Report to Industry - Food Processing Technology Divisionfoodtech.gatech.edu/pdfs/FPAC2003AR.pdf · leader in food processing in the 21st century ... Fiscal Year 2002-2003 Report to

Making Georgia the national and i n t e r n a t i o n a ll e a d e r i n f o o d processing in the 21st century

Georgia’s Traditional IndustriesProgram for Food Processing

Fiscal Year 2002-2003

Report to Industry

FoodPAC

Fiscal Year 2002-2003 Report to Industry

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Table of Contents

Georgia’s Traditional Industries ................................................................................................................................... 2

FoodPAC FY 2002 Organizational Chart ................................................................................................................... 3

FoodPAC 2002-2003 Calendar ................................................................................................................................... 4

FoodPAC FY 2002 Project Summaries ........................................................................................................................ 5

Environmental ProjectsEffect of Food Processing Operations on Wastewater Generation and Treatment Methodologies ............................. 6

Development of Testing Criteria, Performance Analyses, and Life-Cycle Costs for Assessing the Use of RecycledPET-Coated Boxes as a Replacement for Wax Boxes ............................................................................................... 8

Air Emission Factors for Process Control and Pollution Prevention ....................................................................... 10

Effect of Chlorine Dioxide Concentration on Odor and VOC Removal in Rendering Emissions .......................... 12

Development of an Advanced UV Disinfection Technology .................................................................................. 13

Food Safety ProjectsIntervention Strategy to Reduce Campylobacter Carriage in Chicken ..................................................................... 14

Removal and Disinfection of Listeria monocytogenes-Containing Biofilms in Cooked Product Areas of MeatProcessing Plants .................................................................................................................................................. 16

Optimization of Low-Dose Irradiation of Commercial Processed and Ready-to-Eat Meats to InactivateListeria monocytogenes ........................................................................................................................................... 18

Reduction of Campylobacter jejuni on Food Products by Treatment with Generally Recognizedas Safe (GRAS) Chemicals ................................................................................................................................... 20

Process & Product Competitiveness ProjectsProduction of Natural Sweeteners by Fermentation ............................................................................................... 22

Develop Improved Control Methods for Regulating the Factors and Process Procedures That Eliminate theDevelopment of the Pink Color Quality Defects in Cooked Poultry Products ...................................................... 24

On-Farm Degreening of Bell Peppers to Add Value to Georgia Produce ................................................................ 26

Assessment of Flavonoids (Nutraceutical) Components of Selected Georgia Agricultural Food Products ............... 27

Automated Inspection of Food Deboning Processes ............................................................................................... 28

Systemic Defect Detection ..................................................................................................................................... 29

Automated Material Handling in Food Further Processing .................................................................................... 30

Automated Vision-Based Inspection and Control of High-Volume Baking Processes ............................................. 31

Special ProjectSystems to Support the Expansion of Georgia’s Fruit and Vegetable Industry: Promotional Effectiveness of theGrown in Georgia Campaign ............................................................................................................................... 32

Implementation ProjectsThe Food Chain Newsletter .................................................................................................................................... 34

FoodPAC Website ................................................................................................................................................. 34

FoodPAC FY 2003 Projects ...................................................................................................................................... 35


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Georgia’s Traditional Industries

Georgia’s “traditional industries” (pulp and paper; food processing; and apparel, carpet, and textiles) have historicallybeen the backbone of the state’s industrial base. Virtually every county in Georgia is home to at least one of theseindustries, which combined employ 270,000 Georgians, almost half of the state’s manufacturing work force. Despitetheir size, these leading industries in Georgia face serious international challenges to their competitive position, especiallyfrom companies in low-wage regions of the world.

Recognizing the importance of these industries to Georgia, the state established the Traditional Industries Program(TIP) in 1994. TIP is designed to bring industry leaders and university-based researchers together to develop and implementpractical solutions to improve the competitiveness of pulp and paper; food processing; and apparel, carpet, and textilecompanies in Georgia.

Each of the three traditional industries has formed a public-private partnership where industry identifies criticalcompetitiveness problems, then works closely with faculty from Georgia’s colleges and universities to solve those problems.Since 1994, the state has invested more than $45 million to provide research, technology development, and technicalassistance to Georgia’s traditional industries, and industry has matched the state’s investment.

Georgia’s Traditional Industries Program for Food Processing and FoodPAC

Georgia’s Traditional Industries Program for Food Processing was established as part of the state’s strategic economicdevelopment thrust for traditional industries. The program resulted in the formation of a public-private partnershipamong the food industry, Georgia’s institutions of higher education, and Georgia’s state agencies. This partnership iscalled the Food Processing Advisory Council or FoodPAC.

In 1994, FoodPAC defined its vision as seeking to make Georgia the national and international leader in food processingin the 21st century. Toward that end, the Traditional Industries Program for Food Processing was given the mission ofseeking to enhance the competitiveness of Georgia’s food processing and allied industries in order to provide for economicgrowth through the expansion of existing industries and the attraction of new food-related industries.

The program addresses this mission by:• identifying critical issues affecting the competitiveness of the industry,• developing realistic strategies that address identified issues,• enhancing excellence in research and development between colleges and universities in Georgia and the food

processing industry,• developing and delivering high-impact programs targeted on critical needs, and• continually evaluating the overall effectiveness of all activities undertaken.


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FoodPAC FY 2002 Organizational Chart

Steering Coordinators

Executive Coordinator

Gary Black, Georgia Agribusiness Council

State Coordinators

Annie Hunt Burriss, Board of Regents

Bob Donaghue, Georgia Department of

Natural Resources

Charles Estes, Traditional Industries Program

David Sapp, Georgia Department of

Industry, Trade and Tourism

David Tanner, Governor’s Office of Planning

and Budget

Environmental Technical Committee

Reggie Prime, Coca-Cola Enterprises Inc., Chairman

Dale Threadgill, UGA, Coordinator

Judy Adler, Georgia Department of

Natural Resources

Doug Carnes, Mar-Jac Poultry Processing

Dan Craig, Gold Kist Inc.

Kevin Custer, American Proteins, Inc.

Tim Filipowski, Fresh Express Inc.

Rick Frazier, The Quaker Oats Company

Ben Jordan, The Coca-Cola Company

David Lee, D.L. Lee & Sons Inc.

Shellee Pyron, Interstate Brands Corp.

Roger Smith, American Proteins, Inc.

Tom Sublett, King & Prince Seafood Corp.

Lamar Weeks, Tyson Foods, Inc.

David Wicker, Fieldale Farms Corp.

Steve Woodruff, WHEE, Inc.

University Advisor

Jim Walsh, Georgia Tech

Food Safety Technical Committee

Michael Robach, Wayne Farms LLC, Chairman

Mike Doyle, UGA, Coordinator

James Ayres, Gold Kist Inc.

Wes Craig, Excel Corp.

Rex Holt, Georgia Department of Agriculture

Phil Hurwitz, ConAgra Poultry

Bob Lauxen, Fieldale Farms Corp.

Shanna Lively, Fresh Advantage

Billy Thomas, Thomas Packing Company

Bob Wilbanks, Mar-Jac Poultry

Pam York, Ken’s Foods

Chairman

Robert Budd, The Halifax Group Inc.

Vice Chairman

David Lee, D.L. Lee & Sons Inc.

Steering Committee

Lee Bonecutter, Excel Corp.

Fred “Butch” Durand, Durand-Wayland, Inc.

Karen Gunderson, Mrs. Smith’s Bakeries

Charles Hall, Georgia Fruit & Vegetable

Growers Assn.

Jimmy Hill, The Hill Group

Bruce Kotz, Golden Peanut Company

Jim Lovett, Georgia Power

Don Sims, Thomasville-Thomas Chamber

of Commerce

Ralph Yoder, Georgia Peanut Producers Assn.

Technical Committee Chairmen

University Advisors

Ann Carswell, Valdosta State University

Mike Doyle, UGA

Jimmy Solomon, Georgia Southern University

Dale Threadgill, UGA

Craig Wyvill, Georgia Tech

Process & Product Competitiveness

Technical Committee

Wayman Hollis, Hall Equipment, Chairman

Craig Wyvill, Georgia Tech, Coordinator

Poultry & Meat Subcommittee

Dan Cohn, Gold Kist Inc.

Bradley Down, Excel Corp.

Doug Hatley, Fieldale Farms Corp.

Jim Hewell, Dapec, Inc.

Greg Lisso, ConAgra Poultry

Ken Nix, Cagle’s Inc.

Greg Tench, Mar-Jac Poultry Processing

Max Volk, Stork Gamco

Bakery & Snack Subcommittee

Alex Camire, Tom’s Foods

Art Christianson, Rich-SeaPak Corp.

Greg Heck, Southern Company

Bill Leverett, Durand-Wayland, Inc.

Clayton Muggridge, Mrs. Smith’s Bakeries

Confectionery & Other Products Subcommittee

Jeff Harris, M&M Mars

Doug Horn, The Halifax Group Inc.

Bruce Kotz, Golden Peanut Co.

Donnie Morris, Baxley Sunbelt Blueberry Corp.

Gary Peters, South Georgia Pecan Co.

University Advisors

Ann Carswell, Valdosta State University

Wayne Daley, Georgia Tech

Jimmy Solomon, Georgia Southern University

Romeo Toledo, UGA


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August 22, 2002 Steering Committee meets to establish FY 2004 funding request plan

September 1, 2002 FY 2004 funding request plan forwarded to Governor’s Office of Planningand Budget

September 1, 2002 FY 2002 final project reports due

November 1, 2002 Call for FY 2004 research proposals issued

December 6, 2002 FoodPAC’s Fiscal Year 2002-2003 Report to Industry distributed

February 3, 2003 FY 2004 research proposals due

March 3-14, 2003 Technical Committees meet separately to review FY 2004 proposals, hearresearchers’ presentations, and prioritize submissions by focus area

March 14-April 4, 2003 Steering Committee meets to review, adjust, and approve FY 2004research program

April 7, 2003 FY 2004 research program announced

June 30, 2003 FY 2003 research projects completed

July 1, 2003 FY 2004 research projects begin

September 1, 2003 FY 2003 final project reports due

FoodPAC 2002-2003 Calendar


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The FY 2002 FoodPAC Research Program allocated funds totalling $1.208 million with an additional $517,500 inbond funding. A total of 18 projects were approved, including 8 in the Process & Product Competitiveness technicalarea, 5 in Environmental, 4 in Food Safety, and 1 Special project.

The projects are highlighted on the following pages, beginning with those in the Environmental technical area, followedby Food Safety, Process & Product Competitiveness, and the one Special project.

