Thermal Inactivation of Salmonella senftenberg and Listeria innocua in Ground Chicken Breast Patties Processed in an Air Convection Oven R. Y. Murphy,*,1 E. R. Johnson,* B. P. Marks,* M. G. Johnson,† and J. A. Marcy‡ *Department of Biological and Agricultural Engineering and †Department of Food Science, and ‡Department of Poultry Science, University of Arkansas, Fayetteville, Arkansas 72701 patties were processed to a final center temperature of 70 to 80 C, 1 to 4 log10 (cfu/g) of S. senftenberg and 3 to 5 log10(cfu/g) of L. innocua were detected in the cooked patties. A significant difference in the thermal inactivation of S. senftenberg and L. innocua was obtained between the chicken patties cooked in an air convection oven and the patties cooked in a water bath. More surviving S. senftenberg and L. innocua were found in the patties cooked in an air convection oven than in the patties cooked in a water bath. ABSTRACT Ground chicken breast patties were thermally processed in a lab-scale air convection oven at air temperatures of 163, 177, 190, 204, or 218 C to final patty center temperatures of 50, 55, 60, 65, 70, 75, or 80 C. The cooking time increased with increasing product temperature and decreased with increasing oven air temperature. Prior to thermal processing, ∼7 log10(cfu/g) of Salmonella senftenberg and Listeria innocua were inoculated into the chicken patties. Survival of S. senftenberg and L. innocua decreased with increasing patty temperature. After the (Key words: poultry, Salmonella seftenberg, Listeria innocua, convection cooking) 2001 Poultry Science 80:515–521 medium and condition used and is difficult to apply in commercial operations in which real products are processed under completely different sets of conditions such as convection cooking. In their studies, Simpson and Gilmour (1997) found that the pressure tolerance of L. monocytogeneses was greatly affected by the suspended medium. Similarly, Casadei et al. (1998) also found that the heat resistance of L. monocytogenes in dairy products was affected by the growth medium. Therefore, the results derived from the studies in liquid media are not adequate to determine the thermal inactivation of pathogen in real food products under convection cooking (Murphy et al., 1999). Poultry and poultry products could be one of the sources of Salmonella infection in humans (Tietjen and Fung, 1995; Peplow et al., 1999). Several studies have established the D-values for Salmonella in liquid broth (Goodfellow and Brown, 1978). Considerable research had been done on the survival of Salmonella in various cooked meat systems (Bayne et al., 1965; Wilkinson et al., 1965; Bryan et al., 1968; Brown and Twedt, 1972; Goodfellow and Brown, 1978). Although the reported incidents of listeriosis has decreased in recent years, L. monocytogenes continues to be an extremely important foodborne pathogen, primarily due to the severe symptoms and high number fatalities from the disease (Simpson and Gilmour, INTRODUCTION Development of thermal processing methods to increase processing efficiency includes the goals of reducing energy and labor costs, increasing volume, and improving yield. However, any methods that achieve these goals must be evaluated in terms of maintaining or improving the bacterial safety of final products. Inadequate cooking of meat product has been one of the major causes of foodborne disease outbreak associated with pathogens (Wang et al., 1996). Processing methods could directly affect the bacterial safety of the finished meat. Therefore, care must be taken to ensure that any process schedule is capable of eliminating pathogens such as Salmonella and Listeria monocytogeneses to guarantee the safety of such processed food. The heat resistance of pathogens can be affected by many intrinsic and environmental parameters (Fernandez and Peck, 1997; Murphy et al., 1999). One important factor is the nature of the suspending medium (Simpson and Gilmour, 1997; Murphy et al., 1999). Several previous studies on the effects of temperature, pH, water activity, and nitrite on pathogens were conducted in laboratory medium (Whiting and Buchanan, 1994; Oscar, 1999). The information from such studies is limited to the specific Received for publication May 19, 2000. Accepted for publication November 20, 2000. 1 To whom correspondence should be addressed: rymurph@comp. uark.edu. Abbreviation Key: FDA = Food and Drug Administration; TSB = tryptic soy broth. 