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24 Poultry Processing and Products - Texas A&M …

Poultry Processing 24 and Products Douglas P. Smith Prestage Department of Poultry Science, North Carolina State University, Raleigh, North Carolina, USA. Poultry Processing employee areas such as locker rooms, breakrooms, and restrooms; office areas for management and a separate Primary and further Processing of Poultry is a multi- space for USDA employees; accessory areas such as cool- billion dollar industry in the US. The majority of Poultry ers, shipping and receiving docks, warehouse storage, raised and commercially processed in the US is composed maintenance and repair, and box making; and waste of chickens, turkeys, and ducks, with more than 9 billion (offal) and waste water Processing .

24 Poultry Processing and Products Douglas P. Smith Prestage Department of Poultry Science, North Carolina State University, Raleigh, North Carolina, USA 24.1 Poultry processing

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Transcription of 24 Poultry Processing and Products - Texas A&M …

1 Poultry Processing 24 and Products Douglas P. Smith Prestage Department of Poultry Science, North Carolina State University, Raleigh, North Carolina, USA. Poultry Processing employee areas such as locker rooms, breakrooms, and restrooms; office areas for management and a separate Primary and further Processing of Poultry is a multi- space for USDA employees; accessory areas such as cool- billion dollar industry in the US. The majority of Poultry ers, shipping and receiving docks, warehouse storage, raised and commercially processed in the US is composed maintenance and repair, and box making; and waste of chickens, turkeys, and ducks, with more than 9 billion (offal) and waste water Processing .

2 The commonality birds processed in 2010 (Table ). Total retail product among plants is that live birds are processed or further weight exceeded 58 billion pounds, with an estimated processed into food, but any individual plant is uniquely retail value of $100 billion. different from any other plant. The general process of turning live birds into meat is similar for all three species, but details of the process can Preprocessing be distinctly different for specific steps. Differences are due to bird size and physiology differences, requiring Prior to Processing , several steps are taken to prepare unique equipment and species-specific methods. Poultry the live birds. First, feed is removed from broilers approx- meat is further processed into many forms as a result of imately 8 12 h before slaughter.

3 Feed withdrawal is impor- customer and consumer demands that developed in the tant to reduce gastrointestinal contents within the bird, 1980s (Figure ). The industry was able to respond to which reduces the chance of ingesta or fecal contamination this demand since the profit margins were higher for fur- during Processing . One negative aspect of feed withdrawal ther processed items than for raw whole carcasses or parts. is that birds lose weight, which reduces payments to the Also, equipment had been developed to automate further contracted growers. Microbiological problems occur from Processing and packaging on a large scale, and otherwise overly long withdrawal as contamination increases due defective whole carcasses not marketable as raw Grade to gut fragility during evisceration.

4 Also, pH of the crop A could be further processed and sold as value-added. Since increases, which encourages the growth of Salmonella, the vast majority of Poultry meat is represented by broiler adding to potential pathogen contamination. Per animal chickens, the following sections will describe broiler pro- welfare guidelines, birds are not fasted more than 24 h. cessing. Two further sections will address differences spe- The Poultry house is cleared of equipment prior to arri- cific to turkey and duck Processing . val of the catching crew, then birds are loaded into metal The basic steps of broiler chicken Processing are shown multilevel coops. These coops are loaded onto trucks and in Box The Processing plant is divided into a slaugh- birds are transported to the Processing plant.

5 Upon arri- ter area, a separate evisceration area, a chilling area, and, val, the birds are weighed as a group and then are held in a depending on the Products produced, further Processing holding shed to provide some minimal protection from areas. In addition to the Processing areas, plants contain the environment prior to unloading. Food Processing : Principles and Applications, Second Edition. Edited by Stephanie Clark, Stephanie Jung, and Buddhi Lamsal. 2014 John Wiley & Sons, Ltd. Published 2014 by John Wiley & Sons, Ltd. 549. 550 Food Processing : Principles and Applications Table Live weight, number of animals, and pounds inspected of chickens, turkeys, and ducks slaughtered under USDA inspection in 1990, 2000, and 2010 (data from USDA National Agricultural Statistics Service).

6 Live weight Number of animals (individual animal inspected Pounds inspected Species Year of production average, in pounds) (in millions) (in billions). Chicken 1990 2000 2010 Turkey 1990 2000 2010 Duck 1990 2000 2010 90. Whole carcass 80 Cut-up/Parts Further processed 70. 60. Percent 50. 40. 30. 20. 10. 0. 1962. 1967. 1972. 1977. 1982. 1987. 1992. 1997. 2002. 2007. Figure Percent of market share for chickens expressed as whole carcass, cut-up parts, or further processed meat by year from 1962 to 2010 (data from the National Chicken Council, Washington, DC). Primary Processing there may be several thousand shackles. Birds remain on these shackles for the duration of steps in the slaughter Slaughter area, approximately 6 7 min total.

7 The live hang room The coops are unloaded from the truck and a machine is the beginning of the slaughter area. tilts and dumps the entire coop onto a conveyor that On the shackle line, the birds first pass through an elec- transports the birds into the plant to the live hang area. trical stunning device. A non-conductive fiberglass trough Employees pick up each bird and hang them upside down of water (fresh or salted) with a metal mesh grate by the feet on a stainless shackle. Shackles are spaced 6 immersed in the water hangs below the shackles. As the inches apart and are attached to rollers on a continuous bird is pulled through, the head touches the water and track; depending on size of the plant and speed of the line, immersed grate.

8 An electrical control box has one 24 poultry processing and products 551. Box Major steps of broiler Processing and further Processing 1. Preprocessing 2. Slaughter 3. Evisceration Feed withdrawal Live hanging Oil gland removal House preparation Stunning Venter Loading Killing Opener Holding Bleeding Eviscerator Unloading Scalding Inspection traditional Picking Viscera removal/giblet Head removal harvest Hock cutting Crop removal Lung removal Carcass washing IOBW. (Inspection HIMP). Chilling 4. Secondary Processing (no ingredients or heat 5. Further Processing (ingredients or heat 6. Packaging and treatment) applied or both) shipping Cut-up Marination Packing Deboning Coating Labeling Portioning Cooking Palletizing Grinding Glazing Transport Mechanical separation Freezing HIMP, HACCP-based Inspection Models Project; IOBW, inside-outside bird washer.

9 Electrode connected to the metal grate in the water, and including decapitation and pithing, which also provides the other electrode is connected to a metal bar that blood loss. Using an automated killer or neck cutter requires touches the shackle above the bird's feet. The body of a manual back-up method. A person will manually cut the the bird connects the electrical circuit and the bird is neck of any birds that may have been missed by the machine. stunned by the current (approximately 10 20 mA) pass- After the neck is cut, exsanguination takes approxi- ing through the head and body. Stunning as conducted in mately 2 min. Only about 50% of the blood is lost during the US is reversible, and should the bird be removed from exsanguination.

10 The blood loss is necessary to allow the the line immediately after stunning, it will regain full con- bird to fully expire and ensure there is no blood pressure sciousness and mobility in approximately 5 min. In other in skin or muscles so no bruising or discoloration occurs. countries higher voltages and amperages are used to irre- For birds that still have any blood pressure, the skin will versibly stun birds. EU processors electrocute Poultry in turn pink or red during scalding, a condition termed stunners as an alternative method for stunning and killing cadaver, and these carcasses will be condemned as (although birds are still bled immediately after electrocu- not suitable for human consumption.)


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