chill treatments

Rapid surface chilling is the main focus as a chill treatment. This is where nitrogen or air at a very low temperature is sprayed onto the bird to lower the surface temperature and reduce campylobacter. There are a number of variations on this theme, such as the one developed by BOC. The initial trials have demonstrated a 1 to 1.5 log reduction on campylobacter (90% to 95) and the next step for this system is full scale production trials at 10,000+ birds per hour.

Novel packaging

Many retailers are now introducing roast-in-the-bag whole chickens into their stores. By removing the need to handle the bird the intention is to reduce incidences of cross-contamination, and help consumers have good kitchen hygiene practices. The bag with the chicken inside is placed in the oven with the bag being cut open a short time before the end of cooking to allow the bird to brown.

Project Outline

Chlorine Dioxide ClO₂ up to a maximum level of 0.5ppm was added to the water used for the washing of carcases during processing, and comparing the effect against a previous baseline study using potable water.

A minimum of 1 flock per week was sampled.

The neck skins of the carcases were tested for both Campylobacter and for the total viable count (TCVs).

Results

The addition of ClO₂ in wash after evisceration and to the inside /outside wash and ISOS wash made no significant difference to microbiological status of the neck flaps of birds results compared with the baseline study.

ClO₂ was also introduced in the pre-chill water for approx 6 weeks. The results of these flocks appear to show a small improvement compared to baseline but this was based on a small number of flocks and is not statistically significant.

An independent assessment of impact of chlorine dioxide treatment also found no evidence of an effect of the addition of chlorine dioxide to the water in the supply tank on Campylobacter counts.

Conclusion

The addition of Chlorine Dioxide at 0.5ppm to mains water for carcase washing does not reduce the enumeration of Campylobacter on the neck skins.