Poultry Processing

Poultry???
How many people
involve in poultry
sector? Processing Future of
industry? this sectors?
 Current Information
Bangladesh’s poultry sector is gearing up to export eggs and poultry meat by
2024.
One million entrepreneurs and eight million people, involved in poultry sector.
The country will require 17 billion eggs, 2 million tons of poultry meat, 85.8
million day-old chicks, and 7.9 million MT of feed to meet the demand by 2021,
Department of Livestock under the Livestock and Fisheries Ministry, says
country is already producing 15.52 billion eggs against the current annual
demand of 17.13 billion.
The poultry sector supplies 36-40% of total protein intake through meat and egg
consumption. Yearly, 95 eggs are eaten per capita, while consumption of
chicken stands at 6.5kg.
Over 400 mills are supplying 3.61 million tons of feed, meeting up to 96% of
annual poultry feed demand while the remaining 4% demand is met by imported
feed and homemade feed-mix.
Source: (United States Department of Agriculture (USDA)
 Poultry
Poultry can be defined as domestic fowls, including chickens,
turkeys and ducks, raised for the production of meat or eggs and
used as food.
Poultry is the generic term used for farmyard birds, notably
chicken, turkey, duck, goose, guinea fowl and squab.
Is Pigeon A Poultry? Am I
poultry?
Classification of Chicken on The Basis of Production
1. Layer: Layer is for egg production. Some popular layer breeds
are Leghorn, Minorca, Fayoumi, Isa Brown, Babycock, Star
Cross etc.
2.Broiler: Broiler chicken are only for meat production.
Plymouth rock, Cornish, White rock,
Sussex, Dorking, Cochin, Brahma, Asil, Star Brow, Hi-line etc. are
popular broiler breeds.
3.Egg and Meat: This types of breed are used for the purpose of
both egg and meat production. Rhode island red,
New Hampshire, Plymouth Rock etc. are popular breeds for both
meat and egg production.
Classification of Chicken According to Origin
Asiatic: Brahma, longson, cochin, asil etc.

Mediterranian: Leghorn, minorca, fayoumi etc.

American: Rhode island red, new hampshire, plymouth rock

etc.

*****Mediterranean Country: Spain, France, Italy, Slovenia,

Croatia, Bosnia and Herzegovina, Montenegro, Albania,
Greece, Turkey, Syria, Lebanon, Israel, Egypt, Libya etc.
 Composition of Meat (100gm Edible Portion)
Nutrient Broiler Turkey Duck
Water 65-66 70-71 48-49
Protein 18 20 11-12
Total Lipid 15 8 39-40
Carbohydrate Nill Nill Nill
Fibre Nill Nill Nill
Ash 0.80 0.90 0.68
Energy (Kcal) 210 155 404
 How to
calculate
how much energy
? will we get from
100gm Broiler
meat?
 How To Calculate, How Much Energy Will
We Get From 100gm Poultry Meat?
Composition of Meat
We Know that,
1gm carbohydrate gives = 4Kcal Water 65%
1gm Protein gives = 4Kcal Protein18%
1gm fat gives = 9Kcal Total Lipid15%
Now,
Carbohydrate 0%
Energy= carbohydrate x 4 + Protein x
4 + Fat x 9 Fibre0%
= 0 x 4 + 18 x 4 + 15 x 9 Ash 0.8
= 72 + 135 Energy(Kcal) 210
= 207 Kcal.
 Nutritional Value of Poultry Meat

Good source of protein above 12%

Lower percentage in fat
Excellent source of essential amino acids
Also a good source of

• Phosphorus, iron, copper, zinc, B vitamins (B12 & B6)

Poultry skin have higher in fat.
How to Don’t worry.
process It involves
me? many steps.