FoodPAC FY 2002 Project Summaries


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Effect of Food Processing Operations on

Wastewater Generation and Treatment Methodologies

The Georgia poultry industry’s annual contribution tothe state’s economy now exceeds $12 billion. Along withthe benefits of increased jobs and significant fiscal impactGeorgia has seen as a result of the phenomenal growth ofthe poultry industry, there has also been the dramatic impactof increasing government regulation on how each companyoperates its business on a daily basis. From the waterconservation reversing effects of the food safety HACCP(hazard analysis critical control point) program to the evermore stringent limits placed on process wastewaterdischarges, Georgia’s poultry industry must constantlymonitor, modify, and reevaluate its production practices.

In addition, the U.S. Environmental Protection Agencyhas embarked on a multiyear project aimed at thedevelopment of nationwide Effluent Limitation Guidelines(ELGs) for U.S. meat products industries. The final ELGsare scheduled for publication by December 2003. If thefinal ELGs that are imposed on the nation’s poultryprocessing industry are not realistic in terms of currentwastewater treatment technologies or if they require strictcontrol over specific parameters critical only in uniquegeographic locations, the costs incurred by the Georgiapoultry industry will not only be extreme but ultimatelycould make current invested wastewater treatmenttechnologies ineffective.

Project Objectives

To review, compile, and analyze collected data frompoultry processing plants to develop typical wastewaterprofiles for U.S. and Georgia facilities based on facility typeand geographically acceptable wastewater dischargeguidelines; to provide Georgia’s poultry industry withreports that summarize production information, analyzethe relationship between various process operations,measure the effectiveness of various treatment technologies,and estimate overall costs as they relate to wastewater

Project Leader

Jackie Sellers, University of Georgia, (706) 542-8382, [email protected] Participants

William Merka, Brian Kiepper, and Jason Governo, University of Georgia; Jim Walsh, Georgia Institute of Technology;John Starkey, U.S. Poultry & Egg Association

FY 2002 State Funding

$43,081

generation and pollutant loading; and to provide Georgia’spoultry industry with sound economic and engineeringpollution-prevention methods aimed at reducing criticaleffluent parameters identified during the study.

FY 2002 Project Activities and Outcomes

Twenty-six project plants representing 13 U.S. poultryprocessing companies were selected from five establishedU.S. regions for study. The number of plants selected ineach region was based on the percentage of U.S. poultryprocessing companies contained in that geographic area.Of these 13 companies, nine operate multiple plants in morethan one state, while the remaining four companies operatea single facility. Twenty (77%) of the project plants slaughterbroilers; three plants (12%) slaughter turkeys; one plantcooks the processed carcasses of spent breeding fowl; oneplant is a stand-alone further processing plant; and one plantis a stand-alone rendering facility.

As part of each project plant site visit, an intensiveinvestigation of each wastewater treatment process wasconducted. Detailed information on equipment andoperations was obtained by interviews with wastewatertreatment staff or from readily available files. Informationgathered on-site and collected in subsequent contact withplant personnel and local regulatory officials was combinedinto a series of databases for analysis. Based on theaccumulation of project plant data, the followingconclusions were reached:

1) Improved knowledge and operation of physical screensin poultry processing wastewater should receive emphasisboth in plants and future research. Screening is often thefirst, simplest, and most inexpensive form of wastewatertreatment. However, based on project findings, it is oftenone of the least understood for its treatment potential andfiscal impact.

Environmental Projects

Industry’s Concern


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Brian Kiepper, University of Georgia researcher, sets upan automatic wastewater sampling unit to measurethe efficiency of a poultry processing primary rotaryfeather screen.

Impact: Based on project findings, there is significantpotential for improving the removal of particulate matterby screening. Results from research work using laserdiffraction technology to measure particle size distributionin screen effluents indicate that a typical slaughter plantcurrently operating a 0.020-inch (508-mm — micron)secondary screen could expect to remove an additional 19%of unadulterated solids by installing a 200-mm tertiaryscreen. Further processing plants in the study could recoveran additional 29% of solids.

2) Increased research emphasis should be placed onidentifying non-ferric-containing chemicals and otheragents that would improve dissolved air flotation (DAF)efficiency and produce high-value rendering byproducts.Chemicals such as ferric chloride, ferric sulfate, magnesiumhydroxide, sulfuric acid, and organic polymers are addedto DAF wastewater to improve treatment. However, if thechemical dosage is too high, the quality of the skimmingscan be adversely affected. Skimmings that contain excessiveconcentrations of metals, such as aluminum or iron, affectthe color and toxicity of rendered products. Because manyrenderers will not accept poor quality skimmings, processorsare then forced to dispose of the skimmings as waste.

3) Increased research emphasis should be placed onreducing nitrate levels of effluent from direct dischargersusing DAF technology followed by anaerobic (in the formof covered lagoons) and aerobic biological treatment. Oneongoing problem that directly affects six (23%) of theproject plants involves high effluent levels of nitrates thatseem to plague some of these treatment systems, especiallydirect discharges to land-application systems that show highnitrate levels in ground water monitoring wells. It appearsthat efficient DAF operation prior to anaerobic treatmentmay actually be detrimental to the anaerobic treatment(denitrification) process. One possible solution would beto use traditional DAF units without chemical addition.

Impact: Using non-chemical DAF technology would havethree benefits. First, a portion of the heaviest fat, oil, andgrease (the easiest particles to float) would still be removedso that downstream systems will not be overwhelmed.Second, the resulting DAF effluent would contain anadequate amount of organic matter to supply the needs ofthe heterotrophic bacteria in the anaerobic lagoons tocomplete denitrification. And third, the resulting DAF

skimmings would be unadulterated by any polymers orother chemicals and thus could be handled as primary offal,maintaining value as a rendering byproduct.

4) Emphasis should be placed on educatingenvironmental regulatory agencies of the value of site-specific wastewater treatment limits over nationwide ELGs.Project results reveal that parameter limits and theparameters themselves are based on specific geographiccriteria. Not only is there variation on the limitingparameters based on the region of the country where plantsare located, but variations are seen between plants within amatter of miles from each other because limits are specificallybased on the receiving streams or land-application sites fordirect discharges and National Pollutant DischargeElimination System (NPDES) permits of the municipalplants receiving flow from indirect dischargers.

FY 2003 Project Activities

The project is completed, and a report has been generated.


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Environmental Projects, continued

Development of Testing Criteria, Performance Analyses, and Life-Cycle Costs for

Assessing the Use of Recycled PET-Coated Boxes as a Replacement for Wax Boxes

The poultry industry makes extensive use of wax-coatedboxing to ship ice and CO

2-packed fresh product.

Unfortunately, wax-coated boxes cannot be repulped and aretherefore disposed of either in landfills or by burning — anissue that is becoming an increasing concern for grocery chainsand other end product users faced with mounting consumerdemands to find a more environmentally friendly approachto disposing of this material.

That approach may exist in a new technology developedby EvCo Research, LLC. EvCo has developed a recycledpolyethylene terephthalate (PET) material that can be usedto coat paper and paperboard products to make themwaterproof while also allowing them to still be repulped. Therecycling of PET materials is a major issue in and of itself;however, the use of these materials in a product that makespoultry transport boxes recyclable is a win-win situation.

EvCo has attempted in recent years to constructcorrugated boxes coated with its product and to test themin the transport of poultry products. Unfortunately, thesetests have failed to fully define the comparative performanceof this new product to that of the existing waxed product.

Project Objectives

To reinforce the criteria for testing, performance, andapplication of waxed box production; to evaluate the criteriafor testing, performance, and application of plastic-coatedboxes; to support mill trials of plastic-coated boxes; and tocomplete an economic cost analysis.


Researchers developed a new test method for wetcompression strength: the CPST (corrugated paperboardstrength test). The CPST was correlated with existingmethods being used in the industry. Using this criterion,researchers were able to show that chemicals supplied by

Project Leader

Jeffery Hsieh, Georgia Institute of Technology, (404) 894-3556, [email protected] Participants

William Riall, Georgia Institute of Technology; Peter Signoretti, EvCo Research, LLC; David McIntosh, Inland MillsFY 2002 State Funding

$85,795

EvCo could be used as barrier coatings for the corrugatedbox to obtain acceptable performance. This performancecould be improved if PET-based chemicals from EvCo wereadded to the pulp as the paper was being formed (wet-endchemicals). A box was also defined that could perform underthe most difficult packaging conditions; it would includethree types of products supplied by EvCo: barrier coatings,wet-end additives, and vegetable-based products to replacewax-impregnated medium.

In all three instances, the boxes would be fully recyclableand repulpable under standard pulping conditions. This isa big improvement over the petroleum-based, wax-coated,and impregnated boxes currently being used. The currentproducts are, when holistically evaluated, more expensivethan the new technology; boxes coated with them are notrecyclable and have to be landfilled. This puts an additionaleconomic impact as well as an environmental impact onthe users and ultimately the state of Georgia.

The economic impact relates to the fact that paper mills,chicken processors, and users of wax-coated andimpregnated boxes have to send scraps from themanufacturing process and damaged and used boxes tolandfills. In addition, these users would be paid for theirscrap boxes if they were recyclable. This total benefit hasbeen estimated to be $20-25 million for Albertson’s and$12 million for Publix, two major grocers in the UnitedStates, if all of their wax-coated boxes were replaced with arepulpable and recyclable food package. There would beadditional savings to chicken processors, distributors, andcorrugating box plants.

From an environmental perspective, adoption of thisnovel technology by industry would result in less productbeing diverted to landfills. Also, the basic raw material forthe chemicals being supplied by EvCo is recycled beverage



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Samples used for corrugated paperboard strength tests.

and food containers based on PET. The most recognizableproduct in this regard would be the ubiquitous plasticCoke® bottle. In the United States, more than 75% ofthese containers end up in landfills or laying alongside theroad. In Georgia, the figure is even higher, probablyapproaching 80-85%. Utilization of this technology wouldprovide an effective use for the PET bottles, which wouldencourage recycling. Though not a complete solution torecycling PET, this novel technology provides a creativepartial solution.

In summary, the state of Georgia would benefit from lessvolume going to landfills (wax-coated, corrugated boxes)and from the removal of PET bottles from roadsides andlandfills. Georgia paper companies would have access tomore old corrugated cartons (recycled cartons), which havea lower cost than virgin wood. Georgia grocers, chickenproducers, and farmers would have lower costs because thepackaging containers they use would now be a source ofincome as they recycle them back into corrugatedcontainers. The environment of the state would benefit fromthere being less need to cut trees down to supply fiber tothe paper industry.


Researchers will conduct mill trials for thecommercialization of recycled PET-coated boxes as areplacement for waxed boxes. They will perform wet-endPET addition at the pilot-plant level using paper machinetrials in both linerboard and corrugated medium forimproving the strength of repulpable boxes.


