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