Harnessing cold plasma and packaging innovation to elevate poultry food safety

Cold Plasma: powerful nonthermal technology

Ensuring food safety while addressing sustainability concerns is one of the poultry industry’s most pressing challenges. As poultry consumption grows globally, so does the need to adopt innovative technologies that reduce pathogens, limit food waste, and appeal to consumer expectations.

During my master’s and doctoral research at Auburn University, I have been investigating two promising approaches to address these challenges simultaneously: the development of antimicrobial biodegradable packaging and the application of cold plasma technology for microbial reduction.

These two areas - once seen as separate - are now merging to create integrated solutions for shelf-life extension, contamination control, and more sustainable meat processing practices.

Advancing packaging with built-in safety
One of my most exciting projects involves developing an edible, biodegradable film made from chicken-derived skin collagen and natural antimicrobials such as sodium lactate and sodium diacetate. This packaging, which we dubbed “Chicken Packed in Chicken,” targets Listeria monocytogenes - a pathogen of serious concern in ready-to-eat meat-poultry products.

Over a 12-week storage study, this film demonstrated a significant reduction in microbial load on deli meat without affecting sensory quality. It also eliminated the need for synthetic plastic packaging and showed strong potential to replace conventional films in vacuum-sealed poultry products.

Our goal were reducing plastic waste and enhancing food safety by making packaging itself an active component in microbial control.

Cold Plasma: powerful nonthermal technology
While packaging innovation addresses long-term contamination, my work with cold plasma technology focuses on immediate, non-thermal inactivation of pathogens on raw poultry and processing surfaces.

Cold plasma works by creating reactive oxygen and nitrogen species (RONS) that disrupt microbial membranes and DNA without heat damage. This technology is particularly appealing for processors seeking chemical-free, residue-free disinfection methods.

We have used cold plasma to treat surfaces inoculated with Listeria monocytogenes, raw chicken, and eggshell contaminated with Salmonella, observing reductions of over 2 log CFU/cm².

Additionally, I’ve collaborated on studies applying plasma-activated hydrogen peroxide and sodium hypochlorite, which enhance the effectiveness of traditional sanitizers while reducing required concentrations - contributing to safety, chemical reduction and sustainability goals.

Bringing innovation to the processing plant
I’ve worked directly with handheld plasma devices to test microbial reduction on eggshells, raw chicken breasts, and processing surfaces. These tools are low-cost, user-friendly, and can be implemented with minimal infrastructure changes, making them attractive to small and large poultry processors alike.

Moreover, these devices are being paired with plasma-activated cleaning agents that maintain sanitation efficacy while using lower volumes of water and chemicals - a key advantage in regions facing water scarcity or environmental regulatory pressures.

Building the future of poultry safety
Our research aligns with USDA and FDA calls for more sustainable food safety interventions. The technologies I’m helping develop are not only effective but practically intended to be scaled by industry partners seeking to comply with clean-label standards and reduce their environmental footprint.

I have presented this work at several national and international scientific forums, including The International production and processing expo (IPPE), The International Association for Food Protection (IAFP), The Future Technologies and Enabling Plasma Processes conference (FTPP), The American Meat Science Association (AMSA-RMC), and more.

Real impact, real opportunities
For poultry producers, adopting these innovations can mean:

Longer shelf-life: Reduced spoilage bacteria help lower product returns and waste.
Safer products: Lower pathogen counts without thermal or chemical damage.
Sustainability gains: Reduced plastic and sanitizer use meets environmental and regulatory goals.
Market advantage: Clean-label, eco-friendly products appeal to consumers and retailers.
The poultry industry is ready for transformation. I believe cold plasma and biodegradable antimicrobial packaging can be part of that transformation - offering a cleaner, safer, and more sustainable food future.