**2. Methodology**

The study was carried out by observing the production processes of the different plants (hatchery, fattening farm, slaughter plant, depressing plant, and consumption site), with information provided by the different actors in the chain (operating personnel of the company, consumers, company managers, experts, vendors, suppliers, transporters, among others), and by verifying all the documents required during the visits.

Some principles of the HACCP system were used as a tool, since it allows the identification of CCPs and the subsequent definition of corrective and control measures throughout the processes.

## **3. Results and analysis**

The results are presented below according to the stated objective:

The chicken meat production chain is made up of the stages of incubation, fattening, slaughter, depressing, and consumption. For each of the plants and consumption site, data on the location of the plant such as altitude, surroundings, ambient temperature, and relative humidity are indicated, since these are environmental characteristics that can influence, justify, or be related to the hazards identified throughout the process in the poultry chain.

### **3.1 Hazard identification and CCPs**

For the definition of CCPs, it is analyzed whether the operation exists specifically to eliminate or reduce a hazard, if contamination reaches unacceptable levels at that stage, or if a subsequent operation does not eliminate or reduce the hazard to acceptable levels. This is in accordance with the 1993 Codex Committee's Guide for the Application of HACCP.

The operations that make up each of the stages and the analysis of the hazards (physical, chemical and biological) and CCPs identified are presented in the following graphs.

*Identification and Analysis of Safety Hazards and CCPs in a Chicken Meat Production Chain DOI: http://dx.doi.org/10.5772/intechopen.109721*

### **Incubation:**

Plant location data:

Altitude: 288 masl**.**

Surroundings: Vegetation (grass and trees). It is located 314m from a recreational club, 226 m from a Hacienda, 307 m from a hotel, 683 m from another hotel, and 338 m from a condominium.

Ambient temperature: 27.3**–**29.3°C (27.3**–**29.3°F)**.**

Relative Humidity: 66.38%.

**Figure 1** of the incubation stage is shown below:

The hazards identified in each of the operations of the hatchery stage are detailed in **Table 1**, as well as the CCPs:

As an open hatchery, it is exposed to environmental and pest contamination, since it is located in a rural area, surrounded by grass and trees, which increases the risk of biological contamination by animals or pests. With a climate between 27 and 29°C, there are more insects, crawling and flying insects, among others. In accordance with the above, there must be a rigorous cleaning and disinfection process *before* starting the processes.

### **Figure 1.**

*Incubation stage. Source: Own elaboration based on the visit to the hatchery.*



**Table 1.** *Hazards and CCPs at the hatchery stage.*

In egg incubation, the quality of the egg delivered by the supplier is very important, so that it is not contaminated by pathogenic microorganisms, since this determines the contamination from then on in the process.

*Biological* hazards during this stage are caused by deficient or inadequate disinfection practices, since the disinfectant is not correctly *dosed* in the water (milliliters of disinfectant per liter of water) or the retention times are not met, and therefore, there is no guarantee of effective elimination of unwanted microorganisms. Likewise, since immediate verifications are not carried out by means of techniques such as luminescence, the effectiveness of disinfection and corrective actions cannot be checked immediately. This, in addition to the fact that during the visit, there was no evidence of compliance with the processes of disinfecting egg trays and tables prior to reception, and some empty bottles of hand sanitizer were observed. All operations may be affected by cross-contamination due to the lack of hand disinfection, because they are performed manually with direct intervention of the operators.

The variation of temperature, humidity, and time in the incubators and hatchers causes a risk of growth of undesirable microorganisms; however, this equipment has sensors that regulate these variables, and during the visit, the operators were observed keeping records on paper forms for monitoring purposes.

Another risk factor for biohazards is the incorrect preparation of the subcutaneous vaccine or incorrect application of the vaccine, since the vaccine is prepared by plant operators. In relation to the correct application of the vaccine, this liquid has a green color so that this color can be observed in the application area, as evidence of the liquid entering the chick's body. For vaccination by spraying, there is a risk of exposing the chick to the vaccine for more or less time than allowed, since, although there is a timer, it is an activity performed by an operator.

