PHYSICAL, CHEMICAL AND BIOLOGICAL POTENTIAL HAZARDS IDENTIFICATION OF SLAUGHTERHOUSE AND CHICKEN NUGGETS PRODUCTION PROCESS

Chicken nuggets, the one of protein rich foods, is produced from the chicken meat through several stages of the process. This research aimed to identify the potential hazards of chicken nuggets process in final products based on physical, chemical and biological hazards perspectives. The hazardous potentials were performed specifically using observations, interviews and investigations in a slaughterhouse unit and production unit. Furthermore, the finding of data was described qualitatively. The results of this study indicated that there were several potential hazards in physical, chemical and biological in a chicken nugget process. The ear problems, exhausted of workers, watered by heat frying oil were the examples of potential hazards in physical. In addition, contamination of heavy metal in product and the expired of food grade oil were an illustration of chemical potential hazards. Then, microorganisms in end products, the source of the pathogen were the examples of biological hazards potential. Finally, it could be concluded that chicken nugget factory possessed the physical, chemical, and biological potential hazards.


INTRODUCTION
Chicken nuggets, one of the strategic food industries in Indonesia, has a significant role in order to support the requirements of food in Indonesia. This food, which is made from chicken meat or chicken slurry as a raw material, butter, and fried, is the favorite product to be consumed as a protein source. This food is simple to be prepared from the plastic packaging before it is being consumed and also has a unique shape.
Furthermore, this food also keeps and store in the refrigerator and will not expire easily.
Generally, the raw material of chicken nuggets derives from hatching eggs of chicks which is raised up to the mature chickens within three months. During the growth process, the chicks are usually injected with the vaccine and fed by high protein food to increase body weight and health condition. The chicken meats are usually supplied from the chicken breeders. After that, it will be transferred into the slaughterhouse because the chicken must be slaughtered. Furthermore, the raw materials JURNAL BIOLOGI UDAYANA 22 (1) : 25 -34 must be through the several stages until the final product can be processed through the several stages until the end product can be achieved. Tsola et al., (2008) claimed that the process of chicken nuggets productions had potential hazards for workers and products. It included the accident, potential of environmental pollution, and the contamination of products. Tsola et al., (2008) mentioned that physical hazard, chemical hazard, and biological hazard might be found during the production process in a food factory. The Hazard Analysis Critical Control Point (HACCP) has the purposes to prevent the potential hazards in the production process to raise the food safety (Surak, 2002;Tsola et al., 2008).
The emerging issues of hazards (physical, chemical and biological) such as disease, contamination of microorganisms, work accident, exhausted of the employees and environmental sanitation should be considered not merely in a production of high quality products but also maintained the employees work safely and healthy (Ministry of Labor, 1999a;Ministry of Labor, 1999b;Doyle and Ericson, 2006).
Although the factory of chicken nugget has been operated since a long time ago, it is still being evaluated in all of the potential hazards in every stage of the production process. A chicken nugget factory which is located in the Industrial Area. in East Java is one of the largest company in chicken nuggets production. In addition, the management of this factory is focusing continuously on a prevention of the hazard's potential.
The purpose of this study was to analyze and identify the potential hazards in the stages of production in chicken nuggets factory, particularly focusing on slaughterhouse and production unit.

MATERIALS AND METHODS
The stage of the research was started in the chicken nuggets factory. This factory is located in Mojokerto, East Java, Indonesia. The location was in the industrial area which was relatively near other factories such as a plastic factory, metal factory and warehouse. Then, the comparison and identification of findings were described descriptively in the potential of hazards, the preventive actions and the waste in each of production process in accident, product and environment.
Furthermore, the observation was focused on potential hazards (physical, chemical and biological). The observation was started from receiving chicks, slaughterhouse and production process room (evisceration room, production room and packaging room). Then, the interviews were conducted directly with some informants based on the checklist and questionnaire. The informants were a supervisor, manager, and staff from each department. The interviews were started on exposing location for receiving chick, slaughtering room, evisceration room, production room and packaging room which accompanied by the area staff.
The results in observations and interviews were studied and processed according to the Indonesia regulation of occupational health safety and some literature which were related to physical, chemical and biological potential hazards.

