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POULTRY MEAT
PROCESSING
Second Edition
POULTRY MEAT
PROCESSING
Second Edition
Edited by
Casey M. Owens
Christine Z. Alvarado
Alan R. Sams
This book contains information obtained from authentic and highly regarded sources. Reasonable efforts have been
made to publish reliable data and information, but the author and publisher cannot assume responsibility for the valid-
ity of all materials or the consequences of their use. The authors and publishers have attempted to trace the copyright
holders of all material reproduced in this publication and apologize to copyright holders if permission to publish in this
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rectify in any future reprint.
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lized in any form by any electronic, mechanical, or other means, now known or hereafter invented, including photocopy-
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Dedication
This book is dedicated to our mentors and to the memories of Dr. Pam Hargis and
Dr. Doug Janky, two individuals who each had a profound and lasting impact on
the poultry industry and the food and nutritional sciences, as well as the people
involved in them.
Contents
Preface...............................................................................................................................................ix
Contributors.....................................................................................................................................xi
vii
viii Contents
Index..............................................................................................................................................431
Preface
The first edition of this book was the product of some of the best poultry and food scien-
tists in the world. Its concept was born from the need for a good instructional textbook in
the poultry processing and product quality courses taught by many of the contributors.
This second edition has been expanded and updated by the same collection of excellent
scientists with the addition of even more expert contributors. It remains an instructional
and not necessarily exhaustive review of the scientific literature in each of its component
areas. In addition to its teaching use, this book will continue to be a useful reference for
academic researchers, industry personnel, and extension specialists/agents seeking fur-
ther knowledge.
Most of the contributors are active participants in the S-1027 USDA Multi-State Research
Project, and the collaborative relationships fostered by this project have made this second
edition possible. The field of poultry meat processing is grateful for the contributions of
these authors. The editors are also indebted to Elizabeth Hirschler for her excellent tech-
nical and creative assistance, which made the first edition originally possible. As editing
such a book requires much time and attention, the editors appreciate the understanding of
their spouses during the preparation of this book.
Although Alan Sams was the editor of the first edition, Christine Alvarado and Casey
Owens-Hanning have done virtually all of the coordination, facilitation, and editing
involved in the second edition. Without them, this second edition would not exist. It is
evident from their scientific knowledge and editorial skill that they received only the best
education and training and have honed their abilities as they have each established well-
respected and successful careers. Their mentor is very proud of them.
ix
Contributors
James C. Acton Donald E. Conner
Department of Food Science and Human Department of Poultry Science
Nutrition Auburn University
Clemson University Auburn, Alabama
Clemson, South Carolina
Michael A. Davis
Christine Z. Alvarado Department of Poultry Science
Department of Poultry Science Texas A&M University
Texas A&M University College Station, Texas
College Station, Texas
Paul L. Dawson
Sacit F. Bilgili Department of Food Science and Human
Department of Poultry Science Nutrition
Auburn University Clemson University
Auburn, Alabama
Clemson, South Carolina
R. Jeff Buhr
Anne Fanatico
USDA Agricultural Research Center
National Center for Appropriate
R.B. Russell Research Center
Technology
Athens, Georgia
Fayetteville, Arkansas
J. Allen Byrd
Glenn W. Froning
USDA Agricultural Research Center
Southern Plains Agricultural Research Department of Food Science and
Center Technology
College Station, Texas University of Nebraska
Lincoln, Nebraska
David J. Caldwell
Departments of Poultry Science and Billy M. Hargis
Veterinary Pathobiology Department of Poultry Science
Texas A&M University University of Arkansas
College Station, Texas Fayetteville, Arkansas
1
2 Poultry meat processing, second edition
Vertical Integration
Breeder Farm
Breeder Feed Hatching Eggs
Broiler Chickens
Utilities
Labor Processing Plant
Materials Whole Carcasses
Finished Products Parts
Further Processed
Sales
Products
Marketing
Distribution
Figure 1.1 Diagram of the material flow between the components of a vertically integrated poultry
company.
of the production and marketing advantages in various parts of the world, poultry compa-
nies based in the United States are establishing production operations in other regions of
the world. Another factor in the global marketplace is the development of trading blocks
such as the North American Free Trade Agreement (NAFTA), the European Union (EU),
and South America’s Mercosul. These alliances reduce or eliminate trade tariffs between
member nations, standardize many requirements, and regulate trade within and outside
the alliances.
Poultry meat consumption in the United States has increased dramatically in
recent decades to the point where it has the largest per capita consumption of any meat
type. Several factors have contributed to this increased appeal of poultry. First, the
fat in poultry is almost exclusively associated with the skin and is easy to remove in
response to dietary guidelines for reducing dietary fat. This is contrasted with mam-
malian meats such as beef and pork, which have more of their fat actually included in
the lean sections of the commonly consumed portions. However, it should be noted
that, depending on the cuts chosen, lean poultry and lean beef have approximately
the same fat content. The distinction is mainly the ease of fat separation. Second, the
industry has been very responsive to developing new products to meet the changing
consumer needs, which are versatility, variety, and ease of preparation. Examples of
these include the enormous success of nuggets and similarly formed fried products as
well as prepared ready-to-eat meals. During the 1960s–1980s, the most popular type of
poultry purchased was whole bird. In the following 20 years, the change from whole
bird to parts was consumer driven for reasons of increased versatility and variety. For
example, consumers prefer to purchase specific parts based on their needs, instead of
a whole bird with possible parts and meat type (dark versus light) they would not pre-
fer. In today’s market, further-processed products have become an increasing market
segment, and have recently surpassed parts as percentage of production by poultry
processors. It is estimated that, out of the current domestic market segments, an aver-
age of 40% is made up of foodservice, and, of that percentage, the majority is made up
of fast-food poultry products. Finally, poultry is an extremely versatile meat, a factor
Chapter one: Introduction to poultry meat processing 3
that has possibly contributed to the product development efforts. Poultry meat is more
homogeneous in composition, texture, and color than mammalian meat, making poul-
try easier to consistently formulate into products. When compared to beef, poultry
meat also has a milder flavor, which is more readily complemented with flavorings
and sauces.
Economic production through vertical integration, favorable meat characteristics, and
product innovations to meet consumer needs have all contributed to the poultry industry’s
success. However, the safety of poultry products and the use of water in processing are
two issues with which the industry is concerned. Developments in live bird production,
processing plant operations, product characteristics, and inspection systems are all being
made to reduce bacterial contamination of the product and improve its safety. Likewise,
the expense and environmental impact of using large quantities of water in processing,
and then cleaning that water before discharging it, have all prompted intense study in
these areas. The following chapters will provide the reader with an understanding of these
and the many other areas involved in poultry meat processing.