At this incubation stage, the only CCP identified is *vaccination* since this vaccination operation has been specifically designed to eliminate a biological hazard such as Marek's disease, Newcastle disease, and bronchitis. The other operations (egg unloading, egg reception, egg selection, egg sorting, egg temporary storage, loading into setter trays, incubation, transport to hatchers, chick hatching, chick selection, chick sexing, chick temporary storage, chick crates loading to the vehicle, and chick transport to the farm) are not considered CCPs since they are not operations designed to reduce the risk of CCPs. The other operations (unloading eggs, receiving eggs, sorting eggs, selecting chicks, sexing chicks, temporary storage of chicks, loading crates with chicks into the vehicle and transporting chicks to the farm) are not considered CCPs, since they are not operations designed to eliminate a hazard or reduce it to an acceptable level, nor can contamination reach unacceptable levels in these operations.

In relation to *physical* hazards in the incubation stage, feathers and dirt are present on the eggs; however, they are checked and returned if these quality defects are present.

### **Fattening:**

Plant location data:


*Identification and Analysis of Safety Hazards and CCPs in a Chicken Meat Production Chain DOI: http://dx.doi.org/10.5772/intechopen.109721*


**Figure 2** of the fattening stage is shown below:

The hazards identified in each of the operations of the fattening stage are detailed in **Table 2**, as well as the critical control points (CCP) based on the HACCP methodology:

When receiving the chicks, it is important to verify the state of health of the bird delivered by the transporter, so that it does not present diseases, since this determines the contamination from then on in the process.

*Biological* hazards occur at this stage due to the risk of contamination by pathogenic microorganisms either through contaminated water, contaminated feed, transmission by pests, ineffectiveness of the vaccine due to inadequate administration, or poor cleaning and disinfection processes of feeders, drinkers, curtains, and vehicle, among others, and non-compliance with biosecurity measures.

In this fattening stage, the CCP identified is *vaccination and feeding*, since in the case of vaccination, this operation has been specifically designed to eliminate a biological hazard such as Gumboro, Newcastle, and bronchitis diseases. And in the case of feeding, although this stage is not designed to eliminate or reduce a hazard, contamination can reach unacceptable levels, which are not reduced in subsequent operations. It is also possible to have intervention measures to reduce the danger of contamination by pathogens, through the provision of bacteriophages in the feed or similar. The other operations (unloading and reception of chicks, intake and fattening, feeding, loading and transport of chickens to the processing plant) are not considered CCPs, since they are not operations designed to eliminate a hazard or reduce it to an acceptable level, nor can contamination reach unacceptable levels in these operations.

In relation to *chemical* hazards, there is a risk of antibiotic residues in chicken meat, due to non-compliance with the withdrawal times of feed containing growth promoters or medicines given to the birds in case of illness.

### **Figure 2.**

*Fattening stage. Source: Own elaboration based on the visit to the farm.*


**Table 2.**

*Hazards and CCPs in the fattening stage.*

*Identification and Analysis of Safety Hazards and CCPs in a Chicken Meat Production Chain DOI: http://dx.doi.org/10.5772/intechopen.109721*

Sacrifice: Plant location data:

• Altitude: 2625 masl


**Figure 3** of the slaughtering stage is shown below:

The hazards identified in each of the operations of the slaughter stage are detailed in **Table 3**, as well as the critical control points (CCP) based on the HACCP methodology:

The location of the slaughter plant in a cold climate mitigates somewhat the risk of contamination by undesirable microorganisms compared to slaughter plants located in warm climates. Likewise, being located in an urban area, the presence of domestic animals, pests, and flying crawlers is reduced compared to a plant located in a rural area with a warm climate.

A critical operation in the slaughter of poultry is the ante-mortem inspection, since there is a danger of biological contamination of birds with pathogenic microorganisms or diseases; therefore, it is necessary to certify disease-free animals from the farm.