RESULTS
The observations and interviews in the field indicate several potential hazards in physical, chemical and biology. The results of the analysis are shown in Table 1.  The physical potential hazards were on the stage of production such as receiving live chicken, sortation, slaughtering, scalding, tumbling, and frying. Receiving live chicken has physical potential hazards such as digestive full of feed and accident which related with the machine, unsafety meals from postmortem, exhausted of work, and occupational disease (Presidential Decree of Indonesia Republic, 1993). The vehicle is usually washed and cleaned rapidly for reducing the odor, fly and cockroach near the factory. In chemical potentials, there are several findings in receiving chicken process, frying, analyzing the final product, an accident from frying oil and food grade oil (food machinery grease).
The potential findings of chemical potential hazards are from veterinary medicine, heavy metal contamination in the frying process using deteriorated frying oil, food grade oil (food machine grease). In addition, the food P ISSN: 1410-5292, E ISSN: 2599-2856 grade oil was used by dropping on the machine but for the nuggets do not adhere in the frying process. The stock of food grade oil was saved securely in the warehouse because it must be controlled to know the expired date and an explanation of the potential hazards. It was to prevent the opportunity for using the expired food grade oil (food machinery greases).
The observations and interviews in the field indicated several potential hazards in biological. The contamination of microorganisms such as bacteria or virus often grew rapidly in the wastes. Feces, intestine, wastewater were the examples of the media, that microorganisms lived inside. In addition, the biological potential hazards from the process indicated the pathogenic microorganism. Several sources, which have potential hazards from microorganism, were receiving chicken process from the supplier, sortation, slaughtering, bleeding, evisceration, and butter coating.
According to Surak (2002), microorganisms which are found in slaughtered poultry, are from two main sources. They are from an environment of slaughterhouse and a digestive of chicken. The pathogen microorganisms such as bacteria may be found in the poultry meat, are capable of causing born disease in human (Tsola et al., 2008). Furthermore, according to James et al., (2006) several bacteria can be found in internal and external washing, water-air chilling, cutting of bone, and packaging food. The microorganisms are Salmonella sp, Campylobacter spp, C. perfringens, L. monocytegenes and E. coli. Furthermore, the pathogen microorganism can grow near the waste such as feces, organs and wastewater. After that, Salmonella sp and Campylobacter sp causes the deterioration in food quality and food born disease (Tsola et al., 2008).
The wastewater has been flown through the drainage until arrives in the wastewater treatment plant. The source of wastewater composition is from washing vehicle (truck) contains of feces, water from the boiler and washing-result of organs, intestine, gizzard and meals. In addition, the capable of spoiling poultry meat may have microorganisms such as Pseudomonas, Acinobacter, Flavobacterium, Corynebacterium (Kotzekidou-Rouka, 1993;James et al., 2006). The microorganisms in wastewater should be investigated due to prevent the biological hazard potential.

The Handling of Physics Potential Hazard
The handling of physical potential hazards by using the self-safety tools such as ears protection like ear plug might reduce the effect of noise (Labor and Transmigration Regulation of Indonesia Republic, 2010). The ear plug was used by workers with attach those tools in ears. During the survey, the workers have been using the earplug as safety tool for reducing the effect of noise. In addition, they also used safety shoes, safety masks and safety coats for protecting their entire body from potential accident. The value limit of physical factor was in an occupation location about 85 dBA (Ministry of Labor Decree, 1999).
The source of noise was from boiler, which was operated regularly using high temperature water. The using of hot water was for washing and facilitating the removal of chicken feathers. The high noise sound from boiler could decrease or damage the ability and function of ears. The noise could make fatigue and cause headache during their task. The production process had potential hazards like slipped and blistered caused by high temperature oil in frying process and high temperature water from chilling process. Near the frying machine, it had a drainage to flow the oil for reducing those potential hazards.

The Handling of Chemical Potential Hazard
The hazards handling of chemical potential hazards had several processes. The process of receiving chicken has tremendous potential hazards in veterinary medicine and growth agents, heavy metal contamination, deteriorated of frying oil, and deteriorated frying oil or food machinery grease. During the process of each department, the management had a prevention plan with the analyses on final product. This was to reduce the potential contamination of chemical hazards such as heavy metal in final product.
The frying process might have a chemical potential hazards. It might be described as compound in a high temperature of extrusion. It was often claimed as substance such as acrylamide (Mulla et al., 2011). According to Kutting et al., 2008;Mulla et al., 2011 andOracz et al., 2011, acrylamide usually might be found from food grade oil (food machinery grease) and frying oil during the frying process.
Furthermore, acrylamide is a water-soluble, vinyl monomer had multiple chemical and industrial application (Kutting et al., 2008). According to Kutting et al., (2008) acrylamide had serious effect for health and could be found in blood. In addition, Kutting (2008) also claimed that acrylamide cause the tumor and it was a carcinogenic agents on following oral dosing in rat studies. The effects of Acrylamyde must be analyzed in the oil due to those potential problems.
In frying process, the oil used for frying and food grade oil for machine were usually renewed. The deteriorated P ISSN: 1410-5292, E ISSN: 2599-2856 JURNAL BIOLOGI UDAYANA 22 (1) : 25 -34 frying oil would be given into another corporation for the recycling process. The company had a Material Safety Data Sheet (MSDS) documents of food grade oil. Interestingly, MSDS documents had a significant role in identifying hazardous materials and a first aid measure procedure (Cahyono, 2010). In addition, chemical potential hazards of workers have many routes of exposure. Skin contact, eye contact, and inhalation were an illustration of chemical potential hazards (Anonymous, 1997). In the production process, it was observed that the employees always used their safety glasses with chemical resistant gloves, and hair protection. The details of hazards prevention of food grade oil during this study were shown in Table 3. Table 3. Hazards Identification of Oil Food Grade (Food Machinery Grease) (Anonymous, 2007).

