Delaware Poultry Plants Embrace New Chemical-Free Cleaning Technologies

Poultry processing facilities are adopting innovative cleaning methods that eliminate chemicals while maintaining food safety standards. Three new technologies presented at a recent industry summit offer alternatives to traditional chemical treatments, using methods like electrostatic spraying, high-velocity water droplets, and cold plasma to remove harmful bacteria.

Delaware’s poultry processing industry is embracing cutting-edge technologies that eliminate the need for chemical cleaning agents while maintaining strict food safety requirements. These innovations were showcased at the 2025 Poultry Tech Summit in Atlanta, Georgia, offering local processors new ways to reduce costs and environmental impact.

Processing facilities throughout the region are dealing with tighter contamination regulations and rising operational expenses. Three breakthrough technologies – electrostatic spray applications, high-velocity water droplet systems, and cold plasma treatments – provide solutions that address regulatory compliance while supporting environmental sustainability goals.

These advanced systems tackle specific operational challenges while advancing the industry’s commitment to safer, more sustainable food production methods.

Charged Water Droplets Provide Complete Coverage

A revolutionary electrostatic spray system transforms individual water drops into multiple smaller, electrically charged particles that can effectively eliminate pathogens on poultry products.

According to Bruce Whiting, owner and chairman of Electrostatic Spraying Systems Inc., this technology allows charged water particles to “wrap around” and provide complete product coverage.

The innovation combines electrical attraction with antimicrobial agents for pathogen elimination and improves chemical distribution effectiveness. These electrically charged particles stick to grounded surfaces like chicken carcasses and can reach hidden areas where harmful bacteria typically hide, serving as an effective disinfectant.

This approach enables processing facilities to use conventional antimicrobials like peracetic acid more effectively while making advanced treatments such as bacteriophages financially practical.

Processing plants dealing with water scarcity or municipal usage restrictions have implemented this technology, as many regions now impose limits on industrial water consumption, Whiting noted.

Ultra-Fine Water Droplets May Replace Chemicals Entirely

Advanced micro-droplet systems using only clean drinking water could help processors meet both U.S. industry requirements and European Union processing regulations, according to Twan Koenen, processing and hygiene technologist at Innovative Water Concepts.

This technology merges compressed air with water to produce droplets roughly five times larger than Salmonella bacteria, propelling them at speeds between 20 and 140 miles per hour. These tiny droplets generate 50 to 60 times more kinetic force per gallon compared to standard spray systems, allowing penetration into skin pores and feather follicles.

The micro-droplet approach depends on physical kinetic force from high-speed water particles to mechanically eliminate pathogens and biofilms, aiming to completely replace chemical treatments through mechanical action.

This technology helps processors focus on critical contamination periods when Salmonella adheres to poultry skin and removes potential contaminants during evisceration before quality problems develop, Koenen explained.

The system proves particularly valuable for processors seeking to minimize chemical use, including peracetic acid and chlorine, he added.

Plasma Treatment Addresses Heavy Bacterial Contamination

Cold plasma technology shows promise for reducing bacterial contamination on raw chicken products, based on research from Auburn University.

This method applies electrical currents to gases like oxygen or nitrogen, generating plasma that damages bacterial cell walls and DNA of poultry pathogens, explained Katherine Sofia Sierra Melendrez, a graduate student at Auburn University.

Auburn’s laboratory studies using portable plasma devices demonstrated changes in bacterial populations, with species like Pseudomonas showing reduced presence. These results could help processors increase shelf life, decrease costs, and minimize food waste, she noted.

Current technology limitations include treatment time requirements, as applications may need 5 minutes to achieve effectiveness.

However, Melendrez indicated that companies are creating systems capable of activating several gallons of plasma per minute, opening possibilities for integration into existing chiller systems or antimicrobial spray stations. Auburn’s research team continues conducting sensory evaluations to assess impacts on product quality and consumer acceptance.

Reducing Chemical and Water Dependency Becomes Priority

These three technologies represent a significant shift in poultry processing toward decreased chemical reliance.

Processing facilities face mounting pressure to minimize chemical and water usage while exploring alternative pathogen control approaches due to increasing operational costs, stricter regulations, and growing demand for cleaner processing techniques.

Consumer preference for “cleaner” or more sustainable food production accelerates this transformation. Modern consumers increasingly examine food labels and processing methods, creating market demand for processors to implement technologies that maintain food safety while improving sustainability.

A March 2025 report from analyst firm Innova Market Insights shows consumers choosing clean label foods as they prioritize transparency and sustainability globally. Innova also discovered that 30% of worldwide food and beverage companies introduced clean label claims within the past year.

The European Union’s requirement for potable water-only processing establishes a standard that may influence future U.S. regulations. Processors adopting chemical-reduction technologies now could position themselves to meet upcoming standards without experiencing production disruptions.

While processors aren’t required to list processing aids as ingredients on product labels, implementing technologies that decrease water and chemical usage allows poultry producers to market themselves effectively and share their sustainability message with consumers.