Likewise, *biological* hazards during this stage are caused by deficient or inadequate disinfection practices, since the dosage of the disinfectant in the water (milliliters of disinfectant per liter of water) is not correctly carried out, or the retention times are not met, and therefore, there is no guarantee of effective elimination of undesirable microorganisms. Likewise, since immediate verifications are not carried out by means of techniques such as luminescence, the effectiveness of disinfection and corrective actions cannot be checked immediately. The above, in addition to the fact that during the visit, very poor cleaning and disinfection practices were observed, due to excess feathers in the plucking area, excess cuticles in the leg-peeling area, excess viscera and blood in the evisceration areas, viscera cooling tanks and viscera packaging. This is aggravated considering that there is always the risk of contamination with fecal matter coming from the crates where the live birds arrive and during the operations of unloading of birds, weighing of birds, ante-mortem inspection, hanging of birds, desensitization, slaughter, and bleeding and mainly during the evisceration process due to the rupture of the intestines.

The CCPs identified in the slaughter stage correspond to the *evisceration and disinfection of the carcass*. In the evisceration operation, specifically, if the intestine ruptures, given that, although the stage was not designed to eliminate or reduce a risk, contamination can reach unacceptable levels, due to contamination with fecal matter from the rupture of the intestine. In the disinfection operation, the step was specifically designed to eliminate or reduce a hazard; therefore, it is considered a CCP.

### **Figure 3.**

 *Sacrifice Stage. Source : Own elaboration based on the visit to the slaughter plant.* 

 With respect to *chemical* hazards, there is contamination by disinfectants, due to incorrect dosage (addition of more disinfectant than defined), longer retention time, or no rinsing (in cases where this should be done). This type of hazard is observed in the plucking process, since the equipment has spaces that are difficult to access, making cleaning and disinfection difficult and leaving disinfectant residues on the equipment. This risk is also present during the evisceration process, since carcasses that have any contact with dirty areas are disinfected, and during pre-cooling, where carcasses are disinfected prior to packaging. Finally, packaging contaminated with detergents or disinfectants may exist; however, this risk is low in the production plant, since there is evidence of packaging storage in separate rooms from the storage of all types of inputs, in compliance with Good Manufacturing Practices (GMP).

*Identification and Analysis of Safety Hazards and CCPs in a Chicken Meat Production Chain DOI: http://dx.doi.org/10.5772/intechopen.109721*



### *Poultry Farming – New Perspectives and Applications*

*Identification and Analysis of Safety Hazards and CCPs in a Chicken Meat Production Chain DOI: http://dx.doi.org/10.5772/intechopen.109721*



**Table 3.** *Hazards and CCPs in the slaughter stage.*

### *Identification and Analysis of Safety Hazards and CCPs in a Chicken Meat Production Chain DOI: http://dx.doi.org/10.5772/intechopen.109721*

In relation to *physical* hazards, feathers are present at the slaughtering stage and are removed by the plucking machine. Subsequently, at the end of the evisceration line and before pre-cooling, there is a process of visual verification of carcass quality, where any feathers that are still present are removed. Another danger is the cuticles that are removed from the legs and can become cross-contaminated with subsequent processes due to excess cuticles in the area without frequent cleaning of the equipment and the area; however, as mentioned, the carcass is visually inspected before pre-cooling. Fractions or pieces of plastic packaging may be present during the packaging process due to quality defects in the packaging supplied by the supplier; however, this risk is low, since there has been no evidence of such contamination by production plant personnel, and there have been no complaints from customers or consumers. Finally, for physical hazards, there are hairs, which can fall in any of the operations that take place outside the slaughter line tunnel and that have direct contact with food handlers, such as the operations of turning the chicken, cutting the legs of the carcass, hanging the chicken carcass, evisceration, packaging, and packing. However, this risk is low, since they wear a cap that completely covers their hair and ears, reducing this risk to a minimum, especially in the packing process.
