specialty and small-scale poultry processing
DESCRIPTION
Specialty and Small-Scale Poultry Processing. Types of processing On-farm processing Mobile Processing Units (MPUs) Small plants (I.e. pilot plant) Large plants. Activities required for ready-to-cook poultry: Pre-slaughter: catching and transport Immobilization, kill, and bleed - PowerPoint PPT PresentationTRANSCRIPT
Specialty and Small-Scale Poultry Processing
Types of processing
On-farm processing Mobile Processing Units (MPUs)
Small plants (I.e. pilot plant)
Large plants
On-farm Small Large
SizeOutdoor or shed
facility2,000 to 3,000 sq. ft. 150,000 sq. ft.
Equipment Manual Manual/ Mechanical Fully automated
Cost Less than $1,000 Less than $400,000 $25,000,000
Labor Family Family/ hired Hired
Capacity 50-100 birds per day500-5,000 birds per
day250,000 birds per day
Operation
Seasonal; 8 estimated
processing days per
year
Seasonal or year-
round; 20 estimated
processing days per
year
Year-round; process
daily
Marketing
Product sold fresh,
sometimes frozen;
whole birds
Fresh and frozen,
whole and parts
Mainly cut-up, sold
fresh, further-
processed
Comments
Independent
operation; labor-
intensive; usually non-
inspected
Independent or part of
a collaborative group
Part of an integrated
operation including
grow-out, processing,
and marketing
Types of Poultry Processing:
Activities required for ready-to-cook poultry:
Pre-slaughter: catching and transportImmobilization, kill, and bleedFeather removal: scalding and pickingEviscerationChillingPackaging
Feed withdrawalCatchingLoadingTransport
Immobilize/stunKillBleed
Types of scalding equipment:
Homemade scalders and dunkersStockpotUsed electric or propane water heatersVery labor intensive
Scalder bath
Multi-stage scaldersOverflowTemperature controlPathogen control
Scalding 101
Types ofScald
Temp Time Comments
Very hard 160-180F 30-60 sec Waterfowl
Hard 138-148F 30-75 sec Removeouter skin
Avoid 130-138F
Soft 123-130F 90-120 sec Leavesskin andcolor
Types of pickers
Homemade pickersUsed washing machinesPlastic 55-gallon drums
Small pickersDrumTub
In-line pickers
Drum picker
Tubpicker
Tub picker
Remove head, oil glands, and feet
Eviscerate
Evisceration
Guts remain attached to bird for inspection
Avoid tearing gut and causing microbial
Harvest giblets
Wash carcass
Specialty eviscerationNew York dressed
Chilling
Lower temperature of carcass
Broilers(4-lb) 40F within 4 hours
(4-8 lbs) 40F within 6 hours
Turkeys(greater than8 lbs) 40F within 8 hours
Rule of thumb:One pound of ice per pound of meat
Used dairy equipment
Chilling: Ice bath Static
Pre-chilling Prevents cold shortening
Gradual temperature reduction
Water uptake
8-12% water in carcass
Large chillersCounter currentOverflowAir BubblesPaddles or rakes32F45 minutes
Pre-chiller55-60F15 minutes
Air chill
Soft scaldTemperature 20-35FTakes longer: 2 hoursNo water uptake/less microbial contaminationMore expensive equipment, space, utilitiesLess waterHomemade air chill?
Yield67% for broilers without giblets
Whole birdsFurther processed
Cut-upPartsDebonedSizing and portioningFormed
Whole (deli loaves)Comminuted (nuggets)Emulsified (hot dogs)
Curing and smokingBrining
Hand deboning
Aging
Tenderness:Poultry meat must age at least 4 hours before eating or freezing
Rigor mortis
Stress before slaughter can lead to dark, dry meat
Packaging:
On-farm: bags, shrink bagsShelf life: 6 days
Small plants: shrink bags, vacuum packing, totesShelf life: up to 12 days (vacuum)
Large plants: tray packs, bulk ice packsShelf life: 21 days (crust-frozen tray pack)7-28 days (bulk, depending on modified atmosphere)
Storage:Home refrigerators or freezers
Freezing extends shelf life to 6-12 months
Rate of freezing:Slow freezing (3-72 hours): large ice crystals that damage cells
Fast freezing (30 minutes): small ice crystals
Methods of freezing:
Still air (slow) used by home freezers
Blast freezing (fast)
Bone darkening seen in young chickens after freezing
Clean up
On-farm: hoses
Plants: pressure washers.
Waste:Offal, feathers, blood
Wastewater Treatment:Screen out big chunksRemove small particles in water
Fat trapDissolved air flotation
Break down organic matterAerobic lagoonsAnaerobic lagoonsTrickling filtersLand application
Composting
Processing diverse species
Broilers, Cornish game hens, stewing hens, ducks, geese,squab, turkeys
Multispecies processing:RabbitsRed meat and poultry in the same plant
Putting It All Together:
Batch vs continous processing
Processing rate:Working alone with minimal equipment:6 birds per person per hour
Experienced processor with equipment handling at least4 birds at a time:15 birds per person per hour
On-farm processing set-ups:Less than $1000
Less than $15,000
Mobile ProcessingUnits (MPU):
A shared resource
$7,000-$12,000
1
Kentucky MPU - $70,000
Small PlantEstablishment
$100,000-$400,000
Small Plants
Usually enclosed building
Separate areas for killing and eviscerationKeep edible product from coming in contactwith inedible.
GMPSOPSSOPHACCPCode of Federal Regulations