Foodborne pathogens like E. coli O157:H7, Listeria monocytogenes, and Salmonella remain some of the most dangerous threats to the meat and poultry processing industry. Despite decades of intervention strategies, food recalls, consumer illnesses, and even fatalities continue to plague the sector—often traced back to contaminated beef surfaces, biofilms, or gaps in sanitation during chilling and storage.
For food processors in the United States and globally, this reality creates high stakes:
- Regulatory fines and recalls that damage brand reputation
- Increased risk of workplace safety violations
- Costly sanitation downtime and labor strain
- Consumer trust erosion at a time when transparency is demanded more than ever
Traditionally, meat processors have relied on chlorine dioxide, peracetic acid, quaternary ammonium compounds (QACs), and other chemical sanitizers. While once effective, these approaches are showing diminishing returns due to:
- Pathogen resistance and biofilm protection
- Harsh residues left on surfaces and equipment
- Worker safety risks from chemical handling
- Environmental compliance challenges
Simply put: the meat industry needs a safer, more sustainable, and more effective solution.
USDA Research Validates Aqueous Ozone (AO) for Meat Safety
A groundbreaking USDA study published in the Journal of Food Protection provides compelling evidence that aqueous ozone (AO) is a superior intervention for beef processing environments.
The study, “A Novel Aqueous Ozone Treatment as a Spray Chill Intervention Against Escherichia coli O157:H7 on Surfaces of Fresh Beef” (Kalchayanand et al., 2019), compared traditional water spray chilling with aqueous ozone application.
Key Findings from the USDA Study:
- Water spray chilling reduced E. coli O157:H7 by only 0.60 log
- Aqueous ozone reduced the same pathogen by 1.46 log — more than double the effectiveness
- AO also reduced total aerobic bacteria by 0.99 log
- Unlike chemical sanitizers, AO left no residues, breaking down naturally into oxygen and water
This USDA-backed data confirms what HS Ultra has long advocated: aqueous ozone is a powerful, scalable tool for pathogen control in meat and poultry facilities without the drawbacks of chemical sanitizers.
What Makes Aqueous Ozone So Effective?
Aqueous ozone (AO) is ozone gas dissolved in water, creating a highly reactive, fast-acting disinfectant.
Here’s why it works:
- AO oxidizes microbial cell walls, killing bacteria, viruses, and mold spores quickly.
- It penetrates and disrupts biofilms on stainless steel, plastics, drains, conveyors, and chillers.
- It breaks down into oxygen and water, leaving no toxic residues on meat, equipment, or facility surfaces.
This means processors get the benefits of a potent antimicrobial intervention without the regulatory and compliance headaches tied to harsh chemicals.
At HS Ultra, this aligns with our mission to:
- Deliver chemical-free sanitation solutions
- Improve sustainability in food processing facilities
- Protect workers from hazardous residues
- Safeguard consumers from pathogens that cause recalls and outbreaks
Why This Matters for Food and Meat Processing Facilities
For meat and poultry plants in the U.S. and beyond, this research is more than academic—it’s operationally transformative.
HS Ultra’s AO and UV-C disinfection technologies are engineered for real-world plant conditions. We help facilities:
- Comply with FSIS and FDA regulations while minimizing chemical dependency
- Eliminate biofilms from stainless steel, poly, conveyor belts, drains, and chilling systems
- Implement clean-in-place (CIP) protocols that reduce downtime and labor needs
- Improve energy efficiency and cut chemical costs
- Reduce a facility’s carbon footprint through sustainable cleaning practices
From portable AO generators for emergency sanitation to inline automated systems for spray chill and water loop disinfection, HS Ultra tailors solutions to the specific needs of meat and poultry processors.
Aqueous Ozone vs. Traditional Chemical Sanitizers
| Factor | Traditional Sanitizers | Aqueous Ozone (AO) |
| Effectiveness on E. coli O157:H7 | Limited (water spray reduced only 0.60 log) | Superior (AO reduced by 1.46 log) |
| Residue Concerns | Leaves harsh chemical residues | Breaks down into oxygen + water |
| Worker Safety | Requires chemical handling, PPE, risk of exposure | Safe when deployed with controls |
| Environmental Impact | Disposal and compliance challenges | Eco-friendly, chemical-free |
| Biofilm Resistance | Often persists on equipment | AO penetrates and disrupts biofilms |
This comparison underscores why the USDA findings represent a paradigm shift for food safety protocols.
A Better Future for Food Safety with HS Ultra
The food industry is under pressure like never before. Consumers demand clean-label practices, regulators are enforcing stricter oversight, and the risks of outbreaks and recalls are simply too high to maintain the status quo.
With HS Ultra’s USDA-backed aqueous ozone technology, food processors can:
- Strengthen pathogen control protocols
- Cut reliance on harsh sanitizers
- Reduce downtime and sanitation costs
- Improve environmental and worker safety outcomes
- Meet the rising demand for sustainable food processing
Whether you operate a beef plant, poultry facility, or ready-to-eat packaging line, HS Ultra provides validated, chemical-free disinfection strategies that scale with your operation.
Conclusion: The Time to Rethink Meat Safety is Now
The USDA study confirms what innovators have long known: aqueous ozone is a game-changer for meat processing sanitation. It outperforms water sprays, reduces pathogens more effectively, leaves no harmful residues, and supports a safer, more sustainable food industry.
At HS Ultra, we’re not just following science—we’re advancing it. By combining aqueous ozone with UV-C and data-driven disinfection systems, we give meat processors the tools they need to protect consumers, workers, and brands in today’s demanding food safety environment.
The future of food safety isn’t chemical-heavy—it’s chemical-free, science-backed, and scalable.
Ready to learn more? Explore HS Ultra’s food processing sanitation solutions today.