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Air Emission Factors for Process Control and Pollution Prevention

Project Leader

K.C. Das, University of Georgia, (706) 542-8842, [email protected] Participants

James Kastner, University of Georgia; Dan Craig, Gold Kist Inc.FY 2002 State Funding

$60,304

Odorous, volatile organic air pollutants are released fromtypical rendering operations. Emissions can be of concernto the facility due to local complaints, air quality regulations,and permitting. Literature suggests, and recent research hasconfirmed, that emissions are a function of the type ofmaterial being processed, the condition of the materials,and the process conditions (e.g., temperature). Discrete fieldsampling, although effective, gives only a snapshot of theprocess and is limited by process fluctuations, an inabilityto access all sampling ports, and interference from otherprocess conditions such as steam releases, etc. It is knownthat process conditions, e.g., cooker temperature, changerapidly during the operation, and this can have a significantimpact on unit operations downstream. In the past, processdevelopment in rendering has rightly focused on productquality, and there is a need to link this body of knowledgewith the effect of process conditions on emissions.

Project Objectives

To quantify the condition of offal and feathers that havebeen held for different durations at different temperatures;to build a scale model of a batch rendering cooker; and todevelop a database of odorous and volatile organiccompounds (VOCs) emission factors (g-VOC/kg-Product)for various conditions in the rendering process.

Because of a significant cut in the proposed budget (49%of proposed) researchers were only able to accomplishportions of the first objective and all of the second objective.


Researchers conducted incubation studies using offal,feathers, and blood at two temperatures (15 and 35 °C).This is a completion of only a portion of the objectivesbecause of reduced funding. Additional temperatures willbe conducted as part of FY 2003 activities. During the

incubation, samples of headspace gases were collected andanalyzed using a gas chromatograph and an electronic nose.Incubating materials were sampled to determine themicrobial counts during incubation.

Results show that there is a 10- to 20-fold increase inhydrogen sulfide concentrations when comparingincubation at 35 °C to that at 15 °C. Although featherscontain more sulfur compounds (amino acids in keratin),the amount of degradation was less because of therecalcitrant nature of feather. This resulted in lower gaseoussulfur emissions. However, in offal and feathers, the trendswith temperature increase were similar. There was very highvariability in the measured concentrations of hydrogensulfide during higher temperature incubation.

The electronic nose was able to distinguish the presenceof hydrangea sulfide through its clustering algorithm.However, the sensitivity of this instrument was not sufficientto discern between samples that were incubated eight hoursand 24 hours.

A scale model (18-gallon) cooker was designed based ona commercial cooker design. The system was stainless steel,with the capability to hold a pressure of 45 psi and vacuumof 4 inches of mercury. Preliminary tests of cooking offalindicate that heating curves similar to that found incommercial cookers can be replicated, and the productobtained has sufficient quality (36% protein, 51% fat,10.8% moisture, and free fatty acids <1%).


Researchers will complete the incubation studies forheadspace sulfur compounds and microbial growth analyses.Incubations at 20 and 27 °C will complete the four-pointspectrum between 15 and 35 °C.



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In addition to incubation studies, researchers willcomplete the characterization of the scale model cooker andwill begin direct cooking and hydrolysis tests. These testswill simulate conditions similar to that in commercialoperations during the cooking and hydrolysis of poultrybyproducts. Researchers will also measure total VOCemissions and calculate the emission factors under differentoperational scenarios. These tests will be conducted withthe close collaboration of the project’s industrial partner.

A scale model rendering cooker (18-gallon capacity)built for the evaluation of emission factors duringcooking and hydrolysis of poultry byproducts.


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Effect of Chlorine Dioxide Concentration on

Odor and VOC Removal in Rendering Emissions

The promulgation of “Odor Control Rules,” increasingpublic concerns, and the U.S. Environmental ProtectionAgency’s air regulations in non-attainment zones necessitatethe remediation of a wide range of volatile organic compounds(VOCs) generated in the rendering industry. Currently, wetscrubbers using oxidizing chemicals, such as chlorine dioxide(ClO

2, widely used in the rendering industry) and ozone

(O3) are utilized to treat VOCs. However, little information

is available on the kinetics of ClO2 reaction with rendering

air pollutants identified in previous research, thus limitingwet scrubber design and optimization.

Project Objective

To develop a bench-scale system to study the kinetics ofClO

2 reacting with several VOCs identified in rendering

emissions.


Researchers developed a batch of kinetic methods that canbe used to rapidly screen a range of oxidizing agents (e.g.,ClO

2, ozone, HOCl) to determine if they can breakdown

compounds in rendering emissions. Kinetic analysis indicatedthat ClO

2 does not react with hexanal, 2-methylbutanal, and

3-methylbutanal (compounds identified in previous research),all of which constitute a major fraction of VOC emissionsand imply removal in the wet scrubber is primarily via masstransfer (i.e., based on water solubility). Contrary to thealdehydes, ethanethiol (a model compound for methanethiol)and dimethyl disulfide (DMDS) rapidly reacted with ClO

2.

Both methanethiol (MT) and DMDS were previouslyidentified in rendering emissions. The results explain whyaldehyde removal efficiencies are much lower than MT andDMDS in wet scrubbers using ClO

2. Moreover, an increase

in pH from 3.6 to 4.5 exponentially increased the reactionrate of ethanethiol and significantly increased the reactionrate of dimethyl disulfide if increased to pH 9 (these resultsshould also apply to methanethiol). Thus, a small increase in

Project Leaders

James Kastner, University of Georgia, (706) 583-0155, [email protected]. Das, University of Georgia, (706) 542-8842, [email protected]

Project Participants

Kevin Custer, American Proteins, Inc.; Dan Craig, Gold Kist Inc.FY 2002 State Funding

$55,492

Apparatus used to measure the oxidation kineticsof ClO

2 reacting with compounds identified in

rendering emissions.

pH could significantly improve wet scrubber operations forremoval of odor-causing compounds. However, an increasein pH did not improve aldehyde removal. Finally, wetscrubber models have been developed that reasonably predictaldehyde removal (removal based on mass transfer only).


Researchers will continue to develop methods to removethe aldehydes and to develop wet scrubber models usingthe kinetic data developed in this work to predict sulfurcompound removal with ClO

2 (predict mass transfer with

chemical reaction). The kinetic methods and modelsdeveloped in this work are applicable to other oxidizingagents such as ozone that may remove the aldehyde fraction.The wet scrubber model, combined with the kinetic data,could be used to optimize wet scrubber operations usingClO

2 or ozone (i.e., predict VOC removal efficiencies under

different operating conditions).




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Development of an Advanced UV Disinfection Technology

Project Leader

Larry Forney, Georgia Institute of Technology, (404) 894-2825, [email protected] Participants

John Pierson, Carolyn Goodridge, and Robert Wallace, Georgia Institute of Technology; Charles Hall, Georgia Fruitand Vegetable Growers Association


$103,439

On January 23, 2001, the director of the GeorgiaEnvironmental Protection Division noted that droughtconditions were currently expected in southwest Georgiaduring the year 2001. While more efficient irrigationpractices are being used on the farm, beneficial waterconservation, reuse or reclamation practices, and cost-effective technologies for other aspects of the industry areexcluded. Regulatory constraints limit the ability of thefruit and vegetable industry, along with foodmanufacturers in general, to reuse water because thequality of water used for washing and chilling the produceafter it is harvested is critical.

A cost-effective approach is needed that advances waterreclamation opportunities, provides reliable efficiency, andallows variable treatment based on water qualityrequirements. Preferably, the technology would build onestablished water-treatment systems to minimize risk andinvestments, and could be easily scaled up or down to meeta variety of applications. Finally, it should be process- anduser-friendly.

Project Objective

To advance water reuse opportunities for the fruit andvegetable industry by improving disinfection with ultraviolet(UV) irradiation.


Researchers developed a novel reactor that both eliminatesmany of the scale-up problems and increases the photo-efficiency of pathogen inactivation. The design is a Taylor vortexcolumn that consists of a stationary outer cylinder (UVtransparent) with a rotating inner cylinder. UV lamps arepositioned around the periphery. The Taylor column, forexample, uncouples the hyrodynamics from the fluid residencetime and provides a nearly uniform, large UV dosage.Comparisons were made with a conventional UV channel.

Disassembled view of Taylor reactor. From left to right: thequartz stationary cylinder (stator), the aluminum reflector,and the brass rotating cylinder (rotor).

Ultraviolet photolysis of aqueous iodide producing triiodidewas studied in both the Taylor column and channel duringthe first phase of work. Chemistry was used to optimizeperformance before disinfection of target bacteria wasconducted. In the second phase of the work, tests wereconducted on the inactivation efficiency of an indicatororganism, E. coli, in both the Taylor column and the channel.

Specifically, researchers concluded that the Taylor vortexwas more than five times more efficient at achieving a 5-logreduction in E. coli than the UV channel. For simulatedwastewater, suspended solids concentrations did not impactE. coli inactivation in either reactor. Additionally, from theperspective of hydraulic behavior, a critical issue in UV systemdesign appears to be the promotion of plug-flow conditions.


Researchers will demonstrate water reuse opportunities usingdisinfection with ultraviolet irradiation for both high-temperature and turbid food processing waters. As a result ofthe project, performance data and environmental and economicbenefits will be established at a soft drink bottling facility.



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Intervention Strategy to Reduce Campylobacter Carriage in Chicken

Project Leader

Jinru Chen, University of Georgia, (770) 412-4738, [email protected] Participants

Michael Robach, Wayne Farms LLC; Jim Ayres, Gold Kist Inc.FY 2002 State Funding

$152,898

Food Safety Projects

Campylobacter jejuni is the leading bacteriological causeof foodborne illness in the United States with an estimated2 million cases per year. Transmission of C. jejuni isassociated with consumption of many foods includingpoultry. The organism has been isolated from poultryprocessing plants, domestic pets, and the intestinal tractsof animals. Approximately 98% of retail chicken carry C.jejuni. Upon ingestion, as few as 500 cells of C. jejuni areable to cause symptoms in humans and severe complicationsincluding reactive arthritis, and Guillain-Barre syndromemight occur after the infection.

Campylobacter contamination of poultry may come frommany sources, most important of which are silent pathogencarriers in chicken farms and broiler houses. Consideringthat the birds are placed in such close proximity in theseenvironments, the potential for pathogen transmission issubstantial. The infected birds carry C. jejuni intoslaughterhouses and processing plants, contaminating theprocessing facility and ultimately poultry carcasses. Someresearchers address the problem at the postprocessing leveland use techniques such as chemical or acid wash to reducethe load of Campylobacter on processed chicken carcasses.These technologies are difficult to adopt because they bringadditional burdens to the poultry processing industry. Anintervention strategy should be developed at thepreprocessing stage so that transmission of C. jejuni in livingbirds could be prevented.