chapter two
Contents
Introduction...................................................................................................................................... 5
Antemortem factors affecting quality........................................................................................... 6
Harvesting.................................................................................................................................... 6
Feed withdrawal.......................................................................................................................... 8
Live production management............................................................................................ 10
Lighting and cooping........................................................................................................... 10
Environmental temperature................................................................................................ 12
Carcass contamination.............................................................................................................. 12
Short feed withdrawal......................................................................................................... 13
Long feed withdrawal......................................................................................................... 13
Feed withdrawal and microbiological implications............................................................ 15
Live shrink and carcass yield.................................................................................................. 16
Feed withdrawal and biological implications....................................................................... 17
Injuries associated with catching and cooping..................................................................... 18
Heat stress during grow-out or preslaughter activities and biological implications...... 20
Summary......................................................................................................................................... 21
References........................................................................................................................................ 21
Introduction
Approximately 9 billion chickens and 280 million turkeys were grown and processed in
the United States in 2008. During the short time between production and processing, there
are a number of factors, and opportunities for events to occur, that could potentially affect
poultry meat quality and yield. Processing is not just a “stand-alone” operation but rather
can be significantly influenced by poultry production factors that have an impact on the
chemical, physical, and structural changes that occur in the muscle as it is converted to
meat. Because large numbers of birds are involved from a commercial aspect, even a minor
live production event can have a significant economic impact by reducing poultry meat
quality and yield. As more poultry are “further processed” (cut up, deboned, marinated,
and/or coated) to meet consumer specifications, quality defects have become more obvi-
ous, and defects that were previously considered to be insignificant for a whole carcass
are now the primary reason for product rejection. During poultry production and man-
agement, antemortem or preslaughter factors not only exert important effects on muscle
growth, composition, and development but also determine the state of the bird on arrival at
5
6 Poultry meat processing, second edition
Harvesting
Birds are typically reared on litter (wood shavings, saw dust, rice hulls, peanut hulls, shred-
ded paper, etc.) in enclosed houses, with approximately 20,000–25,000 broilers per house,
or 6,000–14,000 turkeys per house, depending on house size (Figure 2.1). In the United
States, broilers are typically grown as mixed-sex flocks, while turkeys are sex-separately
reared. This is done primarily because of the size difference between tom (male) and hen
(female) turkeys and the longer grow-out period for males. Grow-out houses are usually
50′ × 500′ and may cost more than $10/ft2. Most farms have 2 (27%), 4 (43%), or 6 (19%)
houses per farm.6
In the United States, poultry companies are vertically integrated, which means the
company owns the processing plant, hatcheries, and feed mill. Companies contract with
independent farmers (growers) to grow the birds to market age. Grower contracts will
vary from company to company, but usually the grower provides land, labor, housing,
equipment, utilities, and litter. The company provides the birds, feed, veterinarian ser-
vices, medications (no growth hormones), and fuel to heat the house. Growers are paid
according to the number or pounds of live birds delivered to the processing plant and pro-
vided incentives for livability, feed efficiency, and minimal condemnations at the process-
ing plant. This method accounts for disease and environmental growth factors that could
reduce the number of birds brought to market.7,8 Grower contracts are usually on a flock-
to-flock basis (45% of contracts) but, under unusual circumstances, it may be as long as 15
years (8% contracts).6 Bird age at slaughter depends upon the end product (e.g., whole car-
cass, cut-up parts, etc.), but the majority of broilers are processed between the ages of 6 and
8 weeks (4–8 lb live weight), while turkeys are processed between 14 and 22 weeks of age
(14–38 lb live weight). Smaller broilers (<4.25 lb) are used for fast-food and restaurant ser-
vice, while larger broilers (>6.25 lb) provide further-processed products (cut-up, deboned,
marinated, batter or breaded, and tray packed). Turkey hens, which are smaller (12–15 lb),
are typically sold as whole carcasses, and larger tom turkeys (>22 lb) enter the market as
parts (drumsticks, tenders, wings) or further-processed products (luncheon meat, sausage,
ground meat, tray-pack, etc.). In recent years, the industry has been shifting more toward
larger birds because of market demands and because grower compensation per bird is
greater for larger birds that require more time on the farm. Additionally with larger birds,
processing plants can produce the same amount of product in a shorter amount of time
with fewer birds.6
Poultry must be “harvested” before they can be processed, and this involved pre-
paring birds for catching or collection, catching birds, and placing them into containers
(coops, crates, or cages). Figure 2.2 shows a schematic of the preslaughter steps, including
harvesting and up to the point where birds enter the processing plant. Birds are prepared
for catching by raising the feeder and water (feed and water withdrawal, discussed in
next section). In the United States, the majority of broilers are harvested manually using
“catch crews” that consist of 6 to 10 workers per crew. Broilers are usually caught by one
leg, while turkeys may be caught by one or both legs, or by one leg and the opposite
wing. Turkeys may also be loaded into cages using a hydraulic loader or preloader, which
consists of a sloping conveyor belt, with or without aluminum side panels. Turkeys are
herded onto the conveyor belts and transported to the cage opening using the loader or
preloader. Mechanical harvesting equipment is also available for broilers. These systems
vary with manufacturer, but all include an inclined conveyor belt similar to the turkey
loaders and preloaders. While mechanical harvesting seems to reduce the stress on birds
during harvesting, they are not always feasible because of house construction as some
older grow-out houses have center support beams and inadequate space to maneuver
mechanical harvesters.
Some of the major preslaughter problems that occur during harvesting include bird
injuries (bruising, broken or dislocated bones, and skin scratches), bird mortality (suffoca-
tion during improper handling), and bird weight loss due to feed and water deprivation.15
These problems are important because they result in reduced sales from trimming of dam-
aged parts and downgrading of carcasses and parts (not Grade A) products. Bird injuries
and carcass defects will be discussed later in the chapter.
8 Poultry meat processing, second edition
Broiler Feed
and Water
Withdrawal
(8 to 12 hours)
Catching
Transportation
(<2 hours)
Holding at the
Processing Plant
Unloading and
Shackling
Feed withdrawal
Before birds are caught, loaded, and transported to the processing plant, feed and water
are removed to allow time for evacuation of intestinal contents. Removal of feed and
water, or feed withdrawal, reduces incidence of carcass fecal contamination that may
occur during processing.16–22 With the USDA’s requirement of zero tolerance of carcass
Chapter two: Preslaughter factors affecting poultry meat quality 9
fecal contamination in the Pathogen Reduction (PR)–Hazard Analysis and Critical Control
Point System (HACCP) ruling, length of feed withdrawal has become more important to the
poultry industry. Zero tolerance of feces means that carcasses contaminated with visible
fecal material may not enter the immersion chiller. The HACCP regulation is discussed
in depth in Chapter 5. The USDA is encouraging the use of multiple intervention steps to
reduce the contamination of the final product with pathogenic bacteria (bacteria that cause
foodborne illness in humans). As a result, HACCP is now being applied during live pro-
duction, and this includes monitoring feed withdrawal programs. A 2008 survey reported
that 54% of poultry growers participate in a live production HACCP plan.6 In addition,
63%, 52%, and 49% of growers test their flocks for avian influenza, Salmonella, or other
pathogens, respectively, in the weeks prior to processing.6
Numerous factors influence the effectiveness of a commercial feed withdrawal pro-
gram, making it extremely difficult to optimize such a program. Before discussing these
factors, it is important to have a clear understanding of the definition of feed withdrawal
and the precise goals of a feed withdrawal program. Feed withdrawal refers to the total
length of time the bird is without feed prior to slaughter. It includes the length of time birds
are held in the grow-out house without feed before catching plus the length of time they
are in transit and the length of time they are in the live hold area at the processing plant
(time in house + transportation time + plant holding time = total feed withdrawal time).23
During feed withdrawal, there is an increased likelihood that broilers and turkeys will
consume litter or feces, and these contaminates can later end up on the carcass.
Length of feed withdrawal affects the incidence of carcass contamination, carcass
yield, grower payments, processing plant line efficiency, and product safety and quality.
Ideally, the length of feed withdrawal before processing should be the shortest amount of
time required for the birds’ digestive tracts to become empty.16–21,23 However, this time var-
ies because every bird neither eats at the same time nor consumes the same amount of feed.
Some birds will have just eaten when the feeders are raised, while others may have stopped
consuming feed 1 to 4 hours earlier. Moreover, other factors such as house environmental
conditions and management practices can influence feed passage. Recommended length
of time off feed for broilers before processing is between 8 to 12 hours, while 6 to 12 hours
is recommended for turkeys. During these time periods, most of the birds in the flock
will have had enough time to evacuate their gastrointestinal tracts.16,24 However, this feed
withdrawal time is not so great that there is an excessive loss of carcass yield. Live shrink
refers to the amount of weight lost by meat-producing animals during the feed withdrawal
period. Longer feed withdrawal time translates into fewer “pounds” of chicken or turkey
delivered to the processing plant, and fewer pounds delivered to the plant means reduced
grower payments.
