Thermal Inactivation of Salmonella in Not-Ready-to-Eat Breaded Stuffed Chicken Products Using an Air Fryer: Impact on...

Multiple Salmonella outbreaks in the United States have been associated with undercooked not-ready-to-eat (NRTE) breaded stuffed chicken products, which require thorough cooking to ensure pathogen inactivation. Despite manufacturers' safe handling instructions, increasing consumer use of air fryers for these products poses potential food safety risks when no validated cooking guidelines are currently available. This study evaluated Salmonella inactivation and quality changes in NRTE breaded stuffed chicken cooked in two air fryer types (basket and oven-style) across three temperatures (176.7°C/350°F, 190.6°C/375°F, and 204.4°C/400°F) and five time points (10-30 min). Results demonstrated that basket-type air fryers achieved USDA-FSIS recommended 7-log Salmonella reductions and target internal temperatures (>74°C) faster than oven-type models: at 25 min (176.7°C/350°F), 20 min (190.6°C/375°F), and 20 min (204.4°C/400°F) versus 30, 30, and 25 min, respectively, for oven-type units. Color analysis revealed decreasing L* (lightness) and b* (yellowness) values with increasing time/temperature, while a* (redness) values remained higher than control cooking samples. Texture measurements showed MORS force increased with longer processing times. Based on microbiological, color, and texture analysis, specific conditions most closely matched control cooking results: oven-type air frying at 176.7°C (350°F) for 30 min and basket-type air frying at 176.7°C (350°F) for 25 min. These findings provide critical data for developing science-based cooking guidelines for air-fried NRTE stuffed chicken products, addressing an important food safety gap in consumer practices. Further research should validate these parameters across additional product formulations and air fryer models.