Project Objective

To develop a novel approach to reduce C. jejuni carriage inchicken by use of a bacteriophage (a virus that destroys bacteria).


Human and chicken feces, chicken litter, chicken manure,chicken feed, chicken feathers, chicken guts, sewage water,pond water, pond mud, and other poultry environment

samples were collected for isolation of bacteriophage specificfor Campylobacter spp. Existing phages were purchased fromthe American Type Culture Collection. The host ranges ofsome bacteriophages have been determined in FY 2002using a collection of C. jejuni strains. Bacteriophages orbacteriophages mixtures with suitable host ranges have beenidentified. Several bacteriophages were pooled and used toreduce C. jejuni carriage in a small chicken trial.

BacteriophagesResearchers have a total of 44 bacteriophages. Additional

phages will be isolated, if necessary. Among collected samples,potentially useful bacteriophages were isolated from a chickenmanure pile on the grounds of a chicken farm, chicken fecesand litters in chicken houses, and water and mud samplescollected from a pond adjacent to the chicken farm.

Host ranges of bacteriophagesSome of the bacteriophages collected are lytic to C. jejuni.

These bacteriophages caused complete lysis of C. jejuni onBrucella agar at 42 °C under microaerophilic condition (seephoto). Other bacteriophages gave partial lysis, and theplaques formed by these phages were opaque. The natureof our research desires virulent bacteriophage with largeburst size. Bacteriophage of this kind causes complete lysisof C. jejuni hosts and releases large populations of progeniesin each bacteriophage life cycle.

The susceptibilities of 26 C. jejuni strains to 13bacteriophages have been determined. Some of thebacteriophages have promising host ranges and can be usedas probiotics in the chicken trial. Two C. jejuni hosts, bothfrom the U.S. Department of Agriculture-AgriculturalResearch Service in Athens, Georgia, were not sensitive tothe 13 bacteriophages tested in the study. One of the strainsis a presumptive, untyped C. jejuni strain isolated frompoultry carcasses wash, and the other is a C. jejuni strain



page 16

from an unknown source. The identities of these two strainswill be confirmed. In addition, researchers are testing thehost ranges of 31 (9 commercial and 22 isolated) otherbacteriophages and their suitabilities as probiotics to controlC. jejuni in chicken.

Chicken trialResearchers are in the final planning stage of the chicken

trial. Five strains of C. jejuni will be used to constitute acocktail to challenge chickens. A pool of threebacteriophages has been identified for the chicken trial.Specific pathogen-free chickens at 2 weeks of age will beequally divided into two groups, viz., A and B. Group Awill be challenged orally with a five-strain mixture of C.jejuni, and group B will be kept as the control with 0.1%peptone. The inoculation will be repeated once within aweek. After bacterial inoculation, half of the chickens fromeach group will be fed with a mixture of lytic C. jejuni-specific bacteriophages and another half with 0.1% peptonewater. The phage treatment will be given twice a week duringa 2-week period. Fecal C. jejuni populations in treated birdswill be compared with untreated controls.

Unforeseen circumstancesThe inexperience and resignation of a technical staff

member and the reassignment of the principal investigatorto a different administrative unit had tremendous negativeimpacts on this project. However, the principal investigatorand her staff have been doing their best to keep the projecton track. A progress report will be submitted to FoodPACas soon as the chicken trial is completed.


As indicated above, 31 additional bacteriophages haverecently been isolated and collected. Researchers are in theprocess of determining the host ranges of thesebacteriophages. They will be purified, propagated, andproperly stored. New phages will be isolated if necessary.The intervention will be optimized using phage-breadingtechniques in FY 2003. C. jejuni carriage as influenced bythe dose of bacteriophage, time, frequency, and sequenceof the phage treatment will be determined. If time andbudget permit, a field chicken trial will be conducted.

Bacteriophage kills C. jejuni on agar plate. The whitebackground is the lawn of confluent growth of C.jejuni on Brucella agar, whereas the clear circles showC. jejuni killed by bacteriophage.


page 17

Removal and Disinfection of Listeria monocytogenes-Containing

Biofilms in Cooked Product Areas of Meat Processing Plants

Project Leader

Joseph Frank, University of Georgia, (706) 542-0994, [email protected] Participants

Louise Wicker, University of Georgia; Jim Ayres, Gold Kist Inc.FY 2002 State Funding

$88,057

Food Safety Projects, continued

Listeria monocytogenes is a psychrotrophic pathogen thatcauses illness primarily in pregnant women and immune-compromised persons. Preventing food-borne listeriosisrequires preventing recontamination of processed productbecause the microorganism can grow at refrigerationtemperature. Products involved in outbreaks includeprecooked processed meats, precooked refrigerated seafood,and precut, packaged vegetables. Precooked meat productsare of current concern because of recent disease outbreaksand product recalls. Most notable is the 1998 multistateoutbreak of listeriosis in which six adults died and two womenhad spontaneous abortions. Since October 1999, there havebeen 11 recalls of ready-to-eat products for L. monocytogenescontamination, with eight of these involving red meat orpoultry products. In November 1999, 1,500 pounds of hotdogs produced by Robbins Packing Co. of Statesboro,Georgia, were recalled due to L. monocytogenes contamination.

Preventing contamination of meat products with L.monocytogenes presents a difficult challenge for mostprocessors. The pathogen enters the plant with raw productor personnel and then grows in the plant environment onwet surfaces within a biofilm. This biofilm contains productresidues and microbial polymers. Biofilms are difficult toremove through normal cleaning, and they protect theimbedded pathogen from disinfection. Biofilms that formin meat plants are especially difficult to control becausethey often contain fats and proteins that further impedesanitizer effectiveness. Application of cleaning/sanitizingagents in meat processing environments is limited by twoimportant considerations: 1) the process must not produceaerosols, as these may spread pathogens throughout theplant, and 2) the process must use a minimum of labor.The solution is to apply the chemical agents under staticconditions, i.e., no high-pressure water or hand scrubbingis used. Agents are applied as foams or gels and then rinsedoff with low-pressure water. The problem with this approach

is the lack of contact time on vertical surfaces provided byfoams. Newly developed gels allow the operator to increasecontact time. However, even with increased contact time,the question of effectiveness is still unanswered, as traditionalcleaning has always involved water flow or hand scrubbing.

Project Objective

To develop effective cleaning and sanitizing proceduresfor removing and inactivating biofilms containing L.monocytogenes that might be present in the ready-to-eatprocess areas of poultry processing facilities.


Cleaning and sanitizing agents were evaluated at ambientand cold temperature. Evaluation of the use of foam andgel applications in a commercial processing facility was alsocompleted. Specific agents tested include alkali and neutralcleaning compounds, quaternary ammonium compound,peroxyoctanoic acid sanitizer, peracidic acid sanitizer,chlorine dioxide sanitizer, and hypochlorite sanitizer. Agentswere tested against model system biofilms containingpoultry meat residues and L. monocytogenes. Cleaning agentswere evaluated for their ability to remove poultry soil andbiofilm material, and sanitizing agents were evaluated fortheir ability to inactivate L. monocytogenes before and afterapplication of the cleaning agent in the presence and absenceof poultry soil material. The first phase of this project wasdesigned to test treatment options for the food industryunder controlled conditions.

Data indicate that static cleaning and sanitizingprocedures can effectively clean and sanitize surfacescontaining biofilms of L. monocytogenes coated with organicmaterial of poultry origin at both ambient and cold(10 °C) temperature. Effective removal of L. monocytogeneson heavily soiled surfaces relies on using an alkali cleaningagent that remains in contact with the surface for at least



page 18

30 minutes. Following the cleaning step with sanitizertreatment completes L. monocytogenes inactivation.Chlorine dioxide was the most effective sanitizer of thosestudied. If operators must choose between application ofan alkali cleaner and a sanitizer, they should apply the alkalicleaner if the surface is expected to have significant organicload. Acidified sodium chlorite (chlorine dioxide) is thesanitizer that works best in the presence of organic load.The cleaning agents used in this study contained a gellingagent that causes the chemical to cling to vertical surfaces,maintaining a long contact time. Research data show thatcontact time is very important to achieve effective L.monocytogenes control in a static system.

Foam and gel applications of quaternary ammoniumsanitizer were evaluated in a commercial poultry processingfacility. Both formulations effectively sanitized a deboningline. This result indicates that foam systems can be effectiveif they are properly applied to achieve complete coverage.



L. monocytogenes biofilm.


page 19

Optimization of Low-Dose Irradiation of Commercial Processed and

Ready-to-Eat Meats to Inactivate Listeria monocytogenes

Project Leaders

Anna Resurreccion, University of Georgia, (770) 412-4736, [email protected] Chen, University of Georgia, (770) 412-4738, [email protected]. Estes Reynolds, University of Georgia, (706) 542-2574, [email protected]


David Lee, D.L. Lee & Sons, Inc.; Michael Robach, Wayne Farms LLC; Kevin Nanke, Surebeam Corporation;Carl Zinn and Peter Baker, IBA Sterigenics


$84,937


Postprocessing contamination of processed and ready-to-eat meats with Listeria monocytogenes is a concern to theindustry because of the catastrophic consequences that couldresult. L. monocytogenes is found in very low concentrationsin many processed and ready-to-eat meats and poses a foodsafety risk. Processed meats such frankfurters and ready-to-eat meats are potential vehicles for contamination. Chemicalpreservatives are usually used to control bacterial surfacecontamination. However, evidence exists that certain strainsof L. monocytogenes have high tolerances to generallyrecognized as safe chemicals. Irradiation is a cost-effectivetechnology that would inactivate L. monocytogenes and issuitable for large-scale processing.

Project Objectives

To investigate microbial reduction, tailing, and recoveryof L. monocytogenes in commercial processed meat, chickenfrankfurters, and fully cooked, ready-to-eat diced poultrymeat products treated by commercial low-dose irradiationat 1, 2, and 3 kGy at 4 °C and stored at 0, 25, 50, 75, and100% of expected shelf life; to determine the sensoryproperties of the above samples; and to determine consumeracceptance of commercial processed chicken frankfurtersand fully cooked, ready-to-eat diced poultry meat productstreated by commercial low-dose irradiation and stored at 0and 100% of expected shelf life.


Two commercially processed products (a fully cooked,ready-to-eat diced poultry meat product and a processedmeat, chicken frankfurters) were irradiated in a commercialirradiation plant using an electron beam irradiator. Themicrobiological study determined L. monocytogenesreduction in irradiated samples throughout the expectedshelf life of the product. The sensory study determined

sensory characteristics and consumer acceptance ofuninoculated, irradiated samples throughout the expectedshelf life of the products while simultaneously maintainingproduct acceptability.