Although 8 to 12 hours (broilers) and 6 to 12 hours (turkeys) of feed withdrawal is
recommended, a variety of feed-withdrawal schedules are used commercially. Most estab-
lishments target a 10-hour feed-withdrawal plan. However, it is not uncommon to have
some plants processing broilers with minimal carcass contamination using a 6- to 8-hour
feed-withdrawal schedule, while other plants prefer a 12- to 14-hour feed-withdrawal
schedule to achieve the same results. It is important to consider live production man-
agement practices (e.g., house temperature, litter moisture, type of feed, house lighting
program, plant holding time) and processing plant history (number of fecal failures and
carcass Escherichia coli counts) in deciding on a manageable feed-withdrawal schedule. The
goal is to minimize the holding time at the processing plant (yard time) as much as pos-
sible, especially during the summer months when high environmental temperatures can
increase live shrink and heat stress.
10 Poultry meat processing, second edition
60
40
20
0
0 6 12 18 24
42 Days 44 Days 48 Days
Length of Time off Feed (hours)
Figure 2.3 Effects of length of feed withdrawal on broiler viscera weight. (Adapted from Buhr, R. J.
et al. 1998. Poult. Sci. 77, 758.)
When they had access to feed, birds held in the dark were less likely to get up and go to
the feeders. Lighting had no impact on crop contents, except when it was combined with
cooping. Cooped broilers held in darkness for 2 hours had more than twice as much feed
in their crops than cooped broilers held in the light (Figure 2.4). In addition, after 4 hours
of feed withdrawal, there was twice as much feed within the crops of broilers held in
darkness compared to crops of broilers held in light.18 For this reason, poultry companies
usually want growers to leave birds in the grow-out house on litter with water, but no feed,
for 2 to 5 hours before catching. It has been suggested that 4 hours of water consumption
for broilers, and 2 hours of water consumption for turkeys, is optimal after initiation of
feed withdrawal to allow feed passage from the crop. However, in practice, some grow-
ers will not follow the recommendations and will raise both the feeders and waters at the
same time to prepare the house for catch. Following the recommended 8 to 12 hours of
35.00
30.00
Weight of Crop Contents (g)
25.00
20.00
15.00
10.00
5.00
0.00
2 4 6 8
Length of Feed Withdrawal (hours)
Figure 2.4 Effects of lighting and cooping on the crop contents (weight in grams) of 45-day-old broil-
ers held without feed for 2, 4, 6, or 8 hours. (Adapted from May, J. D. et al. 1990. Poult. Sci. 69, 1681.)
12 Poultry meat processing, second edition
feed withdrawal results in empty crops at slaughter regardless of the availability of light
or cooping.
Environmental temperature
In addition to lighting, stress, and possibly cooping, environmental temperatures have been
shown to affect digestive-tract clearance of birds during the feed-withdrawal period.18,28
This may be related to the consumption of less feed during hot weather in conjunction with
reduced bird activity. During the fall and spring, when daily temperatures vary widely,
birds may gorge themselves in the evening after the sun goes down and temperatures
begin to decline. If birds have gorged immediately before feed withdrawal, a normal with-
drawal period may not be long enough to empty the digestive tract of its contents.23 Birds
grown during cold weather with house temperatures below 15.5°C also retain feed in their
digestive tracts longer, and the birds may often be too cold to stand and eat.18,28 If the litter
is wet, birds will have difficulty moving back and forth to the feeders. As indicated by May
and Lott,29 “broilers are nibblers and eat regularly when the temperature is constant, and
lighting is continuous.” When birds do not have normal eating patterns, there is greater
variability in the content and condition of their digestive tracts. This can be detrimental to
the processing plant in terms of carcass contamination.
Carcass contamination
Fecal contamination of broiler carcasses occurs when the contents of the birds’ gastrointesti-
nal tract leak onto the carcass, or intestines are cut or torn during evisceration (Figure 2.5).18
Visible contamination on carcasses is typically removed by online reprocessing in cabinet
washers. These washers spray carcasses with a combination of water and an antimicrobial
compound (chlorine, chlorine dioxide, sodium metasilicate, acidified sodium chlorite, mono-
chloramines, peracetic acid, organic acid blends, etc.; see Chapter 9). Online reprocessing
machines frequently employ rotating brushes that scrub the back, wings, and breast area of
each carcass to remove the contamination. Typically, the brushes are sprayed with an anti-
microbial to minimize cross-contamination. Most processing plants will also have an offline
reprocessing station where plant employees remove fecal contamination from carcasses by
washing, vacuuming, or trimming each carcass and then visibly reinspecting them. Manual
carcass reprocessing and reinspection can delay the operation of the processing plant and
increase the cost of producing a quality product, especially when flocks come through with
a high percentage of contamination.17,19,20,23 The frequency of carcass contamination depends
on the amount of material present in the digestive tract, the condition of the digesta (partially
digested food and feces) remaining in the intestines (watery or firm), the integrity of the
intestines, and the efficiency of the eviscerating equipment and plant personnel.22,23
Several studies have been conducted to evaluate the relationship between feed with-
drawal and digestive tract contents. Northcutt et al.21 conducted a field trial in which the
intestinal tracts of 50 to 125 broilers from each of three different commercial plants in
the United States were evaluated. The contents of the crop and gizzard were noted upon
dissection, and gizzard bile was reported on a percentage basis. Intestinal shape was
observed and recorded as (1) round and containing feed, (2) flat and void of feed, or (3)
round and containing gas. Table 2.2 shows the results of this study, and a discussion of the
findings appears in the next two sections.21 Buhr et al.31 conducted another study in which
the influence of broiler feed withdrawal on viscera weight, diameter, and shear strength
(likelihood of intestinal breakage) was studied. Results from this study are also discussed
in the next two sections.
has been reported to have an effect on intestinal villi and intestinal crypt depth. Ileal villi
width, crypt depth, and mucus decrease with longer feed-withdrawal periods. The intes-
tinal mucus (loss of 2% per hour of feed withdrawal) will be passed with feces (intestinal
sloughing), and may affect intestinal integrity. Weaker intestines have a higher incidence
of intestinal tearing during evisceration. Figure 2.7 shows intestinal strength data of broil-
ers after various feed withdrawal periods.31 The intestinal strength of broilers has been
found to be approximately 10% lower when they were without feed for 14 or more hours
before processing as compared to full-fed broilers. The tensile strength of small intestines
was found to be approximately 20% lower as the length of feed withdrawal was increased
from 6 to 18 hours. Moreover, male birds were reported to have stronger intestines by 15%
than female birds.30 The intestinal villi of other areas of the gastrointestinal tract (jejuna
region) have been found to become longer during feed-withdrawal periods, and this is
likely because this region is the primary sites for nutrient absorption, and villi become
longer to increase the likelihood of absorbing nutrients when the intestines are empty.
400
300
Force (grams)
200
100
0
0 6 10 12 14 18 24
Length of Feed Withdrawal (hours)
Figure 2.7 Intestinal strength of broilers held without feed for various times before processing.
(Adapted from Bilgili, S. F. and Hess, J. B. 1997. J. Appl. Poult. Res. 6, 279.)
