MODULE NO.
18: Primary
processing of poultry
Poultry
Poultry is a category of domesticated birds kept by humans for
the purpose of collecting of their eggs, or killing for
their meat or feathers.
Poultry is the second most widely eaten meat in the world
Poultry comes from the French word poule, itself derived from the
Latin word pullus, which means small animal.
Primary processing of poultry
1. Scalding
2. Picking
3. Evisceration
. 1. Scalding
1
Scalding is the process of submerging the birds/carcass in hot
water to loosen the feather so that they can be easily separated
further.
Scalding process
After bleeding, the birds go through scalding tanks.
Soft-scald is used (about 50° C or 122° F) if retention of the
yellow skin colour is desired, but if a white bird is desired, a higher
scald temperature is used, resulting in the removal of the yellow
pellicle.
A hard scald of 58°C for 2.5 minutes will remove the epidermis of
poultry and this is commonly used for carcasses that will be frozen
so that their appearance is white and attractive.
Scalding method
For birds that are difficult to scald (waterfowl) a wetting agent
or detergent may be added to the water.
For waterfowl and mature birds a higher temperature and
longer submersion time should be used.
For younger birds a lower temperature and shorter time is
recommended.
Semi-scald or slack scald:
Scalding for 30-60 s in 125-130 °F water.
Appearance of the carcass is improved.
Sub-scald :
Sub-scald is the use of water at 138-140 °F for 30-75 seconds
For home processing this method of scalding is recommended
Hard-scald or full scald:
Hard-scald or full scald requires a water temperature of 140-150
°F.
Waterfowl may be scalded at this temperature.
Types of scalding
Automated Scalding:
Hard Scalding
Medium Scalding
Soft Scalding
Manual Scalding
Automated Scalding
Hard Scalding:
Very high temperature ranging from 140 to 160°F for 10 to 90s
is applied to loosen the skin which is removed during the
defeathering process.
Automated hard scalding is performed by immersing the birds
in a tank while they are hanging from an overhead conveyor.
Medium Scalding
The only difference from hard scalding is the temperature and cycle
time.
Values for medium scalding range from 129 -136°F for 60-120
seconds. Faster processing can be achieved by scalding at 140-
145°F for 15-30 seconds.
Soft Scalding
Soft (semi) scalding is used for most broilers and roasters (chickens)
and for young turkeys.
Soft scalding immerses the birds in 124 - 130°F for 45 seconds.
Manual Scalding
The dead bird is immersed in 140-150°F water for about 1
minute.
In most cases, an open tank is used that can accommodate one
to ten birds, and the water is kept hot by a burner located in the
bottom of the tank.
The major advantage of manual scalding processes is low
capital cost.
Large plant scalding process
Large plants may use a bird scrubber (large rotating brushes on
either side of the bird) and also spray the birds with chlorinated
water before putting them in the scalder.
The tanks also have a counter-current flow of water, which produces
a dirty-to-clean gradient
2. Picking
Picking is the process of removal of feathers from the
poultry.
It is the second step in processing of poultry after killing
:
Advantages of dry picking are;
Birds keep better appearance.
Most sanitary method.
Disadvantage of dry picking;
It is slightly more expensive method than scald picking.
Birds to be plucked are subjected to machine and should be
plucked immediately after scalding.
Picking process
Quality of picking is related to scalding process
If scalding water to be used is too cool then the feathers won’t
loose but if it is too hot then skin will tear in picker
Thus pinning process is done which involves removal of pinfeathers
by hand while singeing is another process that involves passing the
bird through flame to burn small hair-like feathers.
Picking machinery
The poultry is subjected to the feather-picking machines,
which are equipped with rubber “fingers” specifically
designed to beat off the feathers
Cont…..
There is an extra step in the process called as wax dipping
which is used for waterfowl as their feathers are more difficult
to remove.
Types of pickers
1. Drum picker
2. Tub or batch picker:
1. Drum picker
A drum picker consists of a cylinder with rubber fingers
around the exterior. The operator holds the bird above the
cylinder, rotating it as the cylinder spins and picks off
feathers.
2. Tub or batch picker:
A tub or batch picker is a rotating tub with rubber fingers
mounted on the inside walls.
It can handle 2 birds at a time.
Elasticity and length of the fingers varies, depending on the
task required, machine speed, etc.
3. Evisceration
Evisceration is the process for removal of edible and inedible
viscera from the carcass.
Evisceration process in poultry involves three basic
objectives:
1. The body cavity of the poultry is opened
2. The viscera is drawn out
3. The edible viscera or “giblets” are separated from the
extracted viscera and washed with water
Evisceration process
The process is done either manually or automatically.
The manual process is performed using a knife and a pair of
scissors or semi-automatically or fully automatically using a
circular cutting blade and a scoop-like arm to withdraw the
viscera.
The latter is done on high-speed lines (i.e., 2,000–8,000 birds
per hour). In all cases, special care should be taken not to
pierce the viscera and contaminate the carcass.
Cont…..
To eviscerate manually, body cavity can be opened by
making a small cut near the vent, extending the cut around the
vent, care should be taken not to cut the intestine or
contaminate the carcass with faecal material, and draw out
the organs.
After all the contents of the cavity are removed the bird
should be thoroughly washed inside and out.
Suggested Readings
Baker, R. C. and C. A. Bruce, 1989. Further Processing of Poultry. In:
Processing of Poultry. G.C. Mead (Editor). Elsevier Applied Science,
London, England. pp. 90-112.
Childs, R. E. and R. E. Walters. 1962. Methods and equipment for
eviscerating chickens. U.S. Dept. Agric. Mktg. Res. Report #549.
Cohen, N., Ennaji, H., Bouchrif, B., Hassar, M. & Karib, H. 2007.
Comparative study of microbiological quality of raw poultry meat at
various seasons and for different slaughtering processes in
Casablanca (Morocco). J. Appl. Poult. Res., 16(4): 502–508.
Fanatico, Anne. 2003. “Small Scale Poultry Processing,” National
Center for Appropriate Technology/ATTRA-National Sustainable
Fletcher, D. L. 1999. Recent advances in poultry slaughter technology. Poultry Sci.
78:277.
Gregory, N. G. 1989. Stunning and slaughter. In: Poultry Processing. Mead, G.C.
(Ed). Elsevier Sci. Publ., Essex, U.K.
Klose, A. A., E. P. Mecchi and M. F. Pool 1961. Observations of factors influencing
feather release. Poultry Sci. 40:1029.
Kiepper, B. H., W. C. Merka, and D. L. Fletcher. 2008. Proximate composition of
poultry processing wastewater particulate matter from broiler slaughter plants.
Poultry Science 87:1633-1636.
Li, Y., T. J. Siebenmorgen and C. L. Griffin. 1993. Electrical stimulation in poultry—
National Agricultural Statistics Service. 1989. Poultry production and value.
Bulletin POU 3–1 (April). U.S. Department of Agriculture, Washington, DC.
Northeast Pastured Poultry Producers Association. 2006. Personal communication,
September.
U.S. Department of Agriculture (USDA). 2006. Guidance for Determining
Whether a Poultry Slaughter or Processing Operation is Exempt from Inspection
Requirements of the Poultry Products Inspection Act. Food Safety Inspection
Service. Available at: [Link]
oppde/rdad/fsisnotices/poultry_slaughter_exemption_0406.pdf
Whitehead W. K., Shupe W. L., Energy requirements for processing poultry,
Transactions of the American Society of Agricultural Engineers 1979, p. 889 -
893.