The microbiological analysis showed that 3 kGy of e-beam was only effective in eliminating 102 CFU/g of L.monocytogenes. Meats inoculated with 104 CFU/g testedpositive for L. monocytogenes after irradiation treatment. Thepopulations of the pathogens on the diced chicken increasedover time during storage at 4 °C. Lower doses, i.e., 1 and 2kGy were ineffective in inactivating L. monocytogenes evenwith the meats that were inoculated at 102 CFU/g.

Irradiation treatment with 3 kGy of e-beam failed to controlpsychrotrophs on diced chicken and frankfurters. At the endof their expected shelf life, the populations of psychrotrophicmicroorganisms were between 9.22 and 10.32 on dicedchicken and were 1.32 and 7.15 on frankfurters.

The consumer test for diced chicken showed no significantdifferences between the control and irradiated diced chickensamples at day 4. No differences were found among overallacceptance, acceptance of appearance, color, flavor, juiciness,tenderness, or mouthfeel/texture. Aroma was significantlyless acceptable in the control samples (0 kGy) than inirradiated samples. At day 18, all control samples (0 kGy)were rated less acceptable than irradiated samples. Flavor,juiciness, tenderness, and mouthfeel of the unirradiatedchicken could not be evaluated due to deterioration. Ratingsfor all irradiated samples were slightly lower on day 18 thanday 4. Samples irradiated at 2 and 3 kGy had higheracceptance ratings for aroma and flavor compared to thoseirradiated at 1 kGy. At day 32, all control and irradiatedsamples were spoiled and could not be evaluated.



page 20

The descriptive analysis for diced chicken showed that therewere significant differences between two attributes, stringiness,which was higher in the unirradiated controls, and toothpackat day 4. At day 11, significant differences were only found forthe attribute, sharp edges. At day 18, the ratings for the controlsamples (0 kGy) differed significantly from the irradiatedsamples (1, 2, and 3 kGy). This is due to the spoilage of thecontrol samples, which could only be evaluated by smelling.At day 25, all samples, unirradiated and irradiated, wereevaluated by smell only. The control samples were rated ashaving a more distinct off-odor than the irradiated samples.At day 32, all control and irradiated samples were spoiled andcould not be evaluated.

The consumer test for frankfurters showed that overallacceptance of frankfurters remained high on unirradiatedand irradiated samples (0, 1, 2, and 3 kGy) until day 32. Atday 32, overall acceptance, acceptance of flavor, juiciness,and tenderness of the control samples were significantlylower than most irradiated samples. There were nodifferences in consumer acceptance among all irradiatedsamples on day 32.

The descriptive analysis for frankfurters did not changeover the shelf life of the product. Off-flavor, wet dog flavor,and sour taste were higher in control samples and samplesirradiated at 1 kGy than samples irradiated at 2 and 3 kGy.

This study has helped to provide information onmicrobiology and consumer acceptability throughout theexpected shelf life of the products that will provide a basisfor recommendations on low-dose irradiation for processedand ready-to-eat meats. This was the first study that utilizedcommercial samples irradiated in a commercial electronbeam irradiation facility; therefore, the technology will bereadily transferred to the poultry industry without the needfor scale-up from laboratory to commercial conditions.

In conclusion, these results have great impact on thepoultry processing industry in its pathogen-reductionprograms by identifying that 3 kGy of irradiation forprocessed and ready-to-eat meats would inactivate L.monocytogenes over the shelf life of the products. Sensoryacceptance would be maintained for 18 days in refrigerateddiced chicken and at least 30 days for frankfurters.



Schematic of an electron beam irradiator.


page 21

Reduction of Campylobacter jejuni on Food Products by

Treatment with Generally Recognized as Safe (GRAS) Chemicals

Project Leader

Michael Doyle, University of Georgia, (770) 228-7284, [email protected] Participant

Tong Zhao, University of GeorgiaFY 2002 State Funding

$120,403


During the past two decades, Campylobacter jejuni hasemerged as the leading cause of acute bacterial gastroenteritisin the United States and many developed countries.Gastroenteritis caused by C. jejuni in the United States hasexceeded the combined rates of salmonellosis and shigellosis.Campylobacter spp. are commonly present as part of thenormal intestinal flora of a wide range of animals and birds.Domestic poultry in particular have been identified as animportant reservoir of Campylobacter strains associated withhuman infection. Campylobacter contamination of rawpoultry meat largely occurs during slaughter and processingoperations. A Campylobacter contamination rate 30% tomore than 90% has been reported in various surveys, withup to 107 Campylobacter spp. per gram of chicken carcass.Cross-contamination of C. jejuni by raw poultry productsto food contact surfaces and other foods also can occurduring food preparation.

Because of the association of poultry with Campylobacterenteritis in humans, practical methods are needed tosubstantially reduce Campylobacter populations oncontaminated carcasses and poultry parts. This will beespecially important if performance standards are enactedby the U.S. Department of Agriculture for C. jejuni onpoultry meat.

Project Objectives

The project included three phases. Phase I determinedthe sensitivity in vitro of C. jejuni to a variety of generallyrecognized as safe (GRAS) chemicals, including organicacids and hydrogen peroxide at different concentrations.Based on results of Phase I, several combinations of selectedchemicals were evaluated in vitro for their efficacy in killingC. jejuni (Phase II). Phase III determined the efficacy ofthe best combinations of chemicals identified in Phases Iand II for killing C. jejuni on chicken wings. The overall

goal of this project was to develop a practical and effectivemethod that could reduce C. jejuni populations by at least5 log

10 on poultry.


Eight chemicals, including 0.01% glycerol monolaurate;0.1 and 0.2% hydrogen peroxide; 0.1, 0.5, 1.0, 1.5, and 2.0%acetic acid; 0.1 and 1.0% lactic acid; 0.1% sodium benzoate;50 and 100 mM sodium chlorate; 50 and 100 mM sodiumcarbonate; and 0.05 and 0.1 N sodium hydroxide, wereindividually tested for their ability to inactivate C. jejuni invitro. Results indicated that treatment at 4 °C for up to 20minutes with 0.01% glycerol monolaurate, 0.1% sodiumbenzoate, 50 and 100 mM sodium chlorate, or 0.01 and 1%lactic acid did not reduce C. jejuni populations; 0.1 and 0.2%hydrogen peroxide for 1, 3, 5, 10, and 20 minutes reducedC. jejuni by ca. 1.0 and 3.0 log cfu/ml, respectively; 0.1, 0.5,1.0, 1.5, and 2.0% acetic acid reduced C. jejuni by 1.0, >8.4,>8.4, and >8.4 log

10 cfu/ml, respectively; 25, 50, and 100

mM sodium carbonate reduced C. jejuni by >7.5 log10

cfu/ml; and 0.05 and 0.1 N sodium hydroxide reduced C. jejuniby >7.3 log

10 cfu/ml.

Based on results obtained from Phase I studies, differentcombinations of chemicals with anti-C. jejuni activity wereevaluated for their combined effect on Campylobacter.Results revealed that 0.5% acetic acid plus 0.05% potassiumsorbate or 0.5% acetic acid plus 0.05% sodium benzoate at4 °C for 20 minutes reduced C. jejuni populations by >7.7log

10 cfu/ml. Substituting 0.5% lactic acid for 0.5% acetic

acid was not an effective treatment with no significantreduction in C. jejuni populations. A combination of acidiccalcium sulfate, lactic acid, ethanol, sodium dodecyl sulfate,and polypropylene glycol (Mionix) reduced C. jejuni by>7.3 log

10 cfu/ml within 1 minute at 4 °C.



page 22

All chemicals or chemical combinations for which therewas a greater than 7 log

10 cfu/g reduction were evaluated

for anti-C. jejuni activity on chicken wings. Fresh chickenwings were dipped in a bacterial solution containing a three-strain mixture of C. jejuni. A treatment at 4 °C of 2% aceticacid for up to 45 seconds reduced C. jejuni populations byca. 1.0 log

10 cfu/g, whereas 100 mM sodium carbonate for

15, 30, or 45 seconds reduced C. jejuni by 1.8 to 2.2 log10

cfu/g. A treatment at 4 °C of 0.1 N sodium hydroxide for15 or 30 seconds reduced C. jejuni populations by 2.1 to3.0 log

10 cfu/g, and a combination of acidic calcium sulfate,

lactic acid, ethanol, sodium dodecyl sulfate, andpolypropylene glycol for 15, 30, or 45 seconds reduced C.jejuni by 4.7 to greater than 5.7 log

10 cfu/g. An additional

study was done with chicken wings that were heavilycontaminated with C. jejuni and held at 4 °C for 24 hoursbefore treatment with the acidic calcium sulfatecombination. Results revealed that this treatment inactivatedmore than 6.5 log

10 C. jejuni/g (to an undetectable level)

for contact times of 15, 30, or 45 seconds.



Chicken wings treated with acidic calcium sulfate andlactic acid.


page 23

Production of Natural Sweeteners by Fermentation

Project Leaders

Mark Eiteman, University of Georgia, (706) 542-0833, [email protected] Kastner, University of Georgia, (706) 583-0155, [email protected]


Christopher Guske, Monsanto-Nutrasweet; Fred Barlow, Rayonier Specialty Pulp ProductsFY 2002 State Funding

$55,050

Process & Product Competitiveness Projects

The opportunities for production of functional foods or“nutraceuticals” by biological processes are tremendous andcontinue to grow. The foodstuffs described by these termsare those that contain food components that confer benefitsbeyond their mere basic nutritive food value. Commonly,the benefit involves human health. Nutrition Business Journalestimates that the market for functional foods ornutraceuticals will be $20 billion in 2000, and with theaging population, that these foods will make up 10% ofthe U.S. food market by 2010.

One example of a potential market for functional foodsis in sweeteners. Americans generally enjoy sweet products,but would like to avoid some of the unhealthy consequencesof this food preference. For example, high fructose cornsyrup derived from corn starch alone now has an annualU.S. consumption of about 60 kg per person. In additionto simply being caloric, sweet products derived from cornstarch or beet sugar cause deterioration of tooth enamel(caries). Although other sweeteners exist that avoid thisproblem, a market continues to grow for safe, alternative,natural sweeteners. This potential market is evidenced by asorbitol fermentation plant (Cargill) that recentlycommenced production in Nebraska. The state of Georgia,with its intellectual, industrial, and natural resources, isuniquely positioned to develop and implement technologyto produce other sweeteners economically. Specifically, thisproposal focuses on developing biological methods for theproduction of thaumatin and xylitol.

