Specialty and Small-Scale Poultry Processing
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Transcript of Specialty and Small-Scale Poultry Processing
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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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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:
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Activities required for ready-to-cook poultry:
Pre-slaughter: catching and transportImmobilization, kill, and bleedFeather removal: scalding and pickingEviscerationChillingPackaging
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Feed withdrawalCatchingLoadingTransport
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Immobilize/stunKillBleed
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Types of scalding equipment:
Homemade scalders and dunkersStockpotUsed electric or propane water heatersVery labor intensive
Scalder bath
Multi-stage scaldersOverflowTemperature controlPathogen control
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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
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Types of pickers
Homemade pickersUsed washing machinesPlastic 55-gallon drums
Small pickersDrumTub
In-line pickers
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Drum picker
Tubpicker
Tub 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 eviscerationNew 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 than8 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 chillersCounter currentOverflowAir BubblesPaddles or rakes32F45 minutes
Pre-chiller55-60F15 minutes
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Air chill
Soft scaldTemperature 20-35FTakes longer: 2 hoursNo water uptake/less microbial contaminationMore expensive equipment, space, utilitiesLess waterHomemade air chill?
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Yield67% for broilers without giblets
Whole birdsFurther processed
Cut-upPartsDebonedSizing and portioningFormed
Whole (deli loaves)Comminuted (nuggets)Emulsified (hot dogs)
Curing and smokingBrining
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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 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)
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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 chunksRemove small particles in water
Fat trapDissolved air flotation
Break down organic matterAerobic lagoonsAnaerobic lagoonsTrickling filtersLand application
Composting
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Processing diverse species
Broilers, Cornish game hens, stewing hens, ducks, geese,squab, turkeys
Multispecies processing:RabbitsRed 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 least4 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 ProcessingUnits (MPU):
A shared resource
$7,000-$12,000
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1
Kentucky MPU - $70,000
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Small PlantEstablishment
$100,000-$400,000
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Small Plants
Usually enclosed building
Separate areas for killing and eviscerationKeep edible product from coming in contactwith inedible.
GMPSOPSSOPHACCPCode of Federal Regulations