Optimization of PAA Usage in Poultry Processing: Cost Reduction, Food Safety, and Worker Protection
IWC International
We help poultry processors to improve quality, product hygiene and save up to 70% on water and energy consumption.
Introduction
Peracetic acid (PAA) is a widely used antimicrobial in U.S. poultry processing to control Salmonella and Campylobacter. While effective, overuse of PAA leads to high operational costs, increased airborne exposure for workers, and potential environmental concerns.
According to OSHA’s PAA Safety and Health Guidelines (Georgia Tech OSHA Consultation Program, 2023), prolonged exposure to high PAA concentrations can cause:
At the same time, scientific research supports a multi-hurdle approach—combining mechanical cleaning, optimized chilling, and alternative antimicrobials—to achieve the same pathogen reduction with lower PAA concentrations (Bauermeister et al., 2008).
This article examines:
? The financial and safety impact of PAA usage in poultry processing.
? Scientific strategies for reducing PAA dependency while maintaining microbial control.
? IWC’s experience with mechanical contaminant removal, demonstrating that cleaner carcasses before chilling result in lower bacterial loads.
PAA Usage, Cost, and Occupational Safety Considerations
A typical US poultry processing plant operates at 8,400 birds per hour, running 16 hours per day, 300 days per year, leading to an annual throughput of 40.32 million birds.
1. Financial Impact of PAA Usage
At an average PAA price of $3.70 per liter ($14 per gallon), poultry plants spend over $500,000 annually on PAA. The table below reflects a realistic cost estimate, including additional washing steps—such as Post-EV Spray—commonly found in processing plants.
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2. Worker Safety Considerations: OSHA Guidelines on PAA Exposure
The OSHA PAA Safety and Health Guidelines emphasize that reducing PAA concentrations could lead to lower airborne PAA levels, improving worker safety.
? Lower PAA Concentrations → Potentially Reduced Airborne PAA Levels
? Lower Worker Exposure Risks → Better OSHA Compliance
Science-Based Strategies for Optimizing PAA Usage
A multi-hurdle approach, combining mechanical, chemical, and process-based interventions, reduces antimicrobial dependency while maintaining pathogen control (Northcutt et al., 2005).
1. Mechanical Contaminant Removal Prior to PAA Application
Research shows that removing organic debris before chemical treatment enhances antimicrobial effectiveness (Fletcher, 2015).
IWC’s Experience with Physical Contaminant Removal
IWC’s mechanical washing solutions, such as Undine? technology, use only water and air to remove contaminants before birds enter antimicrobial processing steps.
? Cleaner carcasses at the end of evisceration (EV) result in lower TVC counts from carcass rinse testing.
? Lower product contamination load before chilling, reducing the microbial burden in spin chillers.
? Lower microbial loads before PAA application allow for reduced PAA concentrations while maintaining food safety.
2. Process Optimization: Water Flow and Turbulence in Chillers
Research shows that improving water agitation and replacement rates in immersion chillers enhances antimicrobial efficiency, allowing for lower PAA concentrations while maintaining pathogen reduction (Bauermeister et al., 2008).
3. Synergistic Use of Alternative Antimicrobials
Studies show that combining alternative antimicrobials—such as citric acid and lactates—with lower PAA concentrations achieves equivalent pathogen reduction compared to high-PAA treatments alone (Yang et al., 2018).
4. Continuous Monitoring and Validation
To comply with USDA-FSIS and OSHA standards, poultry processors must implement real-time microbial testing and air-quality monitoring. IWC’s mechanical washing solutions have consistently demonstrated lower microbial loads before chilling, reducing the need for high PAA concentrations.
Financial and Safety Impact of PAA Optimization
By integrating mechanical washing, process optimization, and alternative antimicrobials, poultry processors can achieve:
? 30% Reduction in PAA Usage → $154,884 Annual Savings
? Lower PAA Concentrations → Potentially Reduced Airborne PAA Levels
? Improved Pathogen Control → Compliance with USDA-FSIS Regulations
? Lower Worker Exposure Risks → Better OSHA Compliance
Conclusion
While PAA is an effective antimicrobial, excessive use leads to high costs and worker safety risks. A multi-hurdle approach, combining mechanical washing, optimized chilling, and alternative antimicrobials, has been scientifically validated to reduce PAA dependency while ensuring food safety.
Next Steps for Poultry Processors
To explore how mechanical washing solutions can optimize PAA usage in your facility, contact us for a data-driven evaluation of your antimicrobial interventions.