The problem
Aviagen operates in one of the most demanding quality environments in food production: high-biosecurity poultry breeding, where Salmonella control is fundamental to product integrity and customer trust. For years, the QC workflow behind that control rested on manual culture plate reading where trained analysts examined each plate by eye, interpreted what they saw, and recorded the result by hand.
That approach had built-in limits. Different technicians could reach different conclusions on the same plate, and results lived in site-level records that were slow to compare and audit. As Aviagen pursued greater standardization, traceability, and operational efficiency across its network, manual workflows no longer aligned with those goals - and the stakes were high: in Salmonella QC, every false negative represents a real contamination risk.
The solution
Reshape replaced manual plate reading with AI-driven, standardized detection, without changing the underlying ISO method or affecting the lab’s validation or compliance status. Colonies are detected automatically and results are recorded digitally as presence/absence, with colony counts included where relevant to the method. Each result is fully traceable from the individual plate through to the final decision, supporting processing of up to 3,000 plates per week.
The results
- 75% fewer false negatives. By reducing the rate from 4% to less than 1%, the system significantly lowers the risk of contaminated products from reaching the market, strengthening overall food safety.
- 80% less time on analysis and documentation. Analysts spend their time on decisions and exceptions rather than routine reading and paperwork.
- A foundation for global digital QC. Standardized methods, centralized data, and consistent quality insights across sites.
"Prior to implementing Reshape, plate screening was performed manually by technicians, requiring each plate to be visually reviewed and interpreted individually. This process was time-consuming and introduced the potential for variability between technicians. With Reshape, plates are digitally imaged and screened using AI-assisted analysis, creating a more standardized and efficient workflow. Technicians can review the digital results and focus their attention on plates requiring further evaluation, reducing manual screening time while maintaining technical oversight."
The detection numbers matter, but the larger shift is structural. QC at Aviagen is moving from a manual, fragmented, site-by-site process to a connected, standardized, and fully auditable operation, every plate read the same way, every result recorded once, every decision traceable.
"Reshape supports traceability by creating a digital record of plate images and associated screening results, allowing results to be reviewed and referenced after the initial analysis. This provides objective documentation to support result interpretation and reduces reliance on handwritten observations or technician memory. During audits or investigations, historical plate images and results can be reviewed to demonstrate how a result was evaluated and provide supporting evidence for the final determination. This improved documentation strengthens traceability, promotes consistency between technicians, and increases confidence in reported results."
