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(HACCP) System in a Poultry Processing Plant

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(HACCP) System in a Poultry Processing Plant Implementation of Hazard Analysis Critical Control Point (HACCP) System in a Poultry Processing Plant BY Amel Mohammed Abdalla Mohammed B. Sc. of Veterinary Science University of Khartoum September 2000 This thesis is submitted to the University of Khartoum in Partial fulfillment for the degree of Master of Veterinary Science Supervisor Prof. Suliman Mohamed El Sanousi Department of Microbiology Faculty of Veterinary Medicine University of Khartoum January 2008 1 PREFACE The work described in this thesis was carried out in the Department of Microbiology, Faculty of Veterinary Medicine, University of Khartoum under the supervision of Professor Suliman Mohamed El Sanousi. The material presented is original and has not been submitted to any other University. 2 DEDICATION To the soul of my father and brother Esam And sincerely to my husband Emad, my little angle Yusr And My family For their tremendous support, encouragement and patience Amel 3 ACKNOWLEDGEMENT First of all, my thanks and praise are due to almighty Allah, the beneficent and the merciful, for giving me the health and strength to complete this work. Then I which to express my indebtedness and sincere thankfulness to my supervisor prof. Suliman Mohamed El Sanousi, for his guidance, continuous encouragement and his kindness with me. I wish to thank prof. Mona Elagab for her encouragement and help. Sincere and faithful thanks are due to Dr. Awad Sukrab the Director, Technical Adminectretion, in SSMO for unlimited help and advice. Also I wish to thank Dr. Omer Abdalla Laboratory Manager in SSMO for help and provision of some relevant literature. Thanks to the staff of microbiology, Faculty of Veterinary Medicine, Fawzia, Mona, M., A/ziz and laboratory workers Abdalla, Abd Elazeem, Seed, and Hassan. Iam also grateful to my colleagues, in SSMO. Then I wish to express my thankfulness to my husband Emad Eldein Hassen for assistance and For giving me much of his time. A lot of thanks to my sister Amani who gave a lot for nothing. My thanks also to Randa Gafer and Masheer for their help in preparation of this thesis. Last but not least, sincere thanks to all the friends who helped me during my study. 4 List of contents Subject Page Preface I Dedication II Acknowledgement III List of contents VII List of tables VIII List of figures IX Abstract X Arabic abstract XI Introduction 1 Objectives 3 Chapter(1) Literature Review 4 1.1 Origins of HACCP 6 1.2 HACCP Principles 8 1.3 Food Spoilage 10 1.3.1 Important sources of spoilage of poultry meat 10 1.3.1.1 Carcass surfaces and equipment 10 1.3.1.2 Processing of poultry 11 1.3.1.3 Water 13 1.3.1.4 Food handlers 15 1.3.1.5 Wall 15 1.4 Food safety 16 1.4.1 HACCP 16 1.4.2 Good Hygienic Practice (GHPs) 16 1.4.3 Good Manufacturing Practice(GMP) 16 1.4.5 Quality Management(ISO series) 17 1.4.6 Total Quality Management(TQM) 18 1.5 Bacterial Count 18 1.6 Isolation of different microorganisms from poultry meat 21 1.7 Bacteria associated with poultry meat 23 1.7.1 Gram-positive 23 1.7.1.1.1 Staphylococcus 23 1.7.1.1.2 Micrococcus 24 1.7.1.1.3 Streptococcus 24 1.7.1.1.4 Enterococcus 25 5 1.7.1.2 Gram-positive bacilli 25 1.7.1.2.1 Bacillus 25 1.7.1.2.2 Corynbacterium 25 1.7.2 Gram-negative bacteria 26 1.7.2.1 Gram-negative bacilli 26 1.7.2.1.1 Salmonella 26 1.7.2.1.2 Moraxella 27 1.7.2.1.3 Enterobacter 27 1.7.2.1.4 Aeromons 28 1.7.2.1.5 Bortetella 28 1.7.2.1.6 Kingella kingae 28 1.7.2.1.7 Sterptobacillus 28 1.7.2.2 Gram-negative cocci 28 1.7.2.2.1 Branhamella 28 Chapter(2) Materials and methods 29 2.1 Field Investigations 29 2.2 Collection of samples 30 2.3 Transportation of samples 30 2.4 Preparation of samples 32 2.5 Culturel media 32 2.5.1 Solid media 32 2.5.1.1 Nutrient agar 32 2.5.1.2 Blood agar 33 , 2.5.1.3 Mac Conkey s agar 33 2.5.1.4 Plate count agar 34 , 2.5.1.5 Simmon s Citrate agar 34 2.5.1.6 Urea agar 35 2.5.1.7 Dorset eggs 36 2.5.1.8 Xylose lysine