Chapter two: Preslaughter factors affecting poultry meat quality 15
In addition to weaker intestines, longer feed-withdrawal times often result in bile con-
tamination of carcasses because bile is continuously produced, and the gall bladder becomes
enlarged. Buhr et al.31 reported that gall bladders recovered from broilers held without feed
for 24 hours were 16% to 21% longer than those recovered from full-fed broilers, but there
was no change in gall bladder width. Enlarged gall bladders may be broken more frequently
during evisceration than smaller gall bladders.21,28,31,32 When the gall bladder reaches maxi-
mum capacity, excess bile backs up into the liver, and is also released into the duodenum and
backflows into the gizzard (Table 2.2). This can alter the appearance of the liver and may alter
liver flavor.21 Liver color has been reported to become darker, less red, and less yellow with
longer feed-withdrawal times.21,31 As a result of the bile, the gizzard lining will have a green
appearance, indicating that feed withdrawal may have been excessive (Table 2.2).21
During feed withdrawal, birds will consume anything that is available, including lit-
ter and fecal material. Thus, there is a mixture of feed, litter, water, and feces in the diges-
tive tract of broilers and turkeys during extended withdrawal periods when the birds are
still on litter. Because of the presence of the other material (residual feed, water, and litter),
feces is not easy to identify in the birds’ digestive tract until they have been without feed for
more than 14 hours (Table 2.2). Consumption of fecal material should be avoided because it
increases the potential for carcass contamination in the plant, and it may affect the plant’s
ability to meet the USDA-established microbiological standards for poultry.21,23,28
Because not every bird eats at the same time, the plant will be processing birds on
feed-withdrawal schedules that vary by approximately 3 hours. For example, if the target
is an 8-hour feed-withdrawal schedule for broilers, some birds have just eaten before feed
is removed, while other birds ate 2 to 3 hours earlier. In a house of 20,000 birds, a catch
crew of 10 will take 2 to 3 hours to empty the house. In a plant running 144 birds per min-
ute, it will take approximately 42 minutes to process the birds on one truck (~6,000 birds).
The three to four trucks needed to catch all the birds in one house will require approxi-
mately 2½ hours to process. A typical schedule would be the following:
Birds on the first truck from this house would have feed-withdrawal times ranging from
8 hours 36 minutes to 9 hours 18 minutes. Birds on the second and third trucks from this
same house would be without feed for approximately 9 hours to 10½ hours.21,23,33 Because
schedules will vary by 2–3 hours of the target, it is possible to be in the feed-withdrawal
range where the intestines begin to weaken.33
According to Hess and Bilgili,32 the effect of feed withdrawal on intestinal strength
varies with season. Experimental trials were conducted using 51- to 52-day-old broilers
grown in open-sided (curtain) houses. The force to tear broiler intestines was 15% higher
in winter than in summer. Moreover, intestinal strength measured during winter did not
decrease with increasing feed withdrawal as was observed during summer.
demonstrated that the length of feed withdrawal has an effect on pathogenic bacteria
in a bird’s digestive tract. Byrd et al.34 reported that feed withdrawal caused a signifi-
cant increase in Campylobacter-positive crop samples, with 25% positive crops before feed
withdrawal and 62.4% positive crops after. Corrier et al.35 reported similar findings for
Salmonella-contaminated crops, which increased from 1.9% before feed withdrawal to 10%
at the end of feed withdrawal. Stern et al.36 observed an increase in both Campylobacter-
positive feathered carcass rinses and ceca in broilers held without feed in coops for 16
to 18 hours. Humphrey et al.37 found that broilers held for 24 hours without feed had
higher levels of Salmonella in their crops, but the speed with which the remaining sections
of the intestine were colonized with Salmonella was reduced when compared to full-fed
broilers. It was suggested that the normal microflora of the crop, specifically lactobacilli
that produce lactic acid, changed during feed withdrawal, become reduced in number
during feed withdrawal, are no longer available to compete with the pathogens, and the
proliferation of Salmonella is no longer suppressed. Hinton et al.38 reported similar find-
ings when broilers were held without feed for 6, 12, 18, or 24 hours. Broilers held without
feed had higher crop pH than full-fed broilers (full-fed crop pH of 5.5 versus 12 hour
withdrawal crop pH 6.5). This increase in crop pH may create a more favorable environ-
ment for pathogenic bacteria to grow, whereas the lower pH of a full-fed broiler would be
a more undesirable environment for the proliferation of pathogenic bacteria. Northcutt et
al.39 studied the relationship between broiler age at slaughter (6, 7, and 8 weeks old), feed
withdrawal (0 or 12 hours), and carcass microbiological contamination before and after
immersion chilling. Feed withdrawal had no effect on the numbers of bacteria recovered
from carcasses, with the exception of Campylobacter on carcasses from 8-week-old broil-
ers. More Campylobacter was recovered in higher levels from broilers held without feed
for 12 hours as compared to those full fed, even with a cotton plug in the vent to pre-
vent intestinal leakage.39 Previous research has shown that there are high microbiological
loads on the exterior surface of broilers before processing. Cason et al.40 tested 7 different
commercial flocks and found that 6 out of 7 flocks were positive for Campylobacter, and
46 out of 50 of the external carcass samples (feathered carcass, head, feet) that were col-
lected were positive for Salmonella compared to only 26 Salmonella-positive samples col-
lected from the broilers’ gastrointestinal tracts (internal). These data show that live birds
carry high numbers of bacteria on the feathers, skin, and feet, and these numbers must be
reduced during processing.
Table 2.3 Live Shrink Weight Loss for Broilers Held without Feed for
10 to 12 Hours
Live shrink rate
Reference (% live weight per hour feed withdrawal)
Henry and Raunikar (1958)42 0.34
Wabeck (1972)16 0.18–0.24
Fletcher and Rahn (1982)43 0.39–0.42
Chen et al. (1983)44 0.22–0.51
Veerkamp (1986)24 0.2–0.25
Papa and Dickens (1989)19 0.31–0.39
Buhr et al. (1998)31 0.27–0.43
Petracci et al. (2001)45 0.27–0.48
Taylor et al. (2002)25 0.3–0.5
before processing (e.g., 15 instead of 12 hours) will weigh approximately 14 grams less than
the same broiler processed 3 hours earlier. For turkeys, the loss is even greater. A 16-week-
old turkey hen held without feed for 3 extra hours would weigh approximately 55 grams
less than the same hen 3 hours earlier. This is a combination of 3 hours of feed for growth
and live shrink. In an operation that processes 250,000 broilers a day or 85,000 turkeys per
day (average size of a U.S. processing plant), for 5 days a week, an extra 3 hours of feed
withdrawal could equate to reducing the amount of live weight by 16,500 kg for broilers,
or 4,675 kg for turkeys per week. This does not mean that birds given no feed withdrawal
will have the highest carcass yields. In fact, birds full of feed that weigh the same as birds
held off feed have lower carcass yields because their initial weight includes digestive tract
contents. Research has shown that carcass yield is greatest for broilers held off feed for 6
hours prior to processing; however, in reality, a 6-hour feed withdrawal schedule would be
difficult to manage, and carcass contamination levels could be high.28,31
the ultimate pH of turkey breast meat by 0.1 pH units and resulted in greater tissue drip
loss as compared to control turkey breast meat (percentage drip loss 3.90 versus 1.66).
Kotula and Wang50 reported that increasing length of feed withdrawal resulted in
decreased pH and glycogen levels in breast, thigh, and liver at the time of death for male
broilers. For breast muscle, initial pH (<3 minute postmortem) ranged from 6.97 for full-fed
broilers to 6.36 for broilers off feed for 36 hours. Breast-muscle glycogen declined from 7.0
to 3.5 mg/g after 36 hours of feed withdrawal. Thigh-muscle glycogen followed a similar
trend. These same researchers found no difference in final muscle pH (34 hours postmor-
tem) due to feed withdrawal; however, muscle glycogen levels were significantly lower
in both breast and thigh from broilers held off feed for longer periods of time before pro-
cessing. These data demonstrate that prolonged feed withdrawal and other preslaughter
stressors (transportation, physical activity, heat, handling, etc.) may deplete muscle tissue
glycogen reserves in poultry, and this may influence meat functionality (pH, water-hold-
ing, etc.).
Figure 2.8 Typical autodump coops (modules) being unloaded from the truck.
Figure 2.9 Bruising caused by ruptured cells and capillaries beneath the skin.
20 Poultry meat processing, second edition
with emphasis on bruise color development, histological tissue damage, and functional
properties of poultry meat during further-processing.