Project Objectives

To develop commercially viable fermentation processesthat will produce thaumatin and xylitol, the latter usinghydrolysed biomass as a substrate. For thaumatin, the goalis to transform the thaumatin-encoding gene from T. danielliinto E. coli construct plasmids, which maximize the foldingof thaumatin. The goal for xylitol is to understand its

production using real agricultural substrates, whichcommonly contain multiple carbohydrates.


Researchers developed a detailed understanding of theinfluence of oxygen and glucose on xylitol production. Theywere able to show that culture redox potential could beused as a predictable determinant of the fermentations. Thevalue of a culture’s redox potential could be measured on-line and controlled to optimize the production of xylitol.Indeed, the conversion of the carbohydrate substrate xylosecould be interchanged between ethanol and xylitol by theselection of redox potential.

Researchers were also able to generate xylitol at a highyield by running the process under nongrowth conditions.That is, judicious selection of operational variables allowedglucose to be used first for cell growth, followed by xyloseconsumption for the formation of xylitol with minimaladditional growth. This observation is important for tworeasons. First, available waste hydrolyzate residues typicallyare mixtures of carbohydrates such as glucose and xylose.The process that the research team developed has maximizedthe utilization of both of these simple sugars. Second, bygenerating xylitol during a nongrowth condition, very littlesubstrate xylose is used for products other than xylitol.Indeed, researchers reproducibly were able to achieve a 90%yield of xylitol from xylose. The process developed used afed-batch mode of operation, wherein substrates were fedinto the reactor during the course of the process.

In parallel to these yeast studies, the research teamtransformed one gene encoding for xylose reductase intobacteria. The researchers have quite a bit of experience withthe particular strain for the production of other commoditychemicals. Unfortunately, they were not able to achievesufficient activity of this enzyme to generate a viable quantity



page 24

of xylose. They anticipate other xylose reductase genes tobe isolated in the near future, which will be available foradditional studies. Substantial reduction in fundingprevented the researchers from continuing the work on thethaumatin portion of this project.

Although much work remains before these results will beseen in an industrial setting, the research team has beencontacted by several companies with a keen interest indeveloping xylitol production processes. Furthermore,several federal initiatives in the area of bio-based productsdemonstrate the timeliness of the research team’s vision ofutilizing Georgia’s vast agricultural and forest resources forthe production of specialty fuels, foods, and chemicals. Theresearchers are therefore optimistic that their two-year initialand successful efforts will permit future developments.



Casey Watkins, undergraduate student, takes samplefrom bench-scale fermenter for xylitol analysis.


page 25

Develop Improved Control Methods for Regulating the Factors and

Process Procedures That Eliminate the Development of the Pink Color

Quality Defects in Cooked Poultry Products

Project Leader

A. Estes Reynolds, University of Georgia, (706) 542-2574, [email protected] Participants

Manjeet Chinnan, Romeo Toledo, Yao-Wen Huang, Katarzyna Holownia, and Gregory LaRue, University of Georgia;Michael Robach, Wayne Farms LLC; Doug Hatley, Fieldale Farms Corporation; Jim Ayres, Gold Kist Inc.; RobinBurruss, Tip Top Poultry, Inc.


$128,867

Process & Product Competitiveness Projects, continued

In the pink defect (pinking, pinkness, or pink tinge) ofcooked poultry meat, white meat exhibits areas that retaina pink color even after the meat has been cooked to aninternal temperature far above 71.1 °C required by the U.S.Department of Agriculture. Consumers may interpret thepink discoloration as indicating undercooked meat that isunsafe to eat. Several factors are related to the pink defect:(1) various classes and types of pigments; (2) preslaughterfactors such as genetics, feed, feed withdrawal, heat andcold stress, and gaseous environment; (3) stunningtechniques; (4) incidental nitrate/nitrite contaminationthrough diet, water supply, and processing equipment; (5)current industry procedures, including the use of differentingredients and cooking methods; and recently, (6)irradiation of precooked products. All of the factorsinfluence specific in situ conditions such as pH, reducingconditions, and the presence, chemical state, and reactivityof pigments. More than 1.25 billion broilers are slaughteredand processed into food products each year in Georgia. Withsuch huge numbers, even a small defect can translate into avery substantial economic loss for the poultry industry.

Project Objective

To develop processing procedures and parameters thatwhen used with poultry product ingredients can inhibit oreliminate the formation of the pink color in cooked product.


Researchers concluded that it was possible to simulatethe undesirable pink color in cooked chicken breast meatusing in situ conditions of raw meat that were induced bysodium chloride, sodium tripolyphosphate, sodiumerythorbate, and sodium nitrite. The results from twoprocessing plants with two replications each showedreproducibility of the pink defect as no significant effect of

plant nor replication was found. (The continuation of thesimulation study will lead to a development of the pinkthreshold as a guideline for the poultry industry. Also,further investigation of occurrence of chemical changesassociated with pinking will aid in developing alternateprocessing methods to eliminate any pink defect.)

The research team also demonstrated that the pH ofcooked poultry breast muscle could be adjusted andmaintained to the desired end points after cooking. Theresults showed that the adjusted pH was significant in theformation of pink color in the cooked poultry breast meat(R2=0.9781). The breast muscle with initial light color andlow pH marinade was not as susceptible to developing pinkcolor as breast muscle with normal or dark initial color in amedium or high pH marinade. The effect of agepostmortem was not significant in predicting pink colorformation from either plant 1 or 2.

The addition of just 2 ppm of sodium nitrite to themarinade was effective in producing pink color in all of thetreatments, regardless of postmortem age, initial musclecolor, or the pH of the marinade. This is highly significantto the poultry industry as water samples from one of theparticipating plants contained nitrate levels as high as 4.1ppm – nitrate is the precursor to nitrite.

The effects of marinade pH and muscle color on the yieldof these treatments have produced a surprising result: adifference of 22%, ranging from a low of 73% yield on lightmuscle in low pH marinade to more than 90% yield for allcolors of muscle in the high pH marinade. This, however,must be correlated with the formation of pink color whenthe low pH breast muscle had minimal color formation.



page 26

Bloody thigh color in product injected with regularmarinade compared with product injected with abrowning accelerator. Both products were cooked at thesame time to an internal temperature of 170 °F.

The poultry industry must ensure that the sources ofnitrate or nitrite in its plants are minimized to eliminateone factor in the cause of pinking in poultry muscle.Maintaining high-quality poultry breast meat with normalpH also will increase yield, but the addition of excessivelevels of high pH marinade will increase the occurrence ofpink color in poultry meat.


Researchers will continue efforts to develop a pinkthreshold standard as a guideline for the poultry industryand investigate the occurrence of chemical changesassociated with pinking.


page 27

On-Farm Degreening of Bell Peppers to Add Value to Georgia Produce

Project Leader

Robert Shewfelt, University of Georgia, (706) 542-5136, [email protected] Participants

Darbie Granberry and Joy Wright, University of Georgia; Doug Horn, OHL, Inc.; William Lee, William Lee FarmsFY 2002 State Funding

$56,398


Georgia is an important producer of fresh vegetables, butmuch of the crop consists of traditional products marketedthrough traditional markets. Opportunities exist for addingvalue to fresh Georgia produce through innovativetechniques. Georgia growers produce large amounts of greenbell peppers and sell them at low prices, while yellow andred bell peppers are bought and sold at much higher prices.At the peak of pepper season, many green peppers are soldat or below the cost of production or are dumped ratherthan being sold. Red and yellow peppers command a higherprice on the wholesale market and could provide an alternatechannel for the pepper crop. Processed peppers of differentcolors are in demand in processed foods as ingredients andfood service as components in salad bars. However, themajority of colored peppers are grown in greenhouses andimported from Europe and Canada.

Project Objective

To investigate the on-farm degreening of bell peppers todetermine the potential of adding value to the Georgia crop.


Studies in a controlled environment clearly showed thathigh-quality red peppers could be obtained by storage ofgreen bell peppers at 20 °C/90% RH (relative humidity)— a condition reasonably achieved at an on-farm location.The two most critical factors in providing an acceptabledegreened pepper are maturity of the green pepper at harvestand RH control during degreening. Peppers harvested atthe “suntan” stage of maturity (first appearance of color inwhich the red pigment begins to develop without the lossof green chlorophyll) did not achieve an acceptable red colorupon degreening. Peppers harvested at the “color break”stage (obvious tinge of red showing) achieved excellentcoloration. A high RH (90%) was necessary to preventshriveling of peppers during degreening. While somedifferences were observed in degreening of different cultivars

or lines, these effects were not as significant as maturity atharvest and RH during storage. No stimulation ofdegreening was observed by treatment with ethylene aspreviously reported.

Researchers found that degreened peppers showed goodstability during the first week of refrigerated storage, but beganto shrivel unacceptably during the following two weeks.However, careful control of RH during refrigerated storageplus effective control of decay microorganisms should enhancethe shelf life of degreened peppers. The researchers also believethat the excellent quality of degreened peppers achieved suggeststhat they would provide processors with a desirable product.As a result, commercialization of degreened peppers in Georgiashows excellent potential. An in-depth marketing study,nonetheless, is needed to determine the commercial potentialof fresh and processed red peppers in the state.



Effect of degreening on selected peppers in the Summer2002 crop. Pictured top: Harvest 2 2002 #134 (6/14-6/26) (226-20 °C) Pictured bottom: Harvest 3 2002#126 (6/21-7/1) (226-20 °C).



page 28

Assessment of Flavonoids (Nutraceutical) Components of

Selected Georgia Agricultural Food Products

Project Leader

Casimir Akoh, University of Georgia, (706) 542-1067, [email protected] Participants

Gerard Krewer and Subramani Sellappan, University of Georgia; Lane Wade, Sunbelt District of Michigan BlueberryGrowers Marketing; Edward Bottoms, Georgia Muscadine Association, Inc.


$83,193

Nutraceutical products are gaining importance amongconsumers due to their health-promoting properties. Theopportunities are enormous for agricultural industriesbecause of the recent market developments in this area.However, the limited availability of scientific data onGeorgia-grown fruits and vegetables on the presence ofnutraceutical compounds is of concern. The identificationand quantification of major compounds in Georgia-grownagricultural products will provide a database on theircomposition. This, in turn, will assist in the effectiveutilization and production of targeted crops for the growingof nutraceutical markets and related industries.

Project Objectives

To extract and analyze the content of flavonoids andantioxidant capacity of Georgia agricultural crops; toconfirm the structure of the detected flavonoids; and tostudy the effect of processing and storage stability on theflavonoid concentrations and their antioxidant capacity.