Processing
 Processing Steps
Pre-slaughter Care and Handling
Ante-mortem inspection
Shackling of each bird by the legs
Stunning with halal method/others
Bleeding
Scalding
Picking
Removal of pinfeathers
Evisceration
Chilling in ice water
Post-mortem inspection (Quality)
Packaging
 Pre-slaughter Care and Handling
A great care has to be exercised in catching and crating the birds. All feeders,
waterers and other accessory equipment should be moved to one corner of the
house before catching and assembling is undertaken.
• The broilers are generally caught at night under very dim light.
• Culled and .spent hens are caught in the cooler hours of the day, preferably in the
afternoon.
Transportation
• Crates, coops or cages are used to transport bird in vans from the farm to poultry
dressing plant. Special attention is paid to prevent overcrowding and suffocation.
• The loading of birds is carried out in dim light either early morning or late evening
to avoid excitement and transported in the cool period without much exposure to
sun to prevent excessive shrinkage.
• Birds should be kept off feed for 12 hrs before slaughter but enough shrinkage
water should be made available.
 Ante-mortem Inspection
The term ante-mortem means “before
death.”
A n t e - m o r t e m i n s p e c t i o n is the
inspection of live animals and birds prior
to being slaughtered.
All livestock must receive ante-mortem
inspection.
Ante-mortem inspection of poultry is
performed on a lot basis.
Ante- mortem ( AM) inspection is
performed either by a Food Inspector
under veterinary supervision.
Which Criteria Should Check During Inspection?
Inspection is carried out to two sides of body, both when the animals
make moves and when they do not.
Inspection result is only valid for 24 hours;
If slaughter is delayed, a new inspection should be carried out.
Animals which are considered sick with no clear information of the
disease should be under surveillance and separated from other healthy
animals,
The things to inspect include:
• general behavior,
• nutrition status,
• body cleanliness, and
• symptoms of disease or abnormality.
Which Criteria Should Check During Inspection?