Bilgili and Horton61 conducted a year-long field study to evaluate the influence of
live production factors on broiler carcass quality and grade. These researchers found that
older, heavier broilers had more bruises, leg problems, breast blisters, and broken or dis-
located bones. In addition, a positive correlation was found between flock age and birds
dead-on-arrival (DOA) at the processing plant. Bird placement density or the amount of
space allowed per bird in the house influence broiler bruising, with a higher incidence
of bruises occurring when space was limited. In 1954, a study conducted on bruising in
turkeys reported that the heavier tom turkeys had 8% fewer bruises than the lighter hen
turkeys.62 These same researchers suggested that bruising accounted for approximately
23% of the turkey carcass defects leading to downgraded carcasses (not grade A).62
Another contributing factor to broiler bruising is the presence of mycotoxins (toxic
metabolite produced by fungi) in grains and feeds. Aflatoxin has been found to increase
the birds’ susceptibility to bruising by increasing capillary fragility and reducing shear
strength of skeletal muscle. As little as 0.625 µg of dietary aflatoxin produced extensive
hemorrhaging in muscles and internal organs.63 Additional information on mycotoxicosis
and bruising may be found in articles published by Tung et al.63 and Hoerr.64
In recent years, both the National Chicken Council (NCC)65 and the National Turkey
Federation (NTF)66 have published animal welfare guidelines and best management prac-
tices for poultry producers. The NCC has also published a welfare audit checklist. NCC
animal welfare guidelines recommend catching procedures (≤5 birds per hand for birds
>4 lb), incentives for catch crews demonstrating proper handling techniques, and no han-
dling of birds by the wing or neck. Guidelines also suggest that, if mechanical harvesters
are used, then the company should have humane protocols. Increased emphasis on animal
welfare concerns has reduced the number of injuries during catching and loading. More
information regarding welfare programs can be found in Chapter 20.
12°C, suggesting that elevated temperatures in the holding period prior to slaughter can
also increase the incidence of PSE meat.
Summary
Poultry meat quality is affected by numerous antemortem factors, in particular, those
occurring during the last 24 hours that the bird is alive. These short-term factors influence
carcass yield (live shrink), carcass defects (bruising, broken/dislocated bones), carcass
microbiological contamination, and muscle metabolic capabilities. There is even evidence
to suggest that stressful conditions during harvesting, such as catching and cooping, affect
the postmortem muscle functional properties. Current issues associated with foodborne
illnesses have forced poultry companies to pay even more attention to live production
than before to satisfy the “farm-to-table” food safety initiative. These issues will continue
to be priorities for the USDA and poultry companies.
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34. Byrd, J. A., Corrier, D. E., Hume, M. E., Bailey, R. H., Stanker, L. H., and Hargis, B. M., Incidence
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35. Corrier, D. E., Byrd, J. A., Hargis, B. M., Hume, M. E., Bailey, R. H., and Stanker, L. H., Presence
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36. Stern, N. J., Clavero, M. R. S., Bailey, J. S., Cox, N. A., and Robach, M. C., Campylobacter spp. in
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38. Hinton, A., Jr., Buhr, R. J., and Ingram, K., Feed withdrawal and carcass microbiological counts,
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broiler age, feed withdrawal, and transportation on levels of coliforms, Campylobacter,
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40. Cason, J. A., Hinton, A., Jr., Northcutt, J. K., Buhr, R. J., Ingram, K. D., Smith, D. P., and Cox,
N. A., Partitioning of external and internal bacteria carried by broiler chicken before process-
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41. Duke, G. E., Basha, M., and Noll, S., Optimum duration of feed and water removal prior to
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45. Petracci, M., Fletcher, D. L., and Northcutt, J. K., The effect of holding temperature on live
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46. Murray, H. C. and Rosenberg, M. M., Studies on blood sugar and glycogen level in chickens,
Poult. Sci., 32, 805, 1953.
47. Shrimpton, D. H., Some causes of toughness in broilers (young roasting chickens). I. Packing
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48. Warriss, P. D., Kestin, S. C., Brown, S. N., and Bevis, E. A., Depletion of glycogen reserves in
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49. Northcutt, J. K., Influence of antemortem treatments on postmortem muscle properties of poul-
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50. Kotula, K. L. and Wang, Y., Characterization of broiler meat quality factors as influenced by
feed withdrawal time, J. Appl. Poult. Res., 3, 103, 1994.
51. Scott, G. B., Poultry handling: A review of mechanical devices and their effect on bird welfare,
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52. Scott, G. B., Catching and handling of broiler chickens, Proc. 9th Eur. Poult. Conf., Glasgow, U.K.,
II, 1994, 411.
53. Lacy, M. P. and Czarick, M., Mechanical harvesting of broilers, Poult. Sci., 77, 1794, 1998.
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56. Hamdy, M. K., Kunkle, L. E., and Deatherage, F. E., Bruised tissue II. Determination of the age
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57. Hamdy, M. K., May, K. N., Flanagan, W. P., and Powers, J. J., Determination of the age of bruises
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60. Northcutt, J. K., Smith, D. P., and Buhr, R. J., Effects of bruising and marination on broiler breast
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61. Bilgili, S. F. and Horton, A. B., Influence of production factors on broiler carcass quality and
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67. Yahav, S., Goldfield, S. Plavnik, I., and Hurwitz, S., Physiological responses of chickens and
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24 Poultry meat processing, second edition
69. McCurdy, R. D., Barbut, S., and Quinton, M., Seasonal effect on pale soft exudative (PSE) occur-
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chapter three
First processing
Slaughter through chilling
Alan R. Sams and Shelly R. McKee
Contents
Introduction.................................................................................................................................... 25
Slaughter......................................................................................................................................... 26
Unloading................................................................................................................................... 26
Stunning...................................................................................................................................... 26
Exsanguination.......................................................................................................................... 29
Feather removal......................................................................................................................... 30
Scalding.................................................................................................................................. 30
Picking.................................................................................................................................... 31
Evisceration................................................................................................................................ 33
Chilling............................................................................................................................................43
Improper chilling and its effects on meat quality................................................................. 47
Summary......................................................................................................................................... 48
References........................................................................................................................................ 49
Selected bibliography.................................................................................................................... 49
Introduction
In commercial poultry-processing plants today, birds are shackled by the legs and pro-
cessed in an automated in-line system that conveys inverted birds through a series of
equipment. The processing steps are a highly coordinated system of mechanized opera-
tions that kill the birds, remove the inedible portions of the carcasses, and package/pre-
serve the edible portions for distribution to the consumer. The efficiency of processing is
largely dependent on the uniformity of the birds, so that each machine can do a repeated
movement with little or no adjustment between birds. Another important factor is the
logistical coordination of carcass flow and production lines, so that adequate birds are
present to make maximum use of the personnel and equipment. These fixed costs are
incurred by the plant regardless of the presence of birds and, therefore, need to be paid by
the production of poultry meat. Because these costs are fixed, it is generally more profitable
to process larger birds. However, the current market segments for poultry require multiple
sizes of birds. The average live weight of broilers is 5.5 lb, but birds can range in size from
3.6 lb up to 8.0+ lb. The smaller birds are generally for fast food, rotisserie, and cut-up
parts, whereas the larger birds tend to be used for further-processing. Since uniformity is
so important to processing efficiency and product yield, poultry processing facilities will
generally process a specific size bird for a targeted market segment. During processing,
the goals are to maximize yield, product quality, and safety. Additionally, to maximize
25
26 Poultry meat processing, second edition
process efficiency and plant yield, it is necessary that every shackle be occupied to produce
the maximum amount of product. This chapter will cover the steps of processing, their
purpose, and how to maintain quality and yield of product throughout processing.