deoxycholate agar 36 2.5.1.9 Brilliant green agar 37 2.5.2 Semi solid media 38 , 2.5.2.1 Hugh and Leifson s 38 2.5.2.2 Triple Sugar iron agar 38 2.5.2.3 Nutrient gelatin 39 2.5.2.4 Motility media 39 2.5.3 Liquid media 40 2.5.3.1 Peptone water sugar 40 2.5.3.2 Buffer peptone water 40 6 2.6.3.3 Tetrathionate medium 40 2.6.3.4 Selenite cystine medium 41 2.5.3.5 Glucose phosphate broth 41 2.5.3.6 4% NaCl 42 2.5.4 Reagents 42 2.5.4.1 Hydrogen peroxide 42 2.5.4.2 Nitrate test reagent 43 2.5.4.3 Oxidase test reagent 43 2.5.4.4 Voges-Proskauer reagent 43 2.5.4.5 Iodine solution 43 2.5.5 Indiccator 44 2.5.5.1 Andrad’s indicator 44 2.5.5.2 Bromothymol blue 44 2.5.5.3 Phenol red 44 2.5.5.4 Bromocresol purple 44 2.5.5.4 Zinc powder 44 2.5.6 Diluents 44 2.5.6.1 Normal saline 44 2.5.6.2 Phosphate buffer saline 45 2.5.6.3 Buffered peptone water 45 2.5.6.4 Ringer solution 45 2.6 Methods of sterilization and disinfection 45 2.6.1 Sterilization 45 2.6.1.1 Dry heat 45 2.6.1.1.1 Hot air oven 45 2.6.1.1.2 Flaming 45 2.6.1.2 Moist heat 46 2.6.1.2.1 Autoclaving 46 2.7 Cultural methods 46 2.7.1 Aerobic viable count 46 2.7.2 Salmonella detection 46 2.7.2.1 Pre-enrichment in non-selective liquid medium 47 2.7.2.2 Enrichment in selective liquid media 47 2.7.2.3 Plating out and recognition 47 2.7.2.4 Confirmation 47 2.7.3 Swabs 47 2.7.4 Aerobic cultivation, purification and preservation 48 2.8 Identification of isolated bacteria 48 2.8.1 Cultural characteristics 48 2.8.2 Primary test 48 7 ’ 2.8.2.1 Gram s stain 48 2.8.2.2 Oxidase test 49 2.8.2.3 Catalase test 49 2.8.2.4 Motility test 50 2.8.2.3 Sugar fermentation test 50 2.8.2.6 Oxidation- fermentation test 50 2.8.3 Secondary test 51 2.8.3.1 Citrate utilization 51 51 8.3.2Urease activity. ٢ 2.8.3.3 Hydrolysis of Gelatin 51 2.8.3.4 Nitrate reduction 51 2.8.3.5 Triple sugar iron 52 2.8.3.6 Agglutination test 52 2.8.3.7 Voges- Proskauer test 53 2.8.3.8 4% NaCl 53 Chapter (3) Results 54 3.1 Aerobic bacterial load 54 3.1.1 Pre evisceration 54 3.1.2 Post evisceration 54 3.1.3 Water 54 3.1.4 Equipment 54 3.1.5 Worker 55 3.1.6 Wall 55 3.2 Bacteria species isolated from different samples 59 3.2.1 Pre-evisceration 59 3.2.2 Post- evisceration 59 Chapter(4) Discussion 92 Recommendations 97 References 98 8 LIST OF TABLES Table(1)Appendix Prevalence of aerobic bacteria ٨٠ in poultry carcasses Table(2) Prevalence of aerobic bacteria in ٥٦ slaughter of broiler examined at various stages of slaughtering Table(3) Type of bacteria isolated from broiler ٥٧ carcasses Table(4) Percentage of bacteria isolated from ٥٨ broiler carcasses Table(5) Characters of Gram-negative bacteria ٦٠ isolated from broiler carcasses Table(6) Characters of Gram-positive bacteria ٦١ isolated from broiler carcasses Table(7) Biochemical reaction of Moraxella spp ٦٢ Table(8) Biochemical reaction of Salmonella spp ٦٣ Table(9) Total viable count of broiler meat and ٦٤ related area Table(10) Total Coliform in water ٦٦ 9 LIST OF FIGURES Figure (1) Process diagram of whole chicken carcass in slaughter house. Figure (2) Triple Sugar Iron Agar (TSI) test ٦٧ Figure (3) Urease test ٦٨ Figure (4) Salmonella poly o factors A - S ٦٩ Figure (5) Urease test Salmonella –ve ٧٠ Figure (6) Salmonella on XLD agar ٧١ Figure (7) Salmonella on BG agar ٧٢ Figure (8) Agglutination test +ve ٧٣ Figure (9) Moraxella on Nutrient agar ٧٤ Figure (10) Moraxella on Blood agar ٧٥ Figure (11) Moraxella on MacConkey agar ٧٦ Figure (12) The prevalence of bacteria in post ٧٧ evisceration group B 10 Figure (13) The prevalence of bacteria in the pre 78 evisceration group A Figure (14) The prevalence of bacteria in pre and post 79 evisceration. 11 ABSTRACT This Study was carried out to detect the bacterial load and types of bacteria on the carcasses of broiler by applying the Hazard Analysis Critical Control Point (HACCP) system. From two Critical Control Points (CCPs); Pre-evisceration, and Post-evisceration, forty samples were collected and examined to determine the load, and type of bacteria. One hundred forty eight aerobic bacteria were isolated.
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