1.Unfit for slaughter: Birds with morbid condition due to clinical

evidence of a contagious disease, heat stroke or traumatic injury
which cannot be treated are declared unfit for slaughter.
2.Suspects: Birds affected with disease conditions not advanced
enough to declare unfit are passed for slaughter as suspect.
 Shackling
Poultry meat processing is
initiated by hanging, or
shackling, the birds to a
processing line.
Birds are transferred from
coops or transport cages to a
dark room
• where they are hung upside
down from shackles attached
to an automated line.
 Stunning
Electrical stunning: Delivers a current through a
water bath to deem the bird unconscious. The current
should be compliant with minimum recommended
current / bird.
Controlled Atmosphere Stunning: Gas stunning
is another form of stunning. Birds are immersed in an
approved gas or mixture of gases (i.e., CO2) in order to
displace Oxygen and render the bird unconscious.
Minimum Electricity Load For Effective Stunting
Electrical Stunning
 Bleeding
After stunning, the birds are passed through an automated knife that
makes an incision on the neck to cut the jugular vein.
With the carcass hanging upside down and the jugular vein cut, the
majority of the blood is drained from the carcass.
Bleeding: In. general, a bleeding time of 1.5 to 2.0 minutes is allowed incomplete
bleeding retards the keeping quality of dressed chicken.
 Scalding
Broiler and young birds are
Scalded at 55°C for 1.5 minutes
whereas culled birds and spent, hens
are scalded at 60°C for 2 minutes.
Scalding helps to loosen the feathers
to facilitate their removal.
This high water temperature
serves to loosen the connection of
feathers to the skin.
 Picking
❖ Picking is a term that refers to feather removal.
❖ The picker removes the feathers on the carcass.
❖The picker is an automated machine that contains rubber
finger-like projections that rotate in a circular motion to remove
feathers without damaging the carcass. Removal of feet, head,
neck and oil glands.
❖ Feet are removed at the knee joints.
❖ The head is cut and removed.
❖ The neck is cut by machine.
 Evisceration
➢ Evisceration refers to the removal of internal organs.
➢The inedible viscera consists of the spleen, esophagus, lungs,
intestines and reproductive organs.
➢The intestines (viscera) are federally inspected for signs of disease
or other problems.
➢Identified disease or other problems results in the removal, or
condemnation, of the carcass from the processing line.
➢The edible viscera, or giblets, consists of the heart, liver, and
gizzard.
➢ The giblets are packaged in the carcass or sold separately.
 Washing The Carcass
The carcasses are cleaned for microbial and visible concerns.
Washing of the carcass done by water.
When processing chicken, microbial bacteria such as E. Coli and
Salmonella are analyzed.
 Chilling
❑ The carcass temperature must be reduced to prevent microbial growth.
❑Chilling& Draining: After washing, the dressed birds are chilled in a chilling
tank Containing slush ice or crushed ice for 30-45 minutes in order to cool the
carcasses to an internal temperature of about 4°C
❑ The USDA specifies the amount of chilling for specific bird sizes.
✓ 4 lb broiler: 40F within 4 hours
✓ 4-8 lb broiler: 40F within 6 hours.
✓ >8 lb broiler: 40F within 8 hours.
❑Submerging the carcass in an ice (chilled) water bath is the most common
method of carcass chilling.
❑ Carcass can also be chilled by air chilling.
❑ Air chilling occurs by passing cold air over the carcass.
❑This is a more expensive process but some consumers are willing to pay more
for air chilling.
Packaging
 Halal Cutting of Chicken
Islamic law requires that animals intended for human consumption be
slain in a certain manner.
Halal slaughter is was one of the more humane methods available to
the meat industry and the only method acceptable for Muslim
consumers.
The conditions for Halal slaughter can be summarized as follows:
• The animal to be slaughtered must be from the categories that are
permitted for Muslims to eat.
• The animal must be alive at the time of slaughter.
• In general, all forms of stunning and unconsciousness of animals are
disliked.
• Stunning through a device with a non-penetrating round head, in a way
that does not kill the animal before its slaughter, is permitted.
 Halal Cutting of Chicken
• The animal must be slaughtered by the use of a sharp knife. The knife
must not kill due to its weight. If it kills due to the impact the meat may
not be permissible.
• The windpipe (throat), food-tract (oesophagus) and the two jugular
veins must be cut.
• The slaughtering must be done in one stroke without lifting the knife.
The knife should not be placed and lifted when slaughtering the animal.
• Slaughtering must be done by a sane adult.
• The name of Allah must be invoked (mentioned) at the time of
slaughtering by saying: Bismillah Allahu Akbar. (In the Name of Allah;
Allah is the Greatest.)
 Halal Cutting of Chicken
• If at the time of slaughtering the name of anyone else other than Allah
is invoked (i.e. animal sacrificed for him/her), then the meat becomes
Haram “unlawful.”
• If a Muslim forgets to invoke the name of Allah at the time of
slaughtering, the meat will remain Halal. However, if he intentionally
does not invoke the name of Allah, the meat becomes Haram.
• Skinning or cutting any part of the animal is not allowed before the
animal is completely dead.
• Slaughtering must be made in the neck from the front (chest) to the
back.
 Halal Cutting of Chicken

• The slaughtering should not be done on a production line where

pigs are slaughtered. Any instrument used for slaughtering pigs
should not be used in the Halal slaughtering.