Slaughter
Unloading
After their arrival at the processing plant, the birds are unloaded for processing. The coops
of birds are removed from the truck and “dumped” onto a conveyor or placed in a position
for them to be manually unloaded. The “dumper” can be a source of carcass damage such as
bruising and broken bones because the birds are allowed to freely fall one or more meters to
the conveyor belt below. Minimizing this distance can reduce the damage. Manual unload-
ing can also cause carcass damage if the birds are handled roughly. Birds should be handled
by their legs to prevent damage to the breast meat. Proper training and supervision are criti-
cal to minimizing damage. When the birds are manually unloaded from the coops, they are
usually directly hung on a shackle and not placed on a separate conveyor belt. Because of
bird size and numbers, dumpers have become the industry norm in the United States, with
manual unloading still occurring in some other parts of the world. Because of their large size
and poor body control, turkeys are usually still unloaded manually worldwide.
The ergonomics and safety of the unloading process has become an issue in recent
years. Coops and/or workers are on platforms of adjustable heights, maintaining the birds
at an optimal position to minimize the bending and lifting required by the worker. The
industry has determined that such ergonomic innovations can yield benefits from reduced
medical claims and better worker performance or retention. Proper ventilation is also
important in the unloading and hanging areas to further improve worker welfare. These
are particularly dusty areas, and the respiratory health of the workers can be a concern.
Wearing masks in the unloading area can help improve the situation. The hanging areas
have traditionally been dark, lit only with “black lights” or dim red lights. This darken-
ing was thought to calm the birds, reducing their struggle against hanging, and thereby
reducing damage to their bodies during handling.
Stunning
The first step in humane slaughter is “stunning” to render the bird unconscious prior to
killing. Stunning is not required by law in the United States for poultry; however, it is
considered humane and provides additional benefits, as mentioned later. Several methods
have been developed to accomplish this goal. The most common and one of the simplest
methods is electrical stunning. While hanging by their feet, the heads of the birds contact
a saline solution (approximately 1% NaCl) that is charged so that an electrical current flows
through the bird to the shackle line that serves as the ground (Figure 3.1). A proper electri-
cal stun will produce about 60 to 90 s of unconsciousness during which the bird is unable
to stand or right itself when removed from the shackle and placed on the floor. This is a
suggested method of evaluating the effectiveness of the stun. Immediately after contact,
the legs are extended, the wings are tight against the body, and the neck is arched. Several
seconds after leaving the stunner contact, the bird’s posture relaxes and the body becomes
almost limp. In addition to humane slaughter, there are other benefits to be gained from
proper stunning, such as immobilization for improved cutting machine efficiency, more
complete blood loss, and better feather removal during picking. Inadequate stunning can
Chapter three: First processing: Slaughter through chilling 27
Figure 3.1 Electrical stunner cabinet containing an electrode covered by a saline solution. Bird
movement is from left to right.
result in carcass defects such as incomplete bleeding, while excessive stunning can cause
quality defects such as broken clavicles (wishbones) and hemorrhages from ruptured
arteries and capillaries. Ruptured capillaries appear as multiple pinpoint blood spots, par-
ticularly near the top of the breast meat, with overstunning. Some commercial poultry is
not stunned because some cultures specifically prohibit preslaughter stunning, requiring
the birds to be conscious when slaughtered (see Chapter 21).
There are different conditions used for electrical stunning, depending on the region
of the world. Although poultry is not required by law to be stunned before slaughter in
the United States, virtually all commercial poultry is stunned for humane, efficiency, and
quality reasons. In the United States, a low-voltage stun (10–25 V) is typically used. The
birds receive 10–20 mA per broiler and 20–40 mA per turkey for 10 to 12 s. The frequency
can range from 50 to 500 Hz (high frequency is common), and the type of current can be
AC or DC. These conditions yield adequate time of unconsciousness for the neck to be
cut, which is within 7 to 10 s, and sufficient blood to be lost so as to kill the bird before it
regains consciousness. In most European countries, laws require poultry to be stunned
with much higher amperages (90 + mA per broiler and 100 + mA per turkeys for 4–6 s).
These laws and high amperages are intended for humane treatment to ensure that the
birds are irreversibly stunned so that there is no chance they will be able to recover and
sense any discomfort. Essentially, these European electrical stunning conditions kill the
bird by electrocution and cardiac arrest, stopping blood flow to the brain. Thus, death is
by loss of blood supply to the brain for both stunning conditions, but one is by removal of
blood, and the other is by stopping blood flow to the brain. The harsher European electri-
cal conditions also result in higher incidences of hemorrhaging and broken bones.1,2
Other methods of stunning have been developed to replace electrical stunning in
areas such as Europe, which require higher electrical conditions. Exposing the birds to
gases to induce either anesthesia or anoxia are methods in commercial use. Carbon diox-
ide is an anesthetic gas used to induce rapid unconsciousness by altering the pH of the
cerebrospinal fluid.3 It can also induce anoxia at high concentrations. Argon and nitrogen
28 Poultry meat processing, second edition
Figure 3.2 Diagram of controlled atmosphere stunning (CAS) device. (Courtesy of Stork Food
Systems.)
are inert gases that displace the air and cause unconsciousness through lack of oxygen.4,5
There are two main types of gas stunning systems for poultry: reversible and irrevers-
ible. First, systems using mixtures of carbon dioxide (10% to 40%), and air (60% to 90%)
are shorter duration (30 to 45 s) and intended to render the bird unconscious but alive for
the killing machine (reversible). Systems using mixtures of argon (55% to 70%), nitrogen
(0% to 15%), and carbon dioxide (30%), or carbon dioxide (40% to 80%) and oxygen are
longer duration (2 to 3 min) and intended to render the bird dead at the time of neck
cutting (irreversible). These gas-stunning systems have been commonly used in Europe,
and gas stunning of poultry is gaining interest in the United States. However, in the
United States, argon is not used due to the high cost of the gas. Rather, mixtures of carbon
dioxide, oxygen, and nitrogen are used. For example, Stork Food Systems’ “Controlled
Atmosphere Stunning” (CAS) system uses a two-stage irreversible stunning method in
which the birds are placed on a conveyor, travel through the gas tunnel, and are hung on
shackles upon exiting when they are dead (Figure 3.2). In this system, the first stage con-
sists of 40% carbon dioxide and 30% oxygen, which is used for 1 min to anesthetize the
birds. In the second stage, 80% carbon dioxide is used for 2 min to induce anoxia. Other
gas-stunning devices are designed so that birds remain in coops or modules through the
stun tunnel, and there is even a new technology that is designed to stun turkeys while
still on the truck (Praxair, Inc.). The device fits around the module of the coops, and then
the mixture of gases is applied (carbon-dioxide-based). An advantage of these systems
is that the birds are stunned prior to their being hung on shackles. Though reversible
and irreversible gas-stunning methods are possible, the irreversible methods are more
common, generally due to welfare issues. Both gas-stunning procedures, reversible and
irreversible, reduce carcass damage relative to high-amperage but not low-amperage elec-
trical stunning.2 This is because low-amperage electrical stunning has an equally low
incidence of carcass damage. An additional note on gas stunning is that these birds are
flaccid on the shackles when entering the killing machine. This differs from the stiffer,
electrically stunned bird, and must be accommodated with minor machine adjustments
for bird orientation.
Chapter three: First processing: Slaughter through chilling 29
Another stunning system that has received attention for reasons of humane animal treat-
ment is captive bolt stunning.6 In this stunning method, the head is immobilized and a metal
pin or probe is shot into the skull and brain causing immediate and irreversible unconscious-
ness. The humane and carcass quality effects of this method are still under investigation.