Research on Georgia agricultural products, especiallyblueberries, grapes (muscadine and European varieties), andonions (Vidalia), was carried out to identify importantflavonoid compounds and determine antioxidant capacityand effect of processing and storage. A wide range offlavonoids (mg/100 g fresh weight, FW) myricetin (269.13- 541.03), ellagic acid (139.07-200.10), quercetin (15.67-54.03), kaempferol (14.33-28.80), and gallic acid (15.13-46.67) were identified in muscadine leaves. Vidalia onionshad (mg/100g FW) quercetin (7.70-46.32), kaempferol(1.54-1.98), and myricetin (2.77-4.13). The total phenolics(mg/g FW) of muscadine seeds were higher (15.36-32.59)compared with the skins (2.62-5.46). European variety hadbetween 7.23-32.42 mg/g FW in seeds and 2.52-9.00mg/g FW in skins. The antioxidant capacity of Vidalia onionswas in the range of 0.92-1.56 TEAC (Trolox equivalent

antioxidant capacity). Muscadine grapes had between 9.81-27.75 TEAC in whole fruits and 164.00-304.00 TEAC inleaves. Further analysis revealed the presence of variousanthocyanins both in muscadine and European grapes.Processing method affected the total antioxidant capacityof blueberry juice. Filtration and flushing with nitrogenimproved the stability of the juice.

Researchers believe these results will promote and encouragefood producers to use Georgia-grown fruits and vegetables toprepare nutraceutical products. The results will also have adirect impact on the marketing of Georgia’s muscadine, Vidaliaonion, and blueberry products, which will help to attract foodand pharmaceutical industries to Georgia as a majornutraceutical and functional foods raw material producer andsupplier. In terms of economic gain, it is expected to increaseat least 10% per year in overall marketability.



Filtration of blueberry juice using membrane filtration.



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Automated Inspection of Food Deboning Processes

Project Leader

George Vachtsevanos, Georgia Institute of Technology, (404) 894-6252, [email protected] Participants

Bonnie Heck, Wayne Daley, Yuhua Ding, Yingchuan Zhang, Nicholas Propes, and Irtaza Barlas, Georgia Institute ofTechnology; Ken Nix, Cagle’s Inc.; Mark Graves and Andrew Marshall, Intelligent Manufacturing Systems, Ltd.


$150,114


The need for a reliable inspection system has risen greatly inthe past five years as the demand for deboned meat has risensharply. The standard inspection process for bones in meat isfor workers to manually feel for bones. It is clear that this time-consuming manual inspection method is insufficient to meetthe increasing demand for deboned meat products.

The alternative to manual inspection is automatic x-rayimaging inspection, a technology currently being installedin several plants in the United States and Europe. The bestof the commercially available systems report accuracy levelsin the range of 95-98% for bones that are at least 2 mmcubed and have sufficient density. However, fan bones arelong and slender with thickness generally less than 2 mm.The x-ray manufacturers make no guarantee of detectingfan bones, but the estimates on detection are on the orderof 50%. An improved method for meat inspection that findsall types of bones is needed before widespread use of thetechnology can be realized.

Project Objectives

To develop an inexpensive machine vision-basedtechnology that will complement x-ray imaging; toinvestigate fundamental properties of bone and meat thatrelate to the inspection process; and to develop methods to“fuse” multiple sensors for improved inspection accuracyand reliability without exceeding targeted costs.


Researchers developed an inspection system that can bea stand-alone unit or a unit that works in conjunction withan x-ray inspection unit. The vision-based unit can detectsurface bones (particularly fan bones), while the x-ray-basedunit can detect bones buried in the meat.

On-line, real-time inspection algorithms were subjectedto α-testing under full-scale laboratory facility settings and

β-testing in a poultry plant. Images of 25 batches of chickenwere tested in the laboratory. The batches contained a totalof 574 parts, 259 with fan bones, while the remaining 315parts were bone-free. Of the 259 fan bone parts, 25 partswere claimed “clean,” and of the 315 “clean” parts, a totalof 12 parts were claimed “fan bone.” The system achieved adetection rate of 90.04% and a false positive rate of 3.9%.In the plant setting, results on the collected images showthat for a total of 282 parts, the system achieved a detectionrate of 88.37% and a false positive rate of 5.76%. Currentcomputation speed facilitates processing of 60 parts perminute on a single processing line.

Researchers believe results of this project will providesignificant benefits to the poultry industry in terms ofreduced processing costs, improved inspection performance,and increased throughput.



Yuhua Ding, research assistant, places chicken parts onthe vision-based inspection system during field tests at aGeorgia-based poultry plant.



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Systemic Defect Detection

Project Leader

Wayne Daley, Georgia Institute of Technology, (404) 894-3693, [email protected] Participants

Ji-Han Bae, Doug Britton, Marlon Moses, John Stewart, and Colin Usher, Georgia Institute of Technology;Allen McManus and George Parmer, Gold Kist Inc.


$140,114

The HACCP (hazard analysis and critical control point)-based inspection program in broiler processing plants hasplaced a greater burden on processors to ensure that foodsafety and other consumer protection concerns are properlymonitored and controlled. Under the program, plantpersonnel are responsible (albeit with U.S. Department ofAgriculture [USDA] oversight) for bird-by-bird sortation andinspection. To help plants succeed under this new program,however, there is a pressing need for screening technologythat would be unchallenged in this performance. This wouldtake the guesswork out of screening performance, instillingconfidence to USDA and the public that any plant’s screeningprogram will exceed the performance of the current U.S.Food Safety and Inspection Service (FSIS) screening system.

This task is currently done visually by FSIS postmorteminspection personnel and plant QA/QC personnel. It is welldocumented that the performance of people conductinginspection or quality control tasks deteriorates significantlyover time. An automated solution would be helpful both inreducing labor costs and increasing the accuracy of detectionand improving line efficiencies. Advances in low-cost cameratechnology now also make it possible to implement systemsin a more modular fashion that would provide flexibility butbe more cost-efficient than previously possible.

Project Objective

To build, install, operate, and evaluate a low-costautomated vision/imaging system to screen for systemicdefects on the kill line.


Researchers completed the development of a smallfootprint, ruggedized imaging cell for determining systemicdefects on the kill line. They constructed and installed asecond-generation imaging cell and field tested the newdesign in a continuous plant operation.

Field tests were conducted at Gold Kist’s poultry processingplant in Carrollton, Georgia. During the tests, the system wasrun continuously while being studied for reliability, accuracy,and marketability. From a reliability standpoint, the designperformed accordingly. The system failed to function on onlya few occasions over the entire test period, and in each case,the failure was due to either human or plant support errorrather than a hardware or software problem. From an accuracystandpoint, the project team used a variety of methods to studythe accuracy of the screening process. While a completeaccuracy evaluation could not be performed (because ofstatistical and logistical impediments), the evaluation completeddid indicate that the system was operating at a level consistentwith that of human sorters screening for systemic defects.Finally, from a marketability standpoint, suggestions were madeby Gold Kist management to add features to the system tohelp improve its overall value to the company. These featuresincluded the detection of broken wings, bruising, empty shacklecounts, line speeds, and mishung birds.



Colin Usher, research scientist, monitors the on-linesystemic defect detection system.



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Automated Material Handling in Food Further Processing

Project Leader

Wiley Holcombe, Georgia Institute of Technology, (404) 894-6144, [email protected] Participants

James Clark, Jacob Leverett, Gary McMurray, Sean Thomas, and Marlon Moses, Georgia Institute of Technology;Bob Purcell, Steve Dickerson, Scott Coleman, Sungsoo Rhim, and Ai-Ping Hu, CAMotion, Inc.; Bruce Hagins, JeffWalker, Dean Conner, Craig Manuel, and John Bartlett, Cryovac, Inc.


$125,795


The poultry industry has been a labor-intensive industrysince its inception. The nature of the product, as well as theproduction volume, have dictated the use of manual labor toperform the various operations in the processing plants. Typicaltasks, such as packing individual poultry pieces in a tray packor arranging the trays in a shipping case, have been consideredappropriate as manual operations in the past. Reasons for thisinclude product variety, speed, lack of exact productspecifications, the difficulty in product handling, and the needfor grading and inspection. Motivations to automate tasks infurther processing of poultry include the cost of labor (wages,insurance, floor space, and training); welfare of workers,reduction of risks and worker injuries; the availability of suitablelabor; and the ability to meet U.S. Occupational Safety andHealth Administration safety requirements.

Project Objective

To install working automation systems in the furtherprocessing areas of poultry slaughter plants.


Researchers completed the development of a low-cost pick-and-place robotic tray-handling system. Two commercializationpartners were added to the project team at the start of thefiscal year: Cryovac, Inc. and CAMotion, Inc.

During the first seven months of the fiscal year, theproject team completed the design and construction of acompletely new case packer with a new PC-based controller.The new case packer has three Cartesian linear axes and awrist rotation, just as the earlier case packer. However, allfour axes on the new machine have servo-electric drives;there are no pneumatic drives. Proprietary controlalgorithms and servo controllers from CAMotion areutilized to minimize the vibration of the machine, even

though it is operating at speeds more than 100 inches/second with accelerations more than 6 g.

The machine can pack No. 3 trays at a throughput of 49to 54 trays per minute (< 1.23 second average cycle time).The design team also completed the construction of a newconveyor system suitable for a weigh/price/label line,including a mechanism to exchange a full case for an emptycase in less than 1 second.



Pick-and-place robotic tray-handling system.



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Automated Vision-Based Inspection and Control of High-Volume Baking Processes

Project Leaders

Wayne Daley, Georgia Institute of Technology, (404) 894-3693, [email protected] Heck, Georgia Institute of Technology, (404) 894-3145, [email protected]


Doug Britton, Brian Galloway, Daniel Sims, John Stewart, George Vachtsevanos, and Yingchuan Zhang, GeorgiaInstitute of Technology; Stephen Smith, BakeTech; J.D. Freeman, Flowers Bakeries, Inc.


$170,114

The bakery industry is the second largest segment of thefood processing industry in the United States. One of itsgrowing market segments is the production of buns androlls for food-service and fast-food customers. Many of thesecustomers are increasing the demands on bakery qualitycontrol operations that screen for bun size, shape, color,and garnish coverage.

Currently, the standard inspection process for bakedproducts is for workers to manually remove samples fromthe line and compare them with customer and industryspecifications. If the results indicate a problem, steps aretaken to adjust the operation to eliminate future qualityproblems. At-line inspection systems have recently begunto emerge that allow these quality checks to be performedimmediately next to the line. However, it is clear that time-consuming manual inspection methods are becominginsufficient to meet the customers’ expectations for productconsistency and uniformity.

Project Objective

To design an on-line inspection system to continuouslymonitor and control product quality on a commercial bread/bun line.


