Specialty and SmallScale

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Specialty and Small-Scale Poultry Processing
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Types of processing On-farm processing
Mobile Processing Units (MPUs) Small plants
(I.e. pilot plant) Large plants
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Activities required for ready-to-cook
poultry Pre-slaughter catching and
transport Immobilization, kill, and bleed Feather
removal scalding and picking Evisceration Chillin
g Packaging
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Feed withdrawal Catching Loading Transport
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Immobilize/stun Kill Bleed
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Types of scalding equipment Homemade scalders
and dunkers Stockpot Used electric or propane
water heaters Very labor intensive Scalder
bath Multi-stage scalders Overflow Temperature
control Pathogen control
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Scalding 101
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Types of pickers Homemade pickers Used washing
machines Plastic 55-gallon drums Small
pickers Drum Tub In-line pickers
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Tub picker
Tubpicker
Drum picker
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Remove head, oil glands, and feet
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Eviscerate
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Evisceration Guts remain attached to bird for
inspection Avoid tearing gut and causing
microbial Harvest giblets Wash
carcass Specialty evisceration New York
dressed
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Chilling Lower temperature of carcass
Broilers (4-lb) 40F within 4 hours (4-8
lbs) 40F within 6 hours Turkeys (greater than 8
lbs) 40F within 8 hours
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Rule of thumb One pound of ice per pound of
meat Used dairy equipment
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Chilling Ice bath Static
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Pre-chilling Prevents cold shortening Gradual
temperature reduction Water uptake 8-12
water in carcass
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Large chillers Counter current Overflow Air
Bubbles Paddles or rakes 32F 45
minutes Pre-chiller 55-60F 15 minutes
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Air chill
Soft scald Temperature 20-35F Takes longer 2
hours No water uptake/less microbial
contamination More expensive equipment, space,
utilities Less water Homemade air chill?
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Yield 67 for broilers without giblets Whole
birds Further processed Cut-up Parts Deboned S
izing and portioning Formed Whole (deli
loaves) Comminuted (nuggets) Emulsified (hot
dogs) Curing and smoking Brining
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Hand deboning
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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
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Packaging On-farm bags, shrink bags Shelf
life 6 days Small plants shrink bags, vacuum
packing, totes Shelf life up to 12 days
(vacuum) Large plants tray packs, bulk ice
packs Shelf life 21 days (crust-frozen tray
pack) 7-28 days (bulk, depending on modified
atmosphere)
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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
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Methods of freezing Still air (slow) used by
home freezers Blast freezing (fast) Bone
darkening seen in young chickens after freezing
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Clean up On-farm hoses Plants pressure
washers.
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Waste Offal, feathers, blood Wastewater
Treatment Screen out big chunks Remove small
particles in water Fat trap Dissolved air
flotation Break down organic matter Aerobic
lagoons Anaerobic lagoons Trickling
filters Land application Composting
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Processing diverse species Broilers, Cornish
game hens, stewing hens, ducks, geese, squab,
turkeys Multispecies processing Rabbits Red
meat and poultry in the same plant
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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 least 4 birds at a time 15 birds per
person per hour
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On-farm processing set-ups Less than 1000
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Less than 15,000
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Mobile Processing Units (MPU) A shared resource
7,000-12,000
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Kentucky MPU - 70,000
1
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Small Plant Establishment
100,000- 400,000
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Small Plants Usually enclosed building Separate
areas for killing and evisceration Keep edible
product from coming in contact with
inedible. GMP SOP SSOP HACCP Code of Federal
Regulations