Exsanguination
Within seconds after stunning, the shackle conveyor moves the bird to the cutting machine
for exsanguination (Figure 3.3). A series of rotating bars grab the wattles and lower-neck
skin to hold and guide the head into the machine for proper presentation to the cutting
blade. The cutting machine uses a rotating circular blade to cut the jugular veins and
carotid arteries on one or both sides of the neck of the bird. Most cutting machines cut both
sets of blood vessels by rotating the head from the bird’s left to right as it passes over the
cutting blade. If the cut is too deep, and the spinal nerve cord is cut, the resulting nervous
stimulation can “set” the feathers and may make picking more difficult. Conversely, if the
cut is too shallow, there will be insufficient bleeding, and the residual blood will cause
engorged vessels and can discolor the skin. Once the neck has been cut (within 7 to 10 s
after stunning), the bird is allowed to bleed for 2–3 min. During this period the bird loses
about 30% to 50% of its blood, which eventually causes brain failure and death. In terms
of overall yield from live weight to processed bird weight (after chilling), blood represents
around 4% of the yield loss during processing. Some processors decapitate (i.e., remove
heads at cutting step) birds to ensure that all birds have been cut for welfare and con-
tainment (i.e., preventing adulteration of products) issues. If decapitation is used, scalding
needs to be adjusted to ensure that the birds are picked effectively, and excess skin around
the neck area needs to be removed to prevent blood from clotting. Insufficient blood loss
can result in minor to major quality problems. The presence of red wing tips after pro-
cessing is a sign of poor bleed out. If this occurs, the cutting machine and bleed out need
Figure 3.3 Picture of a killing machine showing guide bars and bicycle wheel to keep head in
proper alignment for the circular cutting blade below.
30 Poultry meat processing, second edition
to be evaluated for adjustment. Although, red wing tips are a minor problem, the blood
remaining in the wings can significantly reduce the shelf life of this product. Major quality
problems can result if blood loss is insufficient to cause death. If blood loss is insufficient to
cause death, or if the neck cut is missed altogether, the bird may be still alive (heart beating
but not conscious) at the end of the bleeding period when it enters the scalder. In this case,
the blood rushes to the skin surface in response to the scald-water heat, imparting a bright
red color to the carcass. These carcasses are referred to as “cadavers,” or “red birds,” and
are condemned so that they do not enter the food chain.
Feather removal
Scalding
Feathers are difficult to remove in their native condition due to their attachment in the
follicles. To loosen them, the carcasses are submersed in a bath of hot water, which serves
to denature the protein structures holding the feathers in place. Two particular combina-
tions of time and temperature have become industry norms and produce quite different
effects on the carcass. Scalding at 53.35°C (128°F) for 120 s is called soft scalding, and loos-
ens the feathers without causing appreciable damage to the outer skin layers, the stratum
corneum, or “cuticle” (Figure 3.4). Because it leaves this waxy, yellow-pigmented layer of
the skin intact, soft scalding is the preferred scalding method for producing fresh poultry
with the yellow skin exposed. Such skin color is highly desired in some parts of the world
as indicating a healthy bird. If the skin’s cuticle will not be exposed or is not pigmented
with carotenoids from the feed, the carcasses are usually scalded at 62°C to 64°C (145°F to
148°F) for 45 s, a process called hard scalding. Because it loosens the cuticle, this is a harsher
procedure than soft scalding. However, it allows easier feather removal than milder scald-
ing conditions. Once loosened, the outer skin layer and its associated pigmentation are
removed by the abrasion of the mechanical pickers. The loss of the waxy cuticle may be
beneficial to the processor whose product is destined to be coated and fried. Because
of their aqueous basis, fried chicken coatings generally adhere to the skin better in the
absence of this waxy, water-repellent layer of the skin.
The scald conditions given earlier are more commonly used in batch-processing-type
systems. In poultry processing facilities today, it is common to have multiple scalders
Skin Surface
A
Epidermis
B
Dermis
(muscle
and fat)
Figure 3.4 Diagram of skin layers. (Adapted from Suderman, D. R. and Cunningham, F. E. 1981.
J. Food Sci., 45(3), 444.)
Chapter three: First processing: Slaughter through chilling 31
Picking
The goal of picking is to remove feathers that have been loosened during scalding.
Picking machines consist of rows of rotating clusters of flexible, ribbed, rubber “fingers”
(Figure 3.5). While rotating rapidly, the fingers rub against the carcass, and the abrasion
pulls out loosened feathers. By combining a series of these rotating clusters of fingers, each
directed at a different region of the carcass, the whole carcass is picked. Picking machines
adjusted too close to the bird may cause skin tears in the thigh and breast regions, and
broken wing, leg, and rib bones. It is important to note that picking machines do not cause
bruising. Bruising (hemorrhaging) can no longer occur after loss of blood pressure (i.e.,
once the birds are cut and bled out). Unlike problems when the picking machine is too
close, machines that are too distant may not adequately remove the feathers. Pin feathers
are immature feathers that protrude from the skin, still encased in the feather shaft. These
pin feathers are difficult to remove with machines and therefore require manual attention.
Illustrating the importance of live production issues in processing, a more rapidly feather-
ing bird will have fewer pin feathers when processed. The last step in feather removal is
singeing. Carcasses are briefly passed through a flame to burn off the hairlike filoplume
structures on the skin because they are aesthetically offensive to consumers and consid-
ered a carcass defect. Feather loss represents approximately 6.5% of the yield loss during
processing. Additionally, picking has been shown to be an area of major bacterial cross-
contamination; therefore, a postpicking carcass rinse should follow this step.
Before the carcasses leave the picking area, the heads are pulled off of the necks if
they have not already come off in the picking machines or were removed due to decapita-
tion. The heads, along with the feathers, blood, and inedible viscera, are called offal and
are sent to rendering (either in plant or at a different location), where these materials are
ground and cooked into poultry fat and by-product meal for inclusion in animal feed (see
Chapter 19). Heads represent around 3% of the yield loss associated with processing. The
feet are also cut off at the ankle or “hock” joint and sent to be chilled and sorted for sale
or inclusion in the giblets. There are usually two categories of feet quality: those that are
32 Poultry meat processing, second edition
(a)
(b)
Figure 3.5 Picture of a picker head with the flexible rubber fingers (a). Row of defeathering or “pick-
ing” machines with each one targeting its picker heads at a different part of the carcass (b).
Chapter three: First processing: Slaughter through chilling 33
free of defects and those containing defects such as dark pigmentation or footpad lesions.
The feet equate to about 3.5% yield of the carcass. The last step before evisceration is to
transfer the birds from the kill shackle line (hung by feet) to the evisceration shackle line
(hung by hocks). This is done manually or with a transfer machine. If done manually,
this can be a site of bacterial cross-contamination, as one employee handles many birds.
Separation should be maintained between the live and dead areas of the plant to reduce
contamination of the relatively cleaner evisceration room. Traditionally, one kill line could
feed multiple evisceration lines because the kill line could travel at line speeds greater
than evisceration lines. For example, one kill line running at 140 birds per minute (bpm)
could feed two evisceration lines running at 70 bpm each with two inspectors per line
(speed limited due to inspection purposes; see Chapter 5). However, with newer eviscera-
tion equipment, faster line speeds are allowed (see Chapter 5). Therefore, the same kill line
running at 140 bpm can feed one evisceration line running at 140 bpm with four inspectors
on the line. Typically, shackles are on a 6 in. center (shackles 6 in. apart at center); however,
an 8 in. center is required when processing larger birds (>7.5 lb).
Evisceration
Evisceration is the removal of edible and inedible viscera from the carcass. It is a coor-
dinated series of highly automated operations that vary substantially in sequence and
design from plant to plant and from one equipment manufacturer to another. Although
it is becoming more automated, turkey evisceration is still largely manual worldwide. In
broilers, evisceration has three basic objectives: (1) the body cavity is opened by making a
cut from the posterior tip of the breastbone to the cloaca (anus); (2) the viscera (primarily
the gastrointestinal tract and associated organs, reproductive tract, heart, and lungs) is
scooped out; and (3) the edible viscera or “giblets” (heart, liver, and gizzard) are harvested
from the extracted viscera, trimmed of adhering tissues, and washed with water. The edi-
ble viscera or giblets represent approximately 7% of the carcass yield, while the inedible
viscera represents around 3%. The neck is usually part of the giblets but is collected later,
after inspection of the carcass for wholesomeness. Although not technically part of the vis-
cera, the feet (or “paws”) have become a valuable product, primarily for export to cultures
that use them for human food (see Chapter 19, Figure 19.2). In some countries, the paws are
included with the packet of giblets sold with the whole carcass.