Researchers completed a survey of the bakery industry’sprocesses and needs and generated the design for acomputer-vision inspection system. This included the designand construction of a prototype, laboratory-scale machine-vision system that consists of an illumination dome,inexpensive IEEE 1394/Fire Wire cameras, and a personalcomputer. The software development involved generatingalgorithms to identify various bun defects (such as off-color/bake level, garnish coverage and distribution, and two-

dimensional shape and/or size, etc.). Researchers beganinitial tests of the system on a laboratory-scale conveyorsystem and on a production line. Researchers also initiatedfeasibility studies into viable supervisory control strategiesfor completing the feedback loop, and began developmentof appropriate models for the oven and baking process.


Researchers will continue to further develop thecomputer-vision inspection system, including refining theinspection and grading algorithms and enhancing thecontrol strategy. Extensive field tests are also planned.

The prototype machine-vision system being developedfor continuous monitoring and control of productquality on a commercial bread/bun line.



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Systems to Support the Expansion of Georgia’s Fruit and Vegetable Industry:

Promotional Effectiveness of the Grown in Georgia Campaign

Special Project

Project Leaders

Kent Wolfe, University of Georgia Center for Agribusiness and Economic Development, (706) 542-0752,[email protected] McKissick, University of Georgia Center for Agribusiness and Economic Development, (706) 542-9080,[email protected]


$21,449

Georgia produce growers and food processors are facingincreasing competition from within the region, nationally,and internationally. Many states have implementedpromotional programs aimed at increasing consumers’awareness of the benefits of purchasing locally producedand processed foods. For instance, supporting state growersbenefits the state economically but also ensures a supply offresh locally grown produce.

As a result of the success of promotional programs inother southeastern states and increased competition fromnon-Georgia produce, there needs to be a means ofdifferentiating Georgia-grown fresh produce and processedfoods from competing products. Promoting Georgia-grownproduce and products through promotion and labelingprovides a marketing tool to differentiate Georgia’s productsfrom those grown and produced out of state. In addition,Georgians need to be informed of the advantages ofpurchasing Georgia-grown fresh produce, i.e., it is fresherthan produce brought in from out of state.

Project Objective

To measure the effectiveness of the 2001 Grown inGeorgia promotional campaign.


The Center for Agribusiness and Economic Development atthe University of Georgia implemented two surveys to measurethe effectiveness of the 2001 Grown in Georgia promotionalcampaign. The first survey was a consumer intercept survey thatwas administered to respondents as they were exiting the producedepartment of a national supermarket chain. This survey wasused to gauge shoppers’ awareness and perception of the Grownin Georgia campaign. In addition, a telephone survey wasadministered statewide to determine if the food quality, safety,and loyalty issues that were important in the fresh produceindustry were also present in the processed food industry.

The results of this project indicate that the Georgia-grownmarketing campaign has the potential to significantly impactGeorgia’s growers by increasing retail sales of Georgia-grownfresh produce and processed food products. Retail outlets inthe state should be made aware of shoppers’ preferences forGeorgia-grown fresh produce and processed foods and thepotential impact the program might have on sales. Accordingto the survey results, a significant number of shoppers reportedthey would switch stores to be able to purchase Georgia-grownfresh produce and processed foods. This information providesleverage with Georgia’s growers and processors. Retail outletsthat choose not to participate in the program take the chanceof losing customers and the increased potential sales that canbe generated from consumers purchasing additional quantitiesand types of Georgia-grown fresh produce.

In addition, only a handful of shoppers were aware of theGeorgia-grown marketing campaign prior to the day theywere interviewed. However, 94% of the shoppers indicatedthey would purchase Georgia-grown fresh produce overcompeting produce if it was competitively priced and offeredsimilar quality. A similar result was noted for processed foods.Nearly 9-in-10 (88%) of Georgians indicated they wouldpurchase Georgia processed food products over competingproducts given they were similarly priced and of similarquality. Nearly all of the Georgians interviewed indicatedthat labels should be used to identify Georgia-grown freshproduce (99%) and foods processed in Georgia (90%). Theintercept survey found that 61% of shoppers reported thatthe Georgia-grown displays influenced their fresh producepurchase decision. Given the potential impact of thismarketing program, additional resources and effort shouldbe directed to educate and inform consumers in order toincrease the awareness of the campaign.

Georgians need to be informed of the advantages ofpurchasing Georgia-grown fresh produce. For example,



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media advertisements could focus on the quality of Georgia’sfresh produce and the fact that because it is grown locally,it is fresher than produce brought in from out of state. Themarketing campaign should make a clear connectionbetween locally grown fresh produce products, theirdesirable qualities, and the Georgia-grown displays andlogos. The study results suggest implementing an aggressivein-store advertising campaign in coordination with theexisting promotion to increase awareness and encouragepurchases of Georgia products.

Overall, according to the Grown in Georgia analysis, thereis evidence that the promotional campaign was effective inincreasing fresh produce sales and significant marketpotential in the processed food industries. During thepromotional period, the Georgia stores experiencedsignificantly higher produce sales over the previous year thandid the non-Georgia stores. Examining store level data alsosupports the idea that the promotional campaign increasedsales. The cost-benefit ratios are positive, suggesting thatthe retail sales returns to the Grown in Georgia promotionalcampaign far exceed the cost of the campaign.

Given Georgians’ loyalty to products produced in the state,the Grown in Georgia promotional campaign should beaggressively expanded to include processed foods. Thisindustry has not been fully incorporated into the promotionalcampaign and could benefit from this inclusion.

Economic Impact2000 and 2001 Analysis. The Grown in Georgia

campaign increased the promoted product sales by 6.10%when compared with the same stores over the same timeperiod in 2000. The cost of generating this additionalrevenue was $100,000, yielding a cost benefit ratio of 4.37.Therefore, for every dollar spent on the promotion, anadditional $4.37 was realized.

The 6.10% change in sales over 2000 translates into anincrease of $436,513 for Georgia’s Kroger stores. Given thatparticipating food retailer has 25% of the Georgia retailfood market, it is possible to estimate the impact of the2001 program if it was implemented statewide. Multiplyingthe $436,513 by four, it is estimated that the promotionwould have generated $1,746,052 statewide.

Georgia versus Non-Georgia Analysis. The Grown inGeorgia campaign increased revenue by 6.10% in the state.The non-Georgia stores experienced a decrease of 4.23%for the 11 products being featured during the promotionperiod. The difference between the Georgia and non-Georgia stores is 10.33%. Using this figure, it is estimatedthat the program generated an additional $736,774 forGeorgia’s participating food retail stores. The cost ofgenerating this additional revenue was $100,000, yieldinga cost benefit ratio of 7.37.




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The Food Chain Newsletter

FoodPAC continued to publish The Food Chain newsletter, which is distributedbimonthly to more than 700 subscribers. The newsletter provides updates on fiscalyear closeout, start-up, and planning activities, in addition to, program news,organizational changes, and committee meetings.

FoodPAC Website

http://foodpac.gatech.edu

FoodPAC continued to maintain the FoodPAC website. The websiteprovides up-to-date information about FoodPAC operations, Call forProposals, project reports, and past copies of FoodPAC Annual Reportsand The Food Chain newsletter.

Implementation Projects


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FoodPAC FY 2003 Projects

Environmental

Air Emission Factors for Process Control and Pollution PreventionPrincipal Investigator: K.C. Das, University of Georgia, (706) 542-8842, [email protected] 2003 Funding: $63,050

Support Mill Trials for Commercialization of Recycled PET-Coated Boxes as Replacement for Waxed BoxesPrincipal Investigator: Jeffery Hsieh, Georgia Institute of Technology, (404) 894-3556, [email protected] 2003 Funding: $105,730

Low-Cost Microfiltration System for Recycling of Waste Water in a Fresh-Cut Vegetable OperationPrincipal Investigator: Romeo Toledo, University of Georgia, (706) 542-1079, [email protected] 2003 Funding: $48,500

Wet Scrubber and Biofilter Models for Process Design and Improvement of VOC RemovalPrincipal Investigator: James Kastner, University of Georgia, (706) 583-0155, [email protected] 2003 Funding: $90,812

Development of an Advanced UV Disinfection TechnologyPrincipal Investigator: Larry Forney, Georgia Institute of Technology, (404) 894-2825, [email protected] 2003 Funding: $97,382

Food Safety

Control of Listeria monocytogenes in Ready-to-Eat Foods and in Biofilm Formation by Competitive ExclusionBacteriaPrincipal Investigator: Michael Doyle, University of Georgia, (770) 228-7284, [email protected] 2003 Funding: $99,439

A Study to Determine the Feasibility of Developing a Commercial-Scale Food Irradiation Research andDemonstration Facility in GeorgiaPrincipal Investigator: James Daniels, University of Georgia, (706) 542-2574, [email protected] 2003 Funding: $58,200

Intervention Strategy to Reduce Campylobacter Carriage in ChickenPrincipal Investigator: Jinru Chen, University of Georgia, (770) 412-4738, [email protected] 2003 Funding: $59,694

Using Electrolyzed Water for Sanitization and Removing Fecal Materials During Poultry ProcessingPrincipal Investigator: Yen-Con Hung, University of Georgia, (770) 412-4739, [email protected] 2003 Funding: $68,656


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FoodPAC FY 2003 Projects, continued

Process & Product Competitiveness

Develop Improved Control Methods for Regulating the Factors and Process Procedures that Eliminate theDevelopment of the Pink Color Quality Defects in Cooked Poultry ProductsPrincipal Investigator: A. Estes Reynolds, University of Georgia, (706) 542-2574, [email protected] 2003 Funding: $92,635

Automated Vision-Based Inspection of High-Volume Baking ProcessesPrincipal Investigators: Doug Britton, Georgia Institute of Technology, (404) 385-0418, [email protected]

Bonnie Heck, Georgia Institute of Technology, (404) 894-3145, [email protected] 2003 Funding: $164,893

Automatic Detection of Package Integrity on Tray Pack ProductPrincipal Investigator: Wayne Daley, Georgia Institute of Technology, (404) 894-3693, [email protected] 2003 Funding: $138,921

Analysis of Nutraceutical Compounds in Georgia-Grown Blueberries Responsible for Preventing Urinary TractInfectionsPrincipal Investigator: Casimir Akoh, University of Georgia, (706) 542-1067, [email protected] 2003 Funding: $67,359

Assessment of the Polyunsaturated Fatty Acid Content and Palatability of Georgia Grass-Fed BeefPrincipal Investigator: Susan Duckett, University of Georgia, (706) 542-0942, [email protected] 2003 Funding: $67,900

Improving the Profitability and Safety of Fresh Fruit and Vegetables in Packing HousesPrincipal Investigator: Bryan Maw, University of Georgia, (229) 386-3377, [email protected] 2003 Funding: $26,190

Documents

Report to Industry - Food Processing Technology Divisionfoodtech.gatech.edu/pdfs/FPAC2003AR.pdf · leader in food processing in the 21st century ... Fiscal Year 2002-2003 Report to