Storage, Processing and Transport of Halal Meat

• Meat chilled or frozen for export to Muslims should be stored in
separate cold stores other than those in which pork or other non-
Halal meat is stored.
 Kosher Slaughter
Kosher describes what is ‘fit and proper’ for people of the Jewish faith to
consume.
• Kosher food laws are based on interpretation of the Bible and the Torah, the
Judaic scriptures, and set out a range of beverages and foods (including
meat) that are acceptable to drink and eat.
• For meat to be Kosher, the animal must be slaughtered in a particular way,
so the Rabbi in a Kosher abattoir is a specially trained religious slaughterer.
• The animal must be killed so it feels little pain.
• A very sharp knife is used to cut the oesophagus, the trachea, carotid
arteries and jugular veins in one smooth action.
• There must be no pause during the action nor excessive pressure on the
blade.
• Failure to meet these specific requirements renders the animal unkosher.
• Animals must be effectively stunned (unconscious) prior to slaughter
 Spoilage of Poultry Meat
Sources of contamination
•Fecal contamination from intestines.
•Unhygienic processing area
•Contamination from Cutting board
•Conveyor belts
•Due to high Temperature
•Delay between storage and distribution
 Spoilage Types
A. Slimy spoilage
This occurs on the surface and is caused by the buildup of cells of yeasts,
lactobacilli, enterococci or Brochothrix thermosphacta.
Washing the slime off with hot water can restore the product quality.
B. Sour spoilage
Results from growth of lactic acid bacteria (which originate from
contaminated ingredients like milk solids.
These organisms ferment lactose and other carbohydrates to produce
organic acids. Taste is adversely affected but the product is not harmful if
eaten.
C. Greening
This occurs due to H2O2 or H2S production.
Because greening indicates more extensive product breakdown, it is not
recommend eating.
 Poultry Products
Fresh poultry
The birds are generally cut into a
number of pieces, which are placed on
plastic foam trays and covered with a
plastic film. Fresh poultry should be
used within 14 to 21 days after
slaughter and generally should not be
kept in the home refrigerator for more
than three days.
 Poultry Products
Frozen Poultry
It is vacuum-packed in plastic bags and then
frozen in high-velocity freezers.
The birds are kept in cold storage until needed.
Before freezing, poultry may be injected with
various salts, flavorings, and oils in order to
increase the juiciness of the meat. Injections are
usually done with a multi-needle automatic
injector, and information about the added
ingredients is indicated on the package label.
 Poultry Products
Processed Poultry
Poultry may be further processed into other products.
Battering and breading
Some poultry products are battered (e.g., with beer batter) or battered and
breaded (e.g., with cracker meal, bread crumbs, or cornmeal) for frying.
The meat may be either cooked or raw prior to coating. For battered and
breaded poultry, the pieces are passed through a flour-based batter containing
leavening and then through the breading ingredients.
To hold the breading to the poultry, the product is deep-fried for a short time.
If the poultry is fully cooked in this process, the consumer will only have to heat
the product before eating it. Eg: Chicken nuggets
 Poultry By-products
A. Poultry dressing plant waste (on live weight).
i. Feathers 6%
ii. Blood 3.5%
iii. Offal
a. Heads 3%
b. Feet 4%
c. Inedible viscera 9% (intestines, lung, pancreas, spleen etc.)
B. Hatchery waste: Infertile eggs, dead in germs, dead embryos, egg shells.
C. Egg processing unit waste: Unsound eggs and egg shells.
D. Poultry manure
E. Dead birds
 Poultry By-products
Because prions that cause bovine encephalopathy (Mad Cow Disease)
have not been identified in birds, poultry by-products can be fed to all
animals.
Prions are misfolded proteins with the ability to transmit their misfolded
shape onto normal variants of the same protein.
Feathers
As Fertilizer: As fertilizer Feathers are crushed and cooked under pressure
to yield a good quality fertilizer. In places where cooking is not cost effective
but irrigation is not a problem, feathers can be ploughed in the soil to slowly
decompose and release nitrogen.
As livestock feed: Poultry feathers are hydrolyzed to yield feather meal in
by-product processing plant. Since feather meal has a poor amino acid
profile, feathers are generally processed with blood.
 Poultry By-products
Blood
As fish bait: Blood can also be used as a bait during fishing operations.
As livestock feed: blood meal alone is not so palatable to the livestock, blood
and feathers are usually cooked together in a by-product processing plant.
Blood and feather meal has a rich amino acid profile and very good digestibility.
Other by-products from the processing of poultry are also combined into
animal feed ingredients.
The viscera (internal organs), head and feet are available from all poultry.
In addition, further processing of poultry produces bones from the whole bird.
Poultry by-product meal has a high percentage of viscera and low percentage
of bone. As a result, the protein is high, and the mineral or ash content is lower.