There are also some countries where a considerable proportion of the poultry is sold
without evisceration (Figure 3.6). Broilers processed to only remove the blood and feath-
ers are called “New York dressed” and are even sometimes sold without refrigeration.
Cultures preferring this type of product feel that they are fresher because they are whole
and are killed and sold within hours (due to short shelf life). Sometimes these unevisce
rated carcasses are held for several days because of the desired “gamelike” flavor that
develops. Due to the lack of labeling on these carcasses, processors have used adhesive
labels on the skin to promote customer loyalty through brand identification (Figure 3.7).
The basic design of most evisceration machines is rotating, vertical cylinders that have
ten or more “stations” located around the edge. The shackle line containing the birds wraps
around the cylinder and provides the force for rotation, so the shackle line and machines
move at a coordinated speed. As each shackle and bird contact the cylinder, the bird is
grasped and a series of mechanical procedures are performed. When the cylinder has made
a complete rotation and completed the series of events, the bird is released from the machine
to travel to the next machine in the sequence. After releasing each bird, machines usually
have a washing step for the station before it grasps its next bird. Despite this washing, the
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2. While we are engaged in holy duties, especially in the public
ordinances of God’s worship, let us endeavour to maintain a
becoming reverence, and filial fear of God, in whose presence we
are, and a love to his holy institutions, which are instamped with his
authority. Let us moreover watch and strive against the first motions
and suggestions of Satan, and our corrupt hearts, endeavouring to
divert us from, or disturb us in holy duties. And let us often lift up
our hearts to God, by spiritual, short ejaculatory prayers, for help
from him, to enable us to improve the word, and, at the same time,
endeavour to our utmost, to affect our hearts with a sense of the
great worth of gospel-opportunities. Let us also cherish, improve,
and bless God for all the influences of his Holy Spirit, which he is
pleased, at any time, to grant to us; or bewail and lament the want
thereof, when they are withheld.
3. In the intervals between our attendance on the ordinances of
God’s public worship, we are to engage in private duties, and
worship God in, and with our families; and in order hereunto, call to
mind what we have heard, impress it on our own souls, recommend
it to those whom we converse with, and are concerned for; and take
heed that we do nothing, between one public ordinance and another,
which may unfit us for the remaining duties of the day; but, on the
other hand, strive against, and give a check to the least motions
thereof in our own souls.
4. The Sabbath is to be sanctified in the evening thereof, when the
public ordinances are over; at which time we are to call to mind
what we have received from God, with thankfulness, and how we
have behaved ourselves in all the parts of divine worship, in which
we have been engaged. Let us enquire, whether the Sabbath was
welcome to us, and we rejoiced in it as a blessing, as well as set
about the observing of it as a duty? as the Psalmist says, ‘I was glad
when they said unto me, Let us go into the house of the Lord,’ Psal.
cxxii. 1. Moreover, let us enquire, whether our ends were right in all
the duties we performed? whether the glory of God, and the good of
our own souls, has been our great concern? Or, whether we have
been only influenced by custom, and rested in a form of godliness,
without regarding the power thereof, and loved the opinion and
praise of men more than of God? Let us enquire, whether our minds,
our affections and outward gestures have been grave, sedate, and
composed, and we ready to receive whatever God has been pleased
to impart in his word? and whether we have had a due sense of the
divine perfections impressed on our spirits, and of the infinite
distance there is between the great God and us? whether we have
seen our need of the word, as Job says, that he esteemed the words
of God’s mouth more than his necessary food? Job xxiii. 12. and,
whether we have not only attended to, but applied every truth to
our own souls, as desiring to retain, improve, and make it the rule of
our conversation?
We are also to consider, what we have received from God under his
ordinances; whether we have had any sensible communion with him,
any experiences of his love, or impressions of his power on our
hearts? whether we have had fellowship with the Father, and with
his Son Jesus Christ? whether, as we have gone from one ordinance
to another, we have gone from strength to strength, our faith being
more lively, our love to God increased, and our spiritual joy enlarged
by every duty? Let us enquire, whether, we have learned some
doctrine from the word, which we understood not, or, at least, have
been more confirmed therein, after some degree of wavering, or
have been affected with some truth which we never saw such a
beauty and glory in before? whether we have been melted under the
word; if it has been, as the prophet speaks, like fire; or, as the
hammer that breaketh the rock in pieces, Jer. xxiii. 29. or, as the
disciples say one to another, Did not our heart burn within us while
he talked with us by the way, and while he opened to us the
scriptures? Luke xxiv. 32.
And we may comfortably conclude, that we have received good
under the ordinances, if we have been brought into an holy and
lively frame of spirit; and the more we attend to them, the more our
hearts are drawn forth to desire and delight in them; and especially
when public duties fit us for private, and from the advantage that we
receive from such opportunities, we are more disposed to walk with
God in all the affairs and businesses of life, so that our whole
conversation in this world, receives a tincture from the benefit which
we gain by that communion which we enjoy with God in his
ordinances on his own day.
Thus we are to take a view of our behaviour when engaged in public
worship; and if we have received any spiritual advantage, the glory
thereof is to be given to God. But if, on the other hand, upon a strict
and impartial enquiry into the frame of our spirits under the
ordinances, we have, as it too often happens, reason to complain of
our deadness and stupidity under them; if we have not experienced
that sensible communion with God, which we have at other times
enjoyed, or have reason to say, that we wax worse, rather than
better, under them; let us dread the consequence hereof, lest this
should issue in a judicial hardness of heart, and habitual
unprofitableness, under the means of grace. We ought, in this case,
to search out, and be humbled before God, for that secret sin, which
is as a root of bitterness which springs up within us, and troubles us;
and be still pressing after that special presence of God in his
ordinances, that will have a tendency to promote the life and power
of religion in our souls.
And to this we may add; that besides our dealing thus with
ourselves in our private retirements, after having attended on public
worship, we are to endeavour to sanctify the Sabbath in our families,
in the evening thereof. Family-worship is to be neglected no day; but
on the Sabbath, it is to be engaged in with a particular relation to
the duties which we have been performing in public; accordingly it is
mentioned in one of the answers we are explaining, that the charge
of keeping the Sabbath is directed to the governors of families, and
other superiors; inasmuch as they are bound, not only to keep it
themselves, but to see that it be observed by all those who are
under their charge, and not to hinder them, as many are prone to
do, by employing them in those works which are foreign to the
duties of the day. Masters of families are not only to restrain
immoralities in those who are under their care, on the Sabbath-day,
but to lay their commands on them, to engage with them in the
worship of God therein, as they expect a blessing from him on their
undertakings. Thus Joshua resolves, that he and his house would
serve the Lord, Josh. xxiv. 15. and God speaks to the honour of
Abraham, when he says, I know him that he will command his
children and his household after him; and they shall keep the way of
the Lord, Gen. xviii. 19. Superiors have no power to dispense with
any of God’s commandments, to disengage those who are under
them, from yielding obedience thereunto. But, on the other hand,
they are obliged to see that all, under their care, perform their duty
to God, as well as to them, and, particularly, that of sanctifying the
Sabbath. Therefore they are to restrain them from taking their own
diversions, or finding their own pleasure in sinful recreations on the
Lord’s day; and impress on them those suitable exhortations, that
may have a tendency to promote religion in their families; by which
means they may hope for a peculiar blessing from God, in every
relation and condition of life.
Quest. CXIX., CXX., CXXI.
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