Skin absorption
Extensive / prolonged or repeated result in this product, which is caused by an absorption.
Washing the skin with soap and water. Remove the contaminated clothing and it must be washed before reused. After that, immediate get a medical attention if the product is injected under the skin. The contamination of shoes must be cleaned before re-use and discard if oil soaked.

Ingestion
Caused pulmonary injury and possibility of death.
Washing thoroughly with soap and waste contaminated clothing, launder the clothing before reuse.

Inhalation
Repeated and prolonged overexpose to oil mists may have a result in droplet deposition, oil granuloma formation, inflammation, and increased incident of infection.
Get medical attention immediately.

Chronic Effect
Prolonged or repeated contact with petroleum oil may remove natural oils and fats from the skin.
Vapor pressure is very low, inhalation under the ambient condition is normally not a problem, If it overcomes by vapor from physician. If breathing is an irregular or has been stopping, start resuscitation and administer oxygen. In addition, if it overexposed to oil mist, remove from exposure until excessive oil mist condition subsides.

Routes of Expose Skin contact, eyes contact, inhalation
Flushing eyes immediately with plenty of water for at least 15 minutes until getting a medical attention. Furthermore, for a Skin, washing with soap, and a plenty of water. Medical attention should be required in an inhalation accident.

The Handling of Biology Potential Hazard
The biological potential hazards such as contamination from a slaughterhouse until a production unit were caused by a microorganism. The sources were from feces, dead chickens, innards, and wastewater treatment plant. According to Tsola et al., (2008) total bacteria in internal external counted approximately 5.72 ± 0.08, coliform and E. coli approximately at 3.41 ± 0.09, S. aureus at 2.60 ± 0.09. Tsola et al., 2008 reported that total bacteria water-air chilling counted approximately at 4.60 ± 0.08, coliform and E. coli 2.90 ± 0.06, S. aureus 2.63 ± 0.05. Furthermore, 4.72 ± 0.10, coliforms and E. coli 2.86 ± 0.05, S aureus 2.90 ± 0.05. Total bacterial counted approximately at 4.72 ± 0.10, coliforms and E. coli 2.88 ± 0.06, S. aureus approximately at 2.90 ± 0.04. Those microorganisms caused deterioration of food quality and also a foodborne disease in many countries (Tsola et al., 2008).
The amount of those microorganisms potentially contaminated in several areas and in the environment. Specifically to a safety product, the company had a laboratory for checking and analyzing the microbiology aspects and quality of final product. The wastewater contained of microorganism from washing vehicle (truck) has contaminated with feces from the vehicle of the chicken, chill process, and evisceration. The wastewater contained of microorganism. In order to prevent the contamination of pathogen microorganism in the factory, the wastewater from the production process was usually treated in wastewater treatment plant unit. In the fact, the factory has different units of wastewater treatment plant such as grit chamber unit, fat trap unit, equalization tank unit, flocculation unit, coagulation unit, clarifier unit, sedimentation unit, and aeration tank.
Generally, the wastewater would be flown in the communal wastewater treatment plant and it would be processed before the effluent was exiled in the environment. The innards, feet skin, chicken feathers were collected in the container. The innards were commonly sold to the merchant. It showed that corporation had an attention to reuse of the waste and has implemented the prevention actions towards organic waste. However, chicken which was dead in the truck during transportation from breeder to factory, was destroyed in a furnace burner. After that process, it P ISSN: 1410-5292, E ISSN: 2599-2856 JURNAL BIOLOGI UDAYANA 22 (1) : 25 -34 transformed into the bottom ash and will be transferred to other corporation, whose have a specialty to handling the waste. The procedure to reduce the fly and cockroach, which had potential as the disease vector, the firm management usually control packages of the chicken feather in the packaging process and the feces of chicken. Then, they also washed the trucks to clean the feces.
In other words, the top management had several actions to prevent environmental pollution.

CONCLUSION
Chicken nugget factory has the physical, chemical, and biological potential hazards in slaughterhouse unit and production unit. The potential hazards in physical related to an accident in occupation location, noise, slip, damage of ear and watered by high temperature oil should be concerned by management. In addition, the contaminations of heavy metal in end product by oil food grade and frying oil are the illustrations of chemical contaminations category. Biological potential hazards, especially the contamination of products, and the environment by microorganisms were serious issues, which was always supervised and prevented due to enormous problems to the end products and environment.