515 516 MURPHY ET AL. 1997). However, no complete information was found on Salmonella and Listeria survival in convection-cooked chicken products. Reports on thermal inactivation of Salmonella and Listeria in processed meat product by convection cooking are very limited in the literature. At the time of present research, no studies were available in the published literature on evaluating the potential for such treatment to inactivate pathogens in internally and uniformly inoculated ground chicken patties. The objective of this study was to evaluate the thermal inactivation of Salmonella and Listeria in ground chicken breast patties during convection cooking. Based on a previous study on thermal inactivation of Salmonella in chicken meat, Salmonella senftenberg was the most heat resistant among six Salmonella serotypes including S. senftenberg, S. typhimurium, S. heidelberg, S. mission, S. montevideo, and S. california (Murphy et al., 1999). Therefore, S. senftenberg was used in this study. Whereas it would be advantageous to monitor L. monocytogenes under actual process conditions, it is generally undesirable to risk working with this pathogen in food processing laboratories. Often, biological indicators are used in challenge studies, because they are nonpathogenic and are typically more resistant than the pathogen, providing the processor with a margin of safety (Fairchild and Foegeding, 1993). Therefore, L. innocua M1 was used in this study as an indicator organism for L. monocytogenes (Fairchild and Foegeding, 1993). This study was conducted in a laboratory convection oven under five different air temperatures of 163 C (325 F), 177 C (350 F), 190 C (375 F), 204 C (400 F), and 218 C (425 F) to an end-point product temperature of 50, 55, 60, 65, 70, 75, or 80 C. The survival of S. senftenberg and L. innocua upon thermal processing was evaluated. MATERIAL AND METHODS Chicken Meat Chicken breast meat was ground through a 3-mm diameter extruder.2 The proximate analysis was conducted based on AOAC (1990) methods. The total water content was ∼71% (wt/wt, wet basis), using an oven drying method at 110 C for 24 h. The total protein content was ∼96% (wt/wt, dry basis), using the Kjeldahl method.3 The total lipids content was ∼0.2% (wt/wt, dry basis), using the Soxhlet4 method. The total ash content was ∼2.1% (wt/ wt, dry basis), using a gravimetric method and heating the sample at 550 C in a muffle furnace5 for 24 h. 2 Tyson Foods, Inc., Springdale, AR 72764. Labconco Unit, Labconco Corp., Kansas City, MO 63132. 4 Soxtec HT system, Fisher Scientific, Itasca, IL 60143. 5 Thermolyne Furnatrol 133, Fisher Scientific, Itasca, IL 60143. 6 American Type Culture Collection, Rockville, MD 20852. 7 P. M. Foegeding, Department of Food Science, North Carolina State University, Raleigh, NC 27695. 8 DIFCO, Becton Dickinson and Co., Sparks, MD 21152. 9 Model 8287, 1450 W, Montgomery Ward Co., Inc., Chicago, IL. 3 Prior to the thermal treatments, the meat samples were screened, per Food and Drug Administration (FDA) methods (Andrews et al., 1995; Hitchins, 1995), for the presence of naturally occurring Salmonella and Listeria and were found free of both. Bacterial Strains Salmonella senftenberg (ATCC 43845)6 was purchased from American Type Culture Collection. A nalidixic acidresistant culture of S. senftenberg was prepared by growing the organisms in basal medium (tryptic soy broth, TSB) and adding increasing amounts of nalidixic acid. Cells grown on 10 ppm of nalidixic acid media were transferred sequentially to 20 ppm, then 40, 80, 100, and finally 200 ppm of nalidixic acid media. One large colony was streaked onto the agar containing 200 ppm of nalidixic acid and streaked again onto a new plate after incubation. The growth from this plate was used as the starting stock culture. Listeria innocua M1 was obtained from P. M. Foegeding.7 The Listeria culture was resistant to 50 ppm of rifampicin and 250 ppm of streptomycin. The lyophilized culture was revived in TSB8 at 37 C for 24 h before use. Culture Preparation According to Heddleson et al. (1991), the maximum heat resistance of bacteria occurred at 24 h in the stationary phase. Therefore, for each trial, a 24-h culture was prepared individually at 37 C in TSB for Listeria and TSB plus 200 ppm nalidixic acid for the Salmonella. The counts for the Salmonella and Listeria in those 24-h cultures were ∼109 cfu/ml. Preparation of Inoculated Chicken Patties A known weight of refrigerated ground chicken meat was transferred to a sterile mixer bowl and inoculated dropwise with equal volumes of Salmonella and Listeria to obtain ∼107cfu/g. Inoculated meat was mixed for 4 min to ensure even distribution of the organism. Then, the inoculated ground chicken meat was weighed aseptically into 30-g portions. A sterile former was used to form patties of 50 mm diameter × 13 mm thick. The formed patties were refrigerated (4 C) immediately after the inoculation until use for the cooking trial (∼2 h). Two of the inoculated ground chicken patties served as controls. Thermal Processing of the Inoculated Chicken Patties A convection oven9 with a cavity dimension of 375 mm width × 254 mm height × 384 mm depth was used to cook the inoculated chicken patties. An inoculated patty was placed on a metal rack with diagonal-shaped openings of 42 mm length × 22 mm width. The meat on the rack was placed in the center of the oven. The inoculated patties were individually processed under various treat- SALMONELLA AND LISTERIA IN COOKED CHICKEN ment conditions at different combinations of air temperatures 163 C (325 F), 177 C (350 F), 190 C (375 F), 204 C (400 F), and 218 C (425 F) and product temperatures 50.0, 55.0, 60.0, 65.0, 70.0, 75.0, and 80.0 (±0.5) C. Four type E thermocouples were placed at the patty center (parallel to the patty diameter), on the top and bottom surfaces, and in the air to monitor the temperature via a data acquisition system. After thermal treatment, the samples were immediately removed from the oven, placed in a sterile Stomacher bag, broken into smaller segments by hand while still in the bag, and immersed in an ice-water bath. The cooling process was <10 s. Microbial Enumeration Enumerations of Salmonella and Listeria were based on FDA procedures (Andrews et al., 1995; Hitchins, 1995) with the following modifications. The processed patty (30 g) was combined with 270 mL of sterile peptone solution (0.1%) in a Stomacher bag and blended in the bag for 2 min. In each case, the strained fluid was serially diluted, and 0.1 mL (for >10 cfu/g) or 1 mL (for <10 cfu/g) was spread-plated over two or three plates, in duplicate, for each dilution. A total of three to five serial dilutions were plated for each treatment. Salmonella was plated on TSBN agar, containing 200 ppm of nalidixic acid,10 sodium salt. Listeria was plated on TSB-YE-R-S agar, containing 0.6% yeast extract, 50 ppm of rifampicin,10 and 250 ppm of streptomycin.10 The plates were incubated at 37 C for 24 to 72 h for Salmonella and for 48 to 144 h for Listeria, and the colonies were then counted. The plates were returned to the incubator each day and recounted until viable counts did not increase. For the heated chicken meat samples, a minimum 144-h incubation was conducted to allow a completely recovery of heat-injured Listeria cells. Thermal Inactivation Kinetics Although the sample temperature does not vary with the time, the thermal inactivation rate of Salmonella and Listeria can be expressed as a first-order kinetic equation (Toledo, 1991). dN/dt = −kN [1] where N is the number of viable organisms at a given time, t is time in min, and k is a reaction rate constant in min−1, at t = 0, N = N0, which is the original number at inoculation. The reaction rate constant, k, is a function of temperature and the type of microorganism. The effect of temperature on the reaction rate constant, k, might be expressed by an Arrhenius-type equation (Toledo, 1991). 10 Sigma, St. Louis, MO 63178. CR23X Micrologger, Campbell Scientific, Inc., Logan, UT. 11 k = a e−E/RT 517 [2] where a is an empirical constant (Arrhenius constant), R is the gas constant in kilojoules per mole kelvin, T is absolute temperature of sample in kelvin, and E is the activation energy in kilojoules per gram mole. Substituting Equation [2] into Equation [1] and integrating from t = 0 to t: Ln (N0/N) = a ∫ e−E/RT dt [3] In this study, the sample temperature changed with heating time during convection cooking. Therefore, in Equation [3], parameter T was a function of heating time. Empirical equations were be developed to establish the relationship between the survivors of Salmonella and Listeria, the center temperature of patty, and the heating time during convection cooking. A second-order polynomial equation was used to describe the changes of patty center temperature with heating time. T = α t2 + β t + σ [4] where T is the patty center temperature in C; t is the heating time in minutes; and α, β, and σ are the coefficient of the quadratic term, the coefficient of the linear term, and the constant, respectively. A first-order regression was used to fit the changes of Salmonella or Listeria survivors with heating time for the ground chicken breast patties during convection cooking. Log10(N) = δ t + η [5] where N is the survivors of Salmonella or Listeria in colonyforming units per gram, t is heating time in minutes, δ is the slope of the linear regression, and η is the intercept of the linear regression. Calculation of Cumulative Lethality The temperature-time history was recorded by the data acquisition unit.11 The effective process lethality, F0 = ∫ 10(T−To)/z dt, was calculated based on the Simpson’s rule (Toledo, 1991). T(t) was the transient temperature during a process. The reference temperature To was 71.1 C. The z values of 5.4 C (Veeramuthu et al., 1998) and 5.1 C (Moody et al., 1998) were used in the integration of F0 for S. senftenberg and L. innocua, respectively. Data Analysis At each combination of cooking conditions, 4 to 6 patties were individually processed. For each treatment, the means and standard errors of these patties were calculated. Significant differences were evaluated using a t-test. 518 MURPHY ET AL. cooking time increased with increasing final center temperature of the patty. This result is reasonable because more time was required to cook the patties to a higher center temperature than to a lower center temperature. At the same final center temperature, the cooking time decreased with increasing air temperature, which indicated that at a higher air temperature, less time was needed to cook the patties to the same final center temperature. A second-order polynomial equation, T = b t2 + c t + d, was used to correlate the patty temperature T (C) with cooking time t (min). A correlation coefficient (R2) of 0.97 to 0.99 was obtained at an oven air temperature of 163 to 218 C (Table 1). Survival of Salmonella and Listeria FIGURE 1. Temperature and time history of chicken patties cooked at an air temperature of 163 C to a final patty center temperature of 55 C. RESULTS AND DISCUSSION Thermal History and Cooking Time Figure 1 shows examples of thermal profiles used to process patties in the air convection oven. In Figure 1, patties were heated from 4 C to a final center temperature of 55 C at an oven air temperature of 163 C. Depending on the oven air temperature during thermal processing, the surface temperature of the patty could be 4 to 13 C higher than the temperature at the center of the patty. Figure 2 shows the relationship of patty center temperature with cooking at an oven air temperature of 163 to 218 C. For each data point, an average of five replicates was used. The maximum standard error for the data in Figure 2 was 11.6%. At the same air temperature, the For years, the color, or degree of doneness, of meat product has been directly related to the maximum internal temperature attained in the product. Destruction of microorganisms, including Salmonella and Listeria, by heat is time and temperature dependent. This study has evaluated the effect of convection cooking on the survival of Salmonella and Listeria in ground chicken patties. The survival of Salmonella and Listeria decreased with increasing final patty center temperatures (Figures 3 and 4). The maximum standard errors of enumeration were 27.3 and 18.8%, respectively, for Salmonella and Listeria. There were no significant differences (at α = 0.05) on the survivors of Salmonella and Listeria between oven air temperatures of 163 C and 218 C. In this study, Salmonella and Listeria were detected in the patties cooked to a center temperature of 80 C. Four to one log10(cfu/g) of Salmonella were detected in the patties after the patties reached to a final center temperature of 70 to 80 C. Five to three log10(cfu/g) of Listeria were detected in the patties after the patties reached a final center temperature of 70 to 80 C. The results from this study were different from that of Murphy et al. (1999) who found a 7 log10(cfu/g) reduction for Salmonella and Listeria when chicken breast meat was cooked to 70 C in a water bath. For the cooking in a water bath, the cooking medium is saturated with water. However, in this study, because steam was not introduced, the relative humidity in the air convection oven was calculated to be 6 to 10%. Comparing Air Convection Cooking with Water Bath Cooking FIGURE 2. Relationship between final center temperature of chicken patties and total heating time for the patties processed under oven air temperatures of 163 to 218 C. No published information was found on the thermal inactivation of Salmonella and Listeria in ground chicken patties cooked in an air convection oven. Therefore, for S. senftenberg, the results in this study were compared with the study by Veeramuthu et al. (1998) for ground turkey thigh meat cooked in a water bath and that by Murphy et al. (1999) for ground chicken breast meat cooked in a water bath. The activation energy (E) and Arrhenius constant (a) were 380.81 kJ/mol and 5.641 × 1058 min−1, respectively, for S. senftenberg (Veeramuthu et 519 SALMONELLA AND LISTERIA IN COOKED CHICKEN TABLE 1. Regression parameters of the second-order polynomial equations for patty center temperature vs. heating time for ground chicken patties cooked in an air convection oven at different oven air temperatures1 Air temperature (C) Quadratic term Linear term Constant R2 163 177 190 204 218 −0.0338 −0.0576 −0.0587 −0.1379 −0.1979 2.8644 3.7417 4.3725 6.8606 8.4009 23.9930 20.9070 15.4470 −0.0990 −5.2466 0.9697 0.9767 0.9800 0.9930 0.9974 1 The coefficients for the quadratic term, linear term, and the constant are the α, β, and σ in the equation of T = α t2 + β t + σ, in which T is patty center temperature in C, and t is heating time in minutes. al., 1998). From the study by Murphy et al. (1999), the activation energy (E) and Arrhenius constant (a) for Salmonella were 329.63 kJ/mol and 2.177 × 1051 min−1, respectively. For L. innocua, the comparison was made between this study and Murphy et al. (1999) for ground chicken breast meat cooked in a water bath. The activation energy, E, of 342.49 kJ/mol, and Arrhenius constant, a, of 1.557 × 1053 min−1, were obtained for L. innocua (Murphy et al., 1999). Because a relatively small sample size was used in the studies by Veeramuthu et al. (1998, 2 g) and by Murphy et al. (1999, 8.5 g), the temperature throughout the samples cooked in a water bath could be considered uniform. However, in the present study, a temperature gradient existed between the surface and center of a patty (30 g) during convection cooking. For the purpose of comparison, the lowest temperature (at patty center) was used. Figures 3 and 4 show the experimental values of Salmonella and Listeria survivors after convection cooking at oven air temperatures of 163 to 218 C and the values from water bath cooking obtained by Veeramuthu et al. (1998) and Murphy et al. (1999). At a final center temperature of patties lower than 65 C, Salmonella survival was not substantially different between this study and that found in the literature. The FIGURE 3. Comparison of Salmonella senftenberg survival in chicken patties cooked in an air convection oven with the literature values obtained from Veeramuthu et al. (1998) and Murphy et al. (1999) for meat cooked in a water bath. Salmonella survival in this study was especially close to the data from Murphy et al. (1999), apparently because the same raw material (chicken breast meat) was used in both studies. The Salmonella survival in turkey thigh meat (Veeramuthu et al., 1998) was higher than that in this study. When a final center temperature of the patty was greater than 65 C, higher survival of Salmonella and Listeria was obtained in this study than that in the literature. Using the kinetic parameters from water bath cooking would overpredict the thermal lethality of Salmonella by 1.5 to 4 log and the thermal lethality of Listeria by 3 to 5 log for the ground chicken breast patties cooked at an oven air temperatures 163 to 218 C. Because of the existing temperature gradients throughout a patty, the average temperature of a cooked patty was higher than the center temperature. Therefore, if an average patty temperature was used, a greater deviation would be obtained between this study and those conducted in a water bath. Substantial difference in the survival of Salmonella and Listeria in cooked chicken patties between air convection cooking and water bath cooking was likely due to the humidity of the environment during cooking. Other published articles have demonstrated that dry heat roasting of beef had a lower effect than moist heat in killing Salmonella (Blankenship, 1978; Goodfellow and Brown, 1978). FIGURE 4. Comparison of Listeria innocua survival in chicken patties cooked in an air convection oven with the literature values obtained from Murphy et al. (1999) for chicken meat cooked in a water bath. 520 MURPHY ET AL. TABLE 2. Linear regression parameters of the empirical equations for Salmonella and Listeria in chicken patties cooked at different oven air temperatures Culture Air temperature (C) Slope Intercept R2 Salmonella 163 177 190 204 218 163 177 190 204 218 −0.2130 −0.2636 −0.4374 −0.4971 −0.5847 −0.1192 −0.1783 −0.2758 −0.3815 −0.4346 9.162 9.3508 10.895 11.308 11.412 8.4592 8.9094 9.7888 10.780 10.564 0.877 0.903 0.947 0.956 0.929 0.868 0.981 0.931 0.906 0.912 Listeria 1 The linear regression equation is expressed as Log10(N) = δ t + η, in which δ is slope, η is intercept, the Log10(N) is the logarithmic surviving Salmonella or Listeria in Log10(cfu/g), and t is heating time in minutes. Blankenship (1978) demonstrated that Salmonella survived on beef roast after the internal temperature reached 64.2 C in a gas fired oven without humidity control. Goodfellow and Brown (1978) showed that cooking beef in a dry oven below 121 C permitted Salmonella survival on beef. However, when steam was injected into a 79.4 C oven for 30 min, Salmonella was eliminated after the beef was cooked to an internal temperature of 54.4 C (Goodfellow and Brown, 1978). Empirical Equations for Salmonella or Listeria Survivors vs. Heating Time During convection cooking, the patty temperature varied with cooking time. The survivors of Salmonella and Listeria depended on the final temperature of the patties. Therefore, the survival of Salmonella and Listeria was also a function of cooking time. Linear regression was used to fit survivor numbers of Salmonella and Listeria, Log10(cfu/g), vs. cooking time in minutes. A correlation coefficient, R2 of 0.87 to 0.98 was obtained (Table 2). At oven air temperatures of 163 to 218 C, increasing the oven air temperature from 163 to 218 C, caused the slope of the regression to decrease 1.7-fold for Salmonella and 2.6-fold for Listeria (Table 2). This result indicated that the thermal inactivation of Salmonella and Listeria increased with increasing oven air temperature. In the past, thermal processing regulations required that uncured poultry products reach a minimum internal temperature of 71.1 C. In this study, cumulative process lethality, F0, at a reference temperature of 71.1 C was integrated from the temperature-time histories of the processed patties. The z values of 5.4 C (Veeramuthu et al., 1998) and 5.1 C (Moody et al., 1998) were used for S. senftenberg and L. innocua, respectively. Table 3 shows that after the internal temperature of the patty reaches 65 C, the F0 values (at a reference temperature of 71.1 C) are greater than 2 s. Based on the definition of F0, the obtained temperature-time histories in Table 3 should be sufficient to reach 7-D lethality. However, surviving Salmonella and Listeria were detected in all of the trials used for the calculations in the Table 3. The USDA-Food Safety Inspection Service has published a final rule by converting the regulations governing the processing of poultry products into performance standards. The new rule allows the use of any processing schedule that meets a lethality performance standard of a 7-D reduction for Salmonella. However, care should be TABLE 3. Cumulative lethality (F0) calculated at a reference temperature of 71.1 C for Salmonella senftenberg and Listeria innocua Oven air temperature (C) Patty center temperature (C) F0 for S. senftenberg (min) 163 65 70 75 65 70 75 65 70 75 65 70 75 65 70 75 0.1208 1.1850 9.8905 0.0744 1.3998 7.4594 0.0782 0.8152 7.8657 0.0732 0.5918 6.6521 0.0541 0.5706 4.6420 177 191 204 218 ± ± ± ± ± ± ± ± ± ± ± ± ± ± ± 0.0208 0.0922 2.7183 0.0107 0.6946 1.3295 0.0080 0.1557 1.5531 0.0067 0.0913 1.8699 0.0063 0.0165 0.5102 F0 for L. innocua (min) 0.09916 1.0981 10.4511 0.0611 1.2925 7.8620 0.0642 0.7593 8.2602 0.0606 0.5502 7.0183 0.0448 0.5336 4.9142 ± ± ± ± ± ± ± ± ± ± ± ± ± ± ± 0.01719 0.0829 2.9233 0.0088 0.6493 1.3800 0.0067 0.1456 1.6031 0.0058 0.1052 1.9712 0.0053 0.0159 0.5506 1 The z values of 5.4 C (Veeramuthu et al., 1998) and 5.1 C (Moody et al., 1998) were used in the calculation of F0 for Salmonella senftenberg and Listeria